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Automation & Telemetry · Hardware

IIoT Retrofit Kit

Coming soon

Connect legacy machines to data without tearing them apart: wireless node, gateway, dashboard.

Request information Specifications
Open RK-M kit case: gateway, four RT-152 nodes, antennas and power supply in foam cut-outs

Overview

The problem. In cement, sugar, food and metal plants, 15–30-year-old machines (mills, presses, furnaces, compressors, pump sets) are the backbone of production yet invisible: run/stop status, counters, temperature, pressure and current are either unavailable or kept in the operator's logbook. Modern machine-connectivity solutions require a PLC replacement, cabling infrastructure and an IT project; old machines have no PLC or a closed one, and pulling cable means production stops and trenching.

The solution. The kit picks up the machine's existing signals (running/stopped contact, fault contact, 4–20 mA/0–10 V sensors, counter pulses, current transformers) with wireless nodes mounted inside the control panel; the nodes reach the gateway across the plant over 433 MHz LoRa (≥ 300 m indoors targeted, extendable with a repeater). The Wireless Gateway / RTU passes the data to the existing SCADA over Modbus TCP and/or to the Telemetry & Process Intelligence dashboard over MQTT: operating hours, OEE inputs (downtime duration/count, production counter), trends and threshold alarms (SMS/email notification planned). Installation takes hours per node; the machine is not stopped.

PLC replacement / new automationWired I/O + industrial EthernetBattery LoRaWAN sensorsElmes Retrofit Kit
Production downtimeDaysHours–days (cabling)NoneNone / minutes
Cabling / trenchingYesYesNoNo
Uses existing signals (contacts, 4–20 mA)YesYesLimited (sensor replaced)Yes
Outputs (relays)YesYesNoYes (Digital I/O Link relay end)
PowerMainsMainsBattery (replacement)Panel 24 VDC (no battery)
Cost (relative)HighMedium–highLow–mediumLow–medium
Wireless node fitted in an old lathe's electrical box, linked to a gateway on the wall
In use
RK-S, RK-M and RK-L kit cases open, with an increasing number of nodes
Product family

This product is in development or field testing. Contact us for technical information, pilot use and a preliminary quotation.

Features

  • Kits sized by point count: S/M/L; quoted from your point list, with mixed node types.
  • Parallel connection principle: signals are tapped in parallel from existing contacts and sensor lines, with no intervention in the machine circuit; isolated inputs.
  • OEE inputs out of the box: downtime analysis from running/stopped + counter + fault contact (Telemetry & Process Intelligence).
  • Output option: remote start/stop or warning signals through the same node's relays (outside the machine safety circuit).
  • Modbus if you have SCADA, a dashboard if you don't: same gateway.
  • Battery-free: powered from the panel; no battery replacement rounds.
  • TargetRepeater: a single hop for a remote panel or building.
  • TargetMotor load monitoring: via current transformers.
  • TargetPredictive maintenance: a vibration node (VibroBal and Smart Motion & Environmental Sensors data) feeding the predictive maintenance module of Telemetry & Process Intelligence.
  • Target4G connectivity: for plants without a network.

Kit sizes

Kit sizes
KitPointsCommissioning (approx.)Request information
RK-STarget12½ dayRequest information: RK-S
RK-MTarget32 (+4)1 dayRequest information: RK-M
RK-LTarget64 (+8)2 daysRequest information: RK-L

Specifications

Values marked “Target” are design targets, next-generation values or chip-vendor data; they are updated as measurement and certification are completed.

Radio
Band / channels433 MHz ISM, 8 channels, LoRa; the whole kit on the same network ID (NetID)Target
Radio moduleEM-G0L-433 in the nodes, EM-G0LW-433 in the gateway; current generation MODM0 (STM32F070 + SX1268)
Range
Indoors≥ 300 m node → gateway; ×2 with a repeaterTarget
Open field≥ 2000 mTarget
Performance & fail-safe
Nodes per gateway≥ 100Target
Data updatePolling interval 10 s – 10 min, adjustable; events (contact changes) sent immediatelyTarget
Event latency< 2 s contact change → dashboard (single hop)Target
Communication lossA node is flagged offline after 3 polling intervals without a reply; adjustable fail-safe timeout on relay outputs
Inputs / outputs
Kit point countRK-S 12 / RK-M 32 (+4) / RK-L 64 (+8)Target
Digital (per node)8× opto-isolated DI 12–24 V + 8× relay 5 A
Analog (per node)4× 4–20 mA / 0–10 V, 16-bit
Pulse (per node)4× S0/reed, ≤ 10 kHz
Interfaces
Upstream connectionModbus TCP/RTU, MQTT (via the gateway)
Power
Node supply9–36 VDC panel supply, no battery
Gateway supply9–36 VDC or USB
Deployment
Site requirementsDIN-rail space in the panel (node 6 modules wide), 24 VDC, antenna feed-through outside the panel (pigtail)
Installation time (approx.)Node 1–2 hours (inside the panel, from existing terminals), gateway 1–2 hours; commissioning RK-S ½ day, RK-M 1 day, RK-L 2 days

Applications

  • Cement (mills, conveyors, filters)
  • Sugar (campaign-season line monitoring)
  • Food packaging line OEE
  • Metal / foundry (furnaces, presses)
  • Water and wastewater pump sets
  • Compressor rooms
  • Legacy CNC and machine-tool fleet
  • Energy meters (pulse)

Installation flow. During the site survey, a point list is drawn up and a range pre-test is run inside the plant; the kit is then quoted as S/M/L based on that list. Nodes are mounted on a DIN rail inside the panel, signals are tapped in parallel from the existing terminals, and the antenna is brought outside the panel with a pigtail. You can install it yourself with the manual and remote support; turnkey installation and commissioning is also available as an option.

Components. The kit is built from the Elmes wireless product family: Wireless Digital I/O Link, Wireless Analog & Digital Data Transmitter, I/O Carrier Boards (EC), Wireless Meter Reading Node and Wireless Gateway / RTU. Field installations of each component are described on its own page.

Compliance & documentation

The kit is built from Elmes wireless components; each component's compliance status is listed on its own product page.

  • Kit CE declaration of conformity (referencing the component declarations)
    Target
  • Kit datasheet and selection guide
    Target
  • Point-list template for site surveys
    Target
  • Kit installation manual
    Target
  • Telemetry dashboard subscription / SLA agreement
    Target

Frequently asked questions

Do I need to stop the machine?

Usually not; the node is mounted inside the panel and signals are tapped in parallel from the existing terminals. Inserting in series into a 4–20 mA loop may cause a brief interruption.

Can it be fitted to a machine without a PLC?

Yes; contactor auxiliary contacts, thermal overload contacts and sensor signals are enough.

Does it connect to my existing SCADA?

Yes; the gateway serves Modbus TCP/RTU. Without SCADA, the Telemetry & Process Intelligence dashboard is used.

How many machines or points can be connected?

Kits come in S/M/L sizes (approximately 12/32/64 points); at least 100 nodes per gateway are targeted.

Is the range sufficient inside the plant?

≥ 300 m indoors is targeted; a repeater is used for distant panels. A pre-test is carried out during the site survey.

Do batteries need replacing?

No, the nodes run from the panel supply.

Can we install it ourselves?

Yes, with the manual and remote support. Turnkey installation and commissioning is also available as an option.

Is a subscription required?

No; you can use your own SCADA over Modbus. The telemetry dashboard is offered as a subscription.

Get information about this product

Our engineering team replies within 24 hours.

Request information +90 (312) 395 85 86

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