Mastip METICOM CTI Series User manual

METICOM CTI Series
Temperature & Sequential Valve Gate Controller
User Guide

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Temperature Controller METICOM CTI Series
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 system.
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.
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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Temperature Controller METICOM CTI Series
CAUTION
When turning on the system, you should turn on all circuit breakers before powering on the HMI. You
may experience communication issues if you do not follow this sequence.
After turning on the system ensure the fans are running.
Never allow the fan inlets or outlets on the unit become blocked. If these become 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 follow this sequence.
Chapter 1 Introduction
1.1 CTI Series Mainframe Configuration
The CTI controller series 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, and CTI-300.
All the mainframes utilize the same temperature control module CTI-M2, and the same sequential
valve gate control module CTI-V2.
Access to all user serviceable parts, such as fuses, are done through the front of the controller by
loosening the upper and lower screws on each heat sink and removing the modules.
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.
Typical CTI Mainframes
CTI-100 CTI-200 CTI-300
1.2 Control Modules
The mainframes are available with 2 styles of control modules depending on requirements. The
modules are fully interchangeable across all mainframe designs. The externally mounted heat sink
and integrated design reduce maintenance cost and downtime.

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Temperature Controller METICOM CTI Series
Each CTI-M2 temperature control module comes standard with two zones at 15amps per zone.
Each CTI-V2 sequential valve gate control module can control up to six valve gates each module. One
or more power control modules are also required to supply 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
7.0" / 10.2" 10.2"
Max. Total Zones
32 80 120
Max. Temp. Zones
32 80 120
Max. Sequential Zones
24 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)
Temperature Control
(1) Power indicator: green light when powered on.
(2)&(3) Zone A & Zone B status indicator:
green – stop; red – running;
blink fast – communicating with HMI;
green / red alternately: alarm
(1) Power indicator.
(2) Injection signal indicator.
CTI-M2
CTI-V2

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Temperature Controller METICOM CTI Series
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
±1 digit under steady state
Load Capacity
Rated 240Vac, 15A/zone
Overload Protection
Fuses on both heater legs
TC Connector
Various options available
Soft-Start
Uses low voltage for heater
dehumidification
Mold Power Connector
Various options available
Sequential Valve Gate Control
Trigger Signal
DC24V or Dry contact
Trigger Mode
4 modes selectable
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
Various options available
1.4 Features
Cabinet
HMI
Temperature only, Sequential Valve Gate only, or
Combination of both
Full color LCD touch screen
Max. 120 zones English/Spanish/Chinese
CE compliant Fixed on mainframe or Stand-alone
Control Modules
Alarms & Protection
Control module Thermocouple broken /reversed /shorted
2-zone per temperature module (15 Amp per zone) Heater broken /shorted /oversize
6-gate per Sequential Valve Gate module Temperature high / low
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
Start sequence in group Cabinet temperature over-setting
Sensor fault solution Alarm output (optional)

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Temperature Controller METICOM CTI Series
1.5 Typical Power and Thermocouple 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)

Separate Power & Thermocouple Connectors (European style 24 pin series “E”)
Separate Power & Thermocouple Connectors (US style 25 pin series ”A”)

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Temperature Controller METICOM CTI Series
1.6Sequential Valve Gate 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 molding machine.

Valve Gate Input Wiring


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

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Temperature Controller METICOM CTI Series
Power Input Wiring
The CTI temperature controllers can be connected to either 3-phase 4-wire Y / Δ type (200-240Vac) or
3-phase 5-wire Y type (380-415Vac) mains power supplies.
3-Ph+N+E (5 wire) 380-415Vac
3-Ph+E (4 wire) 200-240Vac

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Temperature Controller METICOM CTI Series
1.6 Remote Input & Alarm Output Connectors Wiring
(Where specified)
Remote Input Wiring
Alarm & Normal Output Wiring
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 with no voltage applied.
4. Check connectors for any physical damage.
5. Check AC input power configuration matches the local power supply. 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.
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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Temperature Controller METICOM CTI Series
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 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.
2.3Connecting 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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Temperature Controller METICOM CTI Series
2.4Connecting the Power Input Cable (CTI-200 / CTI-300)
1. Ensure the power input cable meets the international and local electrical code specifications.
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.
5. Connect AC input cord to the input terminal block as shown on the inner side of cover, according
to 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.
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.
Use O-type (ring) terminals 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 the power input cord to your power distribution system until the back terminal
block cover is securely in place.
Ensure the chassis has been earth grounded before applying power.

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Temperature Controller METICOM CTI Series
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. Make sure all 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 sequential valve gate power output meets the requirement of the solenoid valves.
●Confirm that the sequential valve gate trigger signal meets the requirement of the controller.
3.2 Verifying the Connection
1. Connect the mold power and thermocouple cables.
2. Connect the sequential trigger signal cable and output cable (if required).
3. Using an Ohmmeter, touch one test lead 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 the mold power and thermocouple cables, sequential 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.

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Temperature Controller METICOM CTI Series
5. Log in the system (if required).
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, wait 30 seconds before switching on again. System communication
issues can be experienced if the system is turned off and on incorrectly.
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
I
c
o
n
B
u
t
t
o
n
M
o
d
e
,
4
2
-
z
o
n
eper page, Resolution 0.1 is checked

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Temperature Controller METICOM CTI Series
●Function Button:Icon mode is default setting. Text mode can be selected on system setting page.
●24 or 42 zones per page:24-zone is the default setting, but can be changed on system setting page.
●Resolution: 1 is the default setting, 0.1 can be selected on system setting page.
⑴Zone number.
⑵Zone status: alarm information is in red, e.g. No.2 zone.
⑶Actual Temperature (PV):
●resolution 0.1 can be selected on system setting page.
●displayed in red in stop state, e.g. No.3 zone.
●if thermocouple is open, 999 is displayed, e.g. No.2 zone.
●if zone is turned off, OFF is displayed in red, e.g. No.4 zone.
●reading blinks if there is a communication failure.
●click the PV value to set a zone’s parameters and operate it.
⑷Setpoint (SV):
●temperature unit can be selected between Celsius and Fahrenheit by Engineer’s security login.
●displayed in red in stop state, e.g. No.3 zone.
●output percent setting will be displayed in manual mode, e.g. No.1 zone.
●click setting value, output percent and load current can be alternated to show in 42-zone
page.

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Temperature Controller METICOM CTI Series
⑸Power output % .
⑹Sensor type: can be selected between J-type and K-type thermocouple by Engineer’s security
login.
⑺Load current.
[Run] (green)/[Stop](red): Run or Stop temperature & valve gate control of all zones.
In Stop mode, shows Run; and in Run mode, shows Stop.
[Auto]: Places the temperature control of all zones in Auto mode.
[Standby]: Places the temperature control of all zones in Standby mode.
In this mode, the target is 70% of setpoint.
[PgUp]: View the previous page.
[PgDn]: View the next page.
On the last page, you will see [SVG]
[SVG]: Shift to the sequential valve gate control interface.
[Graph]: View the real-time or historical data curve.
[Alarm]: View the alarm record.
[Group]: Enter the group/global setting, pattern/mold files management, and language selected.
[System]: Enter the system setting.
[Login]/[Logout]: Log in/out of the system to achieve the different security authority.
4.1.2Sequential Valve Gate Control

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Temperature Controller METICOM CTI Series
（Icon Button Mode）
[Run] (green)/[Stop](red): Run or Stop temperature & valve gate control of all zones.
In Stop mode, shows Run; and in Run mode, shows Stop.
[Auto]: Place the sequential valve gate control of all zones in Auto mode.
[Manual]: Place the sequential valve gate control of all zones in Manual mode.
In this mode, each valve gate can be opened or closed by manual.
[Temp]: Shift to the temperature control interface.
[Graph]: View the open & close sequence setting of all valve gates.
[Group]: Enter the group/global setting, pattern/mold files management, and language selected .
[TEST]: Used to simulate the trigger signal to test all valve gates control.
[Login]/[Logout]: Log in/out the system to achieve the different security authority.
⑴Gate Number.
⑵Working Status.
⑶Valve Gate Status:
Open, Close or OFF (when zone is set to off).
⑷Control Mode: Auto or Manual.
In Manual mode, touch it to open/close gate.
⑸Start Trigger Indicator: green–off, red–on.
⑹Output signal: 24V or 220V (selected on modules)
⑺Screw position: unit is mm or inch,
selected in screw position’s calibration.
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.

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Temperature Controller METICOM CTI Series
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 a read or write operation could cause data
corruption to the USB disk contents that could result in bad files or prevent 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.

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Temperature Controller METICOM CTI Series
Chapter 5 Security & System Setting
5.1 Login / Logout the System
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.
The operator should also ensure they logout the system after completing any operations to avoid
other people operating the controller by the incorrect security group.
In the absence of user login status, the main interface displays [Login]. Touch it to open the
Login screen, select the corresponding user group and input password to login the system.
In the status of the user login, the main interface shows [Logout]. Touch it and the system
opens a dialog box to confirm your operation. You can click [Yes] to logout the system.
User’s Authorities List
User Group
Authorities
Remarks
Non-Login
Select language.
View data curve, alarm records.
Mute alarms.
Authorized to Change
Setpoint
All authorities above.
Run/Stop system or zone.
Auto/Standby system.
Change the zone temperature setpoint.
Everyone Can Change
Setpoint
Operators
All authorities of Non-Login.
Choose control mode.
View module types and status.
Set system time/ auto-pager time.
Set login authority for operators.
Check the system log.
Clear all data records.
S
elect display resolution, button mode,
etc.
Set temperature setpoint or unit globally.
Initial password is “1”
for the user “Operator”.

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Temperature Controller METICOM CTI Series
Run/Stop/Set setpoint in group.
Engineers
All authorities of Operators.
Modify all parameters of zones.
Set sensor default solutions.
Set heating speed related.
Set data save interval time.
All operations in global setting.
Initial password is “654321”
for the user “Engineer”.
Administrators
All authorities of Engineers.
Manage the users and authorities.
Select OAID display, used to maintenance.
Auxiliary functions setting.
Initial password for the user
“Director” or “Administrator”
is reserved. Please consult
your dealer if necessary.
5.2 System Setting
Touch [System] on the main interface of temperature control, then enter the System Setting
Screen.

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Temperature Controller METICOM CTI Series
5.2.1 Security
●Authorization: You can manage the users, include add, copy, and delete user.
You can also check the user’s properties.
The user group name can be edited.
There are 3 User Groups: Operators, Engineers and Administrators.
Each group has different authorities, you can create more than one user in each group.
Operators: Authorized to use the functions related to production process.
Engineers: Authorized to use all functions except manage users and Clear or Auto-generate
the Module’s ID.
Administrators (the user group name cannot be deleted): All authorities.
●Change Password: You can change the password for the current user.
●Authorized to Change Setpoint / Everyone Can Change Setpoint:
Touch it to change the authority setting for operators login.
Display Authorized to Change Setpoint:
It means current setting is Everyone Can Change Setpoint.
Operators not logged in the system can run/stop the system and change the setpoint.
Display Everyone Can Change Setpoint:
It means current setting is Authorized to Change Setpoint.
Only the operator’s login the system can run/stop the system and change the setpoint.
5.2.2 Time
For the system time initialization, the setting method is:
1) Click the parameter you wish to set, then input the value on the screen keyboard.