ALTUS Nexto Series User manual

User Manual
Nexto Serie CPU
NX3004
MU214616 Rev. B
May 27, 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 ............................................ 5
1.6. Warning Messages Used in this Manual ................................. 5
2. Technical Description ................................................ 6
2.1. Panels and Connections ......................................... 6
2.2. General Features ............................................. 7
2.2.1. Common General Features ................................... 7
2.2.2. Memory ............................................. 8
2.2.3. Protocols ............................................. 10
2.2.4. Serial Interfaces ......................................... 11
2.2.4.1. COM 1 ........................................ 11
2.2.5. Ethernet Interfaces ........................................ 12
2.2.5.1. NET 1 ......................................... 12
2.2.6. Power Supply .......................................... 12
2.2.7. Environmental Characteristics .................................. 13
2.3. Compatibility with Other Products ................................... 13
2.4. Performance ............................................... 13
2.4.1. Application Times ........................................ 14
2.4.2. Time for Instructions Execution ................................. 14
2.4.3. Initialization Times ....................................... 14
2.4.4. Interval Time .......................................... 14
2.5. Physical Dimensions ........................................... 15
2.6. Purchase Data .............................................. 16
2.6.1. Integrant Items .......................................... 16
2.6.2. Product Code .......................................... 16
2.7. Related Products ............................................. 16
3. Installation ..................................................... 18
3.1. Mechanical Installation ......................................... 18
3.2. Electrical Installation .......................................... 18
3.3. Ethernet Network Connection ...................................... 19
3.3.1. IP Address ............................................ 19
3.3.2. Gratuitous ARP ......................................... 19
3.3.3. Network Cable Installation ................................... 19
3.4. Serial Network Connection RS-485/422 ................................ 20
II

CONTENTS
3.4.1. RS-485 Communication without termination .......................... 21
3.4.2. RS-485 Communication with Internal Termination ....................... 22
3.4.3. RS-485 Communication with External Termination ...................... 23
3.4.4. RS-422 Communication without Termination ......................... 23
3.4.5. RS-422 Communication with Internal Termination ....................... 24
3.4.6. RS-422 Communication with External Termination ...................... 25
3.4.7. RS-422 Network Example .................................... 26
3.5. Architecture Installation ......................................... 26
3.5.1. Module Installation on the Main Backplane Rack ....................... 26
3.6. Programmer Installation ......................................... 26
4. Initial Programming ................................................. 27
4.1. Memory Organization and Access .................................... 27
4.2. Project Profiles .............................................. 29
4.2.1. Single .............................................. 29
4.2.2. Basic ............................................... 30
4.2.3. Normal .............................................. 30
4.2.4. Expert .............................................. 30
4.2.5. Custom .............................................. 31
4.2.6. Machine Profile ......................................... 31
4.2.7. General Table .......................................... 32
4.2.8. Maximum Number of Tasks ................................... 33
4.3. CPU Configuration ........................................... 33
4.4. Libraries ................................................. 35
4.5. Inserting a Protocol Instance ....................................... 35
4.5.1. MODBUS RTU ......................................... 35
4.5.2. MODBUS Ethernet ....................................... 36
4.6. Finding the Device ............................................ 38
4.7. Login ................................................... 40
4.8. Run Mode ................................................ 42
4.9. Stop Mode ................................................ 43
4.10. Writing and Forcing Variables ...................................... 44
4.11. Logout .................................................. 44
4.12. Project Upload .............................................. 45
4.13. CPU Operating States .......................................... 46
4.13.1. Run ............................................... 46
4.13.2. Stop ............................................... 46
4.13.3. Breakpoint ............................................ 46
4.13.4. Exception ............................................ 47
4.13.5. Reset Warm ........................................... 47
4.13.6. Reset Cold ............................................ 47
4.13.7. Reset Origin ........................................... 47
4.14. Programs (POUs) and Global Variable Lists (GVLs) .......................... 47
4.14.1. MainPrg Program ........................................ 47
4.14.2. StartPrg Program ........................................ 48
4.14.3. UserPrg Program ........................................ 48
4.14.4. GVL System_Diagnostics .................................... 48
4.14.5. GVL Disables .......................................... 49
4.14.6. GVL IOQualities ........................................ 50
III

CONTENTS
4.14.7. GVL Module_Diagnostics .................................... 51
4.14.8. GVL ReqDiagnostics ...................................... 51
4.14.9. Prepare_Start Function ..................................... 53
4.14.10. Prepare_Stop Function ..................................... 53
4.14.11. Start_Done Function ....................................... 53
4.14.12. Stop_Done Function ....................................... 53
5. Configuration .................................................... 54
5.1. CPU Configuration ........................................... 54
5.1.1. General Parameters ....................................... 54
5.1.1.1. Hot Swap ....................................... 56
5.1.1.1.1. Hot Swap Disabled, for Declared Modules Only ............... 56
5.1.1.1.2. Hot Swap Disabled .............................. 57
5.1.1.1.3. Hot Swap Disabled, without Startup Consistency .............. 57
5.1.1.1.4. Hot Swap Enabled, with Startup Consistency for Declared Modules Only . 57
5.1.1.1.5. Hot Swap Enabled with Startup Consistency ................. 57
5.1.1.1.6. Hot Swap Enabled without Startup Consistency ............... 57
5.1.1.1.7. How to do the Hot Swap ........................... 58
5.1.1.2. Retain and Persistent Memory Areas ......................... 60
5.1.1.3. TCP Configurations .................................. 61
5.1.1.4. Project Parameters .................................. 63
5.1.2. External Event Configuration .................................. 63
5.1.3. Time Synchronization ...................................... 64
5.1.3.1. SNTP ......................................... 66
5.1.3.2. Daylight Saving Time (DST) ............................. 66
5.2. Serial Interfaces Configuration ..................................... 66
5.2.1. COM 1 .............................................. 66
5.2.1.1. Advanced Configurations ............................... 67
5.3. Ethernet Interfaces Configuration .................................... 68
5.3.1. Local Ethernet Interfaces .................................... 68
5.3.1.1. NET 1 ......................................... 68
5.3.2. Reserved TCP Ports ....................................... 68
5.4. Protocols Configuration ......................................... 69
5.4.1. Protocol Behavior x CPU State ................................. 71
5.4.2. MODBUS RTU Master ..................................... 72
5.4.2.1. MODBUS Master Protocol Configuration by Symbolic Mapping .......... 72
5.4.2.1.1. MODBUS Master Protocol General Parameters – Symbolic Mapping Con-
figuration ................................... 72
5.4.2.1.2. Devices Configuration – Symbolic Mapping configuration ......... 75
5.4.2.1.3. Mappings Configuration – Symbolic Mapping Settings ........... 76
5.4.2.1.4. Requests Configuration – Symbolic Mapping Settings ............ 77
5.4.2.2. MODBUS Master Protocol Configuration for Direct Representation (%Q) ..... 82
5.4.2.2.1. General Parameters of MODBUS Master Protocol - setting by Direct Rep-
resentation (%Q) ............................... 82
5.4.2.2.2. Devices Configuration – Configuration for Direct Representation (%Q) . . . 83
5.4.2.2.3. Mappings Configuration – Configuration for Direct Representation (%Q) . . 84
5.4.3. MODBUS RTU Slave ...................................... 86
5.4.3.1. MODBUS Slave Protocol Configuration via Symbolic Mapping .......... 86
5.4.3.1.1. MODBUS Slave Protocol General Parameters – Configuration via Sym-
bolic Mapping ................................. 87
IV

CONTENTS
5.4.3.1.2. Configuration of the Relations – Symbolic Mapping Setting ......... 91
5.4.3.2. MODBUS Slave Protocol Configuration via Direct Representation (%Q) ...... 92
5.4.3.2.1. General Parameters of MODBUS Slave Protocol – Configuration via Di-
rect Representation (%Q) ........................... 92
5.4.3.2.2. Mappings Configuration – Configuration via Direct Representation (%Q) . 93
5.4.4. MODBUS Ethernet ....................................... 95
5.4.5. MODBUS Ethernet Client .................................... 96
5.4.5.1. MODBUS Ethernet Client Configuration via Symbolic Mapping .......... 96
5.4.5.1.1. MODBUS Client Protocol General Parameters – Configuration via Sym-
bolic Mapping ................................. 97
5.4.5.1.2. Device Configuration – Configuration via Symbolic Mapping ........ 99
5.4.5.1.3. Mappings Configuration – Configuration via Symbolic Mapping ......100
5.4.5.1.4. Requests Configuration – Configuration via Symbolic Mapping .......102
5.4.5.2. MODBUS Ethernet Client configuration via Direct Representation (%Q) ......106
5.4.5.2.1. General parameters of MODBUS Protocol Client - configuration for Direct
Representation (%Q) .............................106
5.4.5.2.2. Device Configuration – Configuration via Direct Representation (%Q) . . . 107
5.4.5.2.3. Mapping Configuration – Configuration via Direct Representation (%Q) . . 108
5.4.5.3. MODBUS Client Relation Start in Acyclic Form ..................111
5.4.6. MODBUS Ethernet Server ...................................111
5.4.6.1. MODBUS Server Ethernet Protocol Configuration for Symbolic Mapping . . . . . 111
5.4.6.1.1. MODBUS Server Protocol General Parameters – Configuration via Sym-
bolic Mapping .................................111
5.4.6.1.2. MODBUS Server Diagnostics – Configuration via Symbolic Mapping . . . 113
5.4.6.1.3. Mapping Configuration – Configuration via Symbolic Mapping .......115
5.4.6.2. MODBUS Server Ethernet Protocol Configuration via Direct Representation (%Q) 116
5.4.6.2.1. General Parameters of MODBUS Server Protocol – Configuration via Di-
rect Representation (%Q) ...........................116
5.4.6.2.2. Mapping Configuration – Configuration via Direct Representation (%Q) . . 117
5.4.7. OPC DA Server .........................................119
5.4.7.1. Creating a Project for OPC DA Communication ...................121
5.4.7.2. Configuring a PLC on the OPC DA Server ......................124
5.4.7.2.1. Importing a Project Configuration ......................126
5.4.7.3. OPC DA Communication Quality and Status Variables ...............126
5.4.7.4. OPC DA Server Communication Limits .......................127
5.4.7.5. Accessing data Through an OPC DA Client .....................128
5.4.8. OPC UA Server .........................................130
5.4.8.1. Creating a Project for OPC UA Communication ...................131
5.4.8.2. Types of Supported Variables .............................132
5.4.8.3. Limit Connected Clients on the OPC UA Server ...................133
5.4.8.4. Limit of Communication Variables on the OPC UA Server .............133
5.4.8.5. Encryption Settings ..................................133
5.4.8.6. Main Communication Parameters Adjusted in an OPC UA Client ..........134
5.4.8.6.1. Endpoint URL .................................134
5.4.8.6.2. Publishing Interval (ms) e Sampling Interval (ms) ..............135
5.4.8.6.3. Lifetime Count e Keep-Alive Count .....................135
5.4.8.6.4. Queue Size e Discard Oldest .........................135
5.4.8.6.5. Filter Type e Deadband Type .........................135
5.4.8.6.6. PublishingEnabled, MaxNotificationsPerPublish e Priority .........136
V

CONTENTS
5.4.8.7. Accessing Data Through an OPC UA Client .....................136
5.4.9. EtherNet/IP ...........................................138
5.4.9.1. EtherNet/IP Interface .................................138
5.4.9.2. EtherNet/IP Scanner Configuration ..........................140
5.4.9.2.1. General ....................................140
5.4.9.2.2. Connections ..................................141
5.4.9.2.3. Assemblies ..................................143
5.4.9.2.4. EtherNet/IP I/O Mapping ...........................144
5.4.9.3. EtherNet/IP Adapter Configuration ..........................144
5.4.9.3.1. Module Types .................................144
5.4.9.3.2. EtherNet/IP Module I/O Mapping ......................145
5.5. Communication Performance ......................................145
5.5.1. MODBUS Server ........................................145
5.5.1.1. CPU’s Local Interfaces ................................145
5.5.2. OPC DA Server .........................................146
5.5.3. OPC UA Server .........................................147
5.6. System Performance ...........................................147
5.6.1. I/O Scan Time ..........................................148
5.7. RTC Clock ................................................148
5.7.1. Function Blocks for RTC Reading and Writing .........................149
5.7.1.1. Function Blocks for RTC Reading ..........................149
5.7.1.1.1. GetDateAndTime ...............................149
5.7.1.1.2. GetTimeZone .................................150
5.7.1.1.3. GetDayOfWeek ................................151
5.7.1.2. Function Blocks and Functions of RTC Writing and Configuration .........152
5.7.1.2.1. SetDateAndTime ...............................152
5.7.1.2.2. SetTimeZone .................................153
5.7.2. RTC Data Structures .......................................154
5.7.2.1. EXTENDED_DATE_AND_TIME ..........................154
5.7.2.2. DAYS_OF_WEEK ..................................155
5.7.2.3. RTC_STATUS .....................................155
5.7.2.4. TIMEZONESETTINGS ...............................155
5.8. User Files Memory ...........................................156
5.9. CPU’s Informative and Configuration Menu ..............................158
5.10. Function Blocks and Functions .....................................160
5.10.1. Special Function Blocks for Serial Interfaces ..........................160
5.10.1.1. SERIAL_CFG .....................................164
5.10.1.2. SERIAL_GET_CFG .................................166
5.10.1.3. SERIAL_GET_CTRL ................................167
5.10.1.4. SERIAL_GET_RX_QUEUE_STATUS .......................169
5.10.1.5. SERIAL_PURGE_RX_QUEUE ...........................170
5.10.1.6. SERIAL_RX .....................................172
5.10.1.7. SERIAL_RX_EXTENDED ..............................174
5.10.1.8. SERIAL_SET_CTRL .................................176
5.10.1.9. SERIAL_TX .....................................178
5.10.2. Inputs and Outputs Update ...................................180
5.10.2.1. REFRESH_INPUT ..................................180
5.10.2.2. REFRESH_OUTPUT .................................181
VI

CONTENTS
5.10.3. PID Function Block .......................................182
5.10.4. Timer Retain ...........................................183
5.10.4.1. TOF_RET .......................................183
5.10.4.2. TON_RET .......................................184
5.10.4.3. TP_RET ........................................185
5.11. SNMP ..................................................187
5.11.1. Introduction ...........................................187
5.11.2. SNMP in Nexto CPUs ......................................187
5.11.3. Private MIB ...........................................188
5.11.4. Configuration SNMP ......................................188
5.11.5. User and SNMP Communities .................................190
5.12. User Management and Access Rights ..................................190
6. Maintenance .....................................................191
6.1. Module Diagnostics ...........................................191
6.1.1. One Touch Diag .........................................191
6.1.2. Diagnostics via LED .......................................193
6.1.2.1. DG (Diagnostic) ....................................193
6.1.2.2. WD (Watchdog) ....................................193
6.1.2.3. RJ45 Connector LEDs ................................194
6.1.3. Diagnostics via WEB ......................................194
6.1.4. Diagnostic Explorer .......................................196
6.1.5. Diagnostics via Variables ....................................197
6.1.5.1. Summarized Diagnostics ...............................197
6.1.5.2. Detailed Diagnostics .................................200
6.1.6. Diagnostics via Function Blocks ................................207
6.1.6.1. GetTaskInfo ......................................207
6.2. Graphic Display .............................................209
6.3. System Log ...............................................211
6.4. Not Loading the Application at Startup .................................211
6.5. Common Problems ...........................................211
6.6. Troubleshooting .............................................212
6.7. Preventive Maintenance .........................................212
VII

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: NX3004
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.
2