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Related Manuals for CTI Janus CTI 2500C-J Series
Summary of Contents for CTI Janus CTI 2500C-J Series
- Page 1 CTI 2500P-Jxxx CTI 2500C-Jxxx Janus Programmable Automation Controller Installation and Operation Guide Version 1.07 CTI Janus Programmable Automation Controller IOG...
- Page 2 DOCUMENT DISCLAIMER STATEMENT Every effort has been made to ensure the accuracy of this document; however, errors do occasionally occur. CTI provides this document on an “as is” basis and assumes no responsibility for direct or consequential damages resulting from the use of this document.
- Page 3 1/27/2021 Updated warnings for battery. V1.04 4/14/2021 Changed format of ‘cti.ini’ file used to specify a fixed IP Address using the “SD Card Ethernet Port Setup” (Section 3.2.9). V1.05 5/18/2021 Added front panel picture of Janus Compact Programmable Automation Controller (Section 2.1).
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Page 4: Preface
This Installation and Operation Guide (IOG) provides information regarding installation, setup, and operation of the CTI Janus Programmable Automation Controller, also referred to as the Janus Controller in this manual. This document is not intended to serve as a programming reference for application development. A comprehensive and thorough programming reference for application development is provided by the Janus Workbench online help system. -
Page 5: Usage Conventions
Notes alert the user to special features or procedures. CAUTION Cautions alert the user to procedures that could damage equipment. WARNING Warnings alert the user to procedures that could damage equipment and endanger the user. CTI Janus Programmable Automation Controller IOG... -
Page 7: Table Of Contents
3.2.5 Physical Installation ...................... 25 3.2.6 Connecting the Controller to a Data Network .............. 25 3.2.7 Applying Power to the Base ..................25 3.2.8 Startup from Factory Defaults ..................26 3.2.9 Setting the IP Address....................26 CTI Janus Programmable Automation Controller IOG... - Page 8 CHAPTER 7 LEGACY I/O SUPPORT .................... 43 7.1 RS-485 I/O Support ........................ 43 7.1.1 CTI 2500 Series I/O Support ..................43 7.1.2 Siemens 505 and Series 500 I/O Support ..............43 7.1.3 Connecting to Remote I/O ................... 44 7.1.4 Dual RBC Support ......................47 7.1.5 Configuring Local and Remote I/O ................
- Page 9 Ethernet Port Operation ........................ 75 Alternate IP Subnets ........................76 APPENDIX D: PRODUCT SPECIFICATIONS .................. 78 Environmental Specifications ......................78 Battery Specifications ........................79 Agency Approvals.......................... 79 LIMITED PRODUCT WARRANTY ..................... 80 REPAIR POLICY ..........................82 CTI Janus Programmable Automation Controller IOG...
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Page 10: Chapter 1 Introduction
CHAPTER 1 INTRODUCTION 1.1 Janus Controller Overview The CTI Janus Process Automation Controller (PAC) is an advanced, high-performance CPU with unmatched built-in communications capabilities. All CPU models provide a number of beneficial features. Flexible Programming Support The Janus controller allows you to program in languages that best fit your application requirements and your programming expertise. - Page 11 Compatibility The Janus Controller is designed to work in the same plant environment as the CTI 2500 Series PLC, supporting many of the legacy interfaces. It is compatible with existing CTI 2500 Series and Siemens Series 505 local and remote I/O and Profibus-DP I/O.
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Page 12: Janus Programming Software
Sub-Programs and User Defined Function Blocks (UDFBs) and re-used in multiple applications. Janus Workbench also provides a means to select and configure fieldbus drivers supported by the controller. For more information, refer to the Janus Workbench Help system. CTI Janus Programmable Automation Controller IOG... -
Page 13: Chapter 2 Front Panel
Red- Card Busy 6. SD Card Receptacle 7. Ethernet Ports C and D (1000 Mb) Link LED (LINK) Activity LED (ACT) 8. Clear Exception Button 9. Remote I/O Port 10. Profibus Port (Model Dependent) CTI Janus Programmable Automation Controller IOG... -
Page 14: Janus Compact Controller Front Panel
7. Ethernet Ports A and B (1000 Mb) Link LED (LINK) Activity LED (ACT) 8. Ethernet Ports C and D (100 Mb) Link LED (LINK) Activity LED (ACT) 9. Remote I/O Port 10. Profibus Port (Model Dependent) CTI Janus Programmable Automation Controller IOG... -
Page 15: Status Indicator Leds
Janus Classic controller, all ports are capable of operating at 1000Mb (1Gb) full duplex. For the Janus Compact controller, Ports A and B are capable of operating at 1000Mb (1Gb) full duplex while ports C and D are capable of CTI Janus Programmable Automation Controller IOG... - Page 16 Ethernet link is available. No Ethernet frames are being transmitted on the network to (Activity) which the port is connected. Ethernet frames are being transmitted on the network to (Blinking) which the port is connected CTI Janus Programmable Automation Controller IOG...
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Page 17: External Sd Card Slot
Janus Workbench or the controller web server. See Section 5.3 for more information. NOTE The recessed pushbutton will function only when Switch 3 is in the CLOSED position. Section 3.2.3 Setting the Module Switches CTI Janus Programmable Automation Controller IOG... -
Page 18: Remote I/O Port
On models where the controller can be configured as Profibus master, this DB-9 connector (labeled ‘Profibus-DP’) provides the RS-485 interface to the Profibus-DP network. The pinout for shown below. The cable shield is connected to ‘Chassis Ground’. Pins 5-6 are used for the bias circuit. CTI Janus Programmable Automation Controller IOG... -
Page 19: Chapter 3 Installation
If you or your company are using CTI controllers with processes or equipment that requires the presence of a person (such as an operator or attendant), you should be aware of this potential safety hazard and take appropriate precautions. -
Page 20: Electrical Interference
The Janus controller consumes 10 watts of +5 VDC power. To calculate the total power required for the base, you need to add the power requirements for the other modules you will install in the base. CTI Janus Programmable Automation Controller IOG... -
Page 21: Sd Card Selection
To prevent this damage, the module is shipped in a special anti-static bag. Static control precautions should be followed when removing the module from the bag and when handling the printed circuit card during configuration. CTI Janus Programmable Automation Controller IOG... -
Page 22: Internal Sd Card Installation
Continue insertion until you hear a click, then release. NOTE A replacement SD card must have a write speed rating of at least 10 MB/s (Class 10). CTI recommends you purchase an SD card with an industrial rating. CTI Janus Programmable Automation Controller IOG... -
Page 23: Setting The Module Switches
Enables the ability to clear exceptions, Configuration Reset, and Restore Factory Settings using the embedded web server. 6 - 12 Reserved See the illustration in the preceding Section 3.2.2 for the location of the switches. CTI Janus Programmable Automation Controller IOG... -
Page 24: Inserting The Battery
Batteries should be stored in the original shipping container in a cool well-ventilated area. Dispose of used batteries according the instructions of its manufacturer and in compliance with all federal, state, and local regulations. CTI Janus Programmable Automation Controller IOG... -
Page 25: Physical Installation
CAUTION The high-power battery shipped with the Janus controller is different than the one used in the CTI 2500 Series PLC and should be replaced only with the exact same model. See APPENDIX C for Battery Specifications. Contact CTI for replacement batteries. -
Page 26: Startup From Factory Defaults
This operation requires the following steps: a) Create a file named ‘cti.ini’ using your favorite text editor (Notepad works just fine). The following keywords and associated values must be inserted into this file. The values must be valid network settings expressed in dotted decimal notation. - Page 27 Copy the cti.ini file created above to the root directory of a SD card and insert that card into the front panel SD card slot. The file system of the front panel SD card should be either FAT32 or EXFAT. This is the way they come when newly purchased.
- Page 28 Startup and Alphanumeric Display Options - See Section 4.1 General Settings. • Authentication and Encryption Options – See Section 4.3 Security Settings, • Clock Setting or Time Synchronization Method – See Section 4.4 Clock Settings. CTI Janus Programmable Automation Controller IOG...
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Page 29: Chapter 4 Configuration
Module Identifier: This is an optional text field that identifies the particular controller. If Enhanced Data Cache is configured, this name will be displayed in the CTI 2500 Series PLC Host controller scan statistics. Operation following Module Reset: This selection determines how the application program will execute on startup following a power cycle. -
Page 30: Network Settings
See Ethernet Port Operation in APPENDIX C for more information. Since there may be some applications that require forwarding between networks, you can choose other options that allow forwarding in this web page. CTI Janus Programmable Automation Controller IOG... -
Page 31: Security Settings
Click on the A button to apply settings. A confirmation message should be displayed indicating that the PPLY controller must be reset in order to update the configuration parameters. You must acknowledge this message to continue. CTI Janus Programmable Automation Controller IOG... -
Page 32: Clock Settings
Use Remote NTP Server: Obtains the time from an NTP (Network Time Protocol) server. • Use Data Cache Client Host: Sets clock with time read from the CTI 2500 Series Host PLC – requires use of the Enhanced Data Cache fieldbus protocol. -
Page 33: Chapter 5 Operation
Stored values can be used as “initialization values” for specified variables when application is started using the Warm Start option. • You can save or restore values of all RETAIN variables on demand thru the use of the F_SAVERETAIN and F_LOADRETAIN function blocks. CTI Janus Programmable Automation Controller IOG... - Page 34 ANAGEMENT 7. When a project is downloaded from CTI Workbench while the run-time is stopped, that project is stored on the internal SD card as the “active” application. All project source files are downloaded with the program, and they are also copied to the appropriate folder on the internal SD card.
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Page 35: Controller Startup
This section describes the sequence of events that occur during a power-on startup or after a controller reset. NOTE All CTI boot files are encrypted to provide protection against malicious code by ensuring that only CTI authorized firmware is loaded 1) The yellow ERROR LED is set ON by hardware when power is applied to the controller. -
Page 36: Clear Exception Pushbutton Operation
If the controller is in RUN or LOGIC STOP state when the C event is detected, the ONFIGURATION ESET application will be halted and operational data stored (equivalent to ending the application from Workbench) before the reset is triggered. CTI Janus Programmable Automation Controller IOG... -
Page 37: Http Data Server
Access to the Data Server can be controlled via Username/Password set in the controller web server page. If you wish to encrypt the communications between the web server and the ONFIGURATION ETWORK ETTINGS Janus controller, secure (https:) connections can optionally be selected (see Section 4.3 Security Settings. CTI Janus Programmable Automation Controller IOG... -
Page 39: Chapter 6 Updating Firmware
The procedure requires the following steps: 1) Copy the new firmware file downloaded from CTI website to root directory of a SD card and insert that card into the front panel SD card slot. The firmware file can be a compressed zip file or binary file (boot.bin) extracted from the zip file. -
Page 40: Remote Firmware Update
8) If the validation succeeds, the web page status message is updated to indicate the Firmware Update is complete and controller is rebooting. This action is also reported in the Event Log. 9) The controller then resets to complete the operation and restarts using the updated firmware. CTI Janus Programmable Automation Controller IOG... -
Page 41: Direct File Replacement
/ corrupted SD card. Since the controller is not operational, neither of the traditional methods for updating firmware can be used. 1) Unzip the compressed firmware file downloaded from CTI website (CTI_JANUS_PAC_Vnn_nn.zip) to extract the boot.bin binary file. 2) Copy the boot.bin file to the root directory of a SD card. No other files are required. -
Page 43: Chapter 7 Legacy I/O Support
• 500-5114 and 500-5114A (RS-485) • 500-2114 and 500-2114A (Coaxial) When using a 500-2114 or 500-2114A, you must attach the RBC to the CTI Janus controller using a Siemens 505- 6860 I/O Channel Converter. CTI Janus Programmable Automation Controller IOG... -
Page 44: Connecting To Remote I/O
7.1.3 Connecting to Remote I/O Remote I/O is connected to the CTI Janus controller via RS-485 cable. Cabling is typically connected in a trunk line/ drop line arrangement as shown below. Terminating Line Terminating Resisto Resisto Drop Line Drop Line... - Page 45 1600 ft (488 m) 800 ft (244 m) 2400 ft (732 m) 1533 ft (476 m) 767 ft (234 m) 2300 ft (701 m) 1400 ft (427 m) 733 ft (223 m) 2200 ft (671 m) CTI Janus Programmable Automation Controller IOG...
- Page 46 Termination resistors must be installed at the ends of the trunk line. The resistor value required depends on the trunk cable as specified in the table below Cable Type Resistor Value Belden 9182 150 ohms, 5%, ¼ W ® Belden 9860 or 9271 120 ohms, 5%, ¼ W CTI Janus Programmable Automation Controller IOG...
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Page 47: Dual Rbc Support
The Janus controller supports dual Remote Base Controller (RBC) configurations using an RS-485 network. Coaxial dual media cabling is not supported. A dual RBC configuration consists of two remote base controllers installed in a special base (CTI 2500-R11-A or Siemens 505-6511). These bases also support the installation of dual power supplies, providing redundant sources of power. -
Page 48: Profibus Dp I/O
505-6870 Profibus Remote Base controller. The CTI Janus controller can communicate with up to 64 Profibus slave devices, reading up to 244 bytes per slave and writing up to 244 bytes per slave. The controller supports modular slaves with up to 128 modules per slave. - Page 49 Up to 32 devices can be connected on a single segment. To increase distance or the number of devices supported, segments can be interconnected by using repeaters. Up to 10 segments may be connected together R = Repeater Slave Slave Slave Slave Slave Slave Segment Segment CTI Janus Programmable Automation Controller IOG...
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Page 50: Configuring A Profibus Dp Network
Baud rates greater than 1.5 Mb require special connectors and repeaters. 7.2.2 Configuring a Profibus DP Network The Profibus DP network is configured using Janus Workbench. See the Janus Workbench help for a complete description of the configuration and operation of the Profibus network. CTI Janus Programmable Automation Controller IOG... -
Page 51: Embedded Web Server
Firmware Date • FPGA Version • Build Information 1 & 2: ( CTI development and support information) • Clock Synchronization Mode: Determines how the controller clock is set) • Startup Mode: Determines how the controller starts up when reset or powered up •... -
Page 52: Application Information
The new parameters go into effect immediately after clicking the A button and confirming the action. PPLY NOTE: If both display options are disabled, the front panel alphanumeric display will be blank when no error conditions are active. CTI Janus Programmable Automation Controller IOG... -
Page 53: Network Settings
HTTPS Encryption: Encrypts the communications with the web server when the box is checked.. Checkbox to ‘Use HTTPS Encryption’ when selected (Default = Disabled) When [A ] button is pressed, the updated configuration parameters are saved to the database and a PPLY confirmation message is displayed. CTI Janus Programmable Automation Controller IOG... -
Page 54: Clock Settings
Sync Host IP Address • CTI Data Cache Host PLC The CTI Data Cache interface reads time from the Host PLC immediately after the connection/validation process and in following cases: The Host PLC indicates the PLC Clock time/date has been changed, Approximately every 2 hours. -
Page 55: File Management
] or [D ELETE pushbutton is pressed by selecting a different web page or closing the browser window. Once the button is pressed, the file transfer will continue until successful completion or an error condition occurs. CTI Janus Programmable Automation Controller IOG... -
Page 56: Firmware Update
NOTE: The connection to the PLC web server will be lost after any of the above actions are taken. Any action other than ‘Clear Exception’ will force the PLC to lose its IP address. CTI Janus Programmable Automation Controller IOG... -
Page 57: Event Log
‘Timestamp’ and ‘Repetition Count’ (item 5 above) in the original record instead of creating a new record each time an event is detected. CTI Janus Programmable Automation Controller IOG... -
Page 58: Statistics
8.7 Display All Pages This selection groups all web server pages into a page and provides an easy method for the user to “save all web data and statistics” when required for troubleshooting and analysis. CTI Janus Programmable Automation Controller IOG... -
Page 59: Custom Html (Graphics)
The appropriate security options as set in the Security Settings configuration are applied to all graphics web pages. 8.9 Acknowledgements Displays third-party software used in the CTI products in accordance with their open-source license policies. 8.10 Product Support Opens browser connection to the Control Technology Inc. home page. -
Page 61: Appendix A: System Error Codes
Error is cleared after 2 consecutive checked every minute while probes report no duplicate IP PLC is active. Address (3 minutes max). Configuration Settings Controller stopped. Configure CPU via Web Server. Missing or Invalid Download program from Janus Workbench. CTI Janus Programmable Automation Controller IOG... -
Page 62: Controller Startup Errors
Ethernet/IP Tag Server failed Controller stopped. Reset Controller. to start Contact CTI. MQTT Client driver failed to Controller stopped. Reset Controller. start Contact CTI. HTML5 Data Server driver Controller stopped. Reset Controller. failed to start Contact CTI. CTI Janus Programmable Automation Controller IOG... -
Page 63: Firmware/Configuration Update Errors
Check contents of (Could be detected by ‘SD controller is stopped. ‘cti.ini’ file if error detected by ‘SD Card Firmware Update’ or Card Ethernet Port Setup’ utility. ‘SD Card Ethernet Port Verify firmware file name (*.zip) Setup’... -
Page 64: Execution Errors
Front Panel SD Card Not Controller continues to run Cancel function that is using Accessible (Missing, normally Front Panel SD Card, or correct Incompatible, Unformatted problem with SD card. or Write-Protected) CTI Janus Programmable Automation Controller IOG... -
Page 65: I/O Subsystem Errors
Local I/O Subsystem attempts to Error Base asserted. Controller recover automatically. (Local I/O Driver or FGPA continues to run normally Reset PLC and contact CTI if Interface Task watchdog condition repeats. expired due to communication timeout). Remote I/O RBC Error... -
Page 66: Profibus Network Errors
CTI Data Cache Client has Controller continues to run Remove DC Client from non-CTI MAC Address normally application or force creation of new ‘cti.ini’ file to update MAC Address CTI Data Cache Client Controller continues to run Update Host PLC firmware Incompatible Host PLC... - Page 67 (Connection to broker or normally connection to MQTT broker. communication failed) NTP Server Error Controller continues to run Check configuration and (Connection to NTP Server normally connection to NTP Server. lost/failed) * Not displayed on Alphanumeric Display CTI Janus Programmable Automation Controller IOG...
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Page 68: Hardware Errors
Contact CTI Support. Processor High Controller continues to This indicates a serious issue with Temperature Warning run normally CPU internal temperature. User should lower ambient temperature and/or shutdown CPU if temperature does not return to normal. CTI Janus Programmable Automation Controller IOG... -
Page 69: Appendix B: Ip Address Information
2,097,151 * Address 127 is reserved for loopback testing and inter-process communication on the local computer; it is not a valid network address. Addresses 224 – 239 are used for Class D (IP multicast). CTI Janus Programmable Automation Controller IOG... - Page 70 The Network Mask must allow at least two bits of host address. In addition, a network mask which causes the derived host ID to be 0 or a broadcast address (all Host ID bits set to 1) should not be used. CTI Janus Programmable Automation Controller IOG...
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Page 71: Using The Subnet Mask
Network ID are the same as the dotted decimal values (127.18) of the IP Address. However, since the third octet of the subnet mask is not 255 or 0, you must perform a bitwise “and” calculation using the third octet of the IP Address and Subnet Mask. CTI Janus Programmable Automation Controller IOG... -
Page 72: Cidr Notation
These addresses will not be forwarded by the Internet backbone routers; therefore, you are free to use any address in this group as long as it does not conflict with the usage by your local organization. CTI Janus Programmable Automation Controller IOG... -
Page 73: Selecting A Multicast Address
(224.0.0.1 thru 239.255.255.255). For a current list of IANA assigned multicast addresses, see the IANA website: www.iana.org/assignments/multicast-addresses/ CTI Janus Programmable Automation Controller IOG... -
Page 75: Appendix C: Ethernet Port Operation
Once the port associated with a MAC address is known, the switch will forward a frame whose destination address matches this address to this port only. CTI Janus Programmable Automation Controller IOG... -
Page 76: Alternate Ip Subnets
Devices on this network are members of the IP subnet 172.18.12.0/24 (172.18.12.1, 172.18.12.2, etc.). Port B is connected to an “I/O” network, used to communicate with Ethernet I/O. Devices on this network are members of the IP subnet 172.18.13.0/24 (172.18.13.1, 172.18.13.2, etc.). CTI Janus Programmable Automation Controller IOG... - Page 77 Ethernet Local Area Network. Also, IP subnets are not associated with an application. The internal TCP/IP software (TCP/IP stack) routes data to an application based on the IP port number. CTI Janus Programmable Automation Controller IOG...
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Page 78: Appendix D: Product Specifications
IEC 255-4, Appendix C IEC 4517/79 Com(78) 766 Final, Part 4 IEC 472, 2.5 KV IEC 801 Part 3, Level 3 Radiated Noise MIL-STD-461B, Part 4 RS01, RS02 IEC 801. Part 2, Level 4 (15kV) Electrostatic Discharge CTI Janus Programmable Automation Controller IOG... -
Page 79: Battery Specifications
Replacement Part Number: Tidiran TLM-1550HPM or equivalent Agency Approvals • UL, ULC • FM (Class 1, DIV 2 - Hazardous Location) or equivalent • CE Low Voltage Directive (73/23/EEC) and Electro-magnetic Compatibility Directive (89336/EEC) CTI Janus Programmable Automation Controller IOG... -
Page 80: Limited Product Warranty
Warranty. Control Technology Inc. ("CTI") warrants that this CTI Industrial Product (the "Product") shall be free from defects in material and workmanship for a period of one (1) year from the date of purchase from CTI or from an authorized CTI Industrial Distributor, as the case may be. Repaired or replacement CTI products provided under this warranty are similarly warranted for a period of 6 months from the date of shipment to the customer or the remainder of the original warranty term, whichever is longer. - Page 81 Product reflects these warranty terms and remedies. 8. Force Majeure. CTI will not be liable for any loss, damage or delay arising out of its failure (or that of its subcontractors) to perform hereunder due to causes beyond its reasonable control, including without limitation, acts of God, acts or omissions of the customer, acts of civil or military authority, fires, strikes, floods, epidemics, quarantine restrictions, war, riots, acts of terrorism, delays in transportation, or transportation embargoes.
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Page 82: Repair Policy
In the event that the Product should fail during or after the warranty period, a Return Material Authorization (RMA) number can be requested orally or in writing from CTI main offices. Whether this equipment is in or out of warranty, a Purchase Order number provided to CTI when requesting the RMA number will aid in expediting the repair process.
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