Migrating Your Aging Network from Serial to Ethernet or Wired to Wireless

Wireless modems are easy and quick to install. They are the ideal solution for replacing communication wires in RS485 and RS232 networks. Tell us about your current network and we will work with you for the most cost-effective solution. Whether Ethernet or serial, high or standard speed, short or long-range, or 900 MHz, 2.4 GHz, or 5 GHz—our technical team is here to help you.

Updating an aging industrial network does not have to be painful or exceed your budget. This article presents a structured, staged digital migration plan from start to finish on your schedule—allowing legacy serial PLCs and modern Ethernet controllers to operate side-by-side without operator downtime.

Why Choose a Staged Digital Migration?

Older networks often suffer from approaching end-of-life PLCs and obsolete modems, but replacing every node at once requires immense capital outlays and prolonged plant shutdowns. A staged migration solves this challenge by building a parallel wireless network alongside your existing infrastructure.

• Zero Process Downtime: Central control continues polling legacy serial remotes while new Ethernet PLCs and modems are commissioned in parallel.
• Budget Control: Upgrade your most critical site first (e.g., Master Control or high-priority Remote nodes) and phase in remaining sites over time as funding allows.
• Dual-Protocol Freedom: Dual-port modems like the SRM8200 communicate with both serial (RS232/RS485) and Ethernet devices simultaneously on the same RF network.
• Re-purposed Backup Hardware: Replaced legacy modems can be kept on the shelf as emergency backups for remaining serial nodes until the migration is 100% complete.

Key Steps in the Migration Roadmap

Whether you are migrating from leased telephone lines (LLM1100) or legacy serial wireless modems to a modern 900 MHz Ethernet architecture, follow these steps for a smooth transition:

• Stage 1 (Central Control Prep): Install an SRM8200 Master modem alongside the legacy Master PLC using a serial port splitter or secondary port.
• Stage 2 (Critical Site Upgrade): Upgrade the highest-priority remote site with an SRM8200 modem and an Ethernet PLC. Central control now receives Ethernet and serial data on the same master link.
• Stage 3 (Phased Remote Upgrades): Replace remaining remote sites one by one as budget and scheduled maintenance windows permit.
• Stage 4 (Completion): Retire the legacy Master serial modem and complete the transition to a fully high-speed, edge-ready wireless Ethernet network.

For the complete step-by-step wiring schematics, serial port splitter configurations, and full technical specifications, download the full PDF guide below.