The Role of Media Converters in Industrial Networks

Fiber's popularity has brought with it a heightened focus on media converters.

Weigh Station Antaira
Antaira Technologies

Fiber optic cables are today the fastest-growing transmission medium for industrial network expansions and new builds. This is especially true for applications that demand high bandwidth capacity, long transmission distances and electrical interference immunity. Fiber's popularity has brought with it a heightened focus on media converters that change signals from one type of cable to fiber optic.

In this article, we aim to enhance understanding of these simple yet essential devices, their functions and the various kinds of media converters available for networks, giving you the confidence to manage your industrial network more effectively.

Bridging the Gap

Media converters operate at Layer 2 of the Open Systems Interconnection (OSI) model, which is responsible for moving data between network nodes. Media converters seamlessly convert communication protocols from one media type to another, bridging the gap to ensure reliable integration.

Media Converter Types

Copper-to-fiber and serial-to-fiber converters are the two most widely used types of media converters in industrial networks. 

  1. Copper-to-fiber media converters serve as a bridge in modern networking, allowing for compatibility between legacy copper infrastructures and cutting-edge fiber optics. The converters increase reach and bandwidth without requiring large-scale overhauls, therefore economically optimizing current systems. Typical applications for copper-to-fiber converters are redundant fiber/copper, point-to-point and high-density fiber distribution, among others. Devices of different data rates and interface types can be integrated into a one seamless network thanks to copper-to-fiber converters supporting 10/100 or 10/100/1000 rate switching.
  2. Serial-to-fiber media converters are frequently deployed in industrial control systems, connecting RS-232, RS-422 and RS-485 serial devices to fiber optic networking. By automatically determining the signal baud rate of connected full-duplex serial devices, the converters can support point-to-point and multipoint configurations. Serial-to-fiber converters increase the range of serial networks by up to 40 km over single-mode single-fiber and 120 km over dual fiber. Fiber lines are perfect for data connections close to heavy industrial equipment since they are naturally resistant to EMI/RFI and transient surges.

Media converters come in a variety of form factors. This versatility empowers administrators to specify the most suitable converter for their needs, whether chassis-based for enterprise-class networks, slide-in converters for high-density conversion or compact standalone units for space-sensitive environments. Users can also choose between a managed and unmanaged converter. 

Managed media converters offer more monitoring, fault detection and configuration capabilities than unmanaged media converters, which only enable basic device communication. Unmanaged versions, however, are easier to deploy and less expensive. When devices connect to the unmanaged media converter, they typically communicate automatically.

Besides extending LAN distances, there are several other benefits to media converters.

  • Media converters eliminate the need for costly, time-consuming infrastructure overhauls by enabling administrators to migrate a local network to fiber. This cost-saving benefit ensures that network operations remain financially viable.
  • Media converters are crucial in connecting multiple LANs to form one extensive campus network. This empowers you to expand a network and enhance its operations, putting you in control of its growth and efficiency.
  • With 1550 nm optics, media converters can extend the LAN's reach over single-mode fiber for up to 160 kilometers.
  • Media converters reduce network operating costs by assisting in troubleshooting and remotely configuring network equipment in remote locations.
  • Media converters protect data from electromagnetic interference (EMI) that can cause data corruption over copper links.
  • Media converters allow link speeds from 10 Mbps to 100 Mbps or from 100 Mbps to 1000 Mbps.
  • Some media converters have a link fault feature that elevates network reliability by detecting and responding to link failures.
  • Media converters can be equipped with Power over Ethernet, eliminating the need for a local AC power circuit. PoE media converters are ideal for security cameras, IP phones and WAPs.

Industrial Media Converters

Commercial-grade "non-hardened" media converters are made for controlled environments not subject to wide temperature swings, moisture, vibration or shock. In contrast, industrial media converters withstand extreme temperatures and harsh environments. 

Industrial media converters are housed in rugged metal cases that may be conveniently mounted on walls or DIN rails and offer IP30 protection, redundant power and resistance to extreme shock and vibration. Without this protection, a media converter installed outdoors or within an industrial plant will likely fail in short order.

Use Case: Truck Weigh Station

Truck weigh station infrastructure requires a substantial amount of communication equipment to accurately assess each vehicle that passes through. Devices rely on different protocols; for instance, vehicle message signs use serial connections to transmit data, while IP video cameras are Ethernet-based. Due to their need for wide-area coverage, weigh stations benefit from the use of a fiber optic backbone for long-distance communication, high bandwidth and noise immunity.

Shown in the diagram below, Antaira STF-300C industrial serial-to-fiber converters provide a 1-port RS232/422/485 connection along with a 100Fx fiber optic connection for long distance communication with either daisy-chain or redundancy capabilities to legacy serial devices.

Additionally, the converter extends RS-232 or RS-422/RS-485 transmission distance up to 30km over single-mode fiber at speeds up to 256kbps for RS-232 or up to 1024kbps for RS-422/485. Also shown is the Antaira STE Series Serial-to-Ethernet server.

Conclusion

Since the dawn of networking, media converters have proven a reliable solution to connectivity issues. Media converters are vital in extending LANs, converting link speeds and fiber modes and using legacy infrastructure.

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