Introduction to CTI CTI-2501
Product Description
The CTI CTI-2501 is a high-performance industrial temperature controller designed for precise thermal management in process industries. Manufactured by CTI Control Technologies, a leader in automation and control solutions, this device is engineered to regulate temperatures in applications such as ovens, furnaces, heat treaters, and reaction vessels across sectors including food processing, pharmaceuticals, plastics, and metallurgy.
Featuring advanced PID (Proportional-Integral-Derivative) control algorithms and a user-friendly interface, the CTI-2501 delivers accurate temperature regulation with minimal overshoot and steady-state error. Its robust design includes a durable aluminum alloy front panel and sealed enclosure, ensuring reliability in harsh industrial environments with dust, vibration, and temperature fluctuations. The controller supports multiple sensor inputs and output types, enabling flexible integration into existing heating or cooling systems for seamless process control.
Technical Parameters
- Temperature Range: -200°C to +1800°C (depending on sensor type)
- Sensor Compatibility: Thermocouples (J, K, T, E, R, S, B), RTDs (Pt100, Pt1000), and analog inputs (4-20 mA, 0-10 V)
- Control Algorithm: PID with auto-tuning, on/off, and manual control modes
- Control Outputs:
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- Relay (SPDT, 5A/250V AC)
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- SSR driver (12V DC, 30mA)
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- Analog (4-20 mA, 0-10 V)
- Accuracy: ±0.1% of full scale + 1°C
- Resolution: 0.1°C
- Sampling Rate: 10 samples per second
- Display: 4-digit LED display (PV: process value; SV: set value) with backlight
- Communication: RS485 (Modbus RTU) for remote monitoring and configuration
- Power Supply: 100-240V AC (50/60 Hz), power consumption ≤ 8W
- Operating Temperature: 0°C to +50°C (32°F to +122°F)
- Relative Humidity: 10-90% RH (non-condensing)
- Protection Rating: IP65 (front panel); IP20 (rear terminals)
- Dimensions: 48mm × 96mm × 112mm (W × H × D) – 1/8 DIN size
- Weight: Approximately 200g
Usage Methods
- Installation:
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- Mount the controller in a control panel using the provided mounting bracket, ensuring the front panel is flush with the panel surface.
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- Cut a 45mm × 92mm (W × H) opening in the panel for insertion, then secure the controller with the locking clips.
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- Avoid mounting near heat sources, direct sunlight, or areas with excessive vibration to maintain measurement accuracy.
- Wiring:
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- Connect the power supply (100-240V AC) to the L and N terminals, ensuring correct polarity and using a dedicated 0.5A fuse.
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- Wire the temperature sensor to the input terminals (follow polarity markings for thermocouples and RTDs).
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- Connect the control output (relay, SSR, or analog) to the heating/cooling device, ensuring load currents do not exceed the output rating.
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- For Modbus communication, connect the RS485 terminals (A, B, GND) to the network using twisted-pair shielded cable, with the shield grounded at one end.
- Configuration:
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- Power on the controller and use the front-panel buttons to set the desired temperature (SV) and configure control parameters (P, I, D values).
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- Activate auto-tuning by pressing the dedicated button; the controller will automatically optimize PID parameters by analyzing system response.
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- Set alarm thresholds (high/low temperature limits) and output logic (heating or cooling mode) via the menu system.
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- For remote configuration, use Modbus software to adjust parameters and monitor process values (PV) from a PC or SCADA system.
- Operation and Maintenance:
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- Monitor the display to ensure the process value (PV) stabilizes near the set value (SV); adjust PID parameters if overshoot or oscillations occur.
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- Check alarm indicators (LEDs) for high/low temperature alerts and respond by adjusting the setpoint or inspecting the heating/cooling system.
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- Perform quarterly inspections: verify wiring tightness, clean the display with a soft cloth, and check sensor connections for corrosion.
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- Recalibrate the controller annually using a standard temperature source to maintain accuracy, especially in critical applications.
System Introduction
The CTI CTI-2501 operates as a core component in closed-loop temperature control systems, integrating with three key layers:
- Sensing Layer: The connected sensor (thermocouple, RTD) measures the process temperature and converts it into an electrical signal for input to the controller.
- Control Layer: The controller compares the process value (PV) with the set value (SV), then uses PID logic to adjust the output signal, regulating the heating or cooling device to minimize the difference.
- Actuation Layer: The control output modulates the heater (e.g., electric coil, gas valve) or cooler (e.g., chiller, fan) to maintain the desired temperature.
In a plastic extrusion application, the CTI-2501 monitors the temperature of the extruder barrel via a K-type thermocouple. If the barrel temperature drops below the setpoint (e.g., 200°C), the controller increases the relay output to activate the heating elements. Once the temperature stabilizes, the PID algorithm reduces the output to prevent overshoot, ensuring consistent melt viscosity and product quality.
Related Models in the Series
- CTI-2502: Dual-loop temperature controller, capable of regulating two independent zones (e.g., oven top and bottom heaters), ideal for large-scale heating systems.
- CTI-2501-EX: Explosion-proof version with ATEX/IECEx certification, designed for hazardous areas such as chemical reactors or solvent-based processes.
- CTI-2501-W: Wireless-enabled controller with Wi-Fi and Bluetooth, supporting remote monitoring via mobile apps, suitable for retrofitted systems.
- CTI-2510: High-precision variant with 0.01°C resolution and advanced fuzzy logic control, optimized for laboratory and pharmaceutical applications.
- CTI-2501-L: Low-temperature model with enhanced sensor compatibility for cryogenic systems (-270°C to +200°C), used in food freezing or semiconductor manufacturing.
- CTI-2501-C: Controller with built-in data logging (10,000 points) and USB port for data export, facilitating compliance with quality standards (e.g., FDA, ISO).
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