ALTUS Nexto Xpress User manual

User Manual
Nexto Xpress
MU216600 Rev. O
November 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. 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. Memory ............................................. 7
2.2.3. Protocols ............................................. 8
2.2.4. RS-485 .............................................. 8
2.2.5. CAN ............................................... 9
2.2.6. USB ............................................... 9
2.2.7. Ethernet ............................................. 10
2.2.8. Power Supply .......................................... 10
2.2.9. Digital Inputs .......................................... 11
2.2.10. Fast Inputs ............................................ 11
2.2.11. Digital Outputs ......................................... 12
2.2.12. Fast Outputs ........................................... 13
2.2.13. Analog Inputs .......................................... 14
2.2.14. Analog Outputs ......................................... 15
2.3. Compatibility with Other Products ................................... 16
2.4. Performance ............................................... 16
2.4.1. Interval Time .......................................... 16
2.4.2. Application Times ........................................ 17
2.4.3. Time for Instructions Execution ................................. 17
2.4.4. Initialization Times ....................................... 17
2.5. Physical Dimensions ........................................... 18
2.6. Purchase Data .............................................. 19
2.6.1. Integrant Items .......................................... 19
2.6.2. Product Code .......................................... 19
2.7. Related Products ............................................. 19
3. Installation ..................................................... 21
3.1. Mechanical Installation ......................................... 21
3.1.1. Installing the controller ..................................... 21
3.1.2. Removing the controller ..................................... 23
3.2. Electrical Installation .......................................... 24
II

CONTENTS
3.3. Ethernet Network Connection ...................................... 26
3.3.1. IP Address ............................................ 26
3.3.2. Gratuitous ARP ......................................... 26
3.3.3. Network Cable Installation ................................... 26
3.4. Serial RS-485 and CAN Network Connection ............................. 27
4. Initial Programming ................................................. 28
4.1. Memory Organization and Access .................................... 28
4.2. Project Profiles .............................................. 30
4.2.1. Machine Profile ......................................... 30
4.3. CPU Configuration ........................................... 31
4.4. Libraries ................................................. 33
4.5. Inserting a Protocol Instance ....................................... 33
4.5.1. MODBUS Ethernet ....................................... 33
4.6. Finding the Device ............................................ 35
4.7. Login ................................................... 37
4.8. Run Mode ................................................ 39
4.9. Stop Mode ................................................ 40
4.10. Writing and Forcing Variables ...................................... 41
4.11. Logout .................................................. 41
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 ............................................ 44
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 ...................................... 50
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 .......................................... 55
5.1.3.1. Quality Conversions .................................. 56
5.1.3.1.1. Internal Quality ................................ 56
III

CONTENTS
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
5.2.2. Advanced Configurations .................................... 61
5.3. Ethernet Interface ............................................ 61
5.3.1. NET 1 .............................................. 61
5.3.2. Reserved TCP Ports ....................................... 61
5.4. Controller Area Network Interface ................................... 63
5.4.1. CAN ............................................... 63
5.5. Integrated I/O .............................................. 63
5.5.1. Digital Inputs .......................................... 64
5.5.2. Fast Inputs ............................................ 65
5.5.2.1. High-Speed Counters ................................. 67
5.5.2.1.1. Counter Interrupts ............................... 71
5.5.2.2. External Interruption ................................. 72
5.5.3. Fast Outputs ........................................... 73
5.5.3.1. VFO/PWM ...................................... 74
5.5.3.2. PTO .......................................... 76
5.5.4. Analog Inputs .......................................... 81
5.5.5. RTD Inputs ........................................... 82
5.5.6. Analog Outputs ......................................... 83
5.5.7. I/O Mapping ........................................... 84
5.6. USB Port ................................................. 84
5.6.1. Mass Storage Devices ...................................... 86
5.6.1.1. General Storage .................................... 86
5.6.1.2. Not Loading the Application at Startup ........................ 87
5.6.1.3. Transfering an Application from the USB device ................... 87
5.6.2. USB to RS-232 Converters ................................... 88
5.6.3. Modem Devices ......................................... 89
5.6.4. WiFi Adapters .......................................... 92
5.7. Communication Protocols ........................................ 95
5.7.1. Protocol Behavior x CPU State ................................. 96
5.7.2. Double Points .......................................... 97
5.7.3. CPU’s Events Queue ...................................... 97
5.7.3.1. Consumers ...................................... 98
5.7.3.2. Queue Functioning Principles ............................. 98
5.7.3.2.1. Overflow Sign ................................. 98
5.7.3.3. Producers ....................................... 99
5.7.4. Interception of Commands Coming from the Control Center .................. 99
5.7.5. MODBUS RTU Master .....................................104
5.7.5.1. MODBUS Master Protocol Configuration by Symbolic Mapping ..........104
5.7.5.1.1. MODBUS Master Protocol General Parameters – Symbolic Mapping Con-
figuration ...................................104
5.7.5.1.2. Devices Configuration – Symbolic Mapping configuration .........107
5.7.5.1.3. Mappings Configuration – Symbolic Mapping Settings ...........108
5.7.5.1.4. Requests Configuration – Symbolic Mapping Settings ............109
5.7.6. MODBUS RTU Slave ......................................114
IV

CONTENTS
5.7.6.1. MODBUS Slave Protocol Configuration via Symbolic Mapping ..........114
5.7.6.1.1. MODBUS Slave Protocol General Parameters – Configuration via Sym-
bolic Mapping .................................114
5.7.6.1.2. Configuration of the Relations – Symbolic Mapping Setting .........118
5.7.7. MODBUS Ethernet .......................................119
5.7.8. MODBUS Ethernet Client ....................................121
5.7.8.1. MODBUS Ethernet Client Configuration via Symbolic Mapping ..........121
5.7.8.1.1. MODBUS Client Protocol General Parameters – Configuration via Sym-
bolic Mapping .................................122
5.7.8.1.2. Device Configuration – Configuration via Symbolic Mapping ........123
5.7.8.1.3. Mappings Configuration – Configuration via Symbolic Mapping ......125
5.7.8.1.4. Requests Configuration – Configuration via Symbolic Mapping .......126
5.7.8.2. MODBUS Client Relation Start in Acyclic Form ..................131
5.7.9. MODBUS Ethernet Server ...................................131
5.7.9.1. MODBUS Server Ethernet Protocol Configuration for Symbolic Mapping . . . . . 131
5.7.9.1.1. MODBUS Server Protocol General Parameters – Configuration via Sym-
bolic Mapping .................................131
5.7.9.1.2. MODBUS Server Diagnostics – Configuration via Symbolic Mapping . . . 133
5.7.9.1.3. Mapping Configuration – Configuration via Symbolic Mapping .......135
5.7.10. OPC DA Server .........................................136
5.7.10.1. Creating a Project for OPC DA Communication ...................137
5.7.10.2. Configuring a PLC on the OPC DA Server ......................140
5.7.10.2.1. Importing a Project Configuration ......................143
5.7.10.3. OPC DA Communication Status and Quality Variables ...............143
5.7.10.4. Limits of Communication with OPC DA Server ...................144
5.7.10.5. Accessing Data Through an OPC DA Client .....................145
5.7.11. OPC UA Server .........................................146
5.7.11.1. Creating a Project for OPC UA Communication ...................148
5.7.11.2. Types of Supported Variables .............................150
5.7.11.3. Limit Connected Clients on the OPC UA Server ...................150
5.7.11.4. Limit of Communication Variables on the OPC UA Server .............150
5.7.11.5. Encryption Settings ..................................150
5.7.11.6. Main Communication Parameters Adjusted in an OPC UA Client ..........151
5.7.11.6.1. Endpoint URL .................................151
5.7.11.6.2. Publishing Interval (ms) e Sampling Interval (ms) ..............152
5.7.11.6.3. Lifetime Count e Keep-Alive Count .....................152
5.7.11.6.4. Queue Size e Discard Oldest .........................152
5.7.11.6.5. Filter Type e Deadband Type .........................152
5.7.11.6.6. PublishingEnabled, MaxNotificationsPerPublish e Priority .........153
5.7.11.7. Accessing Data Through an OPC UA Client .....................153
5.7.12. EtherNet/IP ...........................................155
5.7.12.1. EtherNet/IP ......................................155
5.7.12.2. EtherNet/IP Scanner Configuration ..........................156
5.7.12.2.1. General ....................................157
5.7.12.2.2. Connections ..................................158
5.7.12.2.3. Assemblies ..................................159
5.7.12.2.4. EtherNet/IP I/O Mapping ...........................160
5.7.12.3. EtherNet/IP Adapter Configuration ..........................160
5.7.12.3.1. Module Types .................................161
V

CONTENTS
5.7.12.3.2. EtherNet/IP Module I/O Mapping ......................161
5.7.13. IEC 60870-5-104 Server .....................................161
5.7.13.1. Type of data ......................................162
5.7.13.2. Double Points .....................................163
5.7.13.2.1. Digital Input Double Points ..........................164
5.7.13.2.2. Digital Output Double Points .........................165
5.7.13.3. General Parameters ..................................170
5.7.13.4. Data Mapping .....................................170
5.7.13.5. Link Layer .......................................173
5.7.13.6. Application Layer ...................................175
5.7.13.7. Server Diagnostic ...................................177
5.7.13.8. Commands Qualifier .................................178
5.7.14. CANopen Manager .......................................179
5.7.14.1. Installing and inserting CANopen Devices ......................179
5.7.14.2. CANopen Manager Configuration ..........................180
5.7.14.3. CANopen Slave Configuration ............................181
5.8. Remote I/O Mode ............................................183
5.8.1. CANopen Slave .........................................183
5.9. Communication Performance ......................................188
5.9.1. MODBUS Server ........................................188
5.9.1.1. CPU’s Local Interfaces ................................188
5.9.2. OPC DA Server .........................................189
5.9.3. OPC UA Server .........................................189
5.10. User Web Pages .............................................190
5.11. SNMP ..................................................190
5.11.1. Introduction ...........................................190
5.11.2. SNMP in Nexto Xpress Controllers ...............................190
5.11.3. Configuration SNMP ......................................192
5.11.4. User and SNMP Communities .................................193
5.12. RTC Clock ................................................194
5.12.1. Function Blocks for RTC Reading and Writing .........................194
5.12.1.1. Function Blocks for RTC Reading ..........................194
5.12.1.1.1. GetDateAndTime ...............................194
5.12.1.1.2. GetTimeZone .................................195
5.12.1.1.3. GetDayOfWeek ................................196
5.12.1.2. RTC Writing Functions ................................197
5.12.1.2.1. SetDateAndTime ...............................197
5.12.1.2.2. SetTimeZone .................................198
5.12.2. RTC Data Structures .......................................199
5.12.2.1. EXTENDED_DATE_AND_TIME ..........................199
5.12.2.2. DAYS_OF_WEEK ..................................199
5.12.2.3. RTC_STATUS .....................................200
5.12.2.4. TIMEZONESETTINGS ...............................200
5.13. Function Blocks and Functions .....................................201
5.13.1. Special Function Blocks for Serial Interfaces ..........................201
5.13.1.1. SERIAL_CFG .....................................205
5.13.1.2. SERIAL_GET_CFG .................................207
5.13.1.3. SERIAL_GET_CTRL ................................208
VI

CONTENTS
5.13.1.4. SERIAL_GET_RX_QUEUE_STATUS .......................210
5.13.1.5. SERIAL_PURGE_RX_QUEUE ...........................211
5.13.1.6. SERIAL_RX .....................................212
5.13.1.7. SERIAL_RX_EXTENDED ..............................215
5.13.1.8. SERIAL_SET_CTRL .................................217
5.13.1.9. SERIAL_TX .....................................219
5.13.2. Inputs and Outputs Update ...................................221
5.13.2.1. RefreshIntegratedIoInputs ...............................221
5.13.2.2. RefreshIntegratedIoOutputs ..............................221
5.13.3. Timer Retain ...........................................222
5.13.3.1. TOF_RET .......................................222
5.13.3.2. TON_RET .......................................223
5.13.3.3. TP_RET ........................................224
6. Maintenance .....................................................226
6.1. Diagnostics ................................................226
6.1.1. Diagnostics via LED .......................................226
6.1.2. Diagnostics via WEB ......................................227
6.1.3. Diagnostics via Variables ....................................228
6.1.3.1. Summarized Diagnostics ...............................228
6.1.3.2. Detailed Diagnostics .................................229
6.1.4. Diagnostics via Function Blocks ................................236
6.1.4.1. GetTaskInfo ......................................236
6.2. Preventive Maintenance .........................................237
VII

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 using expansion modules (see section
Related Products). Additionally, the number of I/O points can be further expanded through remote (distributed) I/O devices
communicating via protocols such as CANopen, EtherNet/IP, PROFINET and MODBUS.
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,
including motion control applications. 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 – Características Técnicas 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
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 Document 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: 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