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1. Introduction

1. It s recommended the illumination to be based on incandescent bulbs as fluorescent luminaries may cause undesirable interference If the latter are used the following precautions must be made to reduce interference e Grounded metallic grid must be installed between the luminary and the panel in order to reduce the noise emission e The luminary supply cables must be shielded e The switch must be protected by a metallic box and a filter must be placed in the supply network next to the luminary Grounding It is necessary a group of general connectors or ground bar in the panel where all the power sources and modules grounding will be made This bar must be connected to a low resistance ground Electromagnetic Interference Shield The electromagnetic interference EMI is responsible for the great majority of troubles found in the installed equipment These problems can be reduced significantly 1f the due precautions are taken in the panel designing phase Distribute and place the cable in the chutes avoiding mix supply cables with signal cables Inactive metallic parts must be grounded In case there re noise emitter elements it s recommended the use of shields A filter must be used in the panel supply cable Strong EMI sources transformers motors and high current or voltage cables placed inside the panel must be covered by grounded metallic plates when installed less than 50cm from the PLC electronic parts Cables whi
2. Nexto Series User Manual Rev D 09 2015 Doc Cod MU214600 General Conditions for Supply No part of this document may be copied or reproduced in any form without the prior written consent of Altus Sistemas de Automa o S A who reserves the right to carry out alterations without advice According to legislation in force in Brazil the Consumer Defense Code we are giving the following information regarding personal safety and installation by the client The industrial automation equipment built by Altus is strong and reliable due to the stringent quality control it is subjected to However the electronic industrial control equipment programmable controllers numerical commands etc can cause damage to the machines or processes through their controllers when there are defective components and programming or installation errors 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 security so that if necessary the security of the system can be maintained especially during the initial installation and testing It is essential to completely read the manuals and or about the technical characteristics of the product before its installation or use The equipments manufactured by Altus don t cause direct environmental hazards and don t produce any kind of pollution during its utilization However regarding the equipment
3. Figure 4 13 shows an I O module with its frontal cover opened 52 4 Installation 10042902A Figure 4 13 Frontal Cover Opened VO connector insertion for Nexto and Nexto Jet Modules The simple width modules have an extra feature which helps the I O terminal block insertion described below In case of double width module the insertion must be executed manually With the frontal cover opened the terminal block must be inserted partially in the module taking care to insert it in the right position Then the frontal cover must be closed as indicated on Figure 4 14 Observe the connector partially connected 10042907A Figure 4 14 Closing the Frontal Cover At closing the frontal cover the I O connector block is inserted in the module The movement must be done all the way down until the cover is in the final position as presented on Figure 4 15 53 4 Installation 10042901A Figure 4 15 Module with the Frontal Cover Closed The Nexto Jet modules have a different condition to insert the connector in the module because there is no frontal cover that assists to fit the connector The appropriately insertion of the connector in the Nexto Jet modules it is fitting the lower position of the connector according Figure 4 16 and then the upper part of the connector Once the connector positioned properly in its place with a soft pressure finalize fitting in module LLU RON NIDOS Is SOLION IOK IN JODO T M
4. Installation This chapter presents the necessary proceedings for the Nexto Series physical installation as well as the care that should be taken with other installation within the panel where the CPU is been installed Visual Inspection Before resuming the installation process it s 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 WARNING Before taking the modules off the case it s 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 Mechanical Installation Backplane Rack Fixation Drilling The backplane rack fixation must be made through six M4 screws as shown on Figure 4 1 09091650E Figure 4 1 Drilling for Rack Fixation 46 4 Installation Table 4 1 must be consulted to find the respective A and B dimensions according to the backplane rack model mus eamm sme NX9003 140 7 mm 162 9 mm aw rm msnm Table 4 1 Rac
5. One feature that enables the user to evaluate and test many logic and algorithms is the simulation tool This feature enables the design and test of user applications without the need of a connected controller This feature is also interesting for training documentation and test cases evaluation Of 23 1 Introduction course since it is a simulator some limitations may apply when deploying the application the end controller User Documentation amp Help Files Since programming a PLC according the IEC 61131 3 standard languages is a complex task MasterTool IEC XE offers an extensive help file with many hints and descriptions in order to guide and serve as a first knowledge and troubleshooting database to user while designing the logic codes or using any software feature Besides this help file is available in many languages according installation options MasterTool IEC XE 1s also provided to support multiple languages allowing the user to select the preferred language from the options available The idea is to minimize understanding issues that might rise when using a foreign language As part as user documentation MT8500 can print out user application documents like bill of materials BOM POUs and configuration parameters Enhanced Diagnostics One of the key innovative features of Nexto Series is an extensive support of diagnostics This idea comes from requirements of large and complex applications where the correct use of
6. done through the same channel This approach delivers some features Multi functional Ethernet port used to share programming point to point data exchange third party device protocol at application layer network variable data exchange etc Direct access to local CPU variables Remote access and change via Internet for distant sites Firmware updating through Ethernet interface 21 MT8500 MasterTool IEC XE 1 Introduction The MT 8500 is the software suite for programming configuration diagnosis and commissioning and offers as mainly features e EC 61131 3 Programming Languages e Editors for Project Configuration and Hardware Configuration e Object Oriented Programming e Online Debugging and Commissioning features e Simulation e User Documentation amp Help Files e Enhanced Diagnostics e Docking View IEC 61131 3 Programming Languages A a ok ola LEE MA AAA AAA ado sus MasterTool IEC XE offers all ee I GRE a editors defined in the IEC standard Bin mm orem Po AS for application development rsen i E 1 PROGRAM Structured Text ST Sequential Function Chart SFC Function Block Diagram FBD Ladder HF Lb PROGRAM Eg Task Configurat SE MainTask g Configuration Nx3010 Nx3010 Ei m I00 TOH DutPut MAX IN Q c n TL put PT ETF Store av Av gt 2 Timer ES n COH ILPROGRAM Diagram LD Instruction List I
7. Usuario UCPs Serie Nexto Spanish MU299609 MasterTool IEC XE User Manual English MU299048 Manual de Utilizac o MasterTool IEC XE Portuguese MU299800 Manual del Usuario MasterTool IEC XE Spanish MP399609 MasterTool IEC XE Programming Manual English MP399048 Manual de Programac o MasterTool IEC XE Portuguese MP399800 Manual de Programaci n MasterTool IEC XE Spanish MU214601 NX5001 PROFIBUS DP Master User Manual English MU214001 Manual de Utilizac o Mestre PROFIBUS DP NX5001 Portuguese MU214301 Manual del Usuario Maestro PROFIBUS DP NX5001 Spanish MU214608 Nexto PROFIBUS DP Head Utilization Manual English MU214108 Manual de Utilizac o da Cabeca PROFIBUS DP Nexto Portuguese MU214308 Manual de Utilizaci n Cabeca PROFIBUS Nexto Spanish Table 1 2 Documents Related Visual Inspection Before resuming the installation process it s advised to carefully visually inspect the equipments verifying the existence of transport damage Verify if all parts requested are in perfect state In case of damages inform the transport company or Altus distributor closest to you WARNING Before taking the modules off the package it s 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 numbe
8. field sensors and outputs to increase the system reliability in case of field short circuit 29 2 Configuration Step 9 MasterTool IEC XE license choice According to the system requirements it s possible to evaluate the best license option for the MasterTool IEC XE All available options together with the license comparison are described in the MasterTool IEC XE User Manual MU299609 MasterTool IEC XE Graphic Editor MasterTool IEC XE software has a graphic editor which helps the system architecture determination and verification The following functionalities of the MasterTool IEC XE Graphic Editor are listed Compatible components tree All Nexto Series modules are listed on MasterTool IEC graphic editor side To insert any of them in a given backplane rack it s necessary to drag the desired module to the desired slot of the backplane rack Module documentation access Pressing the right button on any module within the bus the graphic editor delivers access to all documentation existent from the respective module helping the immediate access to important information Architecture verification MasterT ool IEC graphic editor is responsible for running several verifications in order to facilitate the correct definition of the architecture to be used Therefore it s recommended the use of the MasterTool IEC graphic editor before the final definition of the architecture and modules to be used Consistencies such as correct
9. for a program creation Procedures and formats rules that allow data transmission and error recovery among devices with the use of control signals Acronym used to indicate serial reception Corresponds to the other system CPU e g the CPU1 in relation to CPU2 and vice versa System that contains reserve elements or doubled to perform a certain task which can tolerate certain types of failure without damaging the task execution Unit interface that transfers data serially Device connected to a communication network that only transmits upon the master requests IEC Variables created in POUs and GVLs during the applicative development which are not addressed directly in the memory Procedure for final clearance of the control system when the programs of all stations and remote CPUs are run together having been developed and verified individually Equipment connected to a PLC or instrumentation network in order to monitor or control the process variables Computer programs procedures and rules related to the operation of a data processing system In a redundant system it s the CPU that oversees the Active CPU not executing the system control but being ready to take control in case of failure on the Active CPU A complete execution of the applicative program in a programmable controller Name associated with a variable or a logic that allows a brief identification of its contents Element that has two stable states alternately e
10. in good shape and well dimensioned before energizing the system DANGER Never replace a fuse by another with higher current limit or the equipment might be irreversibly damaged 67 5 Maintenance 5 Maintenance Module Diagnostics One feature of the Nexto Series is the existence of several indication forms for diagnostics which vary from user application available diagnostics web pages LEDs to LCDs The documentation of each module indicates all available diagnostics In this document the OTD functionality is described which is within all Nexto Series except the modules that make part of Nexto Jet solution Such functionality allows the tag access diagnostics and description of all modules and I O points through the diagnostics keys module display and CPU display One Touch Diag OTD As previously described the tag access functions diagnostics and description of all modules and I O points are related There re three main components that are highly referenced on this explanation e CPU graphic display e Accessed module display e Accessed module diagnostic switch Diagnostics mode access Independently from what is displayed on the CPU display after a short pressing on the diagnostic switch of a specific module the tag and the module s active diagnostics will be shown on the CPU display These data are displayed in the form presented on Figure 5 1 LEVEL 1 Short touch Wait 2s ACTIVE DIAGNOSTICS 1 A
11. of an unexpected failure affecting the active CPU the standby system switches over automatically changing execution of the application program and control of the I O over to the standby CPU with an up to date data context Once they had changed over the stand by CPU becomes the active CPU Configuration of both systems shall be identical CPU modules will be placed at identical slots in both systems After power on one of the CPUs operates as active and another CPU enters standby mode Active CPU will update the system status of standby CPU at the end of every scan So the stand by CPU is always updated with latest I O status and results of program execution in the active CPU This application is easy to set up with no special programming or parameterization needed by the user 18 1 Introduction Minimum Configuration of a Redundant PLC Without PX2612 Panel Usage The redundant PLC is composed at least by two half clusters identically where each half cluster is formed of the following modules rack where the modules are inserted and can be NX9000 NX9001 NX9002 e NX9003 power supply NX8000 the CPU NX3030 the module NX4010 The Figure 1 13 shows an example of minimum configuration of a redundant PLC that can be used with the NX9000 rack Figure 1 13 Minimum Configuration of a Redundant PLC CPU amp Network Interface Modules Redundancy As shown in the previous diagram this architecture has network modules with protoc
12. offers many OD important functions for fast and t po efficient debugging testing and os commissioning 5 A rj BB HER E i 1 Tee a a a The values of declared variables for example are displayed in the Pore program code These values can be changed or forced without ER any difficulty By setting breakpoints and then stepping through the code line by line E errors can easily be detected Breakpoints in MasterTool IEC XE can be assigned to certain conditions to achieve even more precision in the debugging process In a single cycle operation the user can follow the execution of the application through a complete cycle TIERE P priua ea Ero a ace uet que Febo If the application is modified only the actual modifications are compiled and then loaded and activated without having to stop the controller or running the risk of losing variable values Changes to several POUs Program Organization Units variables or data types are also possible This functionality is called online change Shorter development cycles and a faster production process lead to reduced costs and increased competitiveness The sampling trace is a very useful tool when the user wants to record data or even trigger events for testing or commissioning purposes This digital storage media which 1s completely integrated in MasterTool IEC XE can of course also be used to visualize application data Simulation
13. quick and easy electric cable assembly 62 4 Installation QD ds ov NC 24V NC 11080102A TET TT Wwe acacia zar P RERO REOR st ES o D oo D Figure 4 27 Spring Connection I O Module 63 4 Installation NO dp RM m ZZZ e LUUD AA Figure 4 28 Spring Connection To assembly the cable in the connector e Insert the screw driver in the terminal lever to open the spring e Insert the cable terminal in the connector e Remove the screw driver to close the connector Cable Insertion In order to obtain an equal length in all cables connected to a same I O connector block it s recommended the following definition regarding the length difference which each cable beside another must obey before installation It s important to stress that the biggest cable must be always the cable connected to the I O connector pin 1 6 Pin Connector Block NX9401 It s recommended the use of 2 5 mm cables Each cable must be cut with a difference of 4 mm as indicated on Figure 4 29 Each pin must have 2 5 mn terminals crimped ATTENTION Use terminal with length A 12 mm to guarantee the effective contact see Figure 4 30 10 Pin Connector Block NX9402 It s recommended the use of 1 5 mn cables Each cable must be cut with a difference of 8 mm as indicated on Figure 4 29 Each pin must have 1 5 mn terminals crimped ATTENTION Use terminal with length A 12 m
14. such information is important for maintenance troubleshooting and to predict potential issues This feature is also present in MasterTool IEC XE where user can access the complete diagnostics structures via watch windows and the diagnostics web pages when connected to a running CPU Docking View The Docking View technology allows the user to customize MasterTool IEC XE environment to meet his personal needs Additionally the user can edit the menu structure the key assignments and the toolbar as desired This feature provides a friendly user interface to maximize the experience with the software tool 24 1 Introduction I O System The list of I O modules for Nexto Series is presented in the beginning of this document as well a brief description of each of them The following criteria should be considered when selecting the I O modules Rated voltage for the application 24 Vdc 220 Vac voltage or current analog points etc Type of digital output element transistor or relay Need for isolation on digital I Os or analog I Os Maximum currents per I O per group of I Os or per module Filter specifications for all inputs Power supply requirements based on the application configuration Due to the system modularity the user must order each Nexto Series module in a separate order To ensure that the user application and configuration will perform accordingly each technical features document must be checked for each module use
15. CTIVE DIAGNOSTICS 2 ACTIVE DIAGNOSTICS 3 Wait 2s _Wait2s Wait 2s ACTIVE DIAGNOSTICS n lt gt Yes Figure 5 1 CPU Diagnostics Visualization 68 5 Maintenance As presented on Figure 5 1 both the tag and the list of all module s active diagnostics are shown twice on the CPU display then the module goes off the diagnostics mode and the CPU display starts to indicate CPU information once again It s possible to identify that a module is in diagnostic mode when both display segments indicate on Figure 5 2 are blinking Figure 5 2 Module display I O points access After going to diagnostics mode the next short press on the module diagnostic switch selects the first I O point On this moment the display erases the active individual diagnostics indication previously explained and indicates which I O point is selected For selecting the next I O point a short press on the module diagnostic switch is needed When the last I O point is selected a new short press on the module diagnostic switch finishes the diagnostics mode At accessing an I O point the CPU display indicates the I O point respective tag and all active diagnostics from it as indicated on Figure 5 1 For modules without I O points a new short press on the module diagnostic switch after going to diagnostics mode finishes the operation ATTENTION The Nexto Jet modules not have the diagnostics per channel through access button This f
16. L 3 e ME E x 8 Ea ST PROGRAM MAMAN cT nnncnaw I lul X a A and Continuous Function Chart oem M Tines rao msoma dom All editors were specially designed J m omma Eu NN iem to ensure optimal handling Ideas xs E I J and suggestions from experienced e oe oco ee users are incorporated into the T Bla a development process Some examples n um e When working in FBD LD or Er T IA TEN IL you can freely switch Pe HOSS Ne R between these editors e Language elements can either be entered directly or dragged into the editor from a tool box e MT8500 offers an intelligent input assistance and an extended IntelliSense functionality e Standard language constructs IF statements FOR loops variable classes etc can be folded and unfolded in the text editors pa aret ot e Language constructs are automatically created IF END IF e The SFC editor can either be used as defined in the standard or in a simplified version e Acomfortable time monitoring for steps as well as online diagnosis functionality is also available in the SFC editor e Steps and transitions in the SFC editor and all elements in the CFC editor can be encapsulated in macros e MT8500 implements numerous further functions which support the application developer in his work 22 1 Introduction Editors for Project Configuration and Hardware Configurat
17. M 42 Panel trig ofi rod EET 43 Ground E TT O PORO RI nN en DD en De 43 Electromagnetic Iit E eren a Mud 43 Table of Contents E II ee ee 43 NOISE SUP PrE SO Sanini nadie dEle eee eee aE 43 DUDDIV Distribution outside the Panel hehe E S 44 Ershtais Proteo nde tit cad coude du a 45 NST AELA THON UOS RO 46 Visual TAS DG COON 535 O 46 Mechanical Installation aria iai Ls ads ds asa a ua aU DSG WII NIV 46 Backplane Rack Pai ai aaa calde aaa disease nda dad 46 EAS RS UM MEE E DP ME 49 Modules Remova tb a e ah C EA Ba ba re 51 PAG Bo o Ui fe S Ra a aa eae A GS MED MM M EE E 22 hack tC oDHlcctOP D Ebo scu MUI M MM SEE E LIE DUE UE IE SORA eee 61 AP umm 62 SPE CONNCCUORS AAA o 62 Connec ON a 67 POWEES UPN aaa trt 67 iE PAPA E PAE PE PE P A ee eee 67 Se PN D d Oh P dT i Dc a AAA 68 Module Dido HOS LCS eee eet a PEINE EMI MM MM 68 One Douce Dido OTD rai 68 Preventive Maintenance ina Ai AAA AAA ARS sa a AAA 70 A A AA 71 1 Introduction 1 Introduction Nexto Series Features Nexto Series 1s a powerful and complete Programmable Logic Controller PLC series with exclusive and innovative features Due to its flexibility functional design advanced diagnosis resources and modular architecture Nexto PLC can be used for control systems in small medium and large 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 ba
18. Nexto Jet modules cannot be used simultaneously at the same bus or the architecture is formed with Nexto or Nexto Jet modules s O 5 ol Es b 2 O Figure 1 2 Compact CPU with Nexto Jet Modules Single CPU This architecture is based on a single rack called base rack This rack is populated with a CPU a power supply module PSU and the required I O modules for the application as shown on Figure 1 3 The modules order must follow the configuration rules presented in the configuration tool This architecture is intended for use in small applications like machinery automation 1 Introduction eee eee ae a eee a eee essa eee eee See SECs 3b b bl bl b Figure 1 3 Single CPU with Nexto Modules The same architecture using Nexto Jet modules can be checked in Figure 1 4 following Figure 1 4 Single CPU with Nexto Jet Modules Single CPU with Remote Rack Expansion This architecture is based on a base rack where the CPU is placed and remote racks The communication between the base rack and remote racks is done via the bus expansion module Each remote rack needs its own power supply module PSU and bus expansion module Each expansion module can be located 100 m far from the other using standard shielded CATS Ethernet cables The expansion module has two RJ45 ports where one port is for incoming data and another one for outgoing data In this application example the base rack expansion module is conn
19. S rie Nexto Portuguese CS114100 Especificaciones y Configuraciones UCPs Serie Nexto Spanish CE114200 NX8000 Power Supply Module Technical Characteristics English CT114200 Caracter sticas T cnicas Fonte de Alimentac o NX8000 Portuguese CE114810 Nexto Series Accessories for Backplane Rack Technical English Characteristics CT114810 Caracter sticas T cnicas Acess rios para Bastidor S rie Nexto Portuguese CE114902 Nexto Series PROFIBUS DP Master Technical Characteristics English CT114902 Caracter sticas T cnicas do Mestre PROFIBUS DP da S rie Portuguese Nexto CE114903 Nexto Series Ethernet Module Technical Characteristics English CT114903 Caracter sticas T cnicas M dulo Ethernet S rie Nexto Portuguese CE114700 Nexto Series Backplane Racks Technical Characteristics English CT114700 Caracter sticas T cnicas dos Bastidores da S rie Nexto Portuguese CS114700 Caracter sticas T cnicas de los Bastidores de la Serie Nexto Spanish CE 114900 NX4010 Redundancy Link Module Technical Characteristics English CT114900 Caracter sticas T cnicas do M dulo de Redund ncia NX4010 Portuguese CS114900 Caracter sticas T cnicas del M dulo de Redundancia NX4010 Spanish MU214600 Nexto Series User Manual English MU214000 Manual de Utilizac o S rie Nexto Portuguese MU214300 Manual del Usuario Serie Nexto Spanish MU214605 Nexto Series CPUs User Manual English MU214100 Manual de Utilizac o UCPs S rie Nexto Portuguese MU214305 Manual del
20. Technical Features of the respective power supply module The list of all available power supply modules can be found within the Nexto Series modules list in this document It s important to verify 1f the selected power supply module is capable of supply the required current for all modules within a specific backplane rack including the backplane rack itself Another issue to be verified with care is if the selected power source input voltage range is in agreement with the project design Step 7 Bus expansion modules and bus expansion cables The bus expansion modules and its respective cables are responsible for the interconnection between all Nexto Series racks Therefore they are needed only when more than one rack is used In this case all racks must have at least one bus expansion module When bus expansion module redundancy is used each rack must have two modules More information regarding the bus expansion modules utilization can be found in the document NX4000 module Technical Features CE114600 Step 8 External power supply The output voltage and the current capacity of an external power source must be defined regarding the following loads Nexto Series power supply module voltage limit levels Nexto Series power supply module input current Input current for the other modules Digital and analog inputs and field sensors current Current of the loads connected to the outputs It s recommended the utilization of fuses for
21. a e S o Figure 3 2 Nexto Jet 18mm I O Module 32 3 Panel Design 36mm I O Module This module size is used in I O modules which fills two slots in the backplane rack Dimensions in mm 4 448444 AA Ue b A A A 36 00 tt ARARAS 09091457C Figure 3 3 36mm I O Module 33 3 Panel Design CPU Fieldbus Interfaces Power Sources and Special Modules This module size is used for all other modules from the Nexto Series Figure 3 4 shows a NX3020 CPU Dimensions in mm Ll lel Ml Aw YA A VV V X fA AAA 444446 LURRR MAM o u u o e D Figure 3 4 36mm NX3030 CPU modules 34 3 Panel Design 8 Slot Backplane Rack Dimensions in mm e 119 00 re 14121009A Figure 3 5 8 Slot Backplane Rack Without Hot Swap 8 Slot Backplane Rack Dimensions in mm wm e e y 14120101A n a 119 00 Figure 3 6 8 Slot Backplane Rack 35 3 Panel Design 12 Slot Backplane Rack Dimensions in mm E O Q EE E 18 58 Figure 3 7 12 Slot Backplane Rack 16 Slot Backplane Rack Dimensions in mm 312 50 EM i 00 Cc Co Figure 3 8 16 Slot Backplane Rack 09091451D 3 Panel Design 24 Slot Backplane Rack Dimensions in mm 457 30 nn 090914520 Figure 3 9 24 Slot Backplane Rack Assembled module depth in the backplane rack Nexto Seri
22. a redundant application With this flexibility the system can be tailored from simple systems with no redundancy at all to very complex and critical applications where high availability plays an important role 20 1 Introduction Enhanced Diagnostics Every module has its own diagnostics The CPUs Fieldbus Interfaces PSUs and I O modules have various diagnostics available Each module has a multifunctional display for enhanced visual status Besides each module that has a switch on the top of the module can provide different diagnostics information for maintenance personnel These diagnostics can be monitored on the field through the visual displays or via configuration tool Some examples are Capacities Wrong module placed on a rack position No field power supply Short circuit in outputs No configuration for a module that needs to be configured for normal operation I O tag and description visualization on the PLC for modules with OTD IP address visualization In Nexto Series each rack can fit up to 24 18 mm modules or 12 36 mm modules With this architecture a single CPU can control 320 I O points using a single rack This can be expanded up to 25 racks according the CPU model using bus expansion modules CPU Programming amp Firmware Update Nexto Series allows the programming of CPU and firmware update through the embedded CPU Ethernet port Some modules like Fieldbus Interfaces and the CPU can have their firmware update
23. al this software is referenced by its acronym or as MasterTool programming Set of options available and displayed by a program on video and that can be selected by the user to activate or perform a certain task Basic element of acomplete system that has well defined functions Normally the system is connected by connectors and can be easily replaced 71 Module referencing software Module address Non Active CPU Operands PLC Programmable controller Programming language Protocol RX Redundant CPU Redundant System Serial Channel Slave Symbolic Variables Start up Supervision station Software Stand by CPU Sweeping cycle Tag Toggle TX Watchdog circuit WD Word 6 Glossary Part of an application program capable of performing a specific function lt can be run independently or in conjunction with other modules exchanging information via parameter passing Address which the PLC accesses a specific I O module It s the CPU that is not in the active state controlling the system or in the stand by state overseeing the Active CPU It can t assume control of the system Elements on which the instructions work They may represent constants variables or set of variables Acronym for programmable logic controller Also called PLC Equipment which executes a control under the applicative program command It s composed by a CPU a power supply and an I O structure A group of rules and conventions used
24. basic CPU cycle is composed by reading inputs running application algorithms and logic writing outputs and providing communication processes with the supervision system and fieldbus networks Power Supply Module PSU Backplane Bus Backplane Racks VO Modules The power supply module provides power to the modules installed on the backplane racks Each rack must have its own power supply module Application power requirements are shown in the configuration tool A typical system consists of a local rack CPU and its local I O modules and remote racks sets of remote I O modules For the local rack Nexto Series architecture delivers a state of the art high speed real time 100 Mbps Ethernet backplane bus technology Since it is Ethernet based the local rack bus can be easily extended to remote racks using standard Ethernet cables up to 100 m and devices called bus expansion modules These devices convert the internal signals to the standard Ethernet 100BASE TX media Bus expansions can be used in redundant mode to obtain an extremely reliable architecture Each backplane rack can have up to 24 modules and the system can address up to 25 racks The backplane racks have special aluminum chassis with a printed circuit board where all modules are connected They are assembled directly to the panel and deliver high immunity against EMI and ESD if the recommended grounding rules are performed during installation phase The I O module
25. bigger bar indicates the positive pole while the smaller bar indicates the negative pole The voltage must be compatible with the module characteristics This symbol indicates a power supply source which can be direct current or alternate current The voltage must be compatible with the module characteristics This symbol indicates an alternate current power supply source The voltage must be compatible with the module characteristics This symbol indicates a direct current source On this symbol the conventional current flux is indicated by the direction of the arrow inside the circle This symbol indicates a thermocouple sensor connected in an analog input of a Nexto Series module This symbol indicates a resistance or a RTD sensor Resistance temperature detector connected in an analog input of Nexto Series module This symbol indicates that exist options to connect an input or output according with the Nexto Series module characteristics Table 4 2 Installation Diagram Symbols L abel insertion and removal To add the identification number and module description it s necessary to remove the I O module frontal label as shown on Figure 4 22 This figure shows an I O module frontal cover which uses one slot in the rack The same procedure must be executed for modules that use two slots 59 4 Installation 10051803A 10051802A 10051801A Figure 4 22 Label Insertion and Removal Care must be taken for a little l
26. cedure must be followed for any Nexto Series module First the fixation lock must be pressed 1 in order to unlock the module from the bus then it must be rotate as shown on Figure 4 10 2 10041911A Figure 4 10 Bus Unlock If the user follows the described procedures correctly the module will have been perfectly disconnected from the bus and it can be taken off as presented on Figure 4 11 51 4 Installation 10041912A Figure 4 11 Module being Removed from the Backplane Rack I O Modules The Nexto Series I O modules have some specific features described in this subtitle There re two different types of I O modules modules that use one rack slot and modules that use two rack slots In this subtitle the modules that use one rack slot will be called simple width and the modules that use two rack slots will be called double width modules The double width modules use one I O spring connection terminal block pair Each terminal block has 10 pins The simple width modules use one spring connection terminal block with 20 pins Frontal cover All VO modules have a frontal cover which has as main objective to protect the I O connectors Besides the frontal cover has other functions which are described throughout the I O Modules item To access the I O connector the frontal cover must be opened pulling its lower extremity Figure 4 12 indicated how it must be done 10042903A Figure 4 12 Opening the Frontal Cover
27. ch cross the shielded parts must be shielded too or filtered The shielded cables within the panel must be grounded according instructions of each device Noise Suppressors It s extremely important the connections of noise suppressors straight in every inductive loads relays contactors solenoids etc activated or not by the PLC The inductive loads activation generates strong electrical noises which may go over the limits established by standards These noises if not mitigated in its origin might reach the PLC jeopardizing its functioning The protection circuits must be connected close to the load as a rule they mustn t be more than 0 5 meters apart In case of resistive loads incandescent bulbs signal LEDs heating resistances etc the use of such devices isn t need it Figure 3 15 shows some examples of recommended elements for noise suppression in inductive loads 43 3 Panel Design Diode Zener Diode VDR RO ALAN y Z 92052972D Figure 3 15 Inductive Loads Noise Suppressors Circuit with Diode This 1s the most efficient way to limit the inductive circuit voltage on the off moment However 1t can cause troubles as 1t slow down the off time in case the load is for instance a contactor or a solenoid The circuit can be used only for DC voltages and its reverse voltage must be higher than the power source and the curre
28. ck and then the guide pins are correctly placed in the right rack keyways for a specified position Modules that use only one position in the rack has only one guide pin Figure 4 6 shows how the module lower part must be positioned in relation to the rack for the correct insertion Y 10041910A Figure 4 6 NX3010 and Backplane Rack After fitting the module lower part as described above a rotation movement must be executed in order to fit the fixation lock in the rack upper part as shown on Figure 4 7 49 4 Installation A TE ad La S a D T 5 D gt gt T pu A Li J wae J E AMA e A i a AN i 1 Y X mm Y 10041902A Figure 4 7 Backplane rack fitting movement If the user follows the described procedures correctly the module will have been perfectly connected to the bus as presented on Figure 4 8 Y AS a GRES 290090 I i es 2 E 10041903A Figure 4 8 Module Correctly Placed in the Backplane Rack The module mustn t be connected to the rack any other way Wrong insertion of the module may cause irreversible damage to it Figure 4 9 show how to NOT connect the Nexto modules to the rack 50 4 Installation 15 A i 10041909A Figure 4 9 Wrong Insertion Way Modules Removal The following example shows a Nexto Series generic module this pro
29. d for the NX4000 module which is considered a special module but is used in all racks This document presents the complete Nexto Series module list In it it s possible to verify which modules are defined as fieldbus interfaces and special modules e O modules can be used whether in the same CPU rack as in remote racks e The Nexto Series have modules with two different widths This way it s necessary to check the documentation of each module for the number of positions in the rack it requires e The Nexto Series have different kinds of racks Each model has a specified number of slots It s important to remember that besides the CPU the I O modules fieldbus interfaces and special modules each backplane rack needs at least one power source When remote backplane racks are used all of them must have at least one bus expansion module Power supply modules and bus expansion modules must be considered in the used space checking of the rack Step 5 Determine the backplane rack connector cover quantity It s strongly recommended all slots not used to be covered by the Nexto Series Backplane Rack Connector Cover NX9102 This product has the objective to protect the not used slots from dirt dust and accidents that might happen during the product utilization Step 6 Determine the power supply module quantity Each rack must have at least one power supply module More information regarding power supply modules can be found in the document
30. d in the application Environmental Conditions Nexto Series modules comply with the environmental specifications described on the Table 1 1 Storage temperature 25 to 70 C Operational temperature 0 to 60 C Relative humidity 5 to 96 non condensing IEC 61131 CE Electromagnetic Compatibility EMC and Low Voltage Directive LVD Standards C ROHS 2002 95 EC Table 1 1 Environmental Conditions Documents Related to this Manual In order to obtain additional information regarding the Nexto Series other documents manuals and technical features besides this one may be accessed These documents are available in its last version on the site http www altus com br Each product has a document designed by Technical Features CE where the product features are described Furthermore the product may have Utilization Manuals the manuals codes are listed in the CE For instance the NX2020 module has the information for utilization features and purchasing on its CE On the other hand the NX5001 has besides the CE a utilization manual MU The following table lists all documents related to Nexto Series 25 1 Introduction CE114000 Nexto Series Technical Characteristics English CT114000 S rie Nexto Caracter sticas T cnicas Portuguese CS114000 Serie Nexto Especificaciones y Configuraciones Spanish CE114100 Nexto Series CPUs Technical Characteristics English CT114100 Caracteristicas T cnicas UCPs
31. e NJ6100 4 AO Voltage Current Module Ethernet Module PROFIBUS DP Master PROFIBUS DP Head PROFIBUS DP Redundant Head 24 Vdc 16 DI Module 8 AI Voltage Current Module 8 AI Thermocouple Module 8 AI RTD Module 24 Vdc 8 DO Transistor 8 DI Mixed Module 24 Vdc 16 DO Transistor Module 16 DO Relay Module 4 AO Voltage Current Module Power Supply Modules Hacks NX8000 NX9000 NX9001 NX9002 NX9003 NX9010 Special Modules NX4000 NX4010 30 W 24 Vdc Power Supply Module 8 Slot Backplane Rack 12 Slot Backplane Rack 16 Slot Backplane Rack 24 Slot Backplane Rack 8 Slot Backplane Rack Without Hot Swap Bus expansion Module Redundancy Link Module 1 Introduction Software Accessories 1 Introduction MT8500 MasterTool IEC XE LITE MT8500 MasterTool IEC XE BASIC MT8500 MasterTool IEC XE PROFESSIONAL MT8500 MasterTool IEC XE ADVANCED NX9100 Left Right Side Rack Ends NX9101 8 GB microSD memory card with miniSD and SD adapters NX9102 Backplane Rack Connector Cover NX9401 6 Connector Terminal NX9402 10 Connector Terminal with guide for cables NX9403 20 Connector Terminal with guide for cables NX9404 6 Connector Terminal with Fixation 1 Introduction Innovative Features Nexto Series brings to the user many innovations regarding utilization supervision and system maintenance These features were developed focusing a new concept in industrial automation The list bellow shows some n
32. e machine or from the system to be controlled although in the same building it s recommended the following procedure e The transportation of the cables from the panel to the machine must be made through metallic chutes e The chutes grounding must be made every 20 meters e The cables must be distributed in two group 44 3 Panel Design o Digital signal cables up to 60V analog signal shielded cables and shielded cables with up to 230V o Cables with voltage superior to 230V Lightning Protection In external applications where the PLC cables or communication lines containing field signals which are placed outside the room or go through open fields the lightning possibility must be considered It s recommended the use of VDR or arrestors with inert gases in these cables to protect the system against over voltage due to lightning on these lines Some shields are also necessary as shown on Figure 3 16 COMPANY SENSORS Figure 3 16 Protection against lightning It s recommended these protection devices to be installed close to the company entrance or close to the panel itself Figure 3 16 shows the correct way to install the protection against lightning for a generic system Each system has its own installation details therefore it s recommended that each case is studied individually to define the best protection choice In critic cases the Altus support service must be consulted 45 4 Installation 4
33. ected using only one cable and leaving the incoming data port open The last remote rack has the outgoing data port open The remote racks in between will have both ports connected one port connected to previous rack and the other to the next rack Each expansion module has a switch for selecting the rack number Each rack must have a unique address When this kind of architecture is used it is important to remember that in case os Nexto modules usage only this type of module can be used in the local and or expansion rack The same is true in case of Nexto Jet modules usage The next architectures that follow in Figure 1 5 and Figure 1 6 are examples with Nexto and Nexto Jet modules This architecture is intended for medium to large applications where the number of I O points is high 10 1 Introduction O00VXN OOOVXN OOOVXN OLOEXN 0008XN 0008XN 0008XN Figure 1 5 Single CPU with Remote Rack Expansion and Nexto Modules 11 1 Introduction Figure 1 6 Single CPU with Remote Rack Expansion and Nexto Jet Modules Single CPU with Remote Rack Expansion and Loopback This architecture is based on the previous one with a base rack where the CPU is placed and remote racks The communication between the base rack and remote racks is also made via the bus expansion module The only difference is that the outgoing data port in the last bus expansion module is connected to the base rack expansion module incoming data
34. eda in Brezi NEGO 15063001A Figure 4 16 Insertion of Nexto Jet Connector I O connector block removal for Nexto and Nexto Jet Modules All Nexto Series I O modules have a feature to help the connector block removal which is described below As described previously to open the frontal cover it s necessary to pull it by its lower part When the I O connector block must be removed it s necessary to execute the same opening movement besides 54 4 Installation pressing the connector block extraction lever as shown on Figure 4 17 It s important to keep the extraction lever pressed during the whole movement since the beginning 100429044 Figure 4 17 Movement to Remove the I O Connector Block Nexto Modules After the described movement the I O connector block is partially removed simplifying the rest of its extraction Such functionality is available both for the simple width modules as for the double width modules In case of double width modules each I O connector has its own extraction lever Therefore each connector must be removed individually 55 4 Installation 10042905A Figure 4 18 I O Connector Block Removal Nexto Modules The removal of Nexto Jet module connector has a different procedure once that there is no frontal cover with extraction lever So to remove the connector from the Nexto Jet modules should be made a movement as shown in Figure 4 19 using the wire holder as an assistant to disconnec
35. er placed on the connector lower part see Figure 4 31 65 4 Installation Pt i Y a Y a oo ro E OA ET l LUZ 7L a mmn ee nN 15031801A Figure 4 31 Cabling ID and Fixation To identify the wiring e Use numbered wiring or cables with numbered conductors e Use Conexel identifier WKM 8 30 PN 1631910000 for cable identification e Fix with plastic holder the identifier of the wires on the support wire holder located at the bottom of the post Cable removal To remove the cables from the connector block it s recommended the use of a 3 5 mm wide screw driver with isolated handle It must be inserted in the lever beside the cable while the cable is pulled off see Figure 4 26 and Figure 4 27 66 4 Installation Connections The correct fixation of the CPUs and system modules cables guarantee the equipment security and its correct functioning Therefore the following points must be checked e The cables close to the panel connectors must be connected securely and tight e The system parts power and ground connectors must be tight and well connected allowing good current conduction e The ground connection from the equipments to the panel must be tight and well dimensioned to guarantee good grounding and noise immunity Power Supply Fuses Check if the power supply voltages are within the values specified in the technical features It s recommended to check the system fuses verifying 1f they are
36. es module and rack cluster depth can be calculated by summing 2 49 mm to the module depth In the example shown on Figure 3 10 a module 115 30 mm deep was used Considering the rack the resulting cluster depth 1s 117 79 mm Dimensions in mm 09091459B 117 79 Figure 3 10 Assembled module depth in the backplane rack 37 3 Panel Design Spacing between modules and other equipment in the panel The PLC requires some free space around itself This is necessary to allow the correct device handling Besides such space must be respected to allow the air flow through the PLC in the convection form in order to keep the equipment temperature Figure 3 11 and Table 3 1 indicate the necessary spacing for the Nexto Series modules 10081209A Figure 3 11 Free space around the PLC Dimension A Dimension B Dimension C Dimension D Table 3 1 Free space dimension around the PLC Note Dimension C e D It s recommended to use a space at least 4cm wide to allow the side rack ends to fit If necessary this width can be decreased Chute Dimensioning For the chute dimensioning besides the cables used area the internal heating provoked by the heat dissipated from the cables must be observed as it leads to a decrease in the chute use capacity Use the following rule chute area gt cable area sum 0 4 Cable area 3 14 radius 2 Consider the cable area including the isolation 38 3 Panel Desig
37. ew features which the user will find in the Nexto Series Modules Battery Free Operation Nexto Series does not require any kind of battery for memory maintenance and real time clock operation This feature is extremely important because it reduces the system maintenance needs and allows the use in remote locations where maintenance can be difficult to be performed Besides this feature is environmentally friendly Easy Plug System Nexto Series has an exclusive method to plug and unplug I O terminal blocks The terminal blocks can be easily removed with a single movement and with no special tools In order to plug the terminal block back to the module the frontal cover assists the installation procedure fitting the terminal block to the module Multiple Block Storage Several kinds of memories are available to the user in Nexto Series CPUS offering the best option for any user needs These memories are divided in volatile memories and non volatile memories For volatile memories Nexto Series CPUS offer addressable input 1 addressable output Q addressable memory 96M data memory and redundant data memory For applications that require non volatile functionality Nexto Series CPUs bring retain addressable memory Q retain data memory persistent addressable memory Q persistent data memory program memory source code memory CPU file system doc PDF data and memory card interface One Touch Diag One Touch Diag is an exclusi
38. iendly When maintenance comes to the picture the difficulties are higher because reaching the wires is not an easy Job Sometimes it s necessary to disassembly some close modules to access the desired one In Nexto Series these problems were solved by combining a special connector shape with a front cover Besides the easy removal and insertion of terminal blocks the design makes the panel look nice and organized ATTENTION The Nexto Jet modules have a different manner to insert and remove the terminal blocks as can be checked in chapter I O connector insertion for Nexto and Nexto Jet Modules and I O connector block removal for Nexto and Nexto Jet Modules Hobustness Nexto Series delivers an extremely rugged design allowing the use in applications where mechanical vibration is present Transportation applications or moving places are examples that require this feature which is provided without the use of screws or special mounting The whole product design was developed in such a way to deliver this feature without compromising the installation and maintenance procedures Hot Swapping The hot swapping feature allows module replacement without the need of shutting the system down power off The CPU keeps controlling the whole process and the modules can be replaced whenever needed High Availability Nexto Series delivers several different redundant architectures where CPUs PSUs and Fieldbus Interfaces can be mounted in
39. ion With the help of special editors a project can be easily configured in MasterTool IEC XE The graphical tool allows a fast and comprehensive way to configure the system Additionally the user has the complete visualization of the application architecture with the physical position and module information The configuration of fieldbus networks and standard communication protocols like PROFIBUS DP and MODBUS protocols are integrated in the programming tool This feature enables the user to set all configuration parameters in a single place avoiding the need of switching between different software tools Object Oriented Programming MasterTool IEC XE offers object oriented programming with the advantages known from modern high level languages such as JAVA or C classes interfaces methods inheritance and polymorphism dynamic binding The IEC function blocks are seamlessly extended and the extensions made available to all engineering aspects Object oriented programming offers great advantages to the user for example when wanting to reuse existing parts of the application or when working on one application with several developers Online Debugging and Commissioning Features D fe CAD aed ree Tom eke rule The code generated from the a o i ML A S Ii t application is downloaded onto Ts oy PUC pas Dora Pe La TI EXT the target device with a single ame mouse click Once MasterTool Co ese IEC XE is online it
40. ion organization that prepares and publishes international standards for electric electronic and related technologies Generic standard for operation and utilization of PLCs Old IEC 1131 Third parte of generic standard to operate and usage for PCs IEC61131 Device which adapts electrically and or logically the signal transference between two pieces of equipment See Input output Set of analog or digital l O modules and interfaces of a programmable controller Also called I O Data I O devices of a system In case of PLCs typically correspond to digital or analog inputs or outputs modules which monitor or activate the controlled device Module belonging to the inputs and outputs subsystem High priority attending event which temporarily stops the program execution and detour for a specific attending routine Memory quantity unit Means 1024 bytes if 1kbyte Light emitting diode It s a type of diode that emits light when electrically stimulated Used for light indication Graphic matrix or text where are inserted the language instructions of arelay diagram which compose an applicative program A group of logics organized in sequence form a program module Device connected to a communication network originating all the command requests to other network units Identifies the Altus software for PC executable only in Windows which allows the development of applicative for the Nexto Series and Xtorm Series Throughout this manu
41. ional diagnosis about the module status All diagnostics information is also accessible remotely by CPU fieldbus head or by MasterTool IEC XE configuration tool 19 1 Introduction The Nexto I O modules with frontal cover have labels where the user can identify the modules and the terminal blocks High Speed Backplane Bus Nexto Series architecture has a state of the art 100 Mbps Ethernet based backplane bus This backplane bus has real time behavior allowing predicted and cyclic data exchanges The high throughput enables the update of large quantities of inputs in a short time window Besides time critical applications like motion control are possible with this technology The modules are addressed and identified automatically avoiding errors during application set up and field maintenance The backplanes NX9000 NX9001 NX9002 and NX9003 provide special features in order to allow CPU redundancy in the same rack or in different racks using the Redundancy Link Modules Automatic module addressing and identification Hot swap except NX9010 100 Mbps Ethernet based serial bus Extremely accurate time synchronization for I O update or time stamping Single chip hardware solution Terminal Block Insertion amp Hemoval Nexto Series has an innovative and patented mechanism for inserting and extracting the I O modules terminal blocks In many automation applications the density of I Os is high making the field wiring complicated and unfr
42. ities must be considered e Panel effective dissipation surface calculated according DIN VED 0660 standard chapter 500 as indicated by the installation type e The dissipation constant for the painted steel plate in W m C e The panel ventilation conditions installation place e Panel occupancy degree internal air flow impedance From the quantities listed previously only the panel effective dissipation surface can be calculated precisely Panel effective dissipation surface A nv calculation The calculation of the A surface is made according the DIN VDE standard following the panel installation type A 18 H L P e t4 L P A 14 L H P 1 8 P H A 14 L H L 18 L H Panel with one side surface and the back surface obstructed A 1 4 H L P 1 4 L P Panel with both side surfaces obstructed A 18 L H 14 L P P H Panel with both side surfaces and the back surface obstructed A 1 4 L H P P H Panel with both side surfaces the back surface and the front A 1 4 L H 0 7 L P P H surface obstructed Table 3 2 Effective Dissipation Surface Calculation L Width m H Height m P Depth m 39 3 Panel Design In built panels application with painted steel plate for a null air flow surrounding it the heat dissipation constant can be considered 5 5 W m2 C The power dissipated by a panel can then be calculated through the equation Qs k A internal temperature external temperature or obtained from Figu
43. k drilling dimensions Nexto Series backplane rack has 6 holes for fixation DIN 7985 M4 cross recessed pan head screws must be used in all holes These screws can be fixed straight in the panel or using nuts when the panel width is too thin to create a thread At using nuts it s recommended the use of self locking nuts to avoid it become loose Figure 4 1 identifies three types of hole 1 2 and 3 It s extremely important to respect the following fixation rules for the correct assembly of the backplane racks e It s recommended to use M4 washers in the screws type 1 These screws must be mandatorily used e It s not possible to use washers in screws type 2 Therefore the use of self locking nuts or thread locking materials is recommended The screws for the holes type 2 are not needed unless in cases where the assembly robustness must be increased It s important to stress that these screws are placed under the modules assembled in the rack so they must be removed when the screws need to be retighten e It s mandatory the use of toothed washers in the screws type 3 to guarantee the lowest electric resistance possible between the screw and the panel which must be grounded The toothed washer must be type M4 ATTENTION The chapter Panel Design must be consulted to verify the minimum distances which must be respected between Nexto Series backplane rack and the other components placed in the electric panel Assembly First
44. m to guarantee the effective contact see Figure 4 30 20 Pin Connector Block NX9403 It s recommended the use of 0 5 mm cables Each cable must be cut with a difference of 4 mm as indicated on Figure 4 29 Each pin must have 0 5 mn terminals crimped ATTENTION Use terminal with length A 8 mm to guarantee the effective contact see Figure 4 30 6 Pin Connector Block with Fixation NX9404 It s recommended the use of 0 5 mn cables Each cable must be cut with a difference of 4 mm as indicated on Figure 4 29 Each pin must have 0 5 mm terminals crimped ATTENTION Use terminal with length A 8 mm to guarantee the effective contact see Figure 4 30 64 4 Installation 100506016 1 2 3 A L Figure 4 29 Cable cutting 110804 76A OX XS NNUS VN Le ER TE SEE X 0 S a UA a a AS LR leo LPOG Figure 4 30 Terminal Cable assembly Insert the terminals in the connector block starting by pin 10 for the 10 pin connector block or by pin 20 for 20 pin connector block Certify that the terminals are completely inserted in the connector and correctly connected Cable fixation and Identification It is recommended to use numbered wiring or cables with numbered conductors for wiring identification and Conexel identifier WKM 8 30 PN 1631910000 for cable identification Turn the cables to place then under the I O module frontal cover Then tie them together using plastic tie fixing in the wire hold
45. mation unit which can assume state O or 1 Electric signals cluster logically grouped with the function to transmit information and control between different elements of a sub system Information unit composed by 8 bits Information sent simultaneously to all the nodes in a communication network Product code formed by the PO letters followed by four numbers Abbreviation for central processing unit Controls the information flow interprets and executes program instructions and monitors the devices in the system See Programmable controller Pre defined value for a variable used in case there s no definition Procedure used to detect and isolate failures It s also the data group used for such determination which serves for problem analysis and correction Program or configuration load in the PLC Used to indicate diagnosis at LEDs LED error Electrostatic discharge Information unit transmitted in the network Global Variable List object where are declared the global variables used in the application Procedure for replacement of system modules without the need for de energizing the same Usually used in exchanges of I O modules Connector normally connected to the parallel interface of a PC in order to avoid the execution of software illegal copies Physical equipments used in data processing where the programs software are executed Initials for International Electrotechnical Commission is an international normalizat
46. n Horizontal Vertical Assembly Nexto Series allows the PLC utilization in the horizontal position It s not allowed the assembly in the vertical position in the rack Thermal Design Altus equipment is designed to work in a room temperature of up to 60 C except when specified Therefore this must be the maximum internal temperature inside the panel The following issues must be observed in the panel design e Dimension panel with enough internal volume to allow a good air flow e Predict forced ventilation or air exchangers with the room if necessary to avoid temperature levels beyond the specified limit In critic cases is recommended cooling equipment use in order to keep the temperature levels within operation limits e Distribute equally heat sources within the panel e Consider the high current conduction cables heat dissipation to avoid chute overheating ATTENTION In order to obtain the maximum dissipation of each Nexto Series module see the module Technical Characteristic document Following a method to calculate the panel internal temperature is shown regarding its dissipation and power Heat dissipation in an electrical panel Each electric panel dissipates through its surface a defined heat amount for a specific difference between internal and external temperature To calculate the heat dissipation in situations which the temperature difference internal and external reaches up to 50 C the following quant
47. nel Design Convection improved Heat removal through through gaps ventilation clusters GS a qu 3 Sy SN S lt S V SNA ZA Up to 650 700W Approximately 2000W Depending on the module Figure 3 14 Example of Heat Flow Open Installation y iN 01050201 Electrical Design General Information The programmable controllers are manufactured according world standards which establish the acceptable levels of room conditions and noise often found in industrial processes It s also fundamental that the installation of these products follow the designing rules established by installation standards Troubles caused by electromagnetic interference EMI such as communication failures program execution failures analog variables noise and even program loss can be caused by a deficient installation or electrical design The electrical design of the Altus PLCs must respect the IEEE 518 1977 standard Guide for Installation of Electrical Equipment to Minimize Electrical Noise Inputs to Controller External Sources Following the most important subjects are described Panel Supply The control system supply must have a general switch It S recommended the use of connectors for the panel general supply with integrated fuses as the installation of a 127Vac or 220Vac outlet for the programming terminal It s important that this outlet has a ground pin as the pr
48. nt al least the same as the load Circuit with zener diode The circuit with zener diode is used when the circuit off time with diode is excessive As the circuit with diode it can only be used in DC The zener diode voltage must be higher than the power supply peak voltage and the current at least the same as the load Circuit with VDR The circuit with VDR Voltage Dependent Resistor limits the inductive circuit voltage almost the same as the zener diode Its conduction voltage 1s often higher than a zener diode and it s bidirectional allowing its use in DC or AC where is most used It must be selected according to the power source maximum voltage load energy storage and desired lifetime RC Circuit The RC protection circuit resistor connected in series with a capacitor can be assembled parallel to the contact or the load The parallel assembly with the contacts is recommended to DC powered loads and the parallel assembly with the load is recommended to DC or AC powered loads The RC circuits are more efficient when used in voltages higher than 100V In order to select the R and C values it s recommended the resistor to have 0 5 to 1 Ohm for each 1V and the capacitor 0 5 to 1uF for each 1A For instance in a load connected to 220V 1A a 220 Ohms resistor and a uF capacitor can be used the capacitor model must meet the load voltage level Supply Distribution outside the Panel In applications where the panel is far away from th
49. ock existent in the frontal cover inner part The label removal is only possible when it is directed over the lock Besides at inserting it again the label must be placed over the frontal cover side locks in order to remain fixed Figure 4 23 indicates the side lock position where 3 locks can be observed on each side c 1 LS EJ 10051804A Figure 4 23 Label Fixation Locks 60 4 Installation Rack Connector Cover The connector cover must be used on the not used rack positions for protection against undesirable contacts and dust Rack connector cover insertion The connector cover must be placed on the connector starting by the lower part and finishing by the upper part pressing it until it s completely fit as presented on Figure 4 24 On Figure 4 25 the connector cover is presented completely placed 111020764 Figure 4 24 Rack Connector Cover Insertion Rack Connector Cover Removal To remove the connector cover one must just pull it by its upper rim as shown on Figure 4 25 61 4 Installation 11102077A Figure 4 25 Rack Connector Cover Removal Electric Installation Spring Connectors This type of connector has a fixation system based on a high reliability spring even under vibration subjected environment Figure 4 26 and Figure 4 27 To assembly it it s recommended the use of a 3 5 mm wide screw driver with isolated handle Figure 4 28 The advantage of using this connector is the
50. ogramming terminal must be mandatory grounded All panel outlets must have its voltages levels identified Panel Cables Distribution The way the signal and supply cable are distributes is no doubt um of the most important points in the installation of programmable controllers The correct distribution of the cables inside the panel and the correct grounding of the devices guarantee the electromagnetic compatibility EMC of the installation It s important the panel electrical supplies are correctly distributes through distribution bars or connectors From this general distribution points a cable is taken for each specific point to be fed Local jumpers in the modules supply must be avoided decreasing the high current loaded cables length In order to increase the equipment performance it s necessary to separate the circuits regarding their type to decrease electromagnetic interference as follows 42 3 Panel Design e AC supplied circuits and AC and DC loads activation e Low current less than 1A digital inputs and outputs e Analog circuits and communication These circuits must be distributed preferentially in separate chutes or avoiding they are placed parallel to each other The minimum distance of 150mm is recommended between all I O signals and supply voltages higher than 500V Panel Illumination It s very important to install illumination inside the panel activated through a switch to facilitate its operation
51. oints along with complex modules like CPUs fieldbus masters and power supply modules High speed CPU All Nexto Series CPUs were designed to provide an outstanding performance to the user allowing the coverage of a large range of applications requirements For example Nexto CPUS can execute a sum multiplication and subtraction instruction in less than 15 ns for integer type values and in less than 23 ns for real type values Nexto CPUS are able to perform 1 000 PID loops in less than 5 ms 1 Introduction MR iF Product Design Award 2012 Nexto Series was the winner of 1F Product EEI Design Award 2012 in industry skilled trades group This award is recognized internationally as a seal of quality and excellence considered the Oscars of the design in Europe Architecture CPU Nexto Series is capable of addressing many different applications ranging from small high speed machinery automation to large complex process automation For this reason the system is very flexible and modular enabling many different configurations without compromising cost and performance The modules Nexto and Nexto Jet cannot be used together in the same bus it means that the usage of mixed modules in the same bus local remote is not valid consequently the application will not be executed by the chosen CPU The architecture is divided in the following main components The CPU is responsible for the execution of all logic and control functions The
52. ols based on Ethernet There are two network modules for each purpose a control network for CPU to CPU communication and a supervision network for SCADA and OPC usage Both half clusters must have two interfaces for each network forming a full redundant system with CPU interface module and physical layer redundancy Main Features CPUs Modules The CPUs have many integrated functions online programming high memory capacity and many serial channels These devices are powered by latest 32 bit CPUs allowing outstanding performance and integration of many features Even the lowest CPU version has embedded Ethernet port for programming use in MODBUS TCP networks and embedded web server The CPUs NX301 NX3020 and NX3030 have two serial interfaces for connecting local HMIs and MODBUS networks they also have a storage card slot for hosting web pages application source code and other user files The NX3004 have one serial interface for connecting local HMI and MODBUS network and does not have memory card slot All CPUs have web pages with complete status and diagnostics list firmware update and other features The modules carry high density I Os Nexto Series delivers two module form factors slim and full size modules allowing the best I O combination for many applications where high density and panel size can be an issue Every I O module has a display for local diagnosis where each I O point state is presented There is also multifunct
53. onfiguration 2 Configuration This chapter explains how to determine the necessary modules to configure a local or remote bus It s advised to user the reading of the technical characteristics documents and specific manuals in order to allow the series devices in all its flexibility It s advised the MasterTool IEC XE software utilization for system configuration The list of all available products and its documents is easily accessed and the configuration limits easily checked Configuration Steps A system can be dimensioned through the following configuration steps Step 1 Determine necessary I O modules Considering e Solution with Nexto or Nexto Jet evaluating the needs of modules hot swap in application e Necessary I O points quantity regarding the process to be controlled Group the I O points considering its features transistor output relay output sink inputs source inputs etc Chose the module type According to the previous grouping Determine the number of modules of each type to satisfy the I O points Verify the CPU capacity All modules technical features that are needed must be checked in order to certify they satisfy the application Step 2 Determine necessary special modules and network interfaces According to the system necessities it might be necessary to use some special module such as the redundancy link module NX4010 which is used in the Nexto Series half cluster redundancy solution For fu
54. onnector cover quantity cooooccncooccncnncnnnnnnnnnnnnnnnnnnnnnonncnnonanoss 29 Step 6 Determine the power supply module quantity eese 20 Step 7 Bus expansion modules and bus expansion Cables oococoonnnnooccnnoncnnnnncnnnnncnnnonnnnnnnncnnnnanoss 20 Sepo External powefr SUPPI V erreen rca saia 09009 IDE tas 20 SEDI Master T ool TEC XE license CNOICS Sada ai 30 Master Tool IEC XE Graphic Editor ii Ad Aida 30 Compatible components ec ct tato tase a dit 30 Node documentation ACC CSS A NANA ARAN 30 ACME eii ce VCR CAN da 30 E A Pp 30 CONT cura ton ada CONSUMOS ss ii Rue EOM PUO ED UE 30 S PANEL DESIGN ti a Ta 31 Mechanic Desig y O AR E E 0 31 DIMENSIONS AAA AN AAN 31 Assembled module dept m the backplane Ti Ire ed nene le t lau eoo dee Lea ea Da aua uuu 37 Spacing between modules and other equipment in the panel ooooncnccocnnncncnnnnncnnnnncnnnnnnnnnonacononanoss 38 Cure DOS OBI s EE ase N MO II A ran eatin ran han van nme art et 38 Horizontal Vertical ASC e 39 A M sado 39 Heat dissipation in AECA Pd na 39 Electrical Desi P M caads 42 General TED mato ioco ones ene nenne eccrine ed enc n eot anes tu dU Um UNUM UD ANA DU UA TU UON DU CIC U 42 PVCU fm e 42 Panel Cables DISTIN
55. port This architecture allows the system to keep the I O access even in the case of a single failure on extension cables The CPU will detect the damaged cable re route the internal data paths to override this failure and generate user diagnostics This feature 1s interesting for fast maintenance with the system powered on and it increases the overall system availability When this kind of architecture is used it is important to remember that in case os Nexto modules usage only this type of module can be used in the local and or expansion rack The same is true in case of Nexto Jet modules usage The next architectures that follow in Figure 1 7 and Figure 1 8 are examples with Nexto and Nexto Jet modules This architecture is intended for medium to large applications where the number of I O points is high and there is the need of higher availability 12 1 Introduction Figure 1 7 Single CPU with Remote Rack Expansion Loopback and Nexto Modules 13 1 Introduction Figure 1 8 Single CPU with Remote Rack Expansion Loopback and Nexto Jet Modules 14 1 Introduction Single CPU with Redundant Rack Expansion and Loopback Bus This architecture is based on the use of two bus expansion modules in the racks With more than one expansion module the system has an outstanding availability because 1t supports single cable failure or expansion module failure Just as the previous architecture this is intended for sys
56. positioning of each used module compatibility between modules and maximum power required from the power supply are some verification executed by the MasterTool IEC graphic editor Bill of material The MasterTool IEC graphic editor generates a bill of material with the code description and quantity of each module used in the architecture assembled Such function is extremely useful for products purchase Configuration and consuming Beyond the material list the MasterTool IEC graphic editor generates another report configuration and consuming Such report indicates which are the modules used in each system rack Besides that the report indicates each module tag and its description Finally this same report also indicates the modules electrical current consume in a specific backplane rack 30 3 Panel Design 3 Panel Design Mechanic Design Dimensions There are different module sizes in Nexto Series depending on the module type 18 mm Nexto I O Module This module size is used in I O modules which fills one slot in the backplane rack Dimensions in mm 114 62 140 21 18 00 09091456C 117 46 o Figure 3 1 Nexto 18mm I O Module 31 3 Panel Design 18 mm Nexto Jet I O Module This module size is used in I O modules that composes the Nexto Jet solution and which fills one slot in the backplane rack Dimensions in mm Tu 113 00 140 24 m e
57. presents high performance and compact modules that are used together with the CPUs racks communication and field bus modules besides MasterTool IEC XE software The Nexto Jet modules add more versatility and competitiveness to the consecrated Nexto Series keeping the flexibility modular architecture and advanced diagnosis resources Module List Following is the complete list of modules Please contact your sales representative to check availability and lead times For further information please refer to the product documentation of each module CPUS Central Processing Units e NX23004 CPU with 1 Ethernet port 1 serial channel remote rack expansion and integrated power supply e NX3010 High speed CPU 1 Ethernet port 2 serial channels miniSD card interface and remote rack expansion support e NX3020 High speed CPU 2 Ethernet ports 2 serial channels miniSD card interface and remote rack expansion support e NX3030 High speed CPU 2 Ethernet ports 2 serial channels miniSD card interface remote rack expansion and redundancy support Fieldbus Interfaces NX5000 NX5001 NX5110 NX5210 Input Modules Nexto NX1001 NX6000 NX6010 NX6020 Nexto Jet NJ1001 24 Vdc 16 DI Module NJ6000 8 AI Voltage Current Module NJ6010 8 AI Thermocouple Module NJ6020 8 AI RTD Module Mixed I O Modules NX1005 Output Modules Nexto NX2001 NX2020 NX6100 Nexto Jet NJ2001 24 Vdc 16 DO Transistor Modul
58. r as well as software revisions in case they exist This information is necessary in case the Altus Technical Support is contacted 26 1 Introduction Technical Support For Altus Technical Support contact in S o Leopoldo RS call 55 51 3589 9500 For further information regarding the Altus Technical Support existent on other places see www altus com br or send an email to altus O altus com br If the equipment is already installed you must have the following information at the moment of support requesting Model of the used equipment and the installed system configuration CPU serial number Equipment revision and the software version written on the tag fixed on the product side CPU operation mode information acquired through MasterTool IEC XE The application software content acquired through MasterTool IEC XE Configuration tool version Warning Messages Used in this Manual In this manual the warning messages will be presented in the following formats and meanings DANGER Reports potential hazard that if not detected may be harmful to people materials environment and production WARNING Reports configuration application or installation details that must be taken into consideration to avoid any instance that may cause system failure and consequent impact ATTENTION Identifies configuration application and installation details aimed at achieving maximum operational performance of the system 27 2 C
59. re 3 12 Power dissipated through panel surface 2000 30 1500 20 900 800 15 700 a 600 m i 500 Qe W 400 oy 7 5 300 ee 200 S 100 100 01050700 100 1 15 2 3 4 5 67 8910 Panel surface A m according gt to DIN VDE 0660 500 Figure 3 12 Dissipated Power x Surface x Temperature difference However this value may be triple if forced ventilation is applied in the panel interior The air flow inside a panel is obstructed by the equipment installed generating concentrated heating points In this case fans may be installed to increase the air flow within the panel The forced air circulation through fans in the panel interior brings an improvement in the natural convection and tendency to keep the temperature degree equal throughout the panel Without it there s a tendency to form a concentration of heat in the upper part of the panel due to natural convection Examples For a panel free on all sides with an effective area of 3 96 m installed power of 350 W and room temperature of 30 C calculate the internal average temperature Qs k A Ti Te 350 5 5 3 96 Ti 30 Ti 46 C For the same panel calculate the internal temperature for an installed power of 1000W Qs k A Ti Te 1000 5 5 3 96 Ti 30 Tis 76 C 40 3 Panel Design In this case the temperature has exceeded the equipmen
60. rther information regarding which modules are necessary for the half cluster redundancy solution see Nexto Series CPUs User Manual MU214605 CPU NX3030 Redundancy chapter Besides the special modules the necessity for fieldbus interface must be checked Nexto modules list within this document shows all available fieldbus interface modules Step 3 Determine CPU The Table 2 1 presents some available options CPU with 1 Ethernet port 1 serial channel rack expansion support and NX3004 integrated power supply High speed CPU 1 Ethernet port 2 serial channels memory card NX3010 l interface and rack expansion support High speed CPU 2 Ethernet ports 2 serial channels memory card NX3020 interface and remote rack expansion support High speed CPU 2 Ethernet ports 2 serial channels memory card NX3030 l i interface remote rack expansion and redundancy support Table 2 1 CPU Models It s indicated to the user to verify all differences between the CPU options in order to make the best choice for his necessities The documents Nexto Series CPU Technical Features CE114100 and the Nexto Series CPUs User Manual MU214605 indicate the differences between the models 28 2 Configuration Step 4 Determine backplane rack quantity The backplane rack quantity must be defined regarding the following rules e Fieldbus interfaces and special modules can be used in the same rack together with the CPU This rule isn t vali
61. s is not responsible for supplying information about their equipment without formal registration COPYRIGHTS Nexto Ponto Series MasterTool Grano and WebPLC are the registered trademarks of Altus Sistemas de Automa o S A Windows Windows NT and Windows Vista are the registered trademarks of Microsoft Corporation These products use EtherCAT technology www ethercat org Table of Contents Table of Contents M d IMA ra A AR 4 Nexto Series Features incida cacas 4 o II o 4 Intioyattve CAMUS AAA AA A AA RN dU AO Ms QUE A Da DO CODE GE 7 a E o tree pr 8 APP UKEP ALC AR Gly AMDI E anaa lO 9 Ma Fe Cav te UO i m Te TS 19 MI S500 NIASIEEETPOOLDIBC OC iioi loi E co E Aran 22 DOS YS UCT PNE RT e Ono Pr 25 Environmental C ondio esen aadaeiades A dd 25 Documents Related to this Manual escurrir A EA 25 Visual Inspeccion e araras 26 Technical Support mp cCC O 27 Warning Messages Used m this Manual 2 5 2 2 5 bo eio e Depto eap eb ae etd PER E e epa eR RE IET o PR EHE EE A Lee PEN ER Eo EHE Ee Oed eas 27 2 CONFIGURA TIO Nicosia setae ia 28 COMMPMEATION Steps aura daci n 28 Step l Determine necessary VO MOUSE a di eus 28 Step 2 Determine necessary special modules and network interfaces oococooccccnoccnonocnnnnnonnnonacnnonanoss 28 Silo Se nas O 28 Step 4 Determine backplane Tack Quantity cias 29 Step 5 Determine the backplane rack c
62. s are plugged into the racks for adapting the different types of field signals to the CPU or fieldbus heads Nexto Series supports a wide variety of I O types and operating ranges thus covering all the typical needs for an automation system The Nexto modules are hot swappable meaning that they can be unplugged without turning the system off or removing the power and the modules that make part of Nexto Jet solution does not support this functionality Due to 1 Introduction isolation features some I O modules must be supplied by external power supplies Fieldbus Head The fieldbus heads connect Nexto Series modules to different fieldbus networks They can communicate with CPUSs from different vendors supporting several protocols like PROFIBUS DP and others Fieldbus Interface The fieldbus interfaces are fieldbus master nodes and allow the access to remote modules or other equipment based on major industry fieldbus like PROFIBUS DP MODBUS and others The fieldbus interfaces are plugged into local racks and use two I O module slots Application Examples Compact CPU This architecture explores the needs of compact applications a CPU with integrated power supply NX3004 8 positions rack and input and output modules enable the reduction of space and cost in your project These architectures presented in Figure 1 1 and Figure 1 2 are the most indicated to be used in machinery automation It is important to note that the Nexto and
63. s discharge it is important to stress that any electronic components within these products may cause environmental hazard if discharged incorrectly Therefore it s strongly recommended the product to be sent to recycle plants to be discharged with the correct waste treatment Altus guarantees their equipment against genuine production faults for a period of twelve months starting from the shipping date This guarantee is given in terms of factory maintenance that is to say the transportation costs of returning to factory will be borne by the client The guarantee will be automatically suspended if there are modifications introduced to the equipment by personnel not authorized by Altus Altus are exempt from any responsibility with regard to repairs or replacement parts owing to faults created by outside influences through inappropriate use as well as the result of accidents or force maneuver Altus guarantees that their equipment works in accordance with the clear instructions contained in their manuals and or the technical characteristics not guaranteeing the success of any particular type of application of the equipment Altus does not acknowledge any other guarantee direct or implied principally when it is dealing with supply of other companies Requests for additional information about the supply and or characteristics of the equipment and Altus services should be put in writing The address for Altus can be found on the back cover Altu
64. sed on Ethernet fit to several applications such as high speed control for small machines complex distributed processes redundant applications and systems with a large number of I O as building automation Furthermore Nexto Series has modules for motion control communication and interface to 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 allowing input and output information and data to be shared between all modules of the system The I O modules can be easily divided and distributed throughout the whole field allowing the use of bus expansion with the same performance of a local module Furthermore Nexto Series presents a complete tool for user programming configuring simulation and debug MasterTool IEC XE It s flexible and easy to use software which offers six programming languages defined by IEC 61131 3 standard Structured Text ST Sequential Function Chart SFC Function Block Diagram FBD Ladder Diagram LD Instructions List IL and Continuous Function Chart CFC MasterTool IEC XE allows the use of different languages in the same application providing to the user a powerful way to organize the application and reuse codes from previous applications Other modules of Nexto Series made the Nexto Jet solution which is an ideal set of inputs and outputs for small and medium application size beyond distributed systems The solution
65. sients caused by atmospheric discharges must be checked periodically as they might be damaged or destroyed in case the absorbed energy is above limit In many cases the failure may not be clear or easily visible In critical applications it s recommended the varistors periodic replacement even the ones which don t present visible failures 70 6 Glossary 6 Glossary Active CPU Addressable Variables Applicative Program Algorithm AT Variable Baud rate Bit Bus Byte Broadcast Commercial code CPU CP Default Diagnostic Download D E ESD Frame GVL Hot swapping Hardkey Hardware IEC IEC 61131 IEC 61131 3 Interface O I O Subsystem Input output I O Modules Interruption Kbytes LED Logic Master MasterTool IEC XE Menu Module referencing hardware In a redundant system the Active CPU performs the system control reading the input points values executing the applicative program and driving the output values The variable can be accessed directly in the memory using the desired address E g QB0 MW 100 Its the program loaded into a PLC which determines the operation of a machine or process Finite sequence of well defined instructions for problem solution Reserved words in the programming software used to indicate diagnostics Rate in which information bits are transmitted through a serial interface or communication network measured in Bits second bps Basic infor
66. t ON will be visualized on the graphical display ATTENTION When use the function ETD Electronic Tag on Display Diagnostic Explorer or Web Server to visualize the description of tag s I O points the tag s description will be truncated in the first 48 characters of the description given to the tag ATTENTION When use the function ETD Electronic Tag on Display Diagnostic Explorer or Web Server to visualize the module s name the module s name will be truncated in the first 24 characters of the description given to the module s name ATTENTION The modules that make part of Nexto Jet solution haven t the functionality ETD Electronic Tag on Display This feature is exclusively for Nexto modules Short press and long press Table 5 1 indicate the times Minimum Maximum Indication time time condition No press 59 99 ms Press type Pressing and releasing the key within a defined period Pressing for more than 1 second Pressing for more than 20 seconds Short press 0 99 s Long press Stuck key Table 5 1 Diagnostic switch touch times Preventive Maintenance e t must be checked every year if the interconnection cables have its connections tight without dust deposits mainly on the protection devices e In environments subjected to excessive contamination the equipment must be cleaned periodically removing particles dust etc e The varistors used for protection against tran
67. t operation limit 60 C and a solution must be provided to exchange the exceeding heat The installed power limit for the internal temperature limit of 60 C is given by Qs k A Ti Te Qs 5 5 3 96 60 30 Qs 653W this being the limit the exceeding 347W 1000W 653W must be dealt with by an air conditioned device for instance ATTENTION In the previous calculation it must be observed that the internal temperature is always the average and if there s no forced ventilation inside the panel the temperature of the upper part will be higher than the base and concentrated heating points may appear The due security coefficient must be taken for each case Natural Inner forced Inner forced convection Heat removal through air convection convection with heat exchanger conditioner q gt m U1050200 Up to 300 400W From 450 to 680W Approximately 2000W Approximately 2000W Depending on the module Figure 3 13 Example of Heat Flow Closed Installation A much higher heat dissipation comparing with the one obtained previously can be achieved if the room heat exchange is allowed The ventilation is often used introducing ventilation gaps on the side surfaces door or on the back of the panel This will evidently reduce the panel protection degree IP 41 3 Pa
68. t the lower part of the connector from the module and after that remove the connector completely 56 4 Installation 10042905A Figure 4 19 I O Connector Block Removal Nexto Jet Module I O connector block The connectors block from the Nexto Series I O modules use the spring connection for cable fixation not needing screws for cable holding Identification All I O connector block pins are numbered The 10 pins connectors are numbered from 1 to 10 and the 20 pins connectors block are numbered from 1 to 20 The relation between the pin number and its function on a specific module is defined in the module Technical Characteristics document VO module labels Identification number and description Nexto Series I O modules have a frontal label which has two functions allow the user to identify and describe each module and indicate on a short way its installation diagram When the I O modules frontal cover is closed its identification number and description is visible as shown on Figure 4 20 In this example the identification number is indicated by X XXX and the module description by Description Altus S A 57 4 Installation Description Altus S A 110726014 Figure 4 20 Module Identification Installation Diagram At opening the I O frontal covers the module installation diagram becomes visible as presented on Figure 4 21 Figure 4 21 Installation Diagram On Table 4 2 are described all symbols
69. tems where maintenance is an issue and the system must be available for a longer time In this architecture the racks must be mounted as the following diagram where the expansion modules are located on the edges of the racks The CPU must be located at right side of the first expansion module Besides there are unused expansion module ports that must be left unconnected Ly a v LJ a Figure 1 9 Single CPU with Redundant Rack Expansion and Loopback Bus 15 1 Introduction Fieldbus Interfaces This architecture is based on the use of fieldbus interfaces to access networks for distributing remote I Os and other third party devices Figure 1 10 Fieldbus Interfaces 16 1 Introduction Fieldbus Interfaces with Redundancy This architecture is based on the previous one with the difference of using two fieldbus interfaces for accessing the same network Since it has two interfaces the network is redundant providing a system with higher availability Figure 1 11 Fieldbus Interfaces with Redundancy ATTENTION The modules that comprise the solution Nexto Jet not support any kind of redundancy so it s use is not allowed in architectures as described in this section 17 1 Introduction CPU Redundancy For very critical applications Nexto Series 1s capable of having redundancy of CPUs The only CPU model with this feat
70. the side covers assembly must be checked If they are placed they must be removed as shown on Figure 4 2 a u a Figure 4 2 Rack side covers Before inserting the backplane rack in the panel the screws type Figure 4 1 must be partially inserted 47 4 Installation The rack must be aligned with the screws type 1 and placed in the panel until it touches its back Figure 4 3 indicates how this procedure must be executed Ps Some figures used in this subtitle don t show the backplane rack printed circuit board to simplify the process understanding N 090914514 Figure 4 3 Rack fixation Alignment After that the rack must be dragged down in order to fit the screws type 1 in the keyway as presented on Figure 4 4 OPO 1 6524 Figure 4 4 Rack fixation Keyway fitting After the rack insertion is complete all fixation screws must be assembled To finish the process the rack side covers must be inserted as presented on Figure 4 5 48 4 Installation IDA 19 13A Figure 4 5 Rack fixation Side covers Hemoval To remove the rack it s necessary to execute the inverse process described on the Assembly subtitle Module Insertion The following example shows a Nexto Series generic module this procedure must be followed for any Nexto Series module First the module lower part which is used as a guide for the correct insertion must be fit in the backplane ra
71. unctionality is a feature only for Nexto modules Module and I O points description access Besides the tag the modules and I O points can have a description It s indicated to use this description when there s need for extra information besides the tag for a specific module or I O point as for instance Temperature reading module for describing a module or Main pump activation for describing a specific output point To access the description a long press on the diagnostic switch must be done When the module is indicating the tag and its active diagnostics the CPU display shows the module description The same way when the display indicates an I O point it shows on its display the I O point description ATTENTION It is recommendable that the tag and the module name have only alphanumeric characters upper or lower case and text not start with numbers For description is recommended alphanumeric characters upper and lower case the white space and the period The usage of any other character different from those mentioned is not recommended 69 5 Maintenance ATTENTION When use the function ETD Electronic Tag on Display Diagnostic Explorer or Web Server to visualize the tag of I O points the tag s name will be truncated in the 24 first characters right after the string Application of the tag s name I E For the tag Application UserPrg MyTest ON only the string UserPrg MytTes
72. ure is NX3030 These CPUs can be located in the same rack or in different racks known as half clusters In this architecture the system will have one controller running the control task primary controller and another one acting as the standby controller with all current system status for automatic switchover in the event of a primary controller failure This means that critical processes are not affected by control system hardware failures The results are an increased productivity a minimized downtime and low maintenance times The communication between the controllers is established at the end of each CPU cycle through two high speed redundancy links SCADA PC O a so NX5001 NX5001 NX5001 NX5001 PX2612 Figure 1 12 CPU Redundancy At the center of a two half cluster redundant system there is a pair of redundant CPUs The redundancy links between the two CPUs have two channels so single failures on each channel will not affect system performance The Active CPU executes the application program and controls the remote I O The Standby CPU is put as a background resource ready to take over if necessary The standby CPU is connected to the active CPU via a high speed link present on a module called Redundancy Link Module This module must be placed at right side of the CPU The CPU and Redundancy Link module must be placed in certain slots in the racks For details check the CPU user manual In the event
73. used in the installation diagram 58 4 Installation Symbol Oooo O The letter A over the diagram indicates that such diagram is related to the connector block placed left in the module When the module has only one connector the letter A will be used B The letter B over the diagram indicates that such diagram is related to the connector block placed right in the module as shown on the figure below The numbers on the left indicate the connector block pin number e g on the figure on the left the pins 1 2 and 3 are indicated This symbol indicates a load which is being activated by a Nexto Series module output point This symbol indicates a contact responsible for activate or deactivate a specific Nexto Series sid e module input point This contact can be replaced by any output circuit compatible with the input module The 24V symbol indicates the external supply positive input which must be connected to a 24 Vdc supply source 0V The OV symbol indicates the external supply negative input which must be connected to a supply source This symbol indicates a direct current power supply source On this symbol the power supply polarity isn t specified This means the user can choose the polarity according to his demands The voltage must be compatible with the module characteristics This symbol indicates a direct current power supply source On this symbol the power supply polarity is specified according to the inner circle bar The
74. ve feature that Nexto Series brings to PLCs 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 Nexto 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 Nexto Series brings to PLCs is the Electronic Tag on Display This new functionality brings the process of checking the tag names of any I O pin 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 DHW Double Hardware Width Nexto Series modules were designed to save space in user cabinets or machines For this reason Nexto Series delivers two different module widths Double Width two backplane rack slots are required and Single Width only one backplane rack slot is required This concept allows the use of compact I O modules with a high density of I O p
75. xchanged each activation Acronym used to indicate serial transmission Electronic circuit used to verify the equipment function integrity Watchdog Information unit composed by 16 bits 72

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