ALTUS Nexto Xpress User manual

User Manual
Nexto Xpress
MU216600 Rev. L
February 23, 2021

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. Documents Related to this Manual ................................... 2
1.2. Visual Inspection ............................................. 2
1.3. Technical Support ............................................ 3
1.4. Warning Messages Used in this Manual ................................. 3
2. Technical Description ................................................ 4
2.1. Panels and Connections ......................................... 4
2.2. Product Features ............................................. 5
2.2.1. General Features ......................................... 5
2.2.2. RS-485 .............................................. 7
2.2.3. CAN ............................................... 8
2.2.4. USB ............................................... 8
2.2.5. Ethernet ............................................. 9
2.2.6. Power Supply .......................................... 10
2.2.7. Digital Inputs .......................................... 10
2.2.8. Fast Inputs ............................................ 11
2.2.9. Digital Outputs ......................................... 12
2.2.10. Fast Outputs ........................................... 13
2.2.11. Analog Inputs .......................................... 14
2.2.12. Analog Outputs ......................................... 16
2.3. Compatibility with Other Products ................................... 17
2.4. Performance ............................................... 17
2.4.1. Interval Time .......................................... 17
2.4.2. Application Times ........................................ 17
2.4.3. Time for Instructions Execution ................................. 18
2.4.4. Initialization Times ....................................... 18
2.5. Physical Dimensions ........................................... 19
2.6. Purchase Data .............................................. 20
2.6.1. Integrant Items .......................................... 20
2.6.2. Product Code .......................................... 20
2.7. Related Products ............................................. 20
3. Installation ..................................................... 22
3.1. Mechanical Installation ......................................... 22
3.1.1. Installing the controller ..................................... 22
3.1.2. Removing the controller ..................................... 24
3.2. Electrical Installation .......................................... 25
3.3. Ethernet Network Connection ...................................... 27
3.3.1. IP Address ............................................ 27
3.3.2. Gratuitous ARP ......................................... 27
II

CONTENTS
3.3.3. Network Cable Installation ................................... 27
3.4. Serial RS-485 and CAN Network Connection ............................. 28
4. Initial Programming ................................................. 29
4.1. Memory Organization and Access .................................... 29
4.2. Project Profiles .............................................. 31
4.2.1. Machine Profile ......................................... 31
4.3. CPU Configuration ........................................... 32
4.4. Libraries ................................................. 34
4.5. Inserting a Protocol Instance ....................................... 34
4.5.1. MODBUS Ethernet ....................................... 34
4.6. Finding the Device ............................................ 36
4.7. Login ................................................... 38
4.8. Run Mode ................................................ 40
4.9. Stop Mode ................................................ 41
4.10. Writing and Forcing Variables ...................................... 41
4.11. Logout .................................................. 42
4.12. Project Upload .............................................. 42
4.13. CPU Operating States .......................................... 43
4.13.1. Run ............................................... 43
4.13.2. Stop ............................................... 43
4.13.3. Breakpoint ............................................ 43
4.13.4. Exception ............................................ 44
4.13.5. Reset Warm ........................................... 44
4.13.6. Reset Cold ............................................ 44
4.13.7. Reset Origin ........................................... 44
4.13.8. Reset Process Command (IEC 60870-5-104) .......................... 44
4.14. Programs (POUs) and Global Variable Lists (GVLs) .......................... 44
4.14.1. MainPrg Program ........................................ 44
4.14.2. StartPrg Program ........................................ 45
4.14.3. UserPrg Program ........................................ 45
4.14.4. GVL IntegratedIO ........................................ 45
4.14.5. GVL System_Diagnostics .................................... 46
4.14.6. GVL Disables .......................................... 47
4.14.7. GVL Qualities .......................................... 48
4.14.8. GVL ReqDiagnostics ...................................... 49
5. Configuration .................................................... 52
5.1. Controller’s CPU ............................................. 52
5.1.1. General Parameters ....................................... 52
5.1.2. Time Synchronization ...................................... 53
5.1.2.1. IEC 60870-5-104 ................................... 53
5.1.2.2. SNTP ......................................... 54
5.1.2.3. Daylight Saving Time (DST) ............................. 54
5.1.3. Internal Points .......................................... 54
5.1.3.1. Quality Conversions .................................. 56
5.1.3.1.1. Internal Quality ................................ 56
5.1.3.1.2. IEC 60870-5-104 Conversion ......................... 58
5.1.3.1.3. MODBUS Internal Quality .......................... 59
5.2. Serial Interface .............................................. 60
5.2.1. COM 1 .............................................. 60
III

CONTENTS
5.2.2. Advanced Configurations .................................... 60
5.3. Ethernet Interface ............................................ 61
5.3.1. NET 1 .............................................. 61
5.3.2. Reserved TCP Ports ....................................... 61
5.4. Controller Area Network Interface ................................... 62
5.4.1. CAN ............................................... 62
5.5. Integrated I/O .............................................. 62
5.5.1. Digital Inputs .......................................... 63
5.5.2. Fast Inputs ............................................ 64
5.5.2.1. High-Speed Counters ................................. 66
5.5.2.1.1. Counter Interrupts ............................... 70
5.5.2.2. External Interruption ................................. 71
5.5.3. Fast Outputs ........................................... 72
5.5.3.1. VFO/PWM ...................................... 73
5.5.3.2. PTO .......................................... 75
5.5.4. Analog Inputs .......................................... 80
5.5.5. RTD Inputs ........................................... 81
5.5.6. Analog Outputs ......................................... 82
5.5.7. I/O Mapping ........................................... 83
5.6. USB Port ................................................. 84
5.6.1. Mass Storage Devices ...................................... 85
5.6.1.1. General Storage .................................... 85
5.6.1.2. Not Loading the Application at Startup ........................ 86
5.6.1.3. Transfering an Application from the USB device ................... 87
5.6.2. USB to RS-232 Converters ................................... 87
5.6.3. Modem Devices ......................................... 88
5.6.4. WiFi Adapters .......................................... 91
5.7. Communication Protocols ........................................ 94
5.7.1. MODBUS RTU MASTER ................................... 94
5.7.2. MODBUS RTU SLAVE ..................................... 94
5.7.3. MODBUS ETHERNET ..................................... 94
5.7.4. OPC DA Server ......................................... 94
5.7.5. OPC UA Server ......................................... 95
5.7.6. EtherNet/IP ........................................... 95
5.7.7. IEC 60870-5-104 Server ..................................... 95
5.7.8. CANopen Manager ....................................... 95
5.7.8.1. Installing and inserting CANopen Devices ...................... 95
5.7.8.2. CANopen Manager Configuration .......................... 96
5.7.8.3. CANopen Slave Configuration ............................ 97
5.8. Remote I/O Mode ............................................ 98
5.8.1. CANopen Slave ......................................... 98
5.9. User Web Pages .............................................102
5.10. SNMP ..................................................102
5.10.1. Introduction ...........................................102
5.10.2. SNMP in Nexto Xpress Controllers ...............................102
5.10.3. Configuration ..........................................103
5.10.4. User and SNMP Communities .................................104
5.11. RTC Clock ................................................105
5.12. Function Blocks and Functions .....................................105
IV

CONTENTS
6. Maintenance .....................................................106
6.1. Diagnostics ................................................106
6.1.1. Diagnostics via LED .......................................106
6.1.2. Diagnostics via WEB ......................................107
6.1.3. Diagnostics via Variables ....................................108
6.1.3.1. Summarized Diagnostics ...............................108
6.1.3.2. Detailed Diagnostics .................................109
6.1.4. Diagnostics via Function Blocks ................................116
6.2. Preventive Maintenance .........................................116
V

1. INTRODUCTION
1. Introduction
Nexto Xpress is a powerful compact Programmable Logic Controller (PLC) part of Nexto Series family of controllers and
I/O modules. Nexto Xpress delivers high-speed processing power in a compact design with embedded I/O. There are several
options to choose from, allowing the best solution for entry-level applications.
This product portfolio targets small control systems, offering models containing from a few digital inputs and outputs up
to options with 43 I/O points concentrated in a single controller, including analog inputs and outputs with temperature support
(RTD sensors). In case of additional I/O needs, the system can be easily expanded through CANopen using the Remote I/O
Mode. This mode transforms the product into a non-programmable slave I/O device, which can then be connected to a XP3xx
controller with CANopen Manager protocol. It can also be expanded using other available ports like Ethernet and RS-485.
Nexto Xpress is suitable for small applications and remote distributed I/O. It may be applied in verticals such as infrastruc-
ture, building automation, water, wastewater, food, textiles, factory automation, machines and several other OEM solutions.
Additionally, it is an ideal solution for complementing big applications along with Nexto Series portfolio, extending the range
of applications using the same technology and engineering environment. This is a great advantage for OEMs and systems
integrators with needs of small to large applications.
Figure 1: Nexto Xpress
1

1. INTRODUCTION
1.1. Documents Related to this Manual
This manual will focus on information that is specific for the controllers of Nexto Xpress family. For other functionalities
that are identical along all controllers of Nexto Series, this manual will just point to the corresponding manual of Nexto Series
that contains the information. These related manuals are described on the following table, and are available in its last version
on the site http://www.altus.com.br/site_en/.
Code Description Language
CE114000 Nexto Series – Technical Characteristics English
CT114000 Série Nexto – Características Técnicas Portuguese
CS114000 Serie Nexto – Especificaciones y Configuraciones Spanish
MU216600 Nexto Xpress User Manual English
MU216000 Manual de Utilização Nexto Xpress Portuguese
MU214600 Nexto Series User Manual English
MU214000 Manual de Utilização Série Nexto Portuguese
MU214605 Nexto Series CPUs User Manual English
MU214100 Manual de Utilização CPUs Série Nexto 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
MU214606 MQTT User Manual English
MU223603 IEC 60870-5-104 Server Device Profile English
NAP151 Utilização do Tunneller OPC Portuguese
NAP165 Comunicação OPC UA com Controladores ALTUS Portuguese
OPC UA Communication with ALTUS Controllers English
Table 1: Documents Related
1.2. 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.
2

1. INTRODUCTION
1.3. 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].
If the equipment is already installed, you must have the following information at the moment of support requesting:
The model of 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 side
CPU operation mode information, acquired through MasterTool IEC XE
The application software content, acquired through MasterTool IEC XE
Used programmer version
1.4. 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 considera-
tion 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.
3

2. TECHNICAL DESCRIPTION
2. Technical Description
This chapter presents all technical features of Nexto Xpress controllers.
2.1. Panels and Connections
The following figure shows the XP325 front panel:
Figure 2: XP325 front panel
The front panel contains the identification of the I/O and communication interfaces available on Nexto Xpress controllers.
The digital I/O interfaces have one LED for each point to indicate the logic state, while the communication interfaces have one
LED each to indicate activity. The availability of these interfaces on each model is described on next section.
Additionally, on the right side of front panel there are 2 LEDs used to indicate power and diagnostics. The following table
shows the LEDs description. For further information regarding the LEDs status and meaning, see Maintenance chapter.
LED Description
PWR Status of internal power supply
DG Diagnostic indication
Ixx.x Status of digital inputs
Qxx.x Status of digital outputs
D+/- Status of RS-485 interface (blinks on activity)
H/L Status of CAN interface (blinks on activity)
USB Status of USB port (turns on when device is mounted)
ETH Status of Ethernet interface (turns on when connected, blinks on activity)
Table 2: LEDs Description
4