ALTUS Nexto Series User manual

User Manual
Nexto Series CPU
NX3030
MU214615 Rev. C
September 28, 2022

General Supply Conditions
No part of this document may be copied or reproduced in any form without the prior written consent of Altus Sistemas de
Automação S.A. who reserves the right to carry out alterations without prior advice.
According to current legislation in Brazil, the Consumer Defense Code, we are giving the following information to clients
who use our products, regarding personal safety and premises.
The industrial automation equipment, manufactured by Altus, is strong and reliable due to the stringent quality control
it is subjected to. However, any electronic industrial control equipment (programmable controllers, numerical commands,
etc.) can damage machines or processes controlled by them when there are defective components and/or when a programming
or installation error occurs. This can even put human lives at risk. The user should consider the possible consequences of
the defects and should provide additional external installations for safety reasons. This concern is higher when in initial
commissioning and testing.
The equipment manufactured by Altus does not directly expose the environment to hazards, since they do not issue any kind
of pollutant during their use. However, concerning the disposal of equipment, it is important to point out that built-in electronics
may contain materials which are harmful to nature when improperly discarded. Therefore, it is recommended that whenever
discarding this type of product, it should be forwarded to recycling plants, which guarantee proper waste management.
It is essential to read and understand the product documentation, such as manuals and technical characteristics before its
installation or use. The examples and figures presented in this document are solely for illustrative purposes. Due to possible
upgrades and improvements that the products may present, Altus assumes no responsibility for the use of these examples and
figures in real applications. They should only be used to assist user trainings and improve experience with the products and
their features.
Altus warrants its equipment as described in General Conditions of Supply, attached to the commercial proposals.
Altus guarantees that their equipment works in accordance with the clear instructions contained in their manuals and/or
technical characteristics, not guaranteeing the success of any particular type of application of the equipment.
Altus does not acknowledge any other guarantee, directly or implied, mainly when end customers are dealing with third-
party suppliers. The requests for additional information about the supply, equipment features and/or any other Altus services
must be made in writing form. Altus is not responsible for supplying information about its equipment without formal request.
These products can use EtherCAT® technology (www.ethercat.org).
COPYRIGHTS
Nexto, MasterTool, Grano and WebPLC are the registered trademarks of Altus Sistemas de Automação S.A.
Windows, Windows NT and Windows Vista are registered trademarks of Microsoft Corporation.
OPEN SOURCE SOFTWARE NOTICE
To obtain the source code under GPL, LGPL, MPL and other open source licenses, that is contained in this product, please
contact [email protected]. In addition to the source code, all referred license terms, warranty disclaimers and copyright
notices may be disclosed under request.
I

CONTENTS
Contents
1. Introduction ..................................................... 1
1.1. Nexto Series ............................................... 1
1.2. Innovative Features ........................................... 2
1.3. Documents Related to this Manual ................................... 3
1.4. Visual Inspection ............................................. 4
1.5. Technical Support ............................................ 4
1.6. Warning Messages Used in this Manual ................................. 5
2. Technical Description ................................................ 6
2.1. Panels and Connections ......................................... 6
2.2. General Features ............................................. 8
2.2.1. Common General Features ................................... 8
2.2.2. Memory ............................................. 10
2.2.3. Protocols ............................................. 12
2.2.4. Serial Interfaces ......................................... 12
2.2.4.1. COM 1 ........................................ 12
2.2.4.2. COM 2 ........................................ 13
2.2.5. Ethernet Interfaces ........................................ 13
2.2.5.1. NET 1 ......................................... 13
2.2.5.2. NET 2 ......................................... 14
2.2.6. Memory Card Interface ..................................... 14
2.2.7. Environmental Characteristics .................................. 15
2.3. Compatibility with Other Products ................................... 15
2.4. Performance ............................................... 15
2.4.1. Application Times ........................................ 16
2.4.2. Time for Instructions Execution ................................. 16
2.4.3. Initialization Times ....................................... 16
2.4.4. Interval Time .......................................... 16
2.5. Physical Dimensions ........................................... 16
2.6. Purchase Data .............................................. 17
2.6.1. Included Itens .......................................... 17
2.6.2. Product code ........................................... 17
2.7. Related Products ............................................. 18
3. Installation ..................................................... 20
3.1. Mechanical Installation ......................................... 20
3.2. Electrical Installation .......................................... 20
3.3. Ethernet Network Connection ...................................... 21
3.3.1. IP Address ............................................ 21
3.3.2. Gratuitous ARP ......................................... 22
II

CONTENTS
3.3.3. Network Cable Installation ................................... 22
3.4. Serial Network Connection RS-232 ................................... 23
3.4.1. RS-232C Communication .................................... 23
3.5. Serial Network Connection RS-485/422 ................................ 23
3.5.1. RS-485 Communication without termination .......................... 24
3.5.2. RS-485 Communication with Internal Termination ....................... 25
3.5.3. RS-485 Communication with External Termination ...................... 26
3.5.4. Example of Connection of a RS-485 Network with External Termination and Master Redun-
dancy ............................................... 26
3.5.5. RS-422 Communication without Termination ......................... 27
3.5.6. RS-422 Communication with Internal Termination ....................... 28
3.5.7. RS-422 Communication with External Termination ...................... 29
3.5.8. RS-422 Network Example .................................... 29
3.6. Memory Card Installation ........................................ 30
3.7. Architecture Installation ......................................... 31
3.7.1. Module Installation on the Main Backplane Rack ....................... 31
3.8. Programmer Installation ......................................... 31
4. Initial Programming ................................................. 32
4.1. Memory Organization and Access .................................... 32
4.2. Project Profiles .............................................. 34
4.2.1. Single .............................................. 34
4.2.2. Basic .............................................. 35
4.2.3. Normal ............................................. 35
4.2.4. Expert .............................................. 35
4.2.5. Custom ............................................. 36
4.2.6. Machine Profile ......................................... 36
4.2.7. General Table .......................................... 37
4.2.8. Maximum Number of Tasks ................................... 38
4.3. CPU Configuration ........................................... 38
4.4. Libraries ................................................. 39
4.5. Inserting a Protocol Instance ....................................... 40
4.5.1. MODBUS Ethernet ....................................... 40
4.6. Finding the Device ............................................ 41
4.7. Login ................................................... 43
4.8. Run Mode ................................................ 45
4.9. Stop Mode ................................................ 46
4.10. Writing and Forcing Variables ...................................... 46
4.11. Logout .................................................. 47
4.12. Project Upload .............................................. 48
4.13. CPU Operating States .......................................... 49
4.13.1. Run ............................................... 49
4.13.2. Stop ............................................... 49
4.13.3. Breakpoint ............................................ 49
4.13.4. Exception ............................................ 50
4.13.5. Reset Warm ........................................... 50
4.13.6. Reset Cold ............................................ 50
4.13.7. Reset Origen ........................................... 50
4.13.8. Reset Process Command (IEC 60870-5-104) .......................... 50
III

CONTENTS
4.14. Programs (POUs) and Global Variable Lists (GVLs) .......................... 50
4.14.1. MainPrg Program ........................................ 50
4.14.2. StartPrg Program ........................................ 51
4.14.3. UserPrg Program ........................................ 51
4.14.4. GVL System_Diagnostics .................................... 51
4.14.5. GVL Disables .......................................... 52
4.14.6. GVL IOQualities ........................................ 53
4.14.7. GVL Module_Diagnostics .................................... 53
4.14.8. GVL Qualities .......................................... 54
4.14.9. GVL ReqDiagnostics ...................................... 56
4.14.10. Prepare_Start Function ..................................... 57
4.14.11. Prepare_Stop Function ..................................... 58
4.14.12. Start_Done Function ....................................... 58
4.14.13. Stop_Done Function ....................................... 58
5. Configuration .................................................... 59
5.1. CPU Configuration ........................................... 59
5.1.1. General Parameters ....................................... 59
5.1.1.1. Hot Swap ....................................... 61
5.1.1.1.1. Hot Swap Disabled, for Declared Modules Only ............... 62
5.1.1.1.2. Hot Swap Disabled .............................. 62
5.1.1.1.3. Hot Swap Disabled, without Startup Consistency .............. 62
5.1.1.1.4. Hot Swap Enabled, with Startup Consistency for Declared Modules Only . 62
5.1.1.1.5. Hot Swap Enabled with Startup Consistency ................. 62
5.1.1.1.6. Hot Swap Enabled without Startup Consistency ............... 63
5.1.1.1.7. How to do the Hot Swap ........................... 63
5.1.1.2. Retain and Persistent Memory Areas ......................... 65
5.1.1.3. TCP Configurations .................................. 66
5.1.1.4. Project Parameters .................................. 68
5.1.2. External Event Configuration .................................. 68
5.1.3. SOE Configuration ....................................... 70
5.1.4. Time Synchronization ...................................... 72
5.1.4.1. IEC 60870-5-104 ................................... 73
5.1.4.2. SNTP ......................................... 74
5.1.4.3. Daylight Saving Time (DST) ............................. 74
5.1.5. Internal Points .......................................... 75
5.1.5.1. Quality Conversions .................................. 76
5.1.5.1.1. Internal Quality ................................ 77
5.1.5.1.2. IEC 60870-5-104 Conversion ......................... 78
5.1.5.1.3. MODBUS Internal Quality .......................... 79
5.1.5.1.4. Local Bus I/O Modules Quality ........................ 80
5.1.5.1.5. PROFIBUS I/O Modules Quality ....................... 81
5.1.5.1.6. PROFIBUS Digital Inputs Quality ...................... 81
5.1.5.1.7. PROFIBUS Digital Output Quality ...................... 82
5.1.5.1.8. PROFIBUS Analog Inputs Quality ...................... 83
5.1.5.1.9. PROFIBUS Analog Output Quality ...................... 84
5.2. Serial Interfaces Configuration ..................................... 86
5.2.1. COM 1 .............................................. 86
5.2.1.1. Advanced Configurations ............................... 88
IV

CONTENTS
5.2.2. COM 2 .............................................. 89
5.2.2.1. Advanced Configurations ............................... 89
5.3. Ethernet Interfaces Configuration .................................... 90
5.3.1. Local Ethernet Interfaces .................................... 90
5.3.1.1. NET 1 ......................................... 90
5.3.1.2. NET 2 ......................................... 91
5.3.2. Remote Ethernet Interfaces ................................... 91
5.3.2.1. NET 1 ......................................... 91
5.3.3. Reserved TCP/UDP Ports .................................... 91
5.4. NX5000 Module Configuration ..................................... 92
5.5. Protocols Configuration ......................................... 94
5.5.1. Protocol Behavior x CPU State ................................. 96
5.5.2. Double Points .......................................... 97
5.5.3. CPU’s Events Queue ...................................... 97
5.5.3.1. Consumers ...................................... 98
5.5.3.2. Queue Functioning Principles ............................. 98
5.5.3.2.1. Overflow Sign ................................. 99
5.5.3.3. Producers ....................................... 99
5.5.4. Interception of Commands Coming from the Control Center .................. 99
5.5.5. MODBUS RTU Master .....................................104
5.5.5.1. MODBUS Master Protocol Configuration by Symbolic Mapping ..........104
5.5.5.1.1. MODBUS Master Protocol General Parameters – Symbolic Mapping Con-
figuration ...................................104
5.5.5.1.2. Devices Configuration – Symbolic Mapping configuration .........107
5.5.5.1.3. Mappings Configuration – Symbolic Mapping Settings ...........108
5.5.5.1.4. Requests Configuration – Symbolic Mapping Settings ............109
5.5.5.2. MODBUS Master Protocol Configuration for Direct Representation (%Q) . . . . . 114
5.5.5.2.1. General Parameters of MODBUS Master Protocol - setting by Direct Rep-
resentation (%Q) ...............................114
5.5.5.2.2. Devices Configuration – Configuration for Direct Representation (%Q) . . . 115
5.5.5.2.3. Mappings Configuration – Configuration for Direct Representation (%Q) . . 116
5.5.6. MODBUS RTU Slave ......................................118
5.5.6.1. MODBUS Slave Protocol Configuration via Symbolic Mapping ..........118
5.5.6.1.1. MODBUS Slave Protocol General Parameters – Configuration via Sym-
bolic Mapping .................................119
5.5.6.1.2. Configuration of the Relations – Symbolic Mapping Setting .........123
5.5.6.2. MODBUS Slave Protocol Configuration via Direct Representation (%Q) ......124
5.5.6.2.1. General Parameters of MODBUS Slave Protocol – Configuration via Di-
rect Representation (%Q) ...........................124
5.5.6.2.2. Mappings Configuration – Configuration via Direct Representation (%Q) . 125
5.5.7. MODBUS Ethernet .......................................127
5.5.8. MODBUS Ethernet Client ....................................129
5.5.8.1. MODBUS Ethernet Client Configuration via Symbolic Mapping ..........129
5.5.8.1.1. MODBUS Client Protocol General Parameters – Configuration via Sym-
bolic Mapping .................................130
5.5.8.1.2. Device Configuration – Configuration via Symbolic Mapping ........131
5.5.8.1.3. Mappings Configuration – Configuration via Symbolic Mapping ......133
5.5.8.1.4. Requests Configuration – Configuration via Symbolic Mapping .......135
5.5.8.2. MODBUS Ethernet Client configuration via Direct Representation (%Q) ......139
V

CONTENTS
5.5.8.2.1. General parameters of MODBUS Protocol Client - configuration for Direct
Representation (%Q) .............................139
5.5.8.2.2. Device Configuration – Configuration via Direct Representation (%Q) . . . 140
5.5.8.2.3. Mapping Configuration – Configuration via Direct Representation (%Q) . . 141
5.5.8.3. MODBUS Client Relation Start in Acyclic Form ..................143
5.5.9. MODBUS Ethernet Server ...................................143
5.5.9.1. MODBUS Server Ethernet Protocol Configuration for Symbolic Mapping . . . . . 143
5.5.9.1.1. MODBUS Server Protocol General Parameters – Configuration via Sym-
bolic Mapping .................................143
5.5.9.1.2. MODBUS Server Diagnostics – Configuration via Symbolic Mapping . . . 145
5.5.9.1.3. Mapping Configuration – Configuration via Symbolic Mapping .......147
5.5.9.2. MODBUS Server Ethernet Protocol Configuration via Direct Representation (%Q) 148
5.5.9.2.1. General Parameters of MODBUS Server Protocol – Configuration via Di-
rect Representation (%Q) ...........................149
5.5.9.2.2. Mapping Configuration – Configuration via Direct Representation (%Q) . . 150
5.5.10. OPC DA Server .........................................152
5.5.10.1. Creating a Project for OPC DA Communication ...................154
5.5.10.2. Configuring a PLC on the OPC DA Server ......................157
5.5.10.2.1. Importing a Project Configuration ......................159
5.5.10.3. Configuration with the PLC on the OPC DA Server with Connection Redundancy . 159
5.5.10.4. OPC DA Communication Status and Quality Variables ...............160
5.5.10.5. Limits of Communication with OPC DA Server ...................162
5.5.10.6. Accessing Data Through an OPC DA Client .....................162
5.5.11. OPC UA Server .........................................164
5.5.11.1. Creating a Project for OPC UA Communication ...................165
5.5.11.2. Types of Supported Variables .............................167
5.5.11.3. Limit Connected Clients on the OPC UA Server ...................167
5.5.11.4. Limit of Communication Variables on the OPC UA Server .............167
5.5.11.5. Encryption Settings ..................................167
5.5.11.6. Main Communication Parameters Adjusted in an OPC UA Client ..........168
5.5.11.6.1. Endpoint URL .................................168
5.5.11.6.2. Publishing Interval (ms) e Sampling Interval (ms) ..............169
5.5.11.6.3. Lifetime Count e Keep-Alive Count .....................169
5.5.11.6.4. Queue Size e Discard Oldest .........................169
5.5.11.6.5. Filter Type e Deadband Type .........................169
5.5.11.6.6. PublishingEnabled, MaxNotificationsPerPublish e Priority .........170
5.5.11.7. Accessing Data Through an OPC UA Client .....................170
5.5.12. EtherCAT Master ........................................172
5.5.12.1. Installing and inserting EtherCAT Devices ......................172
5.5.12.1.1. Scan For Devices ...............................173
5.5.12.2. Diagnostic Variables .................................174
5.5.12.3. EtherCAT Master Settings ..............................177
5.5.12.3.1. Master Parameters ...............................177
5.5.12.3.2. EtherCAT Master - I/O Mapping .......................179
5.5.12.3.3. Status and Information Tabs .........................180
5.5.12.4. EtherCAT Slave Configuration ............................180
5.5.12.4.1. Slave Parameters ...............................180
5.5.12.4.2. FMMU/Sync .................................184
5.5.12.4.3. FMMU/Sync - FMMU ............................184
VI

CONTENTS
5.5.12.4.4. FMMU/Sync - Sync Manager .........................184
5.5.12.4.5. Process Data and Expert Process Data ....................185
5.5.12.4.6. Process Data and Expert Process Data - Editing the PDO List ........187
5.5.12.4.7. Process Data and Expert Process Data - Definition of the PDO Content . . . 187
5.5.12.4.8. Startup Parameters ..............................188
5.5.12.4.9. Online .....................................188
5.5.12.4.10. EtherCAT Slave - I/O Mapping ........................189
5.5.12.4.11. Status and Information tabs ..........................189
5.5.13. EtherNet/IP ...........................................189
5.5.13.1. EtherNet/IP ......................................190
5.5.13.2. EtherNet/IP Scanner Configuration ..........................191
5.5.13.2.1. General ....................................192
5.5.13.2.2. Connections .................................192
5.5.13.2.3. Assemblies ..................................194
5.5.13.2.4. EtherNet/IP I/O Mapping ...........................195
5.5.13.3. EtherNet/IP Adapter Configuration ..........................195
5.5.13.3.1. Module Types .................................196
5.5.13.3.2. EtherNet/IP Module I/O Mapping ......................196
5.5.14. IEC 60870-5-104 Server .....................................196
5.5.14.1. Type of data ......................................197
5.5.14.2. Double Points .....................................198
5.5.14.2.1. Digital Input Double Points ..........................199
5.5.14.2.2. Digital Output Double Points .........................200
5.5.14.3. General Parameters ..................................205
5.5.14.4. Data Mapping .....................................205
5.5.14.5. Link Layer .......................................207
5.5.14.6. Application Layer ...................................209
5.5.14.7. Server Diagnostic ...................................211
5.5.14.8. Commands Qualifier .................................212
5.6. Communication Performance ......................................213
5.6.1. MODBUS Server ........................................213
5.6.1.1. CPU’s Local Interfaces ................................213
5.6.1.2. Remote Interfaces ...................................214
5.6.2. OPC DA Server .........................................214
5.6.3. OPC UA Server .........................................215
5.6.4. IEC60870-5-104 Server .....................................215
5.7. System Performance ...........................................216
5.7.1. I/O Scan Time ..........................................216
5.7.2. Memory Card ..........................................216
5.8. RTC Clock ................................................217
5.8.1. Function Blocks for RTC Reading and Writing .........................217
5.8.1.1. Function Blocks for RTC Reading ..........................217
5.8.1.1.1. GetDateAndTime ...............................218
5.8.1.1.2. GetTimeZone .................................218
5.8.1.1.3. GetDayOfWeek ................................219
5.8.1.2. RTC Writing Functions ................................220
5.8.1.2.1. SetDateAndTime ...............................220
5.8.1.2.2. SetTimeZone .................................221
VII

CONTENTS
5.8.2. RTC Data Structures .......................................222
5.8.2.1. EXTENDED_DATE_AND_TIME ..........................223
5.8.2.2. DAYS_OF_WEEK ..................................223
5.8.2.3. RTC_STATUS .....................................223
5.8.2.4. TIMEZONESETTINGS ...............................224
5.9. User Files Memory ...........................................224
5.10. Memory Card ..............................................226
5.10.1. Project Preparation .......................................226
5.10.2. Project Transfer .........................................227
5.10.3. MasterTool Access .......................................228
5.11. CPU’s Informative and Configuration Menu ..............................228
5.12. Function Blocks and Functions .....................................231
5.12.1. Special Function Blocks for Serial Interfaces ..........................231
5.12.1.1. SERIAL_CFG .....................................235
5.12.1.2. SERIAL_GET_CFG .................................237
5.12.1.3. SERIAL_GET_CTRL ................................238
5.12.1.4. SERIAL_GET_RX_QUEUE_STATUS .......................240
5.12.1.5. SERIAL_PURGE_RX_QUEUE ...........................241
5.12.1.6. SERIAL_RX .....................................243
5.12.1.7. SERIAL_RX_EXTENDED ..............................245
5.12.1.8. SERIAL_SET_CTRL .................................247
5.12.1.9. SERIAL_TX .....................................249
5.12.2. Inputs and Outputs Update ...................................251
5.12.2.1. REFRESH_INPUT ..................................251
5.12.2.2. REFRESH_OUTPUT .................................252
5.12.3. PID Function Block .......................................254
5.12.4. Timer Retain ...........................................254
5.12.4.1. TOF_RET .......................................254
5.12.4.2. TON_RET .......................................255
5.12.4.3. TP_RET ........................................257
5.12.5. Non-Redundant Timer ......................................258
5.12.5.1. TOF_NR .......................................258
5.12.5.2. TON_NR .......................................259
5.12.5.3. TP_NR ........................................259
5.12.6. User Log .............................................260
5.12.6.1. UserLogAdd ......................................261
5.12.6.2. UserLogDeleteAll ...................................262
5.12.7. ClearRtuDiagnostic .......................................263
5.12.8. ClearEventQueue ........................................263
5.13. SNMP ..................................................264
5.13.1. Introduction ...........................................264
5.13.2. SNMP nas UCPs Nexto .....................................264
5.13.3. Private MIB ...........................................265
5.13.4. SNMP Configuration ......................................265
5.13.5. User and SNMP Communities .................................266
5.14. User Management and Access Rights ..................................267
6. Redundancy with NX3030 CPU ..........................................268
6.1. Introduction ...............................................268
VIII

CONTENTS
6.2. Technical Description and Configuration ................................269
6.2.1. Minimum Configuration of a Redundant CPU (Not Using PX2612 Panel) ..........269
6.2.2. Typical Configurations of a Redundant CPU ..........................270
6.2.2.1. NX5001 Modules Addition for PROFIBUS Networks ................271
6.2.2.2. NX5000 Modules Addition for Ethernet Networks ..................271
6.2.3. NX4010 Module .........................................271
6.2.3.1. NX4010 Features ...................................272
6.2.4. Redundancy Control Panel PX2612 ...............................272
6.2.4.1. PX2612 Features ...................................274
6.2.5. Interconnections between Half-Clusters and the Redundancy Control Panel PX2612 . . . . . 274
6.2.6. General Characteristics of a Redundant CP ...........................275
6.2.7. Purchase Data ..........................................278
6.3. Principles of Operation .........................................279
6.3.1. Identification of an NX3030 CPU ................................279
6.3.2. Single Redundant Project ....................................279
6.3.3. Redundant Project Structure ...................................279
6.3.3.1. Redundancy Template .................................279
6.3.3.2. Single and Cyclic Task MainTask ...........................279
6.3.3.3. MainPrg Program ...................................279
6.3.3.4. ActivePrg Program ..................................280
6.3.3.5. NonSkippedPrg Program ...............................280
6.3.3.6. Redundant and Non-redundant Variables .......................281
6.3.3.7. Redundant and Non-redundant %I Variables .....................281
6.3.3.8. Redundant and Non-redundant %Q Variables ....................281
6.3.3.9. Redundant and Non-redundant %M Variables ....................282
6.3.3.10. Redundant and Non-redundant Symbolic Variables .................283
6.3.4. Multiple Mapping ........................................283
6.3.5. Diagnostics, Commands and User Data Structure .......................284
6.3.6. Cyclic Synchronization Services through NETA and NETB ..................285
6.3.6.1. Diagnostics and Commands Exchange ........................285
6.3.6.2. Redundant Data Synchronization ...........................285
6.3.6.3. Redundant Forcing List Synchronization .......................286
6.3.7. Sporadic Synchronization Services through NETA and NETB .................286
6.3.7.1. Project Synchronization ................................286
6.3.8. Project Synchronization Disabling ...............................287
6.3.9. PROFIBUS Network Configuration ...............................288
6.3.9.1. PROFIBUS Redundancy ...............................288
6.3.9.2. PROFIBUS Failure Modes Vital and Not-Vital ....................288
6.3.10. Redundant Ethernet Networks with NIC Teaming .......................288
6.3.11. IP Change Methods .......................................289
6.3.11.1. Fixed IP ........................................289
6.3.11.2. Exchange IP ......................................289
6.3.11.3. Active IP .......................................290
6.3.11.4. Multiple IP ......................................291
6.3.12. NIC Teaming and Active IP Combined Use ...........................292
6.3.13. Ethernet Interfaces Use with Vital Fault Indication .......................292
6.3.13.1. Failure in Ethernet Interface .............................292
6.3.13.2. Failure in Connected MODBUS Server ........................292
IX

CONTENTS
6.3.14. OPC DA Communication Use with Redundant Projects ....................292
6.3.15. Redundant CPU States .....................................293
6.3.15.1. Not-Configured State .................................293
6.3.15.2. Starting State .....................................294
6.3.15.3. Active State ......................................294
6.3.15.4. Stand-By State ....................................294
6.3.15.5. Inactive State .....................................294
6.3.16. PX2612 Redundancy Command Panel Functions ........................295
6.3.16.1. PX2612 Buttons ....................................295
6.3.16.2. PX2612 LEDs .....................................296
6.3.16.3. PX2612 Relays ....................................296
6.3.17. Transition between Redundancy States .............................296
6.3.17.1. Transition 1 – Not-Configured to Starting ......................297
6.3.17.2. Transition 2 – Starting to Not-Configured ......................298
6.3.17.3. Transition 3 – Starting to Inactive ...........................298
6.3.17.4. Transition 4 – Starting to Active ...........................298
6.3.17.5. Transition 5 – Starting to Stand-by ..........................298
6.3.17.6. Transition 6 – Inactive to Not-Configured ......................298
6.3.17.7. Transition 7 – Active to Not-Configured .......................298
6.3.17.8. Transition 8 – Active to Inactive ...........................299
6.3.17.9. Transition 9 – Active to Stand-by ...........................299
6.3.17.10. Transition 10 – Stand-by to Not-Configured .....................299
6.3.17.11. Transition 11 – Stand-by to Inactive .........................299
6.3.17.12. Transition 12 – Stand-by to Active ..........................299
6.3.18. First Instants in Active State ...................................299
6.3.19. Common Failures which Cause Automatic Switchovers between Half-Clusters ........300
6.3.20. Failures Associated to Switchovers between Half-Clusters Managed by the User .......300
6.3.21. Fault Tolerance .........................................301
6.3.21.1. Simple Failure with Unavailability ..........................302
6.3.21.2. Simple Failure without Unavailability Causing a Switchover ............302
6.3.21.3. Double Failure without Unavailability Causing a Switchover ............302
6.3.22. Redundancy Overhead ......................................303
6.4. Redundant CPU Programming .....................................303
6.4.1. Wizard for a New Redundant Project Creation .........................303
6.4.2. Half-Clusters Configuration ...................................308
6.4.2.1. Fixed Configuration in the 0 to 5 Rack Positions ...................308
6.4.3. Ethernet Ports Configuration in the CPU NX3030 (NET 1 and NET 2) ............308
6.4.3.1. IP Address Configuration ...............................308
6.4.3.2. NIC Teaming between NET 1 and NET 2 ......................309
6.4.3.3. Vital failure setting in NET 1 and NET 2 .......................309
6.4.4. NX5001 Modules Configuration ................................310
6.4.4.1. Insertion or Removal of NX5001 modules ......................310
6.4.4.2. NX5001 Modules Parameters Adjust .........................310
6.4.4.3. PROFIBUS Remotes Configuration .........................311
6.4.5. NX5000 Modules Configuration ................................312
6.4.5.1. NX5000 Modules Insertion or Removal .......................312
6.4.5.2. NX5000 Modules Configuration ...........................312
6.4.5.3. NX5000 Modules Grouping with NIC Teaming Redundancy ............312
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CONTENTS
6.4.5.3.1. Failure Vital Setting ..............................312
6.4.6. NX4010 Redundancy Configuration ..............................312
6.4.7. I/O Drivers Configuration ....................................313
6.4.8. MainTask Configuration .....................................313
6.4.8.1. ActivePrg Program ..................................314
6.4.8.2. NonSkippedPrg Program ...............................314
6.4.9. Redundancy Configuration Object ...............................315
6.4.10. GVL Module_Diagnostics ....................................315
6.4.11. GVLs with Redundant Symbolic Variables ...........................315
6.4.12. POUs from the Program Type with Redundant Symbolic Variables ..............316
6.4.13. Breakpoints Utilization in Redundant Systems .........................316
6.4.14. MODBUS Instances Managing in Redundant System .....................316
6.4.15. Limitations on a Redundant PLC Programming ........................317
6.4.15.1. Limitations in Redundant GVLs and POUs .....................317
6.4.15.2. Non-redundant Program Limitations (NonSkippedPrg) ...............317
6.4.16. Getting the Redundancy State of a Half-Cluster ........................317
6.4.17. Reading Non-Redundant Diagnostics ..............................317
6.5. Redundant CPU Program Downloading .................................318
6.5.1. Initial Downloading of a Redundant Project ..........................318
6.5.1.1. First Step – IP Address Discovering for MasterTool Connection ...........318
6.5.1.2. Second Step – Verifying IP Addresses Conflict ....................319
6.5.1.3. Third Step – Preparing MasterTool Connection (Set Active Path) ..........319
6.5.1.4. Forth Step – Identifying the NX3030 CPU and Verifying the CPU Display . . . . . 319
6.5.1.5. Fifth Step – Redundant Project Downloading ....................320
6.5.2. MasterTool Connection with a NX3030 CPU from a Redundant PLC .............321
6.5.3. Modification Download in a Redundant Project ........................321
6.5.4. Offline and Online Modifications Download ..........................321
6.5.4.1. Modifications which Demand Offline Download and the Interruption of the Pro-
cess Control ......................................322
6.5.4.2. Modifications which Demand Offline Download ...................322
6.5.4.3. Modifications which Allow Online Download ....................322
6.5.5. Online Download of Modifications ...............................323
6.5.6. Offline Download of Modifications with Process Control Interruption .............323
6.5.7. Previous Planning for Offline Modifications without Process Control Interruption ......324
6.5.7.1. Previous Planning for Hot Modifications in Redundant PROFIBUS Networks . . . 324
6.5.7.1.1. Step 1 – Plan Future Expansion of the Remotes Inserted in the PROFIBUS
Network Initial Version ............................324
6.5.7.1.2. Step 2 – Insert the Redundant PROFIBUS Network Initial Version in the
Project .....................................325
6.5.7.1.3. Step 3 – Allocate %I and %Q Variables Areas for the PROFIBUS Network
considering Future Remote Expansion ....................325
6.5.7.2. Previous Planning for Other Hot Modifications ...................326
6.5.7.3. Incompatibility of Applications ............................327
6.5.7.4. Project Update due to MasterTool IEC XE Update ..................327
6.5.7.4.1. Updating Project from Versions Previous to 2.00 to version 2.00 or Higher . 327
6.5.8. Exploring the Redundancy for Offline downloading of Modifications without Interruption of
the Process control ........................................328
6.5.8.1. Step 1 – Verify Basic Requirements Attending ....................328
6.5.8.2. Step 2 – Don’t Download in Group Modifications which can be downloaded Online 329
XI

CONTENTS
6.5.8.3. Step 3 – Previous Project Backup ...........................329
6.5.8.4. Step 4 – Cares in Editing the Offline Downloaded Modifications ..........329
6.5.8.5. Step 5 – Inactive PLC Project Synchronism Disabling ................329
6.5.8.6. Step 6 – Physical Modifications Executing ......................330
6.5.8.7. Step 7 – Download the Offline Modifications in the Non-Active PLC ........330
6.5.8.8. Step 8 – Set the Non-Active PLC Back to Run Mode to make go back to Stand-by
State ..........................................330
6.5.8.9. Step 9 – Execute Switchover between Active and Stand-by PLCs ..........330
6.5.8.10. Step 10 – Projects Synchronism Enabling in the Active PLC ............331
6.5.8.11. Step 11 – Optional Reorganization of PLC and PROFIBUS Networks in Active State331
6.6. Redundancy Maintenance ........................................331
6.6.1. Modules Hot Swapping in a Redundant PLC ..........................331
6.6.2. MasterTool Warning Messages .................................331
6.6.2.1. Blocking of Redundant or Non-Redundant Project Download ............331
6.6.2.2. Warnings before Commands which may stop the Active PLC ............331
6.6.2.3. Alert before Logging in to Non-Active CP ......................332
6.6.3. Redundancy Diagnostics on NX3030 CPU Graphic Display ..................332
6.6.3.1. CP Redundancy Status ................................332
6.6.3.2. Screens below the REDUNDANCY Menu ......................332
6.6.4. Redundancy Diagnostics Structure ...............................332
6.6.4.1. Redundancy Diagnostics ...............................333
6.6.4.2. Redundancy Commands ...............................344
6.6.4.3. User Information Exchanged between PLCA and PLCB ...............347
6.6.4.4. Modbus Diagnostics used at Redundancy ......................347
6.6.4.5. Redundancy Event Log ................................348
6.6.5. PX2612 Panel Test ........................................348
6.6.5.1. Test Mode Entry ....................................348
6.6.5.2. Test Mode Manual and Automatic Outputs ......................348
6.6.5.3. LEDs Testing .....................................348
6.6.5.4. Buttons Test ......................................349
6.6.5.5. Relay Test .......................................349
6.6.5.6. Suggested Sequence for PX2612 Test Executing ...................349
7. Maintenance ....................................................351
7.1. Module Diagnostics ...........................................351
7.1.1. One Touch Diag .........................................351
7.1.2. Diagnostics via LED .......................................353
7.1.2.1. DG (Diagnostic) ....................................353
7.1.2.2. WD (Watchdog) ....................................353
7.1.2.3. RJ45 Connector LEDs ................................354
7.1.3. Diagnostics via WEB ......................................354
7.1.4. Diagnostic Explorer .......................................356
7.1.5. Diagnostics via Variables ....................................357
7.1.5.1. Summarized Diagnostics ...............................357
7.1.5.2. Detailed Diagnostics .................................360
7.1.6. Diagnostics via Function Blocks ................................370
7.1.6.1. GetTaskInfo ......................................370
7.2. Graphic Display .............................................372
7.3. System Log ...............................................374
XII

CONTENTS
7.4. Not Loading the Application at Startup .................................374
7.5. Power Supply Failure ..........................................374
7.6. Common Problems ...........................................375
7.7. Troubleshooting .............................................375
7.8. Preventive Maintenance .........................................376
8. Annex. DNP3 Interoperability ...........................................377
8.1. DNP3 Device Profile ...........................................377
8.2. DNP V3.0 Implementation Table ....................................378
XIII

1. INTRODUCTION
1. Introduction
Nexto Series programmable controllers are the ultimate solution for industrial automation and system control. With high
embedded technology, the products of the family are able to control, in a distributed and redundant way, complex industrial
systems, machines, high performance production lines and the most advanced processes of Industry 4.0. Modern and high-
speed, the Nexto series uses cutting-edge technology to provide reliability and connectivity, helping to increase the productivity
of different businesses.
Compact, robust and with high availability, the series products have excellent processing performance and rack expansion
possibilities. Its architecture allows easy integration with supervision, control and field networks, in addition to CPU and power
supply redundancy. The family’s equipment also offers advanced diagnostics and hot swapping, minimizing or eliminating
maintenance downtime and ensuring a continuous production process.
Figure 1: NX3030
1.1. Nexto Series
Nexto Series is a powerful and complete series of Programmable Controllers (PLC) with exclusive and innovative charac-
teristics. Due to its flexibility, functional design, advanced diagnostic resources and modular architecture, the Nexto PLC can
be used to control systems in small, medium and large scale applications.
Nexto Series architecture has a great variety of input and output modules. These modules combined with a powerful 32
bits processor and a high speed bus based on Ethernet, fit to several application kinds as high speed control for small machines,
complex distributed processes, redundant applications and systems with a great number of I/O as building automation. Further-
more, Nexto Series has modules for motion control, communication modules encompassing the most popular field networks
among other features.
Nexto Series uses an advanced technology in its bus, which is based on a high speed Ethernet interface, allowing input and
output information and data to be shared between several controllers inside the same system. The system can be easily divided
and distributed throughout the whole field, allowing the use of bus expansion with the same performance of a local module,
turning possible the use of every module in the local frame or in the expansion frames with no restrictions. For interconnection
between frames expansions a simple standard Ethernet cable is used.
1

1. INTRODUCTION
Figure 2: Nexto Series – Overview
1.2. Innovative Features
Nexto Series brings to the user many innovations regarding utilization, supervision and system maintenance. These features
were developed focusing a new concept in industrial automation.
Battery Free Operation: Nexto Series does not require any kind of battery for memory maintenance
and real time clock operation. This feature is extremely important because it reduces the system
maintenance needs and allows the use in remote locations where maintenance can be difficult to be
performed. Besides, this feature is environmentally friendly.
Easy Plug System: Nexto Series has an exclusive method to plug and unplug I/O terminal blocks.
The terminal blocks can be easily removed with a single movement and with no special tools. In order
to plug the terminal block back to the module, the frontal cover assists the installation procedure,
fitting the terminal block to the module.
Multiple Block Storage: Several kinds of memories are available to the user in Nexto Series CPUs,
offering the best option for any user needs. These memories are divided in volatile memories and
non-volatile memories. For volatile memories, Nexto Series CPUs offer addressable input (%I),
addressable output (%Q), addressable memory (%M), data memory and redundant data memory.
For applications that require non-volatile functionality, Nexto Series CPUs bring retain addressable
memory (%Q), retain data memory, persistent addressable memory (%Q), persistent data memory,
program memory, source code memory, CPU file system (doc, PDF, data) and memory card interface.
One Touch Diag: One Touch Diag is an exclusive feature that Nexto Series brings to PLCs. With this
new concept, the user can check diagnostic information of any module present in the system directly
on CPU’s graphic display with one single press in the diagnostic switch of the respective module.
OTD is a powerful diagnostic tool that can be used offline (without supervisor or programmer), re-
ducing maintenance and commissioning times.
OFD – On Board Full Documentation: Nexto Series CPUs are capable of storing the complete
project documentation in its own memory. This feature can be very convenient for backup purposes
and maintenance, since the complete information is stored in a single and reliable place.
ETD – Electronic Tag on Display: Another exclusive feature that Nexto Series brings to PLCs is
the Electronic Tag on Display. This new functionality brings the process of checking the tag names
of any I/O pin or module used in the system directly to the CPU’s graphic display. Along with this
information, the user can check the description, as well. This feature is extremely useful during
maintenance and troubleshooting procedures.
2

1. INTRODUCTION
DHW – Double Hardware Width: Nexto Series modules were designed to save space in user cabi-
nets or machines. For this reason, Nexto Series delivers two different module widths: Double Width
(two backplane rack slots are required) and Single Width (only one backplane rack slot is required).
This concept allows the use of compact I/O modules with a high-density of I/O points along with
complex modules, like CPUs, fieldbus masters and power supply modules.
High-speed CPU: All Nexto Series CPUs were designed to provide an outstanding performance to
the user, allowing the coverage of a large range of applications requirements.
iF Product Design Award 2012: Nexto Series was the winner of iF Product Design Award 2012
in industry + skilled trades group. This award is recognized internationally as a seal of quality and
excellence, considered the Oscars of the design in Europe..
1.3. Documents Related to this Manual
In order to obtain additional information regarding the Nexto Series, other documents (manuals and technical features)
besides this one, may be accessed. These documents are available in its last version on the site http://www.altus.com.br/site_
en/.
Each product has a document designed by Technical Features (CE), where the product features are described. Furthermore,
the product may have Utilization Manuals (the manuals codes are listed in the CE).
For instance, the NX2020 module has the information for utilization features and purchasing on its CE. On another hand,
the NX5001 has, besides the CE, a User Manual (MU).
It is advised the following documents as additional information source:
Code Description Language
CE114000 Nexto Series – Technical Characteristics English
CT114000 Série Nexto – Características Técnicas Portuguese
CS114000 Serie Nexto – Características Técnicas Spanish
CE114102 NX3030 Technical Characteristics English
CT114102 Características Técnicas NX3030 Portuguese
CS114102 Especificaciones y Configuraciones NX3030 Spanish
CE114200 NX8000 Power Supply Module Technical Characteristics English
CT114200 Características Técnicas Fonte de Alimentação NX8000 Portuguese
CS114200 Características Técnicas del Fuente de Alimentación NX8000 Spanish
CE114700 Nexto Series Backplane Racks Technical Characteristic English
CT114700 Características Técnicas dos Bastidores da Série Nexto Portuguese
CS114700 Características Técnicas de los Bastidores de la Serie Nexto Spanish
CE114810 Nexto Series Accessories for Backplane Rack Technical
Characteristics English
CT114810 Características Técnicas Acessórios para Bastidor Série Nexto Portuguese
CS114810 Características Técnicas del Cierres Laterales para el Bastidor Spanish
CE114900 NX4010 Redundancy Link Module Technical Characteristics English
CT114900 Características Técnicas do Módulo de Redundância NX4010 Portuguese
CS114900 Características Técnicas del Módulo de Redundancia NX4010 Spanish
CE114902 Nexto Series PROFIBUS-DP Master Technical Characteristics English
CT114902 Características Técnicas do Mestre PROFIBUS-DP da Série Nexto Portuguese
CS114902 Características Técnicas del Módulo Profibus-DP Maestro Spanish
CE114903 Nexto Series Ethernet Module Technical Characteristics English
CT114903 Características Técnicas Módulo Ethernet Série Nexto Portuguese
CS114903 Características Técnicas del Modulo Ethernet Série Nexto Spanish
CE114908 NX5110 and NX5210 PROFIBUS-DP Heads Technical Characteristics English
CT114908 Características Técnicas Interfaces Cabeça PROFIBUSDP NX5110 e
NX5210 Portuguese
CS114908 Especificaciones y Configuraciones PROFIBUS-DP Interfaz Cabezas
NX5110 y NX5210 Spanish
3

1. INTRODUCTION
Code Description Language
CT112500 Características Técnicas do Painel de Controle de Redundância
PX2612 Português
MU214600 Nexto Series User Manual English
MU214000 Manual de Utilização Série Nexto Portuguese
MU214615 NX3030 CPU User Manual English
MU214103 Manual de Utilização UCP NX3030 Portuguese
MU299609 MasterTool IEC XE User Manual English
MU299048 Manual de Utilização MasterTool IEC XE Portuguese
MP399609 MasterTool IEC XE Programming Manual English
MP399048 Manual de Programação MasterTool IEC XE Portuguese
MU214601 NX5001 PROFIBUS DP Master User Manual English
MU214001 Manual de Utilização Mestre PROFIBUS-DP NX5001 Portuguese
MU214608 Nexto PROFIBUS-DP Head Utilization Manual English
MU214108 Manual de Utilização da Cabeça PROFIBUS-DP Nexto Portuguese
MU219000 Ponto Series Utilization Manual English
MU209000 Manual de Utilização da Série Ponto Portuguese
MU209508 Manual de Utilização Cabeça PROFIBUS PO5063V1 e Cabeça
Redundante PROFIBUS PO5063V5 Portuguese
MU219511 PO5064 PROFIBUS Head and PO5065 Redundant PROFIBUS Head
Utilization Manual English
MU209511 Manual de Utilização Cabeça PROFIBUS PO5064 e Cabeça
Redundante PROFIBUS PO5065 Portuguese
MU209020 Manual de Utilização Rede HART sobre PROFIBUS Portuguese
MU223603 IEC 60870-5-104 Server Device Profile Document English
MU214603 Nexto Series HART Manual English
MU214610 Advanced Control Functions User Manual English
NAP151 Utilização do Tunneller OPC Portuguese
NAP165 Comunicação OPC UA com Controladores ALTUS Portuguese
NAP165_ing OPC UA Communication with ALTUS Controllers English
Table 1: Related Documents
1.4. Visual Inspection
Before resuming the installation process, it is advised to carefully visually inspect the equipment, verifying the existence
of transport damage. Verify if all parts requested are in perfect shape. In case of damages, inform the transport company or
Altus distributor closest to you.
CAUTION
Before taking the modules off the case, it is important to discharge any possible static energy
accumulated in the body. For that, touch (with bare hands) on any metallic grounded surface
before handling the modules. Such procedure guaranties that the module static energy limits
are not exceeded.
It’s important to register each received equipment serial number, as well as software revisions, in case they exist. This
information is necessary, in case the Altus Technical Support is contacted.
1.5. Technical Support
For Altus Technical Support contact in São Leopoldo, RS, call [phone]. For further information regarding the
Altus Technical Support existent on other places, see https://www.altus.com.br/en/ or send an email to [email protected].
4

1. INTRODUCTION
If the equipment is already installed, you must have the following information at the moment of support requesting:
The model from the used equipments and the installed system configuration
The product serial number
The equipment revision and the executive software version, written on the tag fixed on the product’s side
CPU operation mode information, acquired through MasterTool IEC XE
The application software content, acquired through MasterTool IEC XE
Used programmer version
1.6. Warning Messages Used in this Manual
In this manual, the warning messages will be presented in the following formats and meanings:
DANGER
Reports potential hazard that, if not detected, may be harmful to people, materials, environ-
ment and production.
CAUTION
Reports configuration, application or installation details that must be taken into consideration
to avoid any instance that may cause system failure and consequent impact.
ATTENTION
Identifies configuration, application and installation details aimed at achieving maximum
operational performance of the system.
5

2. TECHNICAL DESCRIPTION
2. Technical Description
This chapter presents all technical features from NX3030.
2.1. Panels and Connections
The following figure shows the CPU front panel.
Figure 3: NX3030
As it can be seen on the figure, on the front panel upper part is placed the graphic display used to show the whole system
status and diagnostics, including the specific diagnostics of each module. The graphic display also offers an easy-to-use menu
which brings to the user a quick mode for parameters reading or defining, such as: inner temperature (reading only) and local
time (reading only).
Just below the graphic display, there are 2 LEDs used to indicate alarm diagnostics and watchdog circuit. The table below
shows the LEDs description. For further information regarding the LEDs status and meaning, see Diagnostics via LED section.
LED Description
DG Diagnostics LED
WD Watchdog LED
Table 2: LEDs Description
Nexto Series CPUs has two switches available to the user. The table below shows the description of these switches. For
further information regarding the diagnostics switch, see sections One Touch Diag and CPU’s Informative and Configuration
Menu. For further information regarding the MS switch, see section Memory Card.
Keys Description
Diagnostics Switch
Switch placed on the module upper part. Used for diagnostics vi-
sualization on the graphic display or for navigation through the in-
formative menu and CPU configuration.
6