Honeywell EXCEL 800 INSTALLATION AND COMMISSIONING INSTRUCTIONS

HONEYWELL EXCEL 5000 OPEN SYSTEM
INSTALLATION AND COMMISSIONING INSTRUCTIONS
CONTENTS
General Safety Information............................................ 3
Safety Information as per EN60730-1............................ 3
Excel 800
SYSTEM
Connecting via LONWORKS Bus.................................... 31
Connecting via C-Bus .................................................. 32
Connecting HMIs or Laptops ....................................... 32
Connecting Modems .................................................... 32
System Architecture....................................................... 4
I/O Modules ................................................................... 5
Interfaces and Bus Connections .................................... 8
Technical Data............................................................... 8
Overview........................................................................ 9
Transformer Selection ................................................... 9
Fusing Specifications................................................... 10
System Protective Earth Grounding............................. 10
Lightning Protection ..................................................... 10
Panel Bus Topologies.................................................. 10
LONWORKS Bus Topologies.......................................... 11
C-Bus Topologies ........................................................ 11
Accessories ................................................................. 11
Cable Specifications .................................................... 12
Dimensions .................................................................. 15
Mounting/Dismounting Controller/Sockets ................... 17
Mounting/Dismounting Electronic Modules .................. 19
Mounting/Dismounting Manual Disconnect Modules ... 20 Mounting/Dismounting Auxiliary Terminal Packages ... 21
Mounting/Dismounting Cross Connectors.................... 22
Mounting/Dismounting Swivel Label Holders............... 22
General Safety Considerations .................................... 23
Wiring Terminals.......................................................... 23
Connecting Power Supply............................................ 24
Connecting Single Bus Controller Systems ................. 25
Connecting Panel Bus and LONWORKS Bus Mixed
Controller Systems ...................................................... 26
Setting Address of Panel Bus I/O Modules .................. 28
Setting I/O Bus Switch ................................................. 28
Connecting Field Devices ............................................ 29
Commissioning I/O Modules ........................................ 30
Updating Software ....................................................... 30
Overview...................................................................... 33
Features....................................................................... 34
Common Features ....................................................... 39
Analog Input Modules .................................................. 39
Analog Output Modules ............................................... 44
Binary Input Modules ................................................... 49
Relay Output Modules ................................................. 52
Floating Output Module................................................ 57
Mixed Panel Bus I/O Modules...................................... 61
Manual Disconnect Modules........................................ 64
XS814 Auxiliary Terminal Package.............................. 65
XS830 Auxiliary Terminal Package.............................. 65
XS831 Auxiliary Terminal Package.............................. 65
Cross Connectors ........................................................ 66
XAL10 Swivel Label Holders........................................ 66
XAL11 Swivel Label Holders........................................ 66
XS816 Bridge Connectors ........................................... 66
Overview...................................................................... 67
XFL821 Analog Input Module ...................................... 67
XFL(R)822 Analog Output Module............................... 69
XFL823 Binary Input Module ....................................... 71
XFL(R)824 Relay Output Module................................. 72
Testing Wiring Connections ......................................... 73
Troubleshooting on the XCL8010 Controller ................ 73
I/O Modules Troubleshooting....................................... 77
Excel 800 Systems and SELV ..................................... 81
Excel 800 Systems and Standard EN60204-1............. 81
Earth Grounding of EN60204-1 Applicable Systems ... 81
Copyright © 2009 Honeywell GmbH All Rights Reserved EN1B-0375GE51 R0709
3.4
Excel 800
Approved Modems .......................................................83
Modem or ISDN Terminal Adapter Connection ............83
Modem Requirements ..................................................83
Troubleshooting............................................................83
BALCO 500 ..................................................................84
NTC 20 kΩ....................................................................85
PT 1000........................................................................86
NI1000TK5000 .............................................................88
NTC 10 kΩ....................................................................89
PT 3000........................................................................90
Trademark Information
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 XCL8010 Controller
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 Overview Excel 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
XFCxxx XFCLxxx
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
XFL822A XFL823A
XFR822A
XF822A XF823A
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 Outputs Manual 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
XF823 XFL823 Binary input module 12 12 status LEDs
XF824 XFL824 Relay output module – 6
2)
6 status LEDs
XFR824 XFLR824 Relay output module – 6 2) 6 Manual overrides 6 status LEDs
XFR825 Floating output module 3 3 Manual overrides 3 pairs of status LEDs
XF830A Mixed I/O module 20 14 18 status LEDs
XFU830A Mixed I/O module 20 14 18 status LEDs
1)
In addition to the power LED and service LED
2)
Changeover outputs
Table 3 Overview of I/O modules
Corresponding Terminal Sockets
I/O module XF…
…821
…822
…823
…824
…825
Socket Scope of delivery
XS821-22 XSU821-22
XS823 XSU823
1 terminal socket, 1 bridge connector 1 swivel label holder
1 terminal socket, 1 bridge connector 1 swivel label holder
1 terminal socket,
XS824-25 XSU824-25
1 bridge connector 1 swivel label holder 1 long cross connector
Table 4 Pluggable I/O modules and corresponding
terminal sockets
Note
In the following, the Excel 800 I/O modules (Panel Bus/L
ONWORKS Bus, with/without manual overrides) are
referred to as, e.g., …821, …822, etc.
EN1B-0375GE51 R0709 6
Excel 800 System Overview
Auxiliary Parts
Module Type Figure
Corresponding I/O modules XF…
Information
Manual disconnect modules
Auxiliary terminal packages
Cross connectors, short (yellow)
XS812
XS812RO
XS814
XS830
XS831
XS817
A1 A2 A3 A4 A5 A6 A7 A8 A9 B1 B2 B3 B4 B5 B6 B7 B8 B9
A1 B1 A2 B2 A3 B3 A4 B4 G1 G2A5 B5 A6 B6 A7 B7 A8 B8
…821
…822
…823
…824
…825
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 Overview Excel 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
0.40
0.17
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)
TIA568A Cat. 5 24AWG, twisted pair
Table 19 Free topology (singly-terminated) specifications
250 m (825 ft) 450 m (1500 ft)
NOTICE
Unpredictable reflections on the bus due to step change in line impedance characteristics!
Do not use different wire types or gauges on the same
ONWORKS network segment.
L
13 EN1B-0375GE51 R0709
Planning Excel 800
C-Bus Cables
Note
Observe national regulations for C-Bus cables!
For Europe, only shielded cable is permitted.
For the U.S., shielded or unshielded cable can be used.
Cable type Description Recommended for
J-Y-(ST)Y 2 x 2 x 0.8
A-Y-(ST)Y 2 x 2 x 0.8
AK 3702
AK 3740A shielded
Belden 9842 twisted pair Europe, US also possible
Belden 9841 shielded US
AK 3702
AK 3740A shielded
Table 21 C-Bus cable types
Maximum Cable Length
The maximum C-Bus cable length is 1200 m (4000 ft).
See section "C-Bus Topologies" on page 11.
shielded, twisted pair
shielded, twisted pair
unshielded, twisted pair
unshielded, twisted pair
Europe, inside cabinet
Europe, outside cabinet
US not approved for Europe
US (low-cost) not approved for Europe
US not approved for Europe
US (low-cost) not approved for Europe
EN1B-0375GE51 R0709
14
Excel 800 Planning
Dimensions
Controller Module
144
110
Fig. 11 Controller module, dimensions (in mm)
28
32
92.75
45
Pluggable I/O Modules
89.5 94.1
LOCK
45
83
110
67.5
30.6 28
SCREW-TYPE
TERMINALS
38
14
XS814 Aux. Terminal Package (optional)
SWIVEL LABEL HOLDER
51.5
Fig. 12 Pluggable I/O modules (shown with manual overrides), including XS814 Aux. Terminal Package, dimensions (in mm)
15 EN1B-0375GE51 R0709
Planning Excel 800
Mixed I/O Modules
216
75
71
COM a COM b
72
24V~
100
73
24V~0
74
1 12 23 34 45 56 67
Install. Instr.
DI
EN1B-0375GE51
XF830A
12 BI / 8 AI / 8 AO / 6 RO
24V, 15VA, T50
0706AX0001-XFU830A
8
Made in Germany
0532
A5 A6 A7 A8 A9
A1 A2A3A4
CLEARANCE
A1 A2 A3 A4 A5 A6 A7 A8 A9 B1 B2 B3 B4 B5 B6 B7 B8 B9
A
C
Binary Inputs
B8 B9 B10
B7
B11B12
7
8 9 10
11 12
1 2 3 4 5 6
B5 B6
B1 B2B3B4
8 9310411512
7 8 9
10 11 12 17 18 19 20
1 21 222324
2
B5 B6 B7 B8 B9
B1 B2B3B4
4
5
3
6
2
7
24V for relay 1...5
1
8
0
9
S2
F
A
E
B
C
D
J1 J2 J3 J4 J5
Analog Inputs Analog Outputs 24V Relays
AI6
AI7
18 19 20
17 13 14 15 16
AI3
GND
AI8
AO5
AO6 AO7 AO8
25
262728 35
G1 G2
21 22 23 24
AI4 41
42
AO1 AO2 AO 3 AO4 NO1 NO2 NO3 NO4 NO5 NO6
AI5
AI1 AI2
25 26 27 28 35 36 37 38 39 40
6 131415 16
41 42
A5 A6 A7 A8 A9
A1 A2A3A4
A1 B1 A2 B2 A3 B3 A4 B4 G1 G2A5 B5 A6 B6 A7 B7 A8 B8
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.
1 2
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 1 8765 4 32 1
11 1
12 285
13 396
14 410 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
14 4424 5434 64 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
GND GND
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
GND GND
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
14 4424 5434 64 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 Modules Excel 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
socket until snug.
Dismounting Controller / Terminal Sockets / Mixed I/O Modules
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 Modules Excel 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 Modules Excel 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)
0.14 … 1.50 mm
0.25 … 1.50 mm
0.25 … 1.50 mm
0.25 ... 1.50 mm
2
2
2
2
2
2
2
2
Stripping length
Table 23 Screw-type terminals wiring specifications
23 EN1B-0375GE51 R0709
11.0 +1.0 mm
Wiring and Setting Up the System Excel 800
Connecting Power Supply
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/O I/O I/O
CPU
21
B C
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 L Bus 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
PANE L
I/O
1 2
71
PANEL
I/O
PANE L
I/O
74
Fig. 34 Wiring the Panel Bus I/O modules in separate
rooms
76 77 78
75 7672 7773 78
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 System Excel 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
76 77 78
75 7672 7773 78
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 System Excel 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 XCL8010 Controller
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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