The automation landscape has been undergoing transformations driven by the need for greater connectivity, precise diagnostics, and high system availability.
In this context, Altus develops technologies capable of serving everything from small OEM machines to large-scale critical processes, such as oil platforms and major industrial operations.
Here, you will get to know our I/O systems: Nexto NX, Nexto NJ, Nexto XP, and the G Series, covering applications from the smallest to the largest, their functionalities, and the engineering differentiators that make these solutions ready for the control and data acquisition market.
Nexto XP: The All-in-One Solution for Industry 4.0
For applications requiring high connectivity in a compact format, Altus developed the Nexto XP series.
XP controllers already feature integrated inputs and outputs within their structure, reducing the need for additional modules and simplifying system architecture.
Designed to meet the primary demands of Industry 4.0, the XP series stands out as a natively IoT-ready solution, prepared for integration with digital platforms, communication via multiple protocols, and application in scenarios demanding rapid implementation and high connectivity levels.
Even with integrated I/O, Nexto XP controllers can be easily expanded through additional modules using the CANopen protocol for communication.
These modules were designed with a compact form factor and DIN rail mounting, facilitating installation in electrical panels and allowing for the construction of modular, flexible architectures suited to different levels of complexity in industrial applications:
- – XP101: Adds 16 digital inputs at 24 Vdc, expanding signal acquisition capacity.
- – XP106: Adds 8 digital inputs and 6 relay outputs, serving as a versatile option for applications such as motor starting and lighting control.
- – XP201: Adds 16 transistorized digital outputs, ideal for applications requiring higher rapid-triggering capacity.
- – XP600 and XP610: Add analog expansion with 4 input and 4 output channels, allowing precise control of voltage and current loops.
In our architecture example, we present the use of Nexto XP, along with its expansions, applied to a filling machine.
G Series: Robust Remote I/O for Field Operations
The G Series is a solution focused on distributed I/O systems (field remotes) that demand high network flexibility and high point density. Unlike the Nexto series, which are structured in backplane/rack architectures, G Series modules are installed side-by-side on a DIN rail, forming an easily scalable assembly.
One of the primary differentiators of the G Series is its multi-protocol versatility. Through various network adapters (bus couplers), the modules can be integrated with controllers using protocols such as PROFINET, EtherCAT, EtherNet/IP, Modbus TCP, and CANopen. This flexibility allows the series to be used as an I/O solution for controllers from different manufacturers, ensuring total interoperability.
The G Series was also designed with a focus on ease of installation and maintenance. The modules utilize Removable Terminal Blocks (RTB), enabling quick replacement without the need to redo the wiring. Additionally, they feature cable fixation rings and front-facing LEDs that clearly indicate the power status and the status of each individual channel.
Physically, G Series modules are only 12 mm wide, allowing for the connection of up to 63 modules to a single network adapter. The high-speed internal bus is capable of processing 128 bytes in 1 ms, making the line suitable for applications requiring fast response times, such as high-cadence packaging machines and automated assembly lines.
As shown in the architecture below, the G Series is utilized as a remote I/O for data acquisition in conjunction with the new Nexto XF series CPU:
Nexto NJ: High Performance with Compact Design
The Nexto NJ series was developed for applications requiring cost and space optimization. NJ modules are compatible with the CPUs and network adapters of the NX series, sharing the same backplane technology and programming environment, which ensures simpler system integration.
All NJ modules feature a standard width of 18 mm with high I/O density, which is essential for professionals who need to reduce the physical footprint of their electrical panels without compromising control capacity.
The NJ series is best suited for distributed systems and applications where maintenance can be performed during scheduled shutdowns. Despite its focus on optimization, it inherits the ruggedness of the Nexto NX, including galvanic isolation between inputs, outputs, and internal logic, ensuring signal integrity even in environments with high electromagnetic noise.
NJ modules cover everything from basic needs to more advanced data acquisition and control applications, providing flexibility for various levels of complexity in automation projects:
- – NJ1001 and NJ2001: 16-input and 16-output digital modules. The NJ2001 has a current capacity of up to 1.5 A per transistorized output, enabling the direct driving of various loads without the need for auxiliary relays.
- – NJ1005: Offers 8 digital inputs and 8 digital outputs in a single 18 mm module, making it a highly efficient solution for space optimization in compact panels.
- – NJ6001: Featuring 6 analog inputs (12-bit), it provides excellent cost-benefit for reading level and pressure sensors, such as those in water and wastewater systems.
- – NJ6010 and NJ6011: Dedicated modules for temperature reading via thermocouples, featuring 24-bit resolution in the analog-to-digital converter to ensure high resolution and stability in measurements.
- – NJ6020: Supports resistance sensors (RTDs), suitable for temperature control in industrial processes, including tanks and ovens in the food industry.
The automation of feed mills, for instance, is one of the primary applications for the Nexto NJ series. In addition to its ruggedness, this series offers an excellent cost-benefit ratio, making it ideal for this type of operation:
Nexto NX: High Availability for Critical Process Control
The Nexto NX series is the high-performance pillar of the Altus portfolio. Developed for applications where downtime and operational risks are unacceptable, this series combines high processing power with a modular I/O system based on high-speed Ethernet.
The internal backplane, operating at 100 Mbps, ensures deterministic and rapid sharing of field data between modules. This architecture enables the control of complex processes and high-dynamic loops, guaranteeing precision, stability, and reliability even in the most critical scenarios.
However, the greatest differentiator of the Nexto NX series is undoubtedly its full support for Hot Swapping, allowing a module to be replaced without shutting down the main controller or interrupting the power supply to the rack.
Hot swapping is complemented by the Easy Plug System of the NX modules, a technology that enables the connection and disconnection of I/O terminal blocks safely and without the need for tools. The module’s front cover itself acts as a mechanical guide, ensuring the correct positioning of the terminal and the reliable restoration of electrical contact after maintenance interventions.
Another standout feature is One Touch Diag (OTD). Through a graphic display on the CPU, the operator can access diagnostic information for any module in the system simply by pressing a button on the respective module. This tool provides immediate data on the status of each I/O point, short-circuit alarms, loss of external power, or configuration failures, allowing for rapid troubleshooting without needing a connection to programming software during operation.
This series also supports network redundancy through two NX5210 modules, which allow the connection of an I/O bus to two distinct PROFIBUS-DP networks operating in active/standby mode. If a cable breaks in one of the networks, communication is automatically transferred to the secondary network. Additionally, the presence of an integrated firewall and native VPN tunnels in models like the NX3008 protects data traffic against external threats in connected networks.
The diversity of NX series I/O modules allows for meeting the specific needs of each industrial sector:
- – NX1001 (16 digital inputs, 24 Vdc): Delivers galvanic isolation and support for sink/source signals.
- – NX6000 (8 analog inputs, 16-bit): Offers high resolution for reading voltage and current signals for the precise control of variables such as pressure, flow, and temperature.
- – NX6014 and NX6134 (I/O with HART protocol): These modules enable bidirectional communication with intelligent field instruments. Through the HART protocol, the Nexto System can read secondary variables, access device diagnostics, and perform remote parameterization, functioning as an asset management hub without the need for additional hardware.
- – NX1006 (Monitored Digital Inputs): Designed for safety and fire detection systems, this module detects not only the signal state but also open-line or short-circuit conditions in the sensor wiring.
- – NX2025 (Monitored Digital Outputs): Enables the supervision of the electrical installation of the outputs, diagnosing broken wiring or overcurrent.
Our I/O system series with the highest level of embedded technology is ideal for critical applications, such as boiler control and oil platforms:
Maintenance, Lifecycle, and Support
The longevity of an automation system depends on how easily it can be maintained. Altus has designed its I/O series to be robust and easy to diagnose. The use of components with no moving parts and Battery-Free (BFO) technology contribute to a high MTBF (Mean Time Between Failures).
When maintenance is required, features such as the Removable Terminal Blocks of the G Series and the Nexto series ensure that the MTTR (Mean Time to Repair) is minimized.
Furthermore, Altus maintains a structured support and technical assistance program, featuring a help desk and on-call service. The availability of spare parts and emergency repair services reinforce our commitment to the operational continuity of our customers’ industrial plants.
We also invest in the ecosystem’s development through an online Knowledge Base and certified training for integrators, such as the INTEGRA Program in Brasil, ensuring there are always qualified professionals to operate, maintain, and expand systems based on Altus technology.
Whether controlling a hydroelectric power plant, monitoring a sanitation network, or ensuring the precision of a textile machine, Altus I/O systems are ensuring productivity, safety, and innovation for the development of the industry.
