In the realm of modern industrial manufacturing, the seamless flow and security of data communication is paramount. As manufacturing networks evolve, the need to interconnect diverse media types, such as fiber optic and Ethernet cables, becomes increasingly crucial. Enter industrial media converters – the unsung heroes that bridge the gap between disparate media, extend the reach of networks, and bolster the security and reliability in the harsh industrial environments.

In this blog, we delve into the integral role of industrial media converters, exploring how they help businesses and the IT team overcome distance limitations and enable the integration of machines, software and systems into a cohesive whole.

Distance Limitations of Copper in Media Converters

Network administrators oftentimes find themselves needing data transmission beyond copper’s 100 meters (328 feet) limitation. For instance, consider an IP camera in a large warehouse mounted 500 feet away from the nearest available industrial Ethernet switch. A media converter can connect a copper port on the switch to a sufficiently long run of fiber optic cable that, in turn, connects to the ports on the switches and another media converter at the camera, extending reach without interruption or interference. Best of all, to the network it just looks like another Ethernet link.

Copper-to-fiber media converters are the most common design for these devices, typically featuring two ports: an RJ45 port on one side, and a fiber interface on the other. A copper-to-fiber media converter will be designed to convert Ethernet signals on a copper cable to light waves for transmission over fiber optic cables up to a maximum of 120 kilometers or approximately 74.5 miles. Signals move over fiber at the speed of light — a lot faster than electrons through copper — letting you convert link speeds from 10 Mbps to 100 Mbps or from 100 Mbps to 1000 Mbps. Fiber is also immune to electromagnetic interference (EMI), radio frequency interference (RFI), and heavy surges that will cripple copper. Whenever multiple pieces of industrial equipment are interconnected, EMI and RFI are produced, creating adverse effects on data transmission across copper cabling. Only fiber optic cabling can protect data transmission from EMI, RFI and surges.

Most conversion applications require building a pair of media converters, one at each link, although this isn’t always the case. Fortunately, since media converters work with bidirectional links, the same model or device can convert copper to fiber at one end and from fiber to copper at the other.

Linking fiber and copper is the most common application for media converters. However, they can also link Single Mode connectors to multimode fiber optics or extend the data transmission distance of a Multimode network. Fast Ethernet, Gigabit and 10 Gigabit port speeds on media converters are available to cover the most used interfaces today. Serial-to-Ethernet media converters are also available that convert RS232, RS422 or RS485 serial communication to Fast Ethernet, so older serial-based devices like serial PLCs are easily connected to support a TCP/IP network.

Versatility is extended to the mounting of media converters. Chassis-based solutions support high-density “mix and match” conversion applications in data centers, switching rooms and LAN closets. Standalone media converters are highly compact, lightweight and cost-effective. Because they are DIN-rail mountable, standalone media converters are ideal for space-restricted control cabinets, switches and distribution boxes. Yet another choice are slide-in media converter cards installed inside a switch chassis or PC.

As with Ethernet switches, media converters come either managed or unmanaged options. Along with their essential duties, managed media converters provide fault detection, remote configuration and network monitoring features. Another worthwhile feature found on many media converters today is Power over Ethernet (PoE) combining power and data on one cable. PoE-enabled converters make fast work of deploying IP cameras, access control doors, WAPs and other PoE compliant devices. Some PoE converters can reset remote connected devices by performing a power-cycle to solve a problem, therefore saving the hassle of having a technician dispatched to the site.

No matter which media converter product you choose, you’ll find their use to be extremely simple and cost effective. Without a converter, networks that need to connect fiber to Ethernet would have to undergo a full-scale fiber optic network upgrade or the network administrator would need to buy additional industrial switches to bridge the gap between far-flung Ethernet devices. In addition, media converters can save money by simplifying the increasingly popular fiber-to-desktop process due to their ability to withstand high bandwidth.

Industrial Engineered for Industrial Environments

So far, we have only discussed media converters in general terms. Not all media converters offer the same protection to threats faced in industrial settings. As you are well aware, industrial and remote locations expose all network devices to a variety of harsh conditions detrimental to their service life — and media converters are no exception. Extreme temperatures, dust, dirt, water, poor power quality, and vibration will quickly wreck the function of a non-hardened media converter.

That’s why Antaira’s industrial media converters feature metal enclosures rated to ingress protection of IP30 or higher. Antaira protects its media converters from extreme temperatures from -40° to 80°C, as well as heavy vibration, power supply disruptions, or worse, qualifying these sturdy devices for outdoor traffic control and IP video surveillance, along with ensuring stable and reliable data conversion in manufacturing plants, wastewater treatment centers, and factory automation. These use cases are examples of Antaira media converters' versatility and ability to meet specific industrial needs.

Learn more information about the broad line of Antaira media converters and industrial Ethernet switches we offer by emailing us today at sales@antaira.com, or calling us at (714) 671-9000. Our team of live experts is ready to assist in your media converter application.