ALTUS Nexto NX3004 User manual

User Manual
Nexto Series CPUs
NX3004, NX3005, NX3010,
NX3020, NX3030
Rev. K 11/2017
Doc. Code.: MU214605

General Supply Conditions
i
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 use EtherCAT® technology (www.ethercat.org).
COPYRIGHTS
Nexto and MasterTool 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 [e-mail]. In addition to the source code, all referred
license terms, warranty disclaimers and copyright notices may be disclosed under request.

Summary
ii
Table of Contents
1. INTRODUCTION.......................................................................................................................................1
Nexto Series..................................................................................................................................................2
Innovative Features................................................................................................................................3
Documents Related to this Manual .............................................................................................................4
Visual Inspection..........................................................................................................................................5
Technical Support........................................................................................................................................5
Warning Messages Used in this Manual .....................................................................................................5
2. TECHNICAL DESCRIPTION...................................................................................................................6
Panels and Connections...............................................................................................................................6
General Features..........................................................................................................................................8
Common General Features.....................................................................................................................8
Specific Features....................................................................................................................................9
Serial Interfaces...................................................................................................................................12
Ethernet Interfaces...............................................................................................................................13
Power Supply ......................................................................................................................................14
Memory Card Interface........................................................................................................................14
Compatibility with Other Products...........................................................................................................15
Performance...............................................................................................................................................15
Application Times ...............................................................................................................................15
Time for Instructions Execution...........................................................................................................16
Initialization Times..............................................................................................................................16
Interval Time.......................................................................................................................................16
Physical Dimensions ..................................................................................................................................17
NX3004/NX3005.................................................................................................................................17
NX3010/NX3020/NX3030 ..................................................................................................................18
Purchase Data............................................................................................................................................19
Integrant Items.....................................................................................................................................19
Product Code.......................................................................................................................................19
Related Products........................................................................................................................................19
3. INSTALLATION.......................................................................................................................................21
Mechanical Installation .............................................................................................................................21
NX3004 and NX3005 ..........................................................................................................................21
NX3010, NX3020 and NX3030 ...........................................................................................................21
Electrical Installation.................................................................................................................................21
NX3004 and NX3005 ..........................................................................................................................21
NX3010, NX3020 and NX3030 ...........................................................................................................22
Ethernet Network Connection...................................................................................................................23
IP Address...........................................................................................................................................23
Gratuitous ARP ...................................................................................................................................23
Network Cable Installation...................................................................................................................24
Serial Network Connection RS-232...........................................................................................................25
RS-232C Communication....................................................................................................................25
Serial Network Connection RS-485/422....................................................................................................25
RS-485 Communication without termination........................................................................................26
RS-485 Communication with Internal Termination ..............................................................................27
RS-485 Communication with External Termination .............................................................................28
Example of Connection of a RS-485 Network with External Termination and Master Redundancy ......28
RS-422 Communication without Termination ......................................................................................29

Summary
iii
RS-422 Communication with Internal Termination ..............................................................................30
RS-422 Communication with External Termination .............................................................................31
RS-422 Network Example ...................................................................................................................31
Memory Card Installation.........................................................................................................................32
Architecture Installation ...........................................................................................................................33
Module Installation on the Main Backplane Rack.................................................................................33
Programmer Installation...........................................................................................................................33
4. CONFIGURATION...................................................................................................................................34
CPU Configuration....................................................................................................................................34
General Parameters..............................................................................................................................34
External Event Configuration...............................................................................................................43
SOE Configuration ..............................................................................................................................45
Time Synchronization..........................................................................................................................47
Internal Points......................................................................................................................................50
Serial Interfaces Configuration.................................................................................................................59
COM 1 (NX3010/NX3020/NX3030) ...................................................................................................59
COM1 (NX3004/NX3005) and COM 2 (NX3010/NX3020/NX3030) ..................................................62
Ethernet Interfaces Configuration............................................................................................................63
Local Ethernet Interfaces .....................................................................................................................63
Remote Ethernet Interfaces ..................................................................................................................64
Reserved TCP Ports.............................................................................................................................64
NX5000 Module Configuration.................................................................................................................64
Protocols Configuration.............................................................................................................................66
Protocol Behavior x CPU State ............................................................................................................70
Double Points ......................................................................................................................................71
CPU’s Events Queue............................................................................................................................71
Interception of Commands Coming from the Control Center ...............................................................73
MODBUS RTU MASTER...................................................................................................................77
MODBUS RTU SLAVE......................................................................................................................90
MODBUS Ethernet..............................................................................................................................98
OPC DA Server .................................................................................................................................122
Master EtherCAT ..............................................................................................................................134
EtherNet/IP........................................................................................................................................152
IEC 60870-5-104 Server ....................................................................................................................160
Communication Performance .................................................................................................................173
MODBUS Server...............................................................................................................................173
OPC Server........................................................................................................................................175
Server IEC60870-5-104.....................................................................................................................175
System Performance................................................................................................................................176
I/O Scan Time ...................................................................................................................................176
Memory Card ....................................................................................................................................177
RTC Clock...............................................................................................................................................177
Function Blocks for RTC Reading and Writing..................................................................................177
RTC Data Structures..........................................................................................................................181
User Files Memory...................................................................................................................................183
Memory Card ..........................................................................................................................................185
MasterTool Access ............................................................................................................................187
CPU’s Informative and Configuration Menu .........................................................................................188
Function Blocks and Functions ...............................................................................................................191
Special Function Blocks for Serial Interfaces .....................................................................................191
Inputs and Outputs Update.................................................................................................................207
PID Function Block ...........................................................................................................................210
Timer Retain......................................................................................................................................213
Non-Redundant Timer .......................................................................................................................216

Summary
iv
User Log............................................................................................................................................218
ClearRtuDiagnostic............................................................................................................................221
ClearEventQueue...............................................................................................................................221
SNMP.......................................................................................................................................................222
Introduction.......................................................................................................................................222
SNMP in Nexto CPUs .......................................................................................................................222
Private MIB.......................................................................................................................................223
Configuration.....................................................................................................................................226
User and SNMP Communities ...........................................................................................................227
User Management and Access Rights .....................................................................................................228
5. INITIAL PROGRAMMING...................................................................................................................229
Memory Organization and Access ..........................................................................................................229
Project Profiles.........................................................................................................................................231
Single................................................................................................................................................232
Basic .................................................................................................................................................232
Normal ..............................................................................................................................................232
Expert................................................................................................................................................233
Custom..............................................................................................................................................234
Machine Profile .................................................................................................................................234
General Table ....................................................................................................................................235
Maximum Number of Tasks...............................................................................................................235
CPU Configuration..................................................................................................................................237
Libraries...................................................................................................................................................238
Inserting a Protocol Instance...................................................................................................................238
MODBUS RTU.................................................................................................................................239
MODBUS Ethernet............................................................................................................................240
Server IEC 60870-5-104....................................................................................................................242
Finding the Network................................................................................................................................245
Login ........................................................................................................................................................247
Run Mode.................................................................................................................................................248
Stop Mode................................................................................................................................................250
Writing and Forcing Variables ...............................................................................................................250
Logout ......................................................................................................................................................251
Project Upload.........................................................................................................................................251
CPU Operating States..............................................................................................................................253
Run....................................................................................................................................................253
Stop...................................................................................................................................................253
Breakpoint.........................................................................................................................................253
Exception ..........................................................................................................................................253
Reset Warm.......................................................................................................................................253
Reset Cold.........................................................................................................................................253
Reset Origin.......................................................................................................................................253
Reset Process Command (IEC 60870-5-104)......................................................................................254
Programs (POUs) and General Variable Lists (GVLs) ..........................................................................254
MainPrg Program ..............................................................................................................................254
StartPrg Program ...............................................................................................................................254
UserPrg Program ...............................................................................................................................254
GVL Disables....................................................................................................................................254
GVL IOQualities ...............................................................................................................................255
GVL Module_Diagnostics .................................................................................................................256
GVL Qualities ...................................................................................................................................257
GVL ReqDiagnostics.........................................................................................................................259
GVL System_Diagnostics..................................................................................................................261

Summary
v
6. REDUNDANCY WITH NX3030 CPU....................................................................................................263
Introduction.............................................................................................................................................263
Technical Description and Configuration...............................................................................................265
Minimum Configuration of a Redundant CPU (Not Using PX2612 Panel) .........................................265
Typical Configurations of a Redundant CPU......................................................................................265
NX4010 Module................................................................................................................................266
Redundancy Control Panel PX2612 ...................................................................................................267
Interconnections between Half-Clusters and the Redundancy Control Panel PX2612..........................269
General Features................................................................................................................................270
Purchase Data....................................................................................................................................272
Principles of Operation............................................................................................................................273
NX3030 CPU Identification...............................................................................................................273
Single Redundant Project...................................................................................................................273
Redundant Project Structure...............................................................................................................273
Multiple Mapping..............................................................................................................................278
Diagnostics, Commands and User Data Structure...............................................................................279
Cyclic Synchronization Services through NETA and NETB...............................................................280
Sporadic Synchronization Services through NETA and NETB...........................................................281
Project Synchronization Disabling .....................................................................................................282
PROFIBUS Network Configuration...................................................................................................283
Redundant Ethernet Networks with NIC Teaming..............................................................................284
IP Change Methods............................................................................................................................284
NIC Teaming and Active IP Combined Use.......................................................................................288
Ethernet Interfaces Use with Vital Fault Indication.............................................................................288
OPC Communication Use with Redundant Projects............................................................................289
Redundant CPU States.......................................................................................................................289
PX2612 Redundancy Command Panel Functions...............................................................................291
Transition between Redundancy States ..............................................................................................293
First Instants in Active State ..............................................................................................................296
Common Failures which Cause Automatic Switchovers between Half-Clusters..................................296
Failures Associated to Switchovers between Half-Clusters Managed by the User ...............................297
Fault Tolerance..................................................................................................................................298
Redundancy Overhead.......................................................................................................................300
Redundant CPU Programming...............................................................................................................300
Wizard for a New Redundant Project Creation...................................................................................300
Half-Clusters Configuration...............................................................................................................305
Ethernet Ports Configuration in the CPU NX3030 (NET 1 and NET 2) ..............................................305
NX5001 Modules Configuration........................................................................................................307
NX5000 Modules Configuration........................................................................................................309
NX4010 Redundancy Configuration ..................................................................................................310
I/O Drivers Configuration..................................................................................................................311
MainTask Configuration....................................................................................................................311
Redundancy Configuration Object .....................................................................................................313
GVL Diagnostics...............................................................................................................................313
GVLs with Redundant Symbolic Variables ........................................................................................313
POUs from the Program Type with Redundant Symbolic Variables....................................................314
Breakpoints Utilization in Redundant Systems ...................................................................................314
MODBUS Instances Managing in Redundant System ........................................................................314
Limitations on a Redundant PLC Programming..................................................................................314
Getting the Redundancy State of a Half-Cluster .................................................................................315
Reading Non-Redundant Diagnostics.................................................................................................315
Redundant CPU Program Downloading.................................................................................................316
Initial Downloading of a Redundant Project .......................................................................................316
MasterTool Connection with a NX3030 CPU from a Redundant PLC ................................................318
Modification Download in a Redundant Project .................................................................................319

Summary
vi
Off-Line and On-Line Modifications Download.................................................................................319
On-Line Download of Modifications..................................................................................................320
Off-Line Download of Modifications with Process Control Interruption.............................................321
Previous Planning for Off-Line Modifications without Process Control Interruption...........................322
Exploring the Redundancy for Off-Line downloading of Modifications without Interruption of the
Process control...................................................................................................................................327
Maintenance.............................................................................................................................................331
Modules Hot Swapping in a Redundant PLC......................................................................................331
MasterTool Warning Messages ..........................................................................................................331
Redundancy Diagnostics on the NX3030 CPU Graphic Display.........................................................332
Redundancy Diagnostics Structure.....................................................................................................332
PX2612 Panel Test ............................................................................................................................345
7. MAINTENANCE.....................................................................................................................................347
Module Diagnostics..................................................................................................................................347
One Touch Diag.................................................................................................................................347
Diagnostics via LED..........................................................................................................................350
Diagnostics via WEB.........................................................................................................................351
Diagnostic Explorer...........................................................................................................................353
Diagnostics via Variables...................................................................................................................354
Diagnostics via Function Blocks ........................................................................................................368
Graphic Display.......................................................................................................................................370
System Log...............................................................................................................................................372
Not Loading the Application at Startup..................................................................................................372
Power Supply Failure ..............................................................................................................................372
Common Problems ..................................................................................................................................373
Troubleshooting.......................................................................................................................................373
Preventive Maintenance ..........................................................................................................................374
8. GLOSSARY.............................................................................................................................................375
9. ANNEX A. DNP3 INTEROPERABILITY.............................................................................................379
DNP3 Device Profile ................................................................................................................................379
DNP3........................................................................................................................................................379
DEVICE PROFILE DOCUMENT.....................................................................................................379
DNP V3.0 Implementation Table ............................................................................................................380

1. Introduction
1
1.Introduction
Nexto Series CPUs were designed to fulfill several customers’ demands in a variety of applications
present on industrial automation and process control. Due to its compact and rugged body, excellent
performance and fast I/Os update time provided by a unique high-speed communication bus, Nexto
Series CPUs are the best choice for the most demanding control applications. In complex
applications, where reliability, availability and remote I/O operation is required, Nexto Series CPUs
are also a great choice due to its different redundant topologies and bus expansion possibilities.
Nexto Series CPUs provide innovative and unique enhanced diagnostics services. They take the user
to a whole new diagnostics experience. By using a switch located on top of the module and a built-in
compact graphical LCD display, the user has direct access to extensive information regarding I/Os,
fieldbus interfaces and many other modules on the application. In addition, it has user register system
services and ease at debbuging and tasks management, reducing the application cost and installation
time.
Finally, Nexto Series CPUs feature several communication interfaces such as serial and Ethernet
ports, a memory card interface and full IEC 61131-3 programming languages.
Figure 1-1. CPU NX3030

1. Introduction
2
Nexto Series
Nexto Series is a powerful and complete series of Programmable Controllers (PLC) with exclusive
and innovative characteristics. 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. Furthermore, 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.
Figure 1-2. Nexto Series –Overview