The Kletti KM-MICROx is an inline digital temperature controller designed for integration into electrical heating systems—particularly Kletti's own heated hoses, hot melt adhesive delivery lines, and industrial heating circuits. Unlike conventional PID temperature controllers that require manual tuning or one-shot auto-tuning for each new load, the KM-MICROx uses Fast-Adaptive-Tuning (FAT), a proprietary algorithm that continuously monitors the thermal response of the connected heating element and adjusts its control parameters in real time. This makes it uniquely suited to applications where the heating load characteristics vary—for example, when a heated hose assembly is changed, when the hose length is modified, or when the ambient temperature changes significantly between summer and winter production conditions.

How FAT (Fast-Adaptive-Tuning) Works

• Continuous Adaptation, Not One-Shot Tuning: Traditional auto-tuning PID controllers run a tuning cycle once, calculate a set of fixed PID parameters, and then use those parameters until the next manual retune. FAT, by contrast, treats the control loop as a continuously moving target. It constantly analyzes the rate of temperature change, the overshoot or undershoot magnitude, and the recovery time from disturbances, making micro-adjustments to its internal control model on every heating cycle.
• No User Interaction Required: There is no "start auto-tune" button, no PID parameter display, and no need for the operator to understand proportional band or integral time. FAT handles the complexity internally. This dramatically reduces commissioning time—connect the controller to the heating element and power supply, and it begins controlling correctly within the first few temperature cycles.
• Adapts to Changing Loads: In applications like hot melt adhesive delivery, the thermal mass of the system changes when a different hose length is installed, when the adhesive type is changed, or when the hose is moved from an indoor to an outdoor environment. FAT automatically compensates for these changes without reprogramming.

Triac Switching — Solid-State, Arc-Free

• High Switching Capacity: The Triac (bidirectional thyristor) output switches the heating element power directly at the AC mains voltage zero-crossing point, eliminating the electrical arcing that erodes mechanical relay contacts over time. This makes the controller suitable for high-duty-cycle heating applications where a relay-based controller would wear out within months.
• Silent Operation: No audible clicking from contactors or relays during temperature regulation—important in laboratory, cleanroom, and medical device manufacturing environments.
• Fast Response: Because the Triac can switch on and off within a single mains cycle (20 ms at 50 Hz), the FAT algorithm can apply very fine-grained power adjustments to the heating element, minimizing temperature overshoot.

Wide-Range Power Supply & Global Compatibility

• 90–250 V AC Coverage: A single KM-MICROx model operates on any AC mains voltage from 90 V (compatible with 110 V nominal systems in North America and Japan) to 250 V (covering 230 V European and 240 V UK standards). No transformer, no voltage selection switch, no risk of installing the wrong voltage variant.
• DC Operation (12–48 V): The controller also accepts DC supply voltages from 12 V to 48 V, covering mobile equipment, battery-buffer systems, and solar-powered installations. A dedicated DC version is available for applications that exclusively use DC power.

Thermal Protection & Status Indication

• 85 °C Automatic Shutdown: The controller internally monitors its own electronics temperature. If internal heating (due to high ambient temperature combined with full-load Triac conduction) causes the electronics to reach 85 °C, the controller immediately disables the Triac output to prevent damage. It automatically resumes operation once the internal temperature drops back into the safe range—no manual reset required.
• Multi-Color LED: A single multi-color LED on the controller enclosure communicates the full operational status: heating active, temperature at setpoint, overtemperature shutdown, and fault conditions. Installers and maintenance technicians can diagnose the system status at a glance.

Optional IR Control Panel

• Wireless Setpoint Adjustment: For installations where the controller itself is mounted inside a control cabinet or in a difficult-to-access location, the optional infrared (IR) control panel provides wireless access to the controller. The panel displays both the current setpoint and the actual measured temperature, and allows the user to change the setpoint without opening the cabinet.
• Auto-Connect: The IR panel can be activated by pressing any key and will automatically connect to the nearest KM-MICROx controller within range—no pairing procedure, no configuration.
• Clear Readability: The panel display is designed for easy reading in industrial environments, with high-contrast characters and backlighting.

Typical Applications

• Temperature control of electrically heated hoses for hot melt adhesive delivery in packaging and automotive assembly
• Inline heating control for thermoplastic fluid transfer lines in food, pharmaceutical, and chemical processing
• Industrial heat tracing and surface heating where the heating load configuration may change between production runs
• Laboratory and pilot-plant heating systems requiring rapid setup and automatic adaptation to varying experimental setups