The ASCON KM2 is a dual-display PID temperature regulator designed for single‑loop industrial process control. It combines a universal input stage—accepting thermocouples, RTDs, PTC/NTC thermistors, mV signals, and standard mA/V inputs—with a flexible output architecture (relay, SSR drive, or analog) and a dedicated heater break alarm via an external CT input. The controller supports three auto‑tuning algorithms (oscillating, fast, and evoTune) to match different thermal load characteristics, plus single or double‑action PID and ON/OFF control. A 1‑program × 8‑segment mini‑programmer, four independent setpoints, and three configurable alarms provide the flexibility needed for multi‑stage thermal processes. The built‑in wattmeter displays real‑time load power consumption. The 48×48 mm 1/16 DIN panel format with IP65 front protection makes it suitable for densely packed control cabinets in harsh industrial environments.

Heater Break Alarm — Built‑in Load Diagnostics

• How It Works: An external current transformer (CT) is wired to the heater power line and connected to the KM2's dedicated CT input. The controller continuously monitors the load current. If the measured current falls below a user‑configurable threshold while the controller is calling for heat—indicating a broken heating element, a failed SSR, or an open circuit—the HB alarm activates immediately. The alarm can be assigned to any of the three configurable alarm outputs, triggering a local indicator, a remote signal, or an automatic shutdown sequence.
• Why It Matters: In continuous‑operation processes such as extrusion lines, packaging machines, and curing ovens, an undetected heater failure causes a silent temperature drop that leads to out‑of‑spec product, wasted material, and delayed shipments. The HB alarm eliminates this failure mode by detecting the fault at the moment it occurs, rather than waiting for an operator to notice the temperature deviation hours later.
• Diagnostic Value: Because the CT input provides a direct current reading displayed on the controller, maintenance technicians can use the KM2 to verify heater health during routine inspections without disconnecting wiring or using a clamp meter.

Universal Input and Advanced Auto‑Tuning

• True Universal Input: A single KM2 controller accepts thermocouples (J, K, S, R, T, plus J and K infrared sensors), RTDs (Pt100, Pt1000), PTC thermistors (KTY81‑121), NTC thermistors (103AT‑2), mV signals (0/12‑60 mV), and standard analog signals (0/4‑20 mA, 0/1‑5 V, 0/2‑10 V). Input type selection is made entirely via configuration parameters—no hardware jumpers no module swaps. This reduces spare controller inventory across multi‑process facilities.
• Three Auto‑Tuning Algorithms: The KM2 offers oscillating auto‑tune (most accurate, for applications where the process can tolerate controlled oscillation during tuning), fast auto‑tune (minimum time to convergence, for processes requiring rapid setup), and evoTune (the most advanced, providing one‑touch push‑and‑forget tuning that works autonomously without user intervention and supports heat/cool dual action). EvoTune is the recommended default for most applications.
• ±0.5% FS Accuracy: Measurement accuracy is ±0.5% of full scale ±1 digit across all input ranges (except TC S: ±1% FS ±1 digit). A transmitter power supply (12 VDC) is available on‑board for powering external 4‑20 mA loop transmitters, eliminating the need for a separate DC supply.

Flexible Output Architecture and Additional Functions

• Three Outputs, Independently Configurable: OUT1 can be a relay (SPST‑NO, 4 A/240 VAC) for direct contactor drive, an SSR logic output (13 V/15 mA) for high‑speed switching, or an isolated analog output (0/4‑20 mA, 0/2‑10 V) for proportional valves or remote indicators. OUT2 provides a second relay (SPST‑NO, 2 A/240 VAC) or SSR output, typically assigned to cooling control or a second alarm. OUT3 can be configured as an additional SSR output or as a second digital input.
• Wattmeter — Real‑Time Power Monitoring: The integrated wattmeter function calculates and displays the instantaneous power (in watts) consumed by the connected heating load. This data enables process engineers to track energy consumption per batch, detect degrading heating elements through gradual power drift, and identify opportunities for energy optimization—all without external power meters.
• 3 Configurable Alarms: Each alarm can be independently configured for absolute high/low, deviation high/low, or band alarm mode. The alarms can be assigned to any of the three outputs or to the RS‑485 communication interface for centralized monitoring.
• 4 Selectable Setpoints and Mini‑Programmer: Four independent temperature setpoints can be stored and selected via the front panel or digital input. The 1‑program × 8‑segment mini‑programmer enables ramp‑soak temperature profiling for batch processes such as curing, annealing, and sterilization.
• Working Hours/Days Counter: The built‑in counter tracks total operating time for preventive maintenance scheduling—alerting the operator when a heater element, contactor, or sensor has reached its recommended service interval.

Compact 1/16 DIN Panel Mount with IP65 Front Protection

• 48×48 mm Standard Format: The 1/16 DIN panel cut‑out (45×45 mm) allows the KM2 to fit into densely packed control cabinets alongside contactors, motor protectors, and circuit breakers. The total depth is 63.3 mm plus 14 mm for removable terminals—suitable for shallow‑depth control panels where space behind the panel is limited.
• IP65 Front with Gasket: When installed with the optional sealing gasket, the front panel achieves IP65 protection against dust ingress and low‑pressure water jets from any direction. This makes the KM2 suitable for washdown environments in food processing, pharmaceutical cleanrooms, and outdoor installations.
• Dual 4‑Digit LED Display: The process value (PV) is shown on a 15.5 mm high display with three dynamic colors (red, green, amber) for at‑a‑glance status indication. The setpoint (SV) is shown on a second 7.6 mm green display. The dynamic color system allows operators to immediately identify normal operation (green), alarm conditions (red), or transitional states (amber) without reading numerical values.
• Wide‑Range Power Supply: The KM2 operates from any supply voltage between 100 and 240 V AC/VDC at 50/60 Hz, with power consumption limited to 5 VA. This universal supply eliminates the need to specify different voltage variants for different installations—one model covers global industrial mains voltages.
• UL and CE Certified: The KM2 carries both UL and CE certifications, supporting deployment in North American, European, and international markets without additional field testing or recertification.

Applications

• Plastics extrusion and injection molding barrel temperature control
• Packaging machinery: heat sealing, blister forming, shrink‑wrap tunnels
• Industrial ovens and furnaces for heat treatment and curing
• Food processing: ovens, fryers, pasteurization equipment
• Chemical and pharmaceutical reactor heating jacket control
• Any industrial process where heater failure detection, universal input, and IP65 front protection are required in a compact 1/16 DIN format