Echelon, LON, L
trademarks of Echelon Corporation registered in the United
States and other countries.
ONMARK, LONTALK,LONWORKS, Neuron, are
EN1B-0375GE51 R0709 2
Excel 800
Safety Information
General Safety Information
►When performing any work (installation, mounting, start-
up), all instructions given by the manufacturer and in
particular the safety instructions provided in these
Installation and Commissioning Instructions are to be
observed.
►The Excel 800 System (including the XCL8010Controller
Module, I/O modules, manual disconnect modules, and
the auxiliary terminal packages) may be installed and
mounted only by authorized and trained personnel.
►Rules regarding electrostatic discharge should be
followed.
►If the Excel 800 System is modified in any way, except by
the manufacturer, all warranties concerning operation
and safety are invalidated.
►Make sure that the local standards and regulations are
observed at all times. Examples of such regulations are
VDE 0800 and VDE 0100 or EN 60204-1 for earth
grounding.
►Use only accessory equipment which comes from or has
been approved by Honeywell.
►It is recommended that devices are to be kept at room
temperature for at least 24 hours before applying power.
This is to allow any condensation resulting from low
shipping/storage temperatures to evaporate.
►The Excel 800 System must be installed in such a
manner (e.g., in a lockable cabinet) as to ensure that
uncertified persons have no access to the terminals.
Safety Information as per
EN60730-1
Purpose
The Excel 800 System is an independently mounted
electronic control system with fixed wiring.
It is used for the purpose of building HVAC control and is
suitable for use only in non-safety controls for installation on
or in appliances.
Pollution degree Pollution Degree 2,
suitable for use in residential
controls, commercial controls,
in a clean environment.
Overvoltage
category
Rated impulse
voltage
Automatic action Type 1.C
Software class
Ball-pressure test
temperature
Category II
for mains-powered (16A) controls
Category I
for 24 V powered controls
2500 VAC
(micro-interruption for the relay
outputs)
Class A
75 °C for all housing and plastic
parts
125 °C in the case of devices
applied with voltage-carrying parts
and connectors
Electromagnetic
interference
System transformer Europe: safety isolating
Table 1 System data as per EN60730-1
3 EN1B-0375GE51 R0709
Tested at 230 VAC,
with the modules in normal
condition.
transformers according to
IEC61558-2-6
U.S.A. and Canada: NEC Class-2
transformers
System OverviewExcel 800
System Overview
System Architecture
An Excel 800 System consists of the XCL8010 Controller and various I/O modules.
The XCL8010 Controller provides interface connections, which allow connection to external systems.
Auxiliary parts enable special features.
EBI /
SymmetrE
Ethernet LAN/WAN
Modem
XI582 or XI882A
C-Bus
XCL8010 + XF8xx
Panel Interface (<40m)
LON
LON IO (XFL8xx)
Fig. 1 Excel 800 System architecture
Internet
Browser
BNA
XLWeb
C-Bus
XFCxxxXFCLxxx
for distribution within building
OVN = OpenViewNet
IO (XF8xx)
Web-enabled
via OVN
Existing
XL500
Controllers
XL10/12
Fig. 2 XCL8010 Controller and I/O modules
EN1B-0375GE51 R0709 4
Excel 800 System Overview
X
X
X
X
X
X
X
X
I/O Modules
Pluggable I/O Modules
There are 2 variants of pluggable I/O modules:
• Panel Bus I/O modules with communication via Panel
Bus (light-gray housings). Panel Bus I/O modules are
automatically commissioned (with firmware download) by
the XCL8010 Controller.
• L
ONWORKS Bus I/O modules (dark-gray housings) with
communication via L
compatible) for easy integration and use with 3
controllers.
Mixed I/O Modules
Besides the pluggable Panel Bus I/O modules (consisting of
a terminal socket and a removable electronic module), there
are also mixed Panel Bus I/O modules. Specifically: the
XF830A and XFU830A are mixed Panel Bus I/O modules,
featuring an integrated terminal socket and a variety of
inputs and outputs.
Mixed Panel Bus I/O modules have a light-gray housing and
are likewise automatically commissioned (with firmware
download) by the XCL8010 Controller.
ONWORKS (FTT10-A, link power
pluggable
ANALOG INPUT
pluggable
ANALOG OUTPUT
rd
-party
pluggable
BINARY INPUT
Terminal Sockets
Pluggable I/O modules must be mounted on the appropriate
terminal sockets. Pluggable Panel Bus I/O modules and
pluggable L
ONWORKS Bus I/O modules use the same
terminal sockets. These terminal sockets are available with
push-in terminals (XS82…) or with screw-type terminals
(XSU82…).
Mixed I/O modules feature an integrated terminal socket.
Color Coding
To distinguish modules and components, the following color
coding is used:
Color Part
Red All of the user-accessible adjustable
mechanical parts (i.e., bridge connectors
and locking mechanism) and operating
controls (manual overrides, etc.)
Light-gray
Dark-gray
Panel Bus I/O modules
ONWORKS Bus I/O modules
L
Table 2 Color coding of Excel 800 Modules
pluggable
RELAY OUTPUT
pluggable
FLOATING
OUTPUT
MIXED I/Os
LonWorks
BUS MODULES
XFL821A
PANEL
BUS MODULES
XF821A
XCL8010A
CONTROLLER MODULE
XS821-22
XSU821-22
LonWorks or Panel Bus
Fig. 3 Overview of I/O modules
XFLR822A
XFL822AXFL823A
XFR822A
XF822AXF823A
S823
SU823
XFLR824A
FL824A
FR824A
F824A
S824-25
SU824-25
FR825A
XF830A, XFU830A
PANEL BUS I/O MODULES
5 EN1B-0375GE51 R0709
System Overview Excel 800
I/O Module Overview
Panel Bus
module
LONWORKS
Bus module
Description Inputs OutputsManual controls LEDs 1)
XF821 XFL821 Analog input module 8 – – –
XF822 XFL822 Analog output module – 8 – 8 status LEDs
XFR822 XFLR822 Analog output module – 8 8 Manual overrides 8 status LEDs
Module allows disconnection
of individual I/O signals.
Module allows disconnecttion
of individual I/O signal. For
24 V applications, only.
Two groups of seven
For all pluggable Excel
800 I/O modules.
internally-connected push-in
terminals, for distributing
signals/power (see also Fig.
94).
Two groups of nine internallyconnected push-in terminals,
for distributing signals/power
(see also Fig. 96).
XF830A and XFU830A,
only.
Two groups of four pairs of
push-in terminals, for
converting 0…20 mA signals
into 0…10 Vdc signals, and
one push-in ground terminal
per group (see also Fig. 98).
Connects three relay
…824
…825
commons, required in case of
line voltage and low voltage in
the same I/O module.
Table 5 Auxiliary parts
Spare Parts
Module Type Figure
Cross connectors, long
(red)
XS815
Connector bridge XS816
Swivel label holder XAL10
Swivel label holder XAL11
Table 6 Spare parts
Corresponding
I/O modules XF…
…824
…825
All Excel 800 I/O modules
Information
Connects six relay commons.
Connects XCL8010 and I/O
modules.
For all pluggable Excel
800 I/O modules
XF830A and XFU830A,
only
Can be plugged into socket,
for attaching label generated
by CARE.
Can be plugged into module,
for attaching label generated
by CARE.
7 EN1B-0375GE51 R0709
System OverviewExcel 800
Interfaces and Bus Connections
The Excel 800 System can be connected to the following
devices and systems:
Panel Bus
• For communication with up to 16 Panel Bus I/O modules
• Polarity-insensitive
L
ONWORKS Bus
• For communication with other LONWORKS Bus devices
within the building
• FTT10, link power compatible
• Polarity-insensitive
C-Bus
• For communication with other controllers, e.g., existing
Excel 500 Controllers
HMI
• For connecting an operator interface, e.g., XI582,
XI882A, or a laptop, e.g., for CARE
Modem
• For connecting a modem or an ISDN terminal adapter
Technical Data
System Data
Operating voltage 24 VAC, ± 20%, 21 … 30 VDC
Max. number of C-Bus
participants
Power consumption
30
Max. 3.57 A
(1 XCL8010 Controller
+ 16 I/O modules)
Standards
Protection class IP20
Product standard EMC EN 60730-2-9
Testing electrical
components
Certification CE
System transformer
Low-Voltage Device
Safety Assessment
Table 8 Standards
IEC68
The system transformer(s) must
be safety isolating transformers
according to IEC 61558-2-6.
In the U.S.A. and Canada, NEC
Class 2 transformers must be
used.
EN 60730-1
EN 60730-2-9
Operational Environment
Ambient operating
temperature
Ambient operating
humidity
Ambient storage
temperature
Ambient storage
humidity
Vibration under
operation
Dust, vibration According to EN60730-1
RFI, EMI Home environment
Table 9 Operational environment
0 … 50 °C (32 … 122 °F)
5 … 93% relative humidity
(non-condensing)
–20 … 70 °C (–4 … +158 °F)
5 … 95% relative humidity
(non-condensing)
0.024” double amplitude
(2 … 30 Hz),
0.6 g (30 … 300 Hz)
Push-in terminals 1.5 mm2
Screw-type terminals 1.5 mm2
Overvoltage protection
Calculated lifetime of
weakest component
under typical operating
conditions
Table 7 System data
EN1B-0375GE51 R0709
All inputs and outputs are
protected against 24 VAC and
40 VDC overvoltage as well as
against short-circuiting.
MTBF
≥ 13.7 years
8
Excel 800 Planning
Planning
Overview
Engineering with CARE
During CARE engineering, the type of I/O modules, terminal
assignment and module configuration are defined
depending on the application.
Planning
In this step, the following has to be defined, if applicable:
• Power supply
• Fusing
• Earth grounding
• Lightning protection
• Panel Bus wiring
• Design of a L
• Design of a C-Bus network
• Useful accessories
• Cable selection
ONWORKS network
Transformer Selection
Note
In Europe the system transformer(s) must be safety isolating
transformers according to IEC61558-2-6.
In the U.S.A. and Canada, NEC Class-2 transformers must
be used.
Power Consumption
When selecting the appropriate transformer, take into
account the number of individual modules, accessories, and
field devices in determining the total power consumption.
Devices powered
XCL8010 with XI582
(backlight ON) and with
watchdog load (max. 500 mA)
XCL8010 with XI582
(backlight ON) but without
watchdog load
Power consumption
24 VAC 24 VDC
690 mA 640 mA
190 mA 140 mA
…821 130 mA 80mA
…822 160 mA 90 mA
…823 180 mA 130 mA
…824 140 mA 90 mA
…825 140 mA 90 mA
XF830A 200 mA 95 mA
XFU830A 200 mA 95 mA
Table 10 Power consumption of Excel 800 System
components depending on power supply
Connectable Power Supplies
Honeywell CRT Series (Europe)
Transformer Primary side Secondary side
CRT 2 220/230 VAC 24 VAC, 50 VA, 2 A
CRT 6 220/230 VAC 24 VAC, 150 VA, 6 A
CRT 12 220/230 VAC 24 VAC, 300 VA, 12 A
Table 11 Honeywell CRT series transformers data
9 EN1B-0375GE51 R0709
Planning Excel 800
Honeywell 1450 Series (North America)
• 50/60 Hz
• Insulated accessory outputs
• Built-in fuses
• Line transient /surge protection
• AC convenience outlet
• NEC Class-2
Part number
1450 7287
-001 120 VAC 24 VAC, 50 VA
-002 120 VAC
-003 120 VAC
-004 240/220 VAC 24 VAC, 50 VA
-005 240/220 VAC
-006 240/220 VAC
Table 12 Honeywell 1450 series transformers data
Standard Transformers (Europe, North America)
Standard commercially available transformers used to
supply power to Excel 800 Systems must fulfill the following
specifications:
Output voltage Impedance AC current
Primary side Secondary side
2 x 24 VAC, 40 VA,
and 100 VA from separate
transformer
24 VAC, 100 VA,
and 24 VDC; 600 mA
2 x 24 VAC, 40 VA,
and 100 VA from separate
transformer
24 VAC, 100 VA, and
24 VDC, 600 mA
Power Supply of Field Devices
Depending upon the power consumption of the field devices
used, it is possible to use either a single transformer to
power both the XCL8010 Controller and attached field
devices, or it may be necessary to employ an additional
transformer. See also section "Field Device Cables" on
page 13 and connection examples on page 29.
Fusing Specifications
For connection examples see description of the I/O modules
on page 39 and following.
F1 (Fusing for XCL8010 Controller and I/O Modules)
Rating: 4 A, time-lag fuse (slo-blo)
For example:
Manufacturer: Littlefuse
Type: 218004
F2 (Fusing for Active Field Devices)
Depends upon loads in use.
System Protective Earth Grounding
Excel 800 Systems comply with SELV (Safety Extra-Low
Voltage). Earth grounding is therefore not recommended.
However, if compliance with EN60204-1 is required, see
Appendix 1.
Lightning Protection
24.5 VAC to 25.5 VAC
24.5 VAC to 25.5 VAC
24.5 VAC to 25.5 VAC
Table 13 Requirements for standard transformers
RIN-APU24 Uninterruptable Power Supply
The RIN-APU24 Uninterruptable Power Supply can be wired
to power Excel 800 Systems.
See also RIN-APU24 Uninterruptable Power Supply –
Mounting Instructions (MU1B-0258GE51) for detailed wiring
diagrams.
EN1B-0375GE51 R0709
≤ 1.15 Ω
≤ 0.40 Ω
≤ 0.17 Ω
max. 2 A
max. 6 A
max. 12 A
Please contact your local Honeywell representative for
information on lightning protection.
Panel Bus Topologies
• Up to 16 Panel Bus I/O modules can be controlled by a
single XCL8010 Controller.
• Panel Bus I/O modules must be addressed using the
HEX switch.
• Maximum distance between controller and Panel Bus
I/O module: 40 m.
• No bus termination
• Polarity-insensitive
10
Excel 800 Planning
LONWORKS Bus Topologies
The LONWORKS Bus is a 78-kilobit serial link that uses
transformer isolation so that the bus wiring does not have a
polarity. I.e. it is not important which of the two LONWORKS
Bus terminals are connected to each wire of the twisted pair.
The L
ONWORKS Bus does not need to be shielded on the
controller module side.
The LONWORKS Bus can be wired in daisy chain, star, loop
or any combination thereof as long as the maximum wire
length requirements are met.
Configuration
The recommended configuration is a daisy chain with two
bus terminations. This layout allows for max. L
ONWORKS
Bus lengths, and its simple structure presents the least
number of possible problems, particularly when adding on to
an existing bus.
See also “L
ONWORKS Mechanisms”, Product Literature no.:
EN0B-0270GE51.
C-Bus Topologies
Accessories
Besides the auxiliary parts of Table 5 on page 7, the
following accessories are available.
Preconfigured Connection Cables
Type
XW882 XI582 Operator Interface
XW582
+ XW586
XW884
XW885 Laptops
XW585
+ XW586
XW586 Modems
Connecting XCL8010
Controller with
XI582 Operator Interface
Adapter cable for Excel
500/600 Controllers
Laptops
Features
5 m, shielded,
RJ45 plug with clip
See XW582 and
XW586
0.2 m, shielded,
RJ45 – 9 pin sub-D
3 m, shielded,
RJ45 plug with clip
See XW582 and
XW586
1.8 m, RJ45 – 9 pin
sub-D
Via the C-Bus up to 30 C-Bus devices (e.g., controllers, etc.)
can communicate with one another and a PC central. The
C-Bus must be connected via the individual controllers
(open ring).
Note
Star connection is not allowed because uncontrollable line
reflections may occur.
Instead of an Excel 800 Controllers, other C-Bus controllers
(e.g., the Excel 500, Excel 100, Excel 50) can also be
connected.
Fig. 4 C-Bus topology Excel 5000
Table 14 Preconfigured connection cables
XW882 Cable Details
RJ45 plug with clip at front
12
SHIELD
3678
4
5
+5V
XW882
Fig. 5 XCL8010/XI582 cable details
XW884 Cable Details
RJ45 plug with clip at front
12
SHIELD
3678
4
5
+5V
LOOSE
ENDS
R
G
L
E
Y
R
B
G
R
W
H
sub-D female
R
x
R
T
T
x
G
N
XI582
WIRING
TERMINALS
A
Y
n
(
d
e
)
s
u
t
o
W
O
L
T
D
x
W
O
E
V
+
5
N
R
N
E
E
D
x
N
G
D
E
T
I
RS232 plug
1
D
S
D
D
2
3
4
5
1
2
3
4
6
7
8
9
XW884
Fig. 6 XCL8010/Excel 500/600 cable details
11 EN1B-0375GE51 R0709
Planning Excel 800
XW885 Cable Details
RJ45 plug with clip at front
12
SHIELD
3678
4
5
+5V
XW885
Fig. 7 XCL8010/laptop cable details
XW582 Cable Details
to XC5010C
1
6
2
7
3
8
4
9
5
SHIELD
XW582
Fig. 8 XW582 cable details
XW585 Cable Details
RS232 plug
sub-D female
1
6
2
7
+5V
3
8
4
9
5
SHIELD
RS232 plug
sub-D female
x
R
R
T
T
x
N
G
LOOSE
ENDS
TERMINALS
O
L
L
E
Y
W
O
R
B
G
E
E
R
W
T
I
H
RS232 plug
sub-D female
R
x
R
T
T
x
N
G
D
S
D
D
W
N
N
E
D
S
D
D
XI582
WIRING
D
x
T
E
V
+
5
R
D
x
D
N
G
LONWORKS Bus Termination Modules
Type Description
1
209541 LONWORKS Bus termination module
6
2
7
3
8
4
5
9
XAL-Term
L
ONWORKS connection and
termination module, which can be
mounted on DIN rails and in fuse
boxes
Table 15 LONWORKS Bus termination modules
Cable Specifications
Power Supply Cables
When checking the length of the power supply cable, the
1
2
3
4
1
2
3
4
5
connection cables to all I/O modules must be taken into
account.
Max. length 3 m (per side of the controller),
see Fig. 33 on page 25
Cross section
min. 0.75 mm
2
(AWG 18)
Table 16 Power supply cables specification
Panel Bus Cables
Max. length
6
7
Cable type
8
9
Table 17 Panel Bus cables specification
40 m
twisted pair, e.g., J-Y-Y 2 x 2 x 0.8
XW585
Fig. 9 XW585 cable details
XW586 Cable Details
RJ45 plug with clip at front
12
SHIELD
3678
4
5
+5V
RS232 plug
sub-D male
D
C
D
R
S
D
D
x
R
S
R
T
D
x
T
S
T
C
D
R
T
G
D
N
1
2
3
4
5
XW586
Fig. 10 XW586 cable details
EN1B-0375GE51 R0709
6
7
8
9
12
Excel 800 Planning
LONWORKS Bus Cables
Cable type Max. bus length
Belden 85102 (plenum) 2700 m (8900 ft)
Belden 8471 (non-plenum) 2700 m (8900 ft)
Level IV, 22 AWG 1400 m (4600 ft)
JY (St) Y 2 x 2 x 0.8 900 m (3000 ft)
TIA568A Cat. 5 24AWG, twisted pair 900 m (3000 ft)
Table 18 Doubly-terminated bus specifications
Notes
• The cable types listed above are as recommended by
Echelon in their FTT-10A User Guide.
• The cable recommended by Honeywell is the level IV,
22 AWG, solid core, non-shielded cable.
• Belden part numbers are 9H2201504 (plenum) and
9D220150 (non-plenum).
FTT Specification
The FTT specification includes two components that must
be met for proper system operation:
• The distance from each transceiver to all other
transceivers and to the termination must not exceed the
max. node-to-node distance.
• If multiple paths exist, the maximum total wire length is
the total amount of wire used.
Cable type
Max. node-tonode distance
Max. total wire
length
Note
In the event that the limit on the total wire length is
exceeded, the FTT physical layer repeaters (FTT 10A) can
be added to interconnect segments. This increases the
overall length by an amount equal to the original
specification for that cable type and bus type for each
repeater used.
For example, adding repeaters for a doubly-terminated bus
using JY (St) Y 2 x 2 x 0.8 cable increases the maximum
length 900 m (3000 ft) for each repeater.
Field Device Cables
Cross-sectional area
Type of signal
24 VAC power
0…10 V signals 0.081 – 2.08 mm2 (28 – 14 AWG)
Table 20 Cable sizing for connection of field devices
For wiring field devices see page 29.
≤ 100 m (300 ft)
(Fig. 40 on p. 29)
one transformer
1.5 mm2
(16 AWG)
≤ 400 m (1300 ft)
(Fig. 41 on p. 29)
separate
transformers
not allowed for
> 100 m (300 ft)
Belden 85102 500 m (1650 ft) 500 m (1650 ft)
Belden 8471 400 m (1300 ft) 500 m (1650 ft)
Level IV, 22AWG 400 m (1300 ft) 500 m (1650 ft)
JY (St) Y 2 x 2 x 0.8 320 m (1050 ft) 500 m (1650 ft)
D = XS831 Aux. Terminal Package (optional)A, B, and C = XS830 Aux. Terminal Packages (optional)
Fig. 13 Mixed Excel 800 I/O Modules (example shows XF830A with four auxiliary terminal packages), dimensions (in mm)
External
COM a
40
24V
COM b
IN3
IN1 IN2
IN4
36 37 38 39 40
29 30 31 32 33 34
29 30 31 32 33 34
B
B1 B2B3B4
D
24V~
24V~0
IN5 IN6
DO
B5 B6 B7 B8 B9
76
77
78
Honeywell
!
110
69
28
15
SWIVEL LABEL HOLDER
51.5
92.5
38
SCREW-TYPE TERMINALS
(XFU830A)
45
EN1B-0375GE51 R0709
16
Excel 800 Mounting/Dismounting Modules
A
A
Mounting/Dismounting Modules
WARNING
Risk of electric shock or equipment damage!
► Do not touch any live parts in the cabinet.
► Disconnect the power supply before you start to install
the Excel 800 System.
More than one disconnect switch may be required to deenergize the system.
►Do not reconnect the power supply until you have
completed the installation.
Note
The terminal socket of each pluggable I/O module can be
mounted and wired before inserting and locking the
corresponding electronic module.
12
71 COM a
72 COM b
73 24V
~
74 24V 0
~
C-BUS RESET
9.6k all
76k
76k
C-Bus
S1 S2
PC/HMI
Modem
Panel
mid
LON
end
I/O Bus
Rx Tx
LON
8765 4 32 18765 4 32 1
111
12285
13396
14410 7
C-Bus
C-Bus
LON
out
in
4
S1 S2
71 COM a
5
4
3
6
2
7
1
8
0
9
F
A
72 COM b
E
B
D
C
73 24V
~
74 24V 0
~
1
2
AAA
21
31
11
22
32
12
23
33
13
144424543464 25
Fig. 14 XCL8010
mounted on multiple DIN rails
1:ABCDFERTAQWESDERT1
2:ABCDFERTAQWESDERT2
3:ABCDFERTAQWESDERT3
4:ABCDFERTAQWESDERT4
5:ABCDFERTAQWESDERT5
PRESS
COM a
6:ABCDFERTAQWESDERT6
COM b
7:ABCDFERTAQWESDERT7
8:ABCDFERTAQWESDERT8
24V
~
24V 0
~
PRESS
Honeywell
!
8765 4 32 1
Power/
Alarm
5678
1234
21
22 12345678
AUX
GNDGND
9
10 11 12 13 14 15 16 17 18 25 26
5
PRESS
3
41
51
42
52
43
53
Controller Module and I/O modules
PRESS
Honeywell
1234
0
100
AUTO
AAAAA
!
21
22 12345678
616261
62
AUX
6363
GNDGND
9
10 11 12 13 14 15 16 17 18 25 26
S1 S2
5
4
3
6
2
7
1
8
0
9
F
A
E
B
D
C
5678
Honeywell
!
AI/AOV
PRESS
Honeywell
0
AUTO
A
!
AI/AOV
1:ABCDFERTAQWESDERT1
2:ABCDFERTAQWESDERT2
3:ABCDFERTAQWESDERT3
4:ABCDFERTAQWESDERT4
5:ABCDFERTAQWESDERT5
6:ABCDFERTAQWESDERT6
7:ABCDFERTAQWESDERT7
8:ABCDFERTAQWESDERT8
5 6 7 8 9 10
1 234
123456789101112
BI
GND
13 14 15 16 17 18 19 20 21 22 23 24 25 26
S1 S2
PRESS
1234
100
21
31
11
22
32
12
23
33
13
144424543464 25
6
Honeywell
11 12
!
5
4
3
6
2
7
1
8
0
9
F
A
E
B
D
C
Honeywell
56
--1
--0
--AUTO
!
41
51
616261
42
52
62
43
53
6363
Mounting/Dismounting Controller/Sockets
Mounting Sockets
Notes
• When using both Panel Bus and LONWORKS Bus I/O
modules in an Excel 800 System, group both Panel Bus
modules (light-gray) and LONWORKS Bus I/O modules
(dark-gray), e.g., on different rails.
• Up to 10 Panel Bus I/O modules can be mounted to one
side of the controller. In total, up to 16 Panel Bus
I/O modules can be mounted to one controller.
• The XCL8010 Controller Module and the mixed Panel
Bus I/O modules are mounted on the DIN rail in the same
way as a terminal socket.
3
Fig. 15 Max. number of Panel Bus I/O modules
Fig. 16 Max. number of L
power supply via XCL8010
ONWORKS Bus I/O modules with
Legend
1 XCL8010 Controller Module
2 Swivel label holder
3 Cable connection
4 Stopper (from 3
rd
-party supplier)
5 Bridge connectors
6 Auxiliary terminal packages
17 EN1B-0375GE51 R0709
Mounting/Dismounting ModulesExcel 800
►Angle the terminal socket at the upper edge of the DIN
rail until it snaps in.
►Swing the terminal socket down and apply gentle force
until it snaps into position with an audible "click".
►Position controller module and terminal sockets flush with
one another along the rail.
►If desired, mount stoppers at the ends of the rail to
prevent sliding.
Connecting Sockets
Controller, terminal sockets, and mixed I/O modules on the
same DIN rail can be connected mechanically and
electrically with bridge connectors.
Controller and terminal sockets on different DIN rails must
be connected using cables, see Fig. 14 and page 24.
NOTICE
Risk of malfunction!
►Wire Panel Bus I/O modules and LONWORKS Bus
I/O modules separately.
►When using both Panel Bus and LONWORKS Bus
I/O modules in an Excel 800 System, L
I/O modules must be connected to the controller via
LON terminals 11 … 14.
Position the bridge connector on terminals 71 … 74 of the
right-hand terminal socket or mixed I/O module or controller
and on terminals 75 … 78 of the left-hand terminal socket or
mixed I/O module or controller. Then press the bridge
connector down.
ONWORKS Bus
Fig. 17 Mounting terminal sockets
Note
Take care to not bend the Omega clamp, which serves to
establish the electrical contact with the DIN rail and which
located on the back of the terminal socket.
Fig. 18 Connecting terminal sockets with bridge
connector
Notes
• Bridge connectors transmit both communication signals
and power supply between modules.
• Removing bridge connectors will interrupt the trans-
mission of both communication signals and power supply
between the modules.
EN1B-0375GE51 R0709
18
Excel 800 Mounting/Dismounting Modules
Dismounting Sockets
Disconnecting Sockets
Release all bridge connectors before removing the controller
module and/or the terminal sockets and/or mixed I/O
modules from the DIN rail.
►Press down at the same time both the gray side wings
next to the red button and then pull the bridge connector
out of the module.
Fig. 19 Releasing bridge connectors
Mounting/Dismounting Electronic Modules
Mounting Electronic Modules
Note
Electronic modules can be removed from or inserted into the
sockets without switching off the power supply. The
behavior of connected field devices must be taken into
consideration.
►Make sure that terminal socket and electronic I/O module
match, see Table 4 on page 6.
►Make sure that the red locking mechanism is in the open,
i.e., left, position.
►Gently push the electronic module onto the terminal
►Insert a screwdriver into the latch on the underside of the
module and lever the red latch 2–3 mm downwards. The
module can then be swung away from the rail.
Fig. 20 Releasing latch
Fig. 21 Inserting the electronic module
► Lock the red locking mechanism by sliding it to the right.
Fig. 22 Locking the electronic module
Note
The red locking mechanism will not close if the electronic
module is not properly mounted.
19 EN1B-0375GE51 R0709
Mounting/Dismounting ModulesExcel 800
Dismounting Electronic Modules
Note
Electronic modules can be removed from or inserted into the
sockets without switching off the power supply. The
behavior of connected field devices must be taken into
consideration.
►Open the red locking mechanism by sliding it to the left
and then gently pull the electronic module out of the
terminal socket.
Fig. 23 Dismounting the electronic module
Mounting/Dismounting Manual Disconnect
Modules
XS812 and XS812RO Manual Disconnect Modules are
mounted on the terminal socket appropriate for the
electronic module, see Table 4 on page 6. The electronic
module is mounted onto the manual disconnect module.
WARNING
Risk of electric shock or equipment damage!
The XS812RO Manual Disconnect Module is designed
for 24 V applications only!
►Never use the XS812RO Manual Disconnect Module with
line voltage.
Mounting Manual Disconnect Modules
►Make sure that manual disconnect module, electronic
module, and terminal socket match, see Table 4 on
page 6.
►Make sure that the red locking mechanism is in the open,
i.e., left, position.
►Gently push the manual disconnect module onto the
terminal socket until snug.
►Lock the red locking mechanism by sliding it to the right.
EN1B-0375GE51 R0709
Fig. 24 Mounting the manual disconnect modules
20
Excel 800 Mounting/Dismounting Modules
Operating the Individual Switches
►Use a screwdriver to open/close the appropriate
disconnector switches of the manual disconnect
modules.
Fig. 25 Operating the disconnector switches
Dismounting Manual Disconnect Modules
►Open the red lock mechanism by sliding it to the left and
then gently pull the electronic module out of the terminal
socket.
Mounting/Dismounting Auxiliary Terminal
Packages
The XS814 Auxiliary Terminal Package can be mounted on
any pluggable I/O module.
The XS830 and XS831 Auxiliary Terminal Packages are
suitable for mixed I/O modules, only. Specifically, they can
be mounted on the top and/or bottom of the XF830A and on
the bottom of the XFU830A.
For reasons of mechanical stability, a maximum of two rows
of Auxiliary Terminal Packages may be mounted together
on any given I/O module.
Mounting Auxiliary Terminal Packages
►Push the auxiliary terminal package onto the grooves of
the corresponding terminal socket / the mixed I/O
module.
Fig. 26 Mounting the auxiliary terminal package onto the
terminal socket / mixed I/O module
Dismounting Auxiliary Terminal Packages
►Push down the catch of the auxiliary terminal package
and pull it out of the grooves of the terminal socket / the
mixed I/O module.
Fig. 27 Dismounting the auxiliary terminal package from
the terminal socket / the mixed I/O module
21 EN1B-0375GE51 R0709
Mounting/Dismounting ModulesExcel 800
Mounting/Dismounting Cross Connectors
Note
The long cross connector (incl. in the scope of the delivery)
can be mounted to the XS824-25 or XSU824-25, as
required (see Fig. 29). It can be dismounted (see Fig. 28)
and, if desired, replaced with one or two short connectors
(optional accessory, see Table 5 on page 7). It is not
permitted to replace these cross connectors with wire.
►Insert a screwdriver on one end of the cross connector
and swivel it to the right and to the left.
►Insert a screwdriver on the other end of the cross
connecter and swivel it to the right and to left until the
cross connector is released.
►If desired, insert another cross connector.
Mounting/Dismounting Swivel Label
Holders
Note
A swivel label holder is included in the scope of delivery of
each module.
Use only the (short / long) swivel label holders appropriate
for the given type (pluggable or mixed, respectively) of I/O
module.
Mounting Swivel Label Holders
►Snap the swivel label holder onto the hinges of the
terminal socket / mixed I/O module.
►Apply self-adhesive labels to the holders.
Fig. 28 Dismounting the cross connectors (long cross
connector shown here)
Fig. 29 Mounting the cross connectors (short cross
connector shown here)
Fig. 30 Mounting the swivel label holder
Dismounting Swivel Label Holders
►Press the hinges together and remove the swivel label
holder.
EN1B-0375GE51 R0709
22
Excel 800 Wiring and Setting Up the System
Wiring and Setting Up the System
General Safety Considerations
• When connecting the XCL8010 Controller Module or
Excel 800 I/O modules, both VDE, National Electric Code
(NEC) or equivalent, and any local regulations concerning grounding and zero voltage must be observed.
• Electrical work should be carried out by a qualified
electrician.
• The electrical connections must be made at the terminal
blocks. The corresponding connection diagrams are
located on the individual controller module and
I/O modules.
• For Europe only: To comply with CE requirements,
devices with a voltage in the range of 50 ... 1000 VAC or
75 ... 1500 VDC, which are not provided with a supply
cord and plug or with other means for disconnection from
the supply having a contact separation of at least 3 mm
in all poles, must have the means for disconnection
incorporated in the fixed wiring.
WARNING
Risk of electric shock or equipment damage!
► Do not touch any live parts in the cabinet.
► Disconnect the power supply before making connections
to or removing connections from terminals of controller or
I/O modules.
► Do not use spare terminals as wiring support points.
► Do not reconnect the power supply until you have
completed the installation.
►Observe precautions for handling electrostatic sensitive
devices.
Wiring Terminals
Wiring Push-In Terminals
The terminal sockets of the pluggable I/O modules are
available in versions (XF82…) featuring convenient push-in
terminals for easy wiring. Of the mixed I/O modules, the
XF830A likewise features push-in terminals.
For correct wiring, cables must fulfill the following
specifications according to IEC664-1 / VDE 0110 (4.97):
Max. plug gauge
Solid conductor H05/07) V-U
Stranded conductor H05(07) V-K
Stranded conductor with wire end
ferrules (without plastic collar)
Stripping length
Table 22 Push-in terminals wiring specifications
0.14 … 1.50 mm
0.25 … 1.50 mm
0.25 … 1.50 mm
0.25 ... 1.50 mm
8.0 +1.0 mm
Wiring Screw-Type Terminals
The terminal sockets of the pluggable I/O modules are
available in versions (XFU82…) featuring screw-type
terminals. The mixed I/O modules are likewise available in a
version (the XFU830A) featuring screw-type terminals.
For correct wiring, cables must fulfill the following
specifications according to IEC664-1 / VDE 0110 (4.97):
Max. plug gauge
Solid conductor H05/07) V-U
Stranded conductor H05(07) V-K
Stranded conductor with wire end
ferrules (without plastic collar)
The Excel 800 System can be powered by one or more
external transformers.
Note
The maximum length for the power supply cable from a
transformer is 3 m. This also includes the length of the
modules and the connection cables between the rails.
Referring to Fig. 31 the following conditions must be fulfilled:
A + B ≤ 3 m and A + C ≤ 3 m
Single or the First Transformer
►Connect the transformer to terminals 1 and 2 of the
XCL8010
Fig. 31 Wiring power supply from the (first) transformer to
Controller.
I/OI/OI/O
CPU
21
BC
A + B 3 m
AND
A + C 3 m
the controller module
A
Additional Transformer
►Connect the additional transformer in a second room or
cabinet to terminals 73 and 74 or 77 and 78 of an
I/O module.
TRANS-
FORMER 2
Fig. 32 Wiring the power supply from a second
71
72
73
74
MAX. 3 m
transformer
NOTICE
Equipment damage!
►Do not use bridge connectors to connect modules
powered by different transformers.
►When connecting modules powered by different
transformers using cables, be sure to not connect
terminals 73 and 77.
I/OI/O
EN1B-0375GE51 R0709
24
Excel 800 Wiring and Setting Up the System
Connecting Single Bus Controller Systems
This section describes how to connect a controller system
which uses Panel Bus I/O modules, only or LBus I/O modules, only.
Controller and I/O Modules on a Single Rail
►Connect controller and I/O modules using the bridge
connectors.
This provides power supply and communication connection.
No further wiring is necessary.
Controller and I/O Modules on Several Rails in a
Single Cabinet
The rails of a controller system are connected in series.
►Connect the rail ends as follows:
– Power supply
via power supply terminals 73, 74 or 77, 78
– Communication
via communication terminals 71, 72 or 75, 76
71
72
I/O
73
74
I/O
ONWORKS
Panel Bus I/O Modules in Separate Rooms
In this scenario, communication and reference voltage
(24 V0) must be connected between the rooms.
►Connect the last module of room 1 to the first module of
room 2:
– Reference voltage
via power supply terminals 74 or 78
terminals 73 and 77 must not be connected
– Communication
via communication terminals 71, 72 or 75, 76
75
CPU
PANEL
I/O
1 2
71
PANEL
I/O
PANEL
I/O
74
Fig. 34 Wiring the Panel Bus I/O modules in separate
rooms
767778
757672777378
24 V0
MAX. 40 m
I/OI/O
I/O
75
76
77
78
75
76
77
78
71
72
I/O
73
74
71
72
I/O
73
74
71
72
I/O
73
74
CPU
1 2
I/O
Fig. 33 Wiring the power supply and the communication
lines to the I/O modules
Maximum Power Cable Length
The maximum length for power supply cable per side is 3 m.
This also includes the connection cables between the rails,
the lengths of the modules, and the cable from the
transformer.
Maximum Cable Length
The maximum cable length for connecting room 1 and
room 2 is 40 m.
25 EN1B-0375GE51 R0709
Wiring and Setting Up the SystemExcel 800
LonWorks Bus I/O Modules in Separate Rooms
In this scenario, only communication lines must be
connected between the rooms.
►Connect the last module of room 1 to the first module of
room 2:
– via communication terminals 71, 72 or 75, 76
75
CPU
1 2
71
LonWorks
I/O
74
Fig. 35 Wiring the LONWORKS Bus I/O modules in
separate rooms
LonWorks
I/O
LonWorks
I/O
767778
757672777378
Connecting Panel Bus and LONWORKS Bus
Mixed Controller Systems
Connecting I/O Modules with Each Other
For connecting the I/O modules with each other, proceed as
described for single bus controller systems on page 24.
Connecting I/O Modules to the Controller
Panel Bus I/O Modules
►Connect communication terminals 71 …74 or 75… 78 of
Panel Bus I/O modules to communication terminals
71 …74 or 75… 78 of the controller module using either
– Bridge connectors
for flush mounting on a single DIN rail or
– Cables
for separate mounting,
e.g., on multiple rails, separate cabinets, etc.
L
ONWORKS Bus I/O Modules
►Connect communication terminals 71 … 74 or 75 … 78 of
L
ONWORKS Bus I/O modules to LONWORKS terminals
11 … 14 of the controller module using cables.
Maximum Cable Length
For maximum cable lengths and cable specifications of the
communication lines, see Table 18 and Table 19 on
page 13.
EN1B-0375GE51 R0709
26
Excel 800 Wiring and Setting Up the System
Fig. 36 Mixed bus system – correct wiring
Fig. 37 Mixed bus system – incorrect wiring
27 EN1B-0375GE51 R0709
Wiring and Setting Up the SystemExcel 800
Setting Address of Panel Bus I/O Modules
During CARE engineering, each Panel Bus I/O module is
assigned its own unique address. For the sake of clarity for
maintenance personnel, it is recommended that you
address the Panel Bus I/O modules in ascending order
0 through F.
Hex switch
Address
Hex switch
Address
Table 24 HEX switch settings and addresses
►Use the rotary HEX switch to set the address to the one
already defined during CARE engineering.
0 1 2 3 4 5 6 7
01 02 03 04 05 06 07 08
8 9 A B C D E F
09 10 11 12 13 14 15 16
4
4
LOCK
Setting I/O Bus Switch
►Set the I/O Bus switch S2 of the XCL8010Controller
Module depending on the modules connected to
terminals 71 … 78 and the desired communication as
follows:
Communication S2 setting Terminals
LONWORKS Bus
only
Panel Bus and
L
ONWORKS Bus
Table 25 I/O Bus switch settings
LON 71 … 74 L
75 … 78
11 … 14
ONWORKS Bus
LONWORKS Bus
LONWORKS Bus
Panel 71 … 74 Panel Bus
75 … 78 Panel Bus
11 … 14 L
ONWORKS Bus
Fig. 38 HEX switch location
Notes
If the HEX switch is changed, the Panel Bus I/O module
•
will revert to its default configuration.
•
With LONWORKS Bus I/O modules, the HEX switch is
without function.
Fig. 39 S2 I/O Bus switch
EN1B-0375GE51 R0709
28
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