ALTUS Hadron Xtorm User manual

Hadron Xtorm
User Manual
Rev. C 02/2017
Doc. Code: MU223600

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.
COPYRIGHTS
Hadron Xtorm, Nexto, Ponto Series, MasterTool and Grano are the registered trademarks of Altus
Sistemas de Automação S.A.
Windows, Windows NT and Windows Vista are registered trademarks of Microsoft Corporation.
These products use EtherCAT® technology (www.ethercat.org).
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 opens[email protected].br. In addition to the source code, all referred
license terms, warranty disclaimers and copyright notices may be disclosed under request.

Summary
ii
Summary
1. INTRODUCTION.......................................................................................................................................7
Hadron Xtorm Series...................................................................................................................................7
Innovative Features................................................................................................................................8
Main Features........................................................................................................................................9
Documents Related to this Manual ...........................................................................................................10
Technical Support......................................................................................................................................12
Warning Messages Used in this Manual ...................................................................................................12
2. TECHNICAL DESCRIPTION.................................................................................................................13
Panels and Connections.............................................................................................................................13
General Features........................................................................................................................................14
Common General Features...................................................................................................................14
Specific Features..................................................................................................................................16
Serial Interfaces...................................................................................................................................18
Ethernet Interfaces...............................................................................................................................19
IRIG-B ................................................................................................................................................19
Graphic Display...................................................................................................................................20
Memory Card Interface........................................................................................................................20
Compatibility with Other Products...........................................................................................................20
Performance...............................................................................................................................................21
Application Times ...............................................................................................................................21
Time for Instructions Execution...........................................................................................................21
Initialization Times..............................................................................................................................22
Related Products........................................................................................................................................22
3. INSTALLATION.......................................................................................................................................24
Visual Inspection........................................................................................................................................24
Mechanical Installation .............................................................................................................................24
Rack Clamping....................................................................................................................................24
Module Insertion..................................................................................................................................26
Module Removal .................................................................................................................................29
Electrical Installation.................................................................................................................................32
Electrical Safety...................................................................................................................................32
Spring Terminal Blocks .......................................................................................................................33
Connections.........................................................................................................................................36
Supply Voltages...................................................................................................................................36
Fuses ...................................................................................................................................................36
CPU Electrical Installation........................................................................................................................37
Ethernet Network Connection...................................................................................................................37
IP Address...........................................................................................................................................38
Free ARP.............................................................................................................................................39
Network Cable Installation...................................................................................................................39
Serial Network Connection (COM 1)........................................................................................................40
RS-232C Communication....................................................................................................................41
RS-485 Communication without Termination ......................................................................................41
RS-485 Communication with Internal Termination ..............................................................................41
RS-485 Communication with External Termination .............................................................................42
Serial Network Connection (COM 2)........................................................................................................43
RS-485 Communication without Termination ......................................................................................43

Summary
iii
RS-485 Communication with Internal Termination ..............................................................................44
RS-485 Communication with External Termination .............................................................................45
RS-422 Communication without Termination ......................................................................................46
RS-422 Communication with Internal Termination ..............................................................................47
RS-422 Communication with External Termination .............................................................................48
RS-422 Network Example ...................................................................................................................49
IRIG- B Connection...................................................................................................................................50
IRIG-B Connection Pins ......................................................................................................................52
Memory Card Installation.........................................................................................................................53
Programmer Installation...........................................................................................................................54
4. CONFIGURATION...................................................................................................................................59
CPU Configuration....................................................................................................................................59
General Parameters..............................................................................................................................60
Time Synchronization..........................................................................................................................63
Internal Points......................................................................................................................................67
Engineering Conversion.......................................................................................................................73
Alarms.................................................................................................................................................74
Event Grouping ...................................................................................................................................75
Serial Interfaces Configuration.................................................................................................................77
COM 1 ................................................................................................................................................77
COM 2 ................................................................................................................................................80
Ethernet Interfaces Configuration............................................................................................................81
Local Ethernet Interfaces .....................................................................................................................81
Reserved TCP Ports.............................................................................................................................82
Ethernet Interfaces Advanced Configurations.......................................................................................82
Double Points.............................................................................................................................................83
Protocols Configuration.............................................................................................................................83
CPU Event Queue................................................................................................................................86
Interception of Commands from Control Center...................................................................................88
MODBUS –Data Types ......................................................................................................................93
MODBUS RTU Master .......................................................................................................................93
MODBUS RTU Slave........................................................................................................................102
MODBUS Ethernet............................................................................................................................106
MODBUS Ethernet Client .................................................................................................................108
MODBUS Ethernet Server.................................................................................................................116
DNP3 –Data Types...........................................................................................................................121
DNP3 Ethernet Client ........................................................................................................................121
DNP3 Ethernet Server........................................................................................................................137
IEC 60870-5-104 –Data Types..........................................................................................................147
IEC 60870-5-104 Server ....................................................................................................................148
IEC61850 Server ...............................................................................................................................157
Communcation Performance ..................................................................................................................173
MODBUS Communication Performance............................................................................................173
DNP3 Communication Performance ..................................................................................................175
IEC 60870-5-104 Communication Performance.................................................................................176
System Performance................................................................................................................................176
I/O Scanning......................................................................................................................................176
Memory Card ....................................................................................................................................177
RTC Clock...............................................................................................................................................177
Function Blocks and Functions for RTC Reading and Writing............................................................178
RTC Data Structure ...........................................................................................................................182
User Files Memory...................................................................................................................................183
Memory Card ..........................................................................................................................................186
Access in MasterTool ........................................................................................................................188

Summary
iv
Informative Menu and of CPU’s Configuration .....................................................................................189
Function Blocks and Functions ...............................................................................................................192
Inputs and Outputs Update.................................................................................................................192
RetainTimer.......................................................................................................................................194
Non-Redundant Timer .......................................................................................................................198
User Log............................................................................................................................................200
ClearRtuDiagnostic............................................................................................................................203
ClearEventQueue...............................................................................................................................203
User Management and Access Rights .....................................................................................................204
User Management and Project’s Access Rights ..................................................................................204
UCP’s User Management and Access Rights......................................................................................211
5. INITIAL PROGRAMMING...................................................................................................................219
Memory Organization and Access ..........................................................................................................219
Project Profiles.........................................................................................................................................221
Profile for RTU..................................................................................................................................221
Custom Profile...................................................................................................................................222
New Project..............................................................................................................................................223
Adding Modules.......................................................................................................................................228
Creating POUs.........................................................................................................................................230
Creating Tasks.........................................................................................................................................232
Task Configuration............................................................................................................................233
POU –Task Connection.....................................................................................................................235
Maximum Number of Tasks...............................................................................................................235
CPU Configuration..................................................................................................................................237
Libraries...................................................................................................................................................238
Inserting a Protocol Instance...................................................................................................................239
RTU MODBUS.................................................................................................................................239
Ethernet MODBUS............................................................................................................................241
DNP3 Server .....................................................................................................................................243
Servidor IEC 60870-5-104.................................................................................................................245
Finding the Network................................................................................................................................246
Compiling a Project.................................................................................................................................248
Login ........................................................................................................................................................249
Run Mode.................................................................................................................................................251
Stop Mode................................................................................................................................................252
Monitoring, Writing and Forcing Variables...........................................................................................253
Variables Used in Several Sources ..........................................................................................................254
Logout ......................................................................................................................................................254
Simulation Mode......................................................................................................................................255
Project Upload.........................................................................................................................................256
CPU Operating States..............................................................................................................................258
Run....................................................................................................................................................258
Stop...................................................................................................................................................258
Breakpoint.........................................................................................................................................258
Exception ..........................................................................................................................................258
Reset Warm.......................................................................................................................................258
Reset Cold.........................................................................................................................................258
Reset Origin.......................................................................................................................................258
Reset Process Command (IEC 60870-5-104)......................................................................................259
6. HX3040 REDUNDANCY........................................................................................................................260
Introduction.............................................................................................................................................260
Configurations of a Redundant CPU ......................................................................................................261

Summary
v
Identification of a HX3040 CPU........................................................................................................261
General Features................................................................................................................................262
Operation Principles................................................................................................................................264
Single Redundant Project...................................................................................................................264
Redundant Project Structure...............................................................................................................264
Multiple Mapping..............................................................................................................................267
Diagnostics, Commands and User Data Structure...............................................................................268
Cyclic Synchronization Services through Redundancy Synchronism Channels...................................268
Sporadic Synchronization Services through Redundancy Synchronism Channels ...............................269
Redundant Ethernet Networks with NIC Teaming..............................................................................270
IP Change Methods............................................................................................................................271
NIC Teaming and Active IP Combined Use.......................................................................................272
Redundant CPU States.......................................................................................................................272
Commands of the Redundancy Menu of the CPU’s Display ...............................................................274
Transition between Redundancy States ..............................................................................................274
First Instants in Active State ..............................................................................................................277
Common Failures which Cause Automatic Switchovers between CPUs .............................................278
Failures Associated to Switchovers between CPUs Managed by the User...........................................278
Failure Tolerance...............................................................................................................................279
Redundancy Overhead.......................................................................................................................280
Redundant CPU Programming...............................................................................................................282
Wizard for a New Redundant Project Creation...................................................................................282
Project Configuration with CPU Redundancy.....................................................................................287
HX3040 CPU Ethernet Ports Configuration (NET 1 to NET 6) ..........................................................287
I/O Drivers Configuration..................................................................................................................288
MainTask Configurations...................................................................................................................288
ProtTask Configurations ....................................................................................................................295
GVLs with Redundant Symbolic Variables ........................................................................................296
Program POUs with Redundant Symbolic Variables ..........................................................................296
Breakpoints Use in Redundant Systems .............................................................................................296
Limitations in the Programming of a Redundant CPU........................................................................296
Getting the Redundancy State of a CPU.............................................................................................297
Non- Redundant Diagnostics Reading................................................................................................297
Programs Load in a Redundant CPU .....................................................................................................297
Initial Load of a Redundant Project....................................................................................................297
MasterTool connection with a HX3040 CPU from a Redundant CPU.................................................299
Load of Changes to a Redundant Project ............................................................................................299
Load of Changes in Offline and Online Mode ....................................................................................300
Load of Changes in Online Mode.......................................................................................................301
Offline Load of Changes with Interruption of Process Control............................................................301
Redundant RTUs Maintenance...............................................................................................................301
MasterTool Warning Messages..........................................................................................................301
Interaction with the redundancy through the HX3040 CPU graphics display ......................................302
Redundancy Diagnostics Structure.....................................................................................................302
Redundancy Event Logs ....................................................................................................................309
7. MAINTENANCE.....................................................................................................................................311
CPU Module Diagnostics.........................................................................................................................311
One Touch Diag.................................................................................................................................311
Diagnostics via LED..........................................................................................................................314
Diagnostics via WEB.........................................................................................................................314
Diagnostics via Variables...................................................................................................................319
Diagnostics via Function Blocks ........................................................................................................327
Graphic Display.................................................................................................................................328
System Log...............................................................................................................................................331

Summary
vi
I/O Modules Diagnostics..........................................................................................................................331
Not Loading the Application at Startup..................................................................................................334
Power Supply Failure ..............................................................................................................................334
Common Problems ..................................................................................................................................335
Troubleshooting.......................................................................................................................................336
Preventive Maintenance ..........................................................................................................................336
8. ELECTRIC PANEL DESIGN ................................................................................................................337
Mechanical Design...................................................................................................................................337
Dimensions........................................................................................................................................337
Depth of Rack-mounted Module........................................................................................................337
Spacing between modules and other equipment in the panel...............................................................338
Gutter Sizing .....................................................................................................................................338
Horizontal/Vertical Mounting ............................................................................................................338
Thermal Design........................................................................................................................................339
Heat dissipation in an electrical panel.................................................................................................339
Electrical Design......................................................................................................................................342
General Information...........................................................................................................................342
Cabinet Power ...................................................................................................................................342
Distribution of Cables in the Cabinet..................................................................................................342
Cabinet Lighting................................................................................................................................343
Grounding .........................................................................................................................................343
Electromagnetic interference..............................................................................................................343
Shielding ...........................................................................................................................................343
Noise suppressors ..............................................................................................................................343
Distribution of power supply out of the cabinet ..................................................................................346
Lightning protection ..........................................................................................................................346
9. GLOSSARY.............................................................................................................................................348

1. Introduction
7
1.Introduction
Hadron Xtorm Series
Hadron Xtorm Series is the state-of-the-art solution regarding the Remote Terminal Units (RTUs).
The series presents an ideal set of high performance features, ease of use, accurate and complete
diagnostics, modern and robust design, as well as several innovative features. Hadron Xtorm features
an intelligent and versatile architecture, offering modularity in inputs/outputs points (I/O),
redundancy options, high-speed communication protocols such as IEC 61850, and logic
implementation in accordance with IEC 61131- 3 standard. As a result, it is an ideal RTU for all
supervisory applications and control of generation, transmission and distribution of electricity
systems such as hydroelectric power plants (HPPs) and power substations.
Hadron Xtorm Series holds an advanced technology on its bus. Due to a high-speed Ethernet
interface it enables the sharing of inputs/outputs and data information within multiple controllers in
the same system. The system can be easily divided and distributed throughout the field, enabling the
use of expansion racks providing the same performance as local module. Therefore, all types of
modules can be used both on the local rack and on its expansions without restrictions. In order to
interconnect the rack expansions the user may use a simple Ethernet cable.
Figure 1-1. Hadron Xtorm Series –Overview

1. Introduction
8
Innovative Features
Hadron Xtorm Series brings several innovations in system usage, supervision and maintenance.
These features were developed focusing on a new concept in automation of hydroelectric power
plants, substations and other applications of this segment. The list below shows some new features
that users will find in the Hadron Xtorm Series:
Battery Free Operation: Hadron Xtorm 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.
Multiple Block Storage: Several kinds of memories (volatile and non-volatile
memories) are available in Hadron Xtorm Series CPUs, offering the best option for
any needs. Hadron Xtorm Series CPUs offer addressable input (%I), addressable
output (%Q), data memory and symbolic variables. For applications that require
non-volatile memory functionality, Hadron Xtorm Series bring retain addressable
memory (%Q), retain data memory, symbolic variables, persistent data memory,
program memory, source code memory, CPU file system (DOC, PDF, images, data,
among others) and memory card interface.
One Touch Diag: One Touch Diag is an exclusive feature of Hadron Xtorm Series.
With this new concept, the user can check diagnostic information of any module
present in the system directly on CPU’s graphic display with one single press in the
diagnostic switch of the respective module. OTD is a powerful diagnostic tool that
can be used offline (without supervisor or programmer), reducing maintenance and
commissioning times.
OFD –On Board Full Documentation: Hadron Xtorm Series CPUs are capable of storing the
complete project documentation in its own memory. This feature can be very convenient for backup
purposes and maintenance, since the complete information is stored in a single and reliable place.
ETD –Electronic Tag on Display: Another exclusive feature that Hadron Xtorm Series presents is
the ETD. This new functionality brings the process of checking the tag names of any I/O point or
module used in the system directly to the CPU’s graphic display. Along with this information, the
user can check the description, as well. This feature is extremely useful during maintenance and
troubleshooting procedures.

1. Introduction
9
Main Features
CPUs
The CPUs have several built-in functions, online programming, high memory capacity and serial
channels. These devices have a modern 32-bit processor that delivers excellent performance as well
as the integration of various functions. The CPU has Ethernet ports for programming, used in
MODBUS, DNP3 networks and embedded web server. In addition, they provide two serial interfaces
for connecting local HMIs and MODBUS networks. The CPUs have a memory card position for
hosting web pages, application source code, and firmware update among other features.
Modules
The modules present high density I/Os. Each I/O module has a display for local diagnostics, which
shows the status of I/O each point. There are also multi-functional diagnostics on the status of the
modules. All diagnostic information can also be accessed remotely by the CPU, communication
protocols or through the MasterTool Xtorm configuration tool.
High Speed Bus
Hadron Xtorm Series architecture features a state-of-the art bus based on Ethernet 100 Mbps. The
high throughput allows the updating of large amounts of inputs in a short period of time. The
modules are automatically addressed and identified avoiding eventual errors during the application
configuration and field maintenance. The bus provides special features that allow CPU redundancy in
the same rack, among other features.
Automatic addressing and identification module
Hot swapping
Serial Bus based on Ethernet 100 Mbps
Time synchronization for I/O updating or precise time stamp
Single chip hardware solution
Hot Swapping
The hot-swap feature allows the modules replacement without the system powering off. The CPU
tracks the whole process and the modules can be replaced whenever necessary.
High Availability
Hadron Xtorm Series offers several different redundancy architectures, where CPUs, Power Supplies
and Network Interfaces can be mounted in a redundant application. Through this flexibility, the
system can be adjusted from simple systems with no redundancy to complex and critical applications
where high availability is essential.
Enhanced Diagnostics
Each module contains its own diagnostics. CPUs, Network Interfaces, Power Supplies and I/O
modules show several diagnostics. Each module has a multifunctional display to report its status. In
addition, each module offers a button on its front to provide different diagnostic information for
maintenance staff. These diagnostics can be monitored through displays or via configuration tool.
Examples:
Module placed in the wrong position in the rack
No power supply
Short circuit in the outputs
No need for configuration for modules in normal operation
Tag view and I/O descriptions of the IO
IP address view