Mastip CTI Series User manual

Temperature controller CTI Series
Copyright Mastip Technology Limited. Information Subject to Alteration V4.3 www.mastip.com
CTI Series
Temperature & Sequential Valve Gate Controller
User Guide

Temperature controller CTI Series
Copyright Mastip Technology Limited. Information Subject to Alteration V4.3 www.mastip.com
Content
WARRANTY ......................................................................................................................................................... - 4 -
SAFETY................................................................................................................................................................ - 4 -
CAUTIONS ........................................................................................................................................................... - 5 -
Chapter 1 Introduction........................................................................................................................................ - 5 -
1.1 CTI Series Mainframe Configurations .................................................................................................. - 5 -
1.2 Control Modules.................................................................................................................................... - 6 -
1.3 Specifications ..................................................................................................................................... - 6 -
1.4 Features ............................................................................................................................................. - 7 -
1.5 Typical Thermocouple & Mold Power Output Connector Wiring ........................................................ - 8 -
1.6 Sequential Trigger & Output Connectors Wiring................................................................................. - 8 -
1.7 Remote Input & Alarm Output Connectors Wiring ............................................................................ - 10 -
Chapter 2 Inspection & Installation ................................................................................................................. - 11 -
2.1 Unpacking and Inspection .................................................................................................................. - 11 -
2.2 Mounting the HMI (only for CTI-200 Series) ...................................................................................... - 11 -
2.3 Connecting the HMI (Standalone HMI Only) ...................................................................................... - 11 -
2.4 Connecting the Power Cable (CTI-200/CTI-300) ............................................................................... - 12 -
Chapter 3 Connecting the System to the Mold................................................................................................ - 13 -
3.1 Prior to Start Up ................................................................................................................................. - 13 -
3.2 Verifying the Connection .................................................................................................................... - 13 -
3.3 Startup Procedure Checklist .............................................................................................................. - 13 -
Chapter 4 Operator Interface ........................................................................................................................... - 15 -
4.1 Main Interface ..................................................................................................................................... - 15 -
4.1.1 Temperature Control................................................................................................................ - 15 -
4.1.2 Temperature Zone Introduction............................................................................................... - 16 -
4.1.3 Multiple Temperature Zone Selection..................................................................................... - 17 -
4.1.4 Sequence Valve Gate Control.................................................................................................. - 18 -
4.2 USB Port.............................................................................................................................................. - 19 -
4.3 RJ45 network port .............................................................................................................................. - 19 -
Chapter 5 User Authority & System Setting.................................................................................................... - 20 -
5.1 Login / Logout the System & User Authority .................................................................................... - 20 -
5.2 System Setting................................................................................................................................. - 23 -
5.2.1 Security .................................................................................................................................... - 23 -
5.2.2 Time.......................................................................................................................................... - 26 -
5.2.3 Cabinet Temperature & ID ....................................................................................................... - 26 -
5.2.4 System...................................................................................................................................... - 26 -
5.2.5 Language.................................................................................................................................. - 26 -
5.2.6 Control Modules....................................................................................................................... - 27 -
5.2.7 Auxiliary Functions .................................................................................................................. - 27 -
5.2.8 42-zone / 24-zone Display Shifting ......................................................................................... - 29 -
5.2.9 Clear Operation Log & Historical Data .................................................................................... - 29 -
5.2.10 Sensor Fault Solution ............................................................................................................ - 29 -
5.2.11 Speed Related Setting ........................................................................................................... - 30 -

Temperature controller CTI Series
Copyright Mastip Technology Limited. Information Subject to Alteration V4.3 www.mastip.com
5.2.12 Help......................................................................................................................................... - 32 -
5.2.13 Back ........................................................................................................................................ - 32 -
Chapter 6 Temperature Control Operations .................................................................................................... - 33 -
6.1 Control Modes..................................................................................................................................... - 33 -
6.2 Soft Start (dehumidify) Function........................................................................................................ - 33 -
6.3 Detail Parameters for Each Zone ....................................................................................................... - 34 -
6.4 Zone Setting ........................................................................................................................................ - 36 -
6.4.1 Operator Login Status........................................................................................................... - 36 -
6.4.2 Engineer Login Status........................................................................................................... - 36 -
6.4.3 Director / Administrator Login Status................................................................................. - 37 -
6.5 Group Config & Tools ....................................................................................................................... - 39 -
6.5.1 Group Setting ........................................................................................................................... - 39 -
6.5.2 Tools Management................................................................................................................... - 40 -
6.5.3 Back .......................................................................................................................................... - 43 -
6.6 Graph................................................................................................................................................... - 43 -
6.6.1 Real-time Curve ....................................................................................................................... - 44 -
6.6.2 History Curve ........................................................................................................................... - 44 -
6.7 Alarms................................................................................................................................................. - 48 -
6.7.1 Alarm Record............................................................................................................................ - 48 -
6.7.2 Mute Function........................................................................................................................... - 48 -
6.7.3 Alarm Status.......................................................................................................................... - 49 -
6.8 Simple Working Mode......................................................................................................................... - 50 -
6.8.1 Working mode selection. ......................................................................................................... - 51 -
6.8.2 Soft Start Setting ..................................................................................................................... - 53 -
6.8.3 Other Parameters Setting........................................................................................................ - 53 -
Chapter 7 Sequential Valve Gate Control Operations ................................................................................. - 55 -
7.1 Control Modes .................................................................................................................................. - 55 -
7.2 Start Trigger Modes............................................................................................................................ - 56 -
7.3 Gate Open/Close Trigger Modes ........................................................................................................ - 59 -
7.4 Detailed Parameters for Each Gate................................................................................................. - 59 -
7.5 Gate Setup ........................................................................................................................................ - 59 -
7.5.1 Operator Login Status........................................................................................................... - 59 -
7.5.2 Engineer / Director / Administrator Login Status............................................................... - 60 -
7.6 Test ...................................................................................................................................................... - 61 -
7.7 Preview the Setting............................................................................................................................. - 61 -
Chapter 8 Run/Stop System ............................................................................................................................ - 62 -
8.1 Run System ......................................................................................................................................... - 62 -
8.2 Stop System ........................................................................................................................................ - 62 -

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WARRANTY
We warrant that this product will be free from defects in materials and workmanship for a period of two (2)
years from the date of shipment. If any such product proves defective during this warranty period, we, at
our option, either will repair the defective product without charge for parts and labor, or will provide a
replacement in exchange for the defective product.
This warranty shall not apply to any defect, failure or damage caused by improper use or improper or
inadequate maintenance and care. We shall not be obligated to furnish service under this warranty; a) to
repair damage resulting from attempts by personnel other than our representatives to repair or service the
product; b) to repair damage resulting from improper use or connection to incompatible equipment; or c) to
service a product that has been modified or integrated with other products when the effect of such
modification or integration increases the time or difficulty of servicing the product.
This warranty excludes replacement of fuses, triac, calibration, contact points and damage to the
module from the use of improper styles of fuses. The maximum allowable fuse rating is 15 amps. Lower
ratings may be used for improved protection.
SAFETY
Our products have been designed to be safe and simple to operate. As with any electronic equipment, you
must observe standard safety procedures to protect both yourself and the equipment.
Read all the instructions before connecting power and turning on the systems.
Service and installation of this equipment should only be performed by qualified service personnel
familiar with high voltage electrical circuits.
All national and local electrical codes must be followed when connecting this equipment.
Only persons with knowledge of the system's operation and capabilities should operate the system.
Unless specifically explained in this manual or directed by us, do not attempt to repair the system
yourself. Doing so could result in damage to the system, or serious personal injury.
Do not apply voltage to a terminal that exceeds the range specified for that terminal.
Do not connect thermocouples to any live areas of the heaters. Lock out and tag the controller and mold
and make sure there is electrical insulation between the thermocouple and any live areas.
Do not operate this product from a power source that applies more than the voltages specified.
Do not operate this product with covers or panels removed. All unused slots of a main frame must be
covered with the appropriately sized blank panels.
Do not operate this product when wet.
Do not operate this product in an explosive atmosphere.

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CAUTIONS
When turning on the system, you should turn on all circuit breakers before power on the HMI. You may
experience communication issues if you do not obey this sequence.
After turning on the system, you should make sure that fans are running.
Never allow the fan inlets or outlets on the unit become blocked. If these becomes blocked insufficient
airflow can cause damage to the system.
When switching off the system, you must wait 30 seconds before switching on. You may experience
communication issues if you do not wait the required 30 seconds.
Chapter 1 Introduction
1.1 CTI Series Mainframe Configurations
The CTI controller is made up of 3 different models of mainframes depending on the number of zones
required. These are referred to as CTI-100, CTI-200, CTI-300.
All the mainframes utilize the same temperature control module CTI-M2, and the same sequence
valve gate control module CTI-V6.
Access to all users’ serviceable parts, including fuses, are done through the front of the controller by
loosening the upper and lower screws on each heat sink and using the attached tool or screwdriver
to lever the module out.
The connectors for the mold-power and thermocouple cables, and the connectors for valve gate
control cables, are located at the rear of the mainframe.
CTI Mainframes
CTI-SH CTI-S CTI-MH CTI-M

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1.2 Control Modules
The main frames are available with 2 styles of control modules depending on the requirements. The
modules are fully interchangeable across all mainframe designs. The externally mounted heat sink
and integrated design reduce maintenance cost and downtime.
Each CTI-M2 temperature control module comes standard with two zones at 15amps per zone.
Each CTI-V6 sequence valve gate control module can control six valve gates each module. One or
more power control modules are also required to supply the power requirements to the system
solenoid valves. The position and quantity of power control modules and valve gate control modules
In the mainframe are configured depending on the initial specification request, and are fixed to the
specific slot position.
1.3 Specifications
Model
CTI-100
CTI-200
CTI-300
User Interface
Full color LCD touch screen
Display Size
10.2"
Max. Total Zones
32 80 120
Max. Temp. Zones
32 80 120
Max. Sequence Zones
24
Power Supply
3-Ph+E(4 wire) 200-240Vac
3-Ph+N+E(5 wire) 380-415Vac
Working Conditions
0~55℃(32~131℉), 10~80%RH (No condensing)
Storage Conditions
-20~70℃(-4~158℉), 10~80%RH (No condensing)
(1) Power indicator: green, lighted when power on.
(2)&(3) Zone A & Zone B status indicator
green – stop red – running
blink fast – communicating with HMI
(1) Power indicator
(2) Injection signal indicator
(3) Output indicator
CTI-M2
CTI-V6

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Temperature Control
Control Mode
Auto-PID / Manual
Measurement Range
0~500℃（32~932℉）
Output Control
Zero Cross / Phase Angle
Setting Range
0~450℃（32~842℉）
Thermocouple
J or K-Type,
software selectable
Temperature Unit
℉or ℃
,
software selectable
Calibration Accuracy
±0.25% FS
Control Stability
±1digit-under steady state
Load Capacity
Rated 240Vac, 15A/zone
Overload Protection
Fuses on both heater legs
TC Connector
Varies options available
Soft-Start
Using low voltage for
heater dehumidify
Mold Power Connector
Varies options available
Sequence Valve Gate Control
Trigger Signal
DC24V or Dry contact
Trigger Mode
4 modes selected
Screw Position Signal
DC 0~10V
Screw Position Unit
mm or inch
Control Mode
Auto / Manual
Time Resolution
1s, or 0.1s, or 0.01s
Output Signal
DC24V, or AC220V
or Relay contact
Output Connector
Varies options available
1.4 Features
Cabinet
HMI
Temperature only, Sequential Valve Gate only, or
Combination of both Full color LCD touch screen
Max. 100 zones English/Spanish/French
CE compliant Fixed on mainframe or Stand-alone
Control Modules
Alarms & Protection
“All in one” control module Sensor Broken /Reversed /Error
2-zone per temperature module (15 Amp per zone) Load broken /shorted /over current
6-gate per SVG module Over Temp / Under Temp
Other Functions
Fuse blown
Stopping system remotely (optional) Heating invalid
Standby system remotely (optional) Triac breakdown
All zones’ temperature in tolerance output (optional) Power supply over-voltage
Alarm output (optional) Cabinet temperature over-setting
Sensor fault solution Leakage

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1.5 Typical Thermocouple & Mold Power Output Connector Wiring
The system can be supplied with either European style or US style power and Thermocouple mold
connectors, typically wired as follows (Custom wiring available)

Thermocouple & Mold Power Combination Wiring
Wiring Mode 1 Wiring Mode 2

Thermocouple & Mold Power Separated Wiring
Wring Mode 3 Wiring Mode 4
1.6 Sequential Trigger & Output Connectors Wiring
The valve gate sequence can be started by either a 24Vdc Trigger Input from the injection molding
machine start cycle, or by a 0-10Vdc Screw Position source from the injection machine.


Valve Gate Input Wiring

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Valve Gate Output Wiring (European style 24 pin series “A “)
Signal
Pins
Description
Type
Trigger Input 1 & 2 Sees a closed condition or DC24V as a signal to start the
timer on the valve sequence
Normally Open Dry Contact
Or DC24V
Screw
Position 3 & 4
Accepts a voltage source input that relates to the main
screw position.
A calibration routine within the controller adjusts actual
input to actual screw position.
0 to 10 Volts
Power Input Wiring
The CTI Temperature controllers can be connected to either 3-phase 4 wire type(200-240Vac) or
3-phase 5-wire type(380-415Vac) mains power supplies.
3-Ph+N+E (5 wire) 380-415Vac

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3-Ph+E (4 wire) 200-240Vac
1.7 Remote Input & Alarm Output Connectors Wiring
(Where specified)
Remote Input Wiring
Alarm & Normal Output Wiring
Signal
Pins
Description
Type
Standby
Signal 1 & 2
After a delay time (adjustable) since the contact is closed,
the controller will work in standby mode until AUTO
button is pressed on HMI.
Normally open dry contact
Stop Signal 3 & 4 When the contact is closed, the
controller will stop
running, same as pressing STOP button on HMI. Normally open dry contact
Alarm
Output 1 & 2 Contact is closed when any alarm happens, and it will be
reset by silence button on the alarm history page.
Normally open dry contact
1A/250Vac
Normal
Output 3 & 4
Contact is closed when all zones’ temperature are in
normal output tolerance.
Normally open dry contact
1A/250Vac

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Chapter 2 Inspection & Installation
2.1 Unpacking and Inspection
1. After unpacking, inspect the mainframe and check for any damage that may have occurred during
shipment.
2. Check the circuit breaker disconnect and neon phase voltage indicators for damage.
3. Check for proper operation of circuit breaker by flipping breaker on and off with no voltage
applied.
4. Check connectors for any physical damage.
5. Check AC input power specification. The power specification label is located on the back cover of
the mainframe’s power input terminal block. The label indicates the input voltage configuration
that was prewired at the factory. Make sure it matches what you ordered.
6. Inspect the HMI and check for any damage that may have occurred during shipment.
7. Check power connector/cable and communication connector/cable of HMI for any physical
damage.
2.2 Mounting the HMI (only for CTI-200 Series)
1. Connect the HMI’s power cable and communication cable to corresponding plug on the
mainframe.
2. Mount the HMI on the mainframe by screws provided.
2.3 Connecting the HMI (Standalone HMI Only)
1. Place or mount the HMI on the position required.
2. Connect the HMI and the mainframe with communication cable.

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2.4 Connecting the Power Cable (CTI-200/CTI-300)
1. Select the power input wire size according to the load power, and the national and local electrical
codes. (if required)
2. Remove the metal cover of the power input terminal block by removing screws around its
perimeter.
3. Remove the plastic panel of the terminal block.
4. Insert power input cable through access hole provided on the cover. (if use this type cover)
5. Connect AC input cord to the input terminal block as shown on the inner-side of cover, for the
input voltage configuration you are attaching to.
6. Connect the earth cord to the ground terminal beside the input terminal block.
7. Cover the plastic panel on the terminal block.
8. Take up excess slack in cable and secure with strain relief clamp provided on the terminal block
cover. (if use this type cover)
9. Mount the metal cover of the power input terminal block on the mainframe.
(1) (2) (3)
(4) (5)
CAUTIONS!
Service and installation of this equipment should only be performed by qualified service
personnel familiar with high voltage electrical circuits.
All international and local electrical codes must be followed when connecting this equipment.
Should use O-type terminal on the power input cord connected to the terminal block.
Do not apply power to this cable or the unit when the back terminal block cover is removed.
Do not connect AC power input cord to your in-plant power distribution system until the back
terminal block cover is securely in place.
Ensure that the chassis has been earth grounded before applying power.

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Chapter 3 Connecting the System to the Mold
3.1 Prior to Start Up
●Check that the system is completely disconnected from the power source.
●Clean up any water, oil, dirt, cleaning fluids etc. that may have spilled during a mold change or
since the last production run.
●Check all the cable connections between the system and the mold (if required). Make sure all of the
cables are free from wear or damage.
●Check that the earth/ground connection is in good condition. Verify the system and the mold have
the same ground reference.
●Check the output power and thermocouple wiring configuration on the mainframe and cable is the
same as on the mold.
●Confirm that the sequence valve gate control output meets the requirement of the solenoid valves.
●Confirm that the sequence valve gate trigger signal meets the requirement of the controller.
3.2 Verifying the Connection
1. Connect the thermocouple and mold power cables
2. Connect the sequence trigger signal cable and output cable (if required).
3. Using an Ohmmeter, touch one test led to the mold and the other to the mold ground terminal on
the system. Resistance must be less than 1Ω.
4. Check all the circuit breakers and make sure they are in the OFF position prior to connection of
the controller to the power source.
3.3 Startup Procedure Checklist
1. Connect mold power & thermocouple cables, sequence control cables between the mold and
controller (if required).
2. Connect the controller to the power source.
3. Switch the circuit breakers ON.
4. Turn on the HMI, then select the language.
5. Log in the system (if required).

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6. Load a mold setup (if required).
7. Checking the mold setup zone by zone on HMI.
8. Correct any faults found during diagnostics.
9. Touch “Run” to start the system.
10. Check that the controller is functioning correctly.
IMPORTANT!
When switching off the system, you must wait 30 seconds before switching on. You may experience
communication issues if you turn off and, on the system, incorrectly.

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Chapter 4 Operator Interface
4.1 Main Interface
The main interface is used to monitor, log in the system and general operations.
4.1.1 Temperature Control
Icon Button Mode, 24 zone per page Resolution 0.1 is not checked
Icon Button Mode, 42 zone per page Resolution 0.1 is checked

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●Function Button:Icon mode is the default setting. Text mode can be selected on system setting
page.
●24 or 42 zones per page: 24-zone is the default setting, can be alternated on system setting page
●Resolution:1 is the default setting, 0.1 can be selected on system setting page
[Run]:(green) Run selected zones or all zones of temperature & valve (if no zones selected)
[Stop]: (red) Stop selected zones or all zones of temperature & valve (if no zones selected)
[Auto]: Place all zones or selected zones run in Auto mode.
[Standby] Place all zones or selected temperature zones in Standby mode. In standby mode,
the control target value is 70% of set value.
Note: Currently display set value remains the same
[PgUp]: Used to view the previous page.
[PgDn]: Used to view the next page
On the last page, you will see .[SVG]
[SVG]: Shift to the sequence valve gate control interface
[Alarm]: Used to view the alarm record.
[Group]: Enter the group parameter setting, pattern/mold files management, and language selected.
[Setting]: Used to enter the system setting and working mode setting interface.
[Login] / [Logout]: Used to log in/out the system to achieve the different authority.
4.1.2 Temperature Zone Introduction
1. Zone number: Current temperature zone ID number, cannot be modified.
2. Zone name: Current temperature ID name can be customized; default background is blue.
This temperature zone name customization needs supervisor or above authority.
3. Zone status: Auto, Stop, Standby, Manual, Alarm (display in red)
4. Present Temperature Value (PV):
●resolution 0.1 can be selected on system setting page.

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●displayed in red color in stop state
●if thermocouple is open, 999 will be displayed
●if zone is turned off, OFF is displayed in red color
●blinking when communication fails
●Touch it to set zone’s parameters and operate it.
5. Setpoint (SV):
●temperature unit can be selected between Celsius and Fahrenheit by Engineer’s parameter.
●displayed in red color in stop state
●output percent setting will be displayed in manual mode
●Touch setting value, output percent and load current can be alternated to show in 42-zone
page
6. Sensor type: can select J-type and K-type in zone setting or group setting
7. Load current: display current real- time output current value
8. Power output percentage: display the current real-time power output percentage
9. Temperature zone on/off button: control single temperature zone on and off directly
4.1.3 Multiple Temperature Zone Selection
Touch different sections of the temperature zone for different actions.
Section 1: Touch the upper half part of the zone, enter temperature zone setting.
Section 2: ●Touch the bottom half part of the zone, select current zone (zone blinking).
●Touch again to cancel selection
●Select multi zones, users can execute batch operation of on/Stop/Auto/Standby
●And can execute group operation (modify general parameters)
Note: The selected zone will keep blinking all the time if no operation or modify parameters

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4.1.4 Sequence Valve Gate Control
[Stop]: (red) Stop valve gate control of all zones.
[Run]:(green) Run valve gate control of all zones.
[Auto] / [Manual]: Place the valve gate control of all zones in Auto / Manual mode.
Each gate can be opened or closed by manual, usually used for system debugging.
[Temp]: Shift to the temperature control interface
[TEST]: Used to simulate the trigger signal to test all valve gates control.
[Graph]: Used to view the open & close sequence setting of all gates.
[Alarm]: Used for viewing the alarm record.
[Group]: Enter the group/global setting, pattern/mold files management, and language selection.
[Setting]: Used to enter system setting.
[Login] / [Logout]: Used to log in/out the system to achieve the different authority.

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1. Gate Number: Current valve ID number, cannot be modified
2. Gate Name: Current valve ID name, can be modified
3. Gate Status: Run, Stop, Manual
4. Gate Setting value: Display in red color under setting status and
black color under working status
5. Control mode: Auto, Manual, OFF
6. Input signal lamp and screw position: screw position’s unit is
mm or inch, selected in screw position’s calibration
7. Output signal and type: 24V or 220V
Note: For lamps in 6/7, no signal show green lamp; signal generates shows red lamp.
4.2 USB Port
The USB port on the CTI series is intended to be used to copy mold setup files to and from the system.
The screen for importing or exporting mold setups is displayed in the Group Setup Screen.
These mold setup files can be copied to other CTI controllers that support the same file type.
The USB port is also be used to export the historical data record (in csv format) from the system. The
screen for exporting data record is displayed in the History Data Curve Screen.
CAUTION!
•Never power on the unit with a device in the USB port.
•Never connect a powered USB hub or other device to the USB port.
•Removing the USB disk from the system during read or write operation could cause data
corruption to the USB disk contents that could result in bad files or the entire drive from
being usable.
The following warnings and restrictions should be observed when using the USB port:
•Only supports USB disks that use a File Allocation Table (FAT or FAT32) format.
•Only supports USB versions 2.0 and 1.1.
•Use an empty USB disk or one that contain as few files as possible.
4.3 RJ45 network port
The RJ45 network port on the CTI series controller is used for Internet networking, supporting network
port networking and MODBUS TCP communication protocol.
It supports remote reading of system operating status and working parameters, remote start/stop of
the system, remote single stage start/stop, and remote modification of the temperature target value.

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Chapter 5 User Authority & System Setting
5.1 Login / Logout the System & User Authority
To avoid accidental changes and protect the system data, the controller is set up with different
operator levels which have different security authorities.
To achieve the corresponding authority, the operator should login the system by their security group
name and password before operation.
5.1.1 Login / Logout the System
●The main interface displays [Login] when no user login. Touch the icon and enter the Login
interface, select the corresponding username and input password to login the system.
●The main interface displays [Logout] when user login. you can Touch the icon and choose
“Yes” to log out the current user.