Industrial Hardware Release

Ethernet Smart Controller

MODEL: KS2-ESC

An industrial-grade communications bridging device operating on Layer 1 and Layer 2 of our 4-layer architecture, engineered to interface peripheral sensors and serial networks (any RS-485 protocol, RS-232, SPI or I2C) to IP network devices and servers. Powered by a high-performance processor for real-time edge processing, it enables automated triggering of dual solid-state relays based on sensor telemetry. We offer a highly customisable, bespoke approach to tailor the integration precisely to your operational requirements. The KS2-ESC is also available to purchase with the Fast Ethernet Switch Expansion Board (KS2-FES), adding a 2-port switch to easily daisy-chain the device in existing systems where limited connectivity is present.

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Hardwired TCP/IP Architecture

Powered by a high-speed 32-bit ARM Cortex-M3 core. Processes network sockets directly in hardware for flood-proof, deterministic reliability.

Ethernet
10/100 Mbps
Serial
2× RS-485 + RS-232
Relays
2× Solid-State
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Deterministic Core

Powered by a 32-Bit ARM Cortex-M3 processor. Hardware TCP/IP offloading eliminates software network stack overhead and provides immunity against network floods.

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Industrial Serial Interfacing

Dual independent RS-485 channels with multi-stage TVS surge protection, bulk voltage clamps, and common-mode filtering, plus a dedicated RS-232 serial port.

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Solid-State Relays

Two galvanically isolated PhotoMOS solid-state relay outputs for silent, infinite-cycle switching of external logic signals or contactor drivers.

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Wide Power Protection

Wide 12V–24V DC power input with multi-stage protection: resettable PTC fuse, high-energy TVS voltage clamp, and input common-mode choke filter.

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Transparent RS-485 Forwarding

Support for RS-485 forwarding either through a raw TCP connection or Modbus over TCP. This allows you to interface with RS-485 field devices directly from external applications and servers over IP.

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Auxiliary Hardware Ready

SPI and I2C expansion ports are available for external sensors and device integration. This allows connection to a wide range of peripheral devices, enabling complete customization of automation within the systems the KS2-ESC is integrated into.

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Fast Ethernet Switch Expansion

Available to purchase with the KS2-FES (Fast Ethernet Switch) Expansion Board. It seamlessly interfaces with the KS2-ESC to add an industrial-grade 2-port 10/100 Ethernet switch (with 1 internal uplink). This allows installing the KS2-ESC into existing setups by daisy-chaining network devices without requiring additional ethernet cable pulls.

Technical Specifications

Input Voltage Range
12V to 24V DC (Industrial Input Protection)
Processor Architecture
32-Bit ARM Cortex-M3 Core
Ethernet PHY & Engine
10/100 Mbps, Hardwired TCP/IP Core (8 Hardware Sockets)
Ethernet Isolation
1.5 kV RMS Galvanic Isolation
Serial Ports
2× RS-485 (Half-Duplex) + 1× RS-232 (Full-Duplex)
Relay Outputs
2× Isolated Solid-State PhotoMOS Relays (Max 60V / 500mA)
Expansion Connectors
High-Speed SPI & I²C Interfaces (JST-XH)
Operating Temperature
-40°C to +85°C (Industrial Grade)
Board Dimensions
100 mm × 60 mm (4× M3 Mounting Holes)

Connector & Interface Overview

Function Connector Type Interface Description
Power Input 3.81mm Pluggable Terminal (2-Pin) DC Power Input (12V–24V DC & GND)
10/100 Ethernet Isolated RJ45 Connector Standard MDI / Integrated Status LEDs
RS-485 Channels 1 & 2 3.81mm Pluggable Terminal (3-Pin ×2) RS-485 Differential A (+), B (-), and Signal GND
Bus Termination 2.54mm Header Selectable 120 Ω RS-485 Bus Termination Jumpers
Relay Outputs 1 & 2 3.81mm Pluggable Terminal (2-Pin ×2) Isolated Solid-State Contacts (Max 60V / 500mA)
RS-232 Port JST-XH Header (3-Pin) Full-Duplex RS-232 Serial (TXD, RXD, GND)
Expansion Ports JST-XH Headers High-Speed SPI and I²C Expansion Interfaces
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ONVIF OSD Overlay & Edge Automation (Profile T)

The controller captures incoming peripheral sensor telemetry (RS-485 serial data, environmental readings, or dry contact sensor triggers) and dynamically burns custom On-Screen Display (OSD) text directly onto IP camera video streams via ONVIF interfaces at a target IP address.

Expand edge capabilities utilising the high-speed expansion ports, and enable hardware-level automation to interact with the environment via the dual solid-state relays based on sensor telemetry.

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Modbus RTU to IP Gateway

Bridge Modbus RTU instruments, power meters, and PLC serial buses to Modbus TCP or custom IP cloud services over Ethernet. Beyond simple TCP/IP forwarding, the ESC provides smart edge processing to analyse telemetry data locally and execute real-time automated actions through the onboard relays. Coupled with our bespoke, customer-oriented engineering approach, this allows for seamless and custom implementations into your already established APIs and environments.

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PTZ Camera Telemetry

Translate legacy Pelco-D and Pelco-P RS-485 commands into TCP/IP telemetry. The Ethernet Smart Controller enables your legacy hardware to interface flawlessly with modern systems, either through dedicated APIs or standardised ONVIF commands. It features seamless two-way protocol translation to bridge the gap between legacy installations and modern VMS platforms, all while unlocking custom on-edge processing and system enhancements.

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Building Automation & Control

Utilise the onboard solid-state relays to trigger external contactors, sirens, or access control barriers via network commands. Go beyond passive data collection—empower your infrastructure with smart edge processing to enable true localised data processing and automation capabilities.

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Cloud-Integrated Edge Telemetry

Seamlessly bridge isolated SPI, I²C, RS-485, and RS-232 peripheral sensors to modern IP cloud infrastructure. The KS2-ESC ingests raw serial telemetry and publishes structured data to your custom dashboard or cloud environment. Engage our engineering team to architect a bespoke cloud integration tailored to your specific analytics requirements.

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Automated Industrial Safety Control

Implement deterministic, hardware-level safety automation without relying on external servers. The controller continuously monitors configured environmental thresholds (such as thermal limits or high-frequency machinery vibration) and instantly triggers onboard solid-state relays, serial overrides, or TCP/IP alerts to gracefully shut down equipment before catastrophic failure occurs.

Ready to Evaluate the KS2-ESC?

Contact our engineering team to request technical documentation, evaluation units, or custom hardware integration.

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