Description
1. Product Introduction
The PROSOFT ANC-100E is a compact, high-reliability Ethernet connectivity module developed by ProSoft Technology, tailored to address the “last-mile” connectivity challenge in industrial automation. Unlike complex gateways, this module focuses on simplifying Ethernet integration for legacy or low-cost industrial devices that lack native Ethernet capabilities—such as basic PLCs, sensors, and actuators.
In modern industrial networks, where Ethernet/IP or Modbus TCP has become the standard for data exchange, many older devices remain limited to serial communication (e.g., RS-232/485). The ANC-100E acts as a “serial-to-Ethernet translator,” enabling these legacy devices to connect to Ethernet-based control systems (e.g., Allen-Bradley ControlLogix, Siemens S7) or SCADA platforms. This not only extends the lifespan of $100k+ worth of existing equipment but also eliminates the need for costly hardware replacements, making it a cost-effective solution for factories, water treatment plants, and energy facilities undergoing phased network modernization.
2. Functional Features
2.1 Serial-to-Ethernet Protocol Conversion
The ANC-100E’s core strength lies in its ability to seamlessly translate between serial protocols (RS-232/485) and Ethernet protocols (Modbus TCP, TCP/IP). For example, a food processing plant uses the ANC-100E to connect legacy RS-485 temperature sensors to a Modbus TCP SCADA system: the module converts sensor data from Modbus RTU (serial) to Modbus TCP (Ethernet), allowing the SCADA system to monitor 24/7 temperature trends without replacing the 50+ existing sensors. This conversion supports baud rates up to 115200 bps, ensuring no loss of real-time performance compared to direct serial communication.
2.2 Dual Serial Ports for Flexible Connectivity
Equipped with two independent RS-232/485 serial ports (configurable via DIP switches), the ANC-100E can connect to two separate serial devices simultaneously. A manufacturing plant leverages this feature to link both a legacy RS-232 barcode scanner and an RS-485 VFD to a single Ethernet network: Port 1 handles scanner data (Modbus RTU) while Port 2 manages VFD speed commands, eliminating the need for two separate conversion modules. This dual-port design cuts hardware costs by 50% and reduces rack space usage in control cabinets.
2.3 Easy Configuration via Web Interface
The ANC-100E features a built-in web server that eliminates the need for specialized software. Users can access the module’s configuration page via any standard web browser (Chrome, Firefox) to set parameters such as IP address, protocol type (Modbus TCP client/server), and serial port settings (baud rate, parity). A technician at a water treatment plant configures 12 ANC-100E modules in under 1 hour—compared to 4 hours with command-line tools—by simply entering the module’s default IP (192.168.1.10) and saving settings. This simplicity reduces training requirements for on-site staff.
2.4 Industrial-Grade Reliability
Designed for harsh industrial environments, the ANC-100E withstands wide temperature ranges (-20 °C to +60 °C) and vibration (5 g, 10–500 Hz)—critical for applications like mining or automotive assembly. Unlike consumer-grade serial-to-Ethernet adapters (which fail within 6 months in industrial settings), the ANC-100E uses industrial-grade components (e.g., shielded ports, surge protection) to ensure 99.99% uptime. A mining operation reports the module operating continuously for 2+ years in underground facilities, where dust, humidity, and temperature swings are common.
2.5 Support for Pass-Through Mode
For scenarios where direct serial communication is still needed (e.g., troubleshooting legacy devices), the ANC-100E offers a “pass-through” mode. This allows a technician to connect a laptop to the module’s Ethernet port and access the serial device as if directly connected via a serial cable. A maintenance team at an oil refinery uses this feature to calibrate a legacy RS-232 pressure transmitter remotely: instead of physically accessing the transmitter (located in a hazardous area), they use the ANC-100E’s pass-through mode to send calibration commands via Ethernet, improving safety and cutting troubleshooting time by 70%.
PROSOFT ANC-100E
3. Technical Specifications
| Parameter Name | Parameter Value |
| Product Model | PROSOFT ANC-100E |
| Manufacturer | ProSoft Technology |
| Product Category | Serial-to-Ethernet Conversion Module |
| Supported Protocols | Ethernet: Modbus TCP, TCP/IP, UDP; Serial: RS-232, RS-485 (2-wire/4-wire), Modbus RTU (master/slave) |
| Serial Ports | 2x RS-232/485 (configurable via DIP switches); Baud rate: 1200–115200 bps; Parity: None/Even/Odd |
| Ethernet Port | 1x 10/100 Mbps RJ45 port; Auto-MDI/MDI-X (no cross-over cable needed) |
| Power Requirements | 12–24 VDC (18–30 VDC tolerance); Power consumption: < 3 W (max); Reverse polarity protection: Yes |
| Physical Dimensions | DIN rail-mountable (TS 35/7.5); 30 mm (width) × 85 mm (height) × 100 mm (depth); Weight: ~150 g |
| Environmental Ratings | Operating temperature: -20 °C to +60 °C; Storage temperature: -40 °C to +85 °C; Relative humidity: 5%–95% (non-condensing); Vibration: 5 g (10–500 Hz, IEC 60068-2-6); Shock: 30 g (11 ms half-sine, IEC 60068-2-27) |
| Safety & Compliance | CE (EN 61010-1, EN 61326-1); UL 61010-1 (USA/Canada); RoHS 2 compliant (2011/65/EU); EMC: EN 61000-6-2 (immunity), EN 61000-6-3 (emissions) |
| Configuration | Web-based interface (HTTP); Default IP: 192.168.1.10; No software installation required |
| Additional Features | Pass-through mode for remote serial access; LED indicators (power, Ethernet link, serial activity); Firmware update via Ethernet |
PROSOFT ANC-100E
4. Application Scenarios
4.1 Legacy Sensor Integration in Food Processing
A snack food factory uses 30 ANC-100E modules to connect RS-485 humidity sensors (installed in oven zones) to a Modbus TCP SCADA system. The modules convert sensor data to Ethernet, allowing the SCADA system to adjust oven humidity in real time—reducing product moisture variation by 15% and cutting waste by 8%. The ANC-100E’s -20 °C to +60 °C operating range withstands the factory’s hot, humid environment, while its dual serial ports enable future expansion to add temperature sensors.
4.2 VFD Control in Water Treatment
A municipal water treatment plant uses the ANC-100E to connect legacy RS-485 VFDs (controlling pump speed) to an Allen-Bradley CompactLogix PLC (Ethernet/IP). The module translates PLC commands from Ethernet/IP to Modbus RTU, allowing the PLC to adjust pump speed based on water demand. During a peak usage period, the ANC-100E ensures pump speed updates within 100 ms—critical for maintaining consistent water pressure. This integration avoids replacing 12 VFDs (valued at $15k each) and extends their lifespan by 5+ years.
4.3 Remote Monitoring of Energy Meters
A solar farm uses 18 ANC-100E modules to connect RS-232 energy meters (installed at each inverter) to a Modbus TCP monitoring platform. The modules send real-time energy output data (kWh) to the platform, enabling the farm to track daily yield and identify underperforming inverters. The ANC-100E’s web interface allows remote configuration—technicians can adjust meter polling intervals (5–60 seconds) without visiting the farm, reducing travel costs by $20k annually.
5. Installation, Commissioning, and Maintenance
5.1 Installation
Mounting: Attach the ANC-100E to a TS 35/7.5 DIN rail in a control cabinet (leave 5 mm clearance for airflow). Ensure the cabinet is protected from direct moisture or dust (IP20 minimum).
Wiring:
Power: Connect 12–24 VDC to the terminal block (red = +, black = -); verify reverse polarity protection is enabled.
Serial Ports: Use shielded twisted-pair cable (Belden 3071A for RS-485) to connect Port 1/2 to serial devices. For RS-485, wire A/B terminals to match the device’s polarity.
Ethernet: Connect a Cat5e/Cat6 cable to the RJ45 port (link to switch or PLC).
Power-On: Turn on power—verify the green “Power” LED illuminates; the yellow “Ethernet” LED should blink once connected to the network.
5.2 Commissioning
Access Web Interface: Connect a laptop to the same Ethernet network as the ANC-100E. Enter the default IP in a web browser; log in with default credentials (admin/admin).
Configure Settings:
Ethernet: Assign a static IP (match network subnet) to avoid IP conflicts.
Serial Ports: Set baud rate, parity, and stop bits to match connected devices (e.g., 9600 bps, even parity for Modbus RTU sensors).
Protocol: Select “Modbus TCP Server” (to send serial data to Ethernet) or “Modbus TCP Client” (to receive Ethernet commands for serial devices).
Test Communication: Use a Modbus TCP tool (e.g., Modbus Poll) to verify data transfer. For a sensor, check if the ANC-100E forwards sensor values to the SCADA system; for a VFD, send a test speed command to confirm the module translates it to serial.
5.3 Maintenance
Monthly Checks: Inspect LEDs (Power = green, Ethernet = blinking green, Serial = blinking yellow when active). Clean the module with a dry cloth to remove dust.
Troubleshooting: If communication fails:
Verify Ethernet cable continuity (use a cable tester).
Check serial wiring (ensure A/B polarity matches devices).
Use the web interface’s “Diagnostics” tab to view serial/Ethernet traffic logs.
Firmware Updates: Download the latest firmware from ProSoft’s website and upload via the web interface (takes <5 minutes, no downtime for connected devices).
Spare Storage: Store spare ANC-100E modules in a dry environment (-20 °C to +50 °C) to ensure quick replacement in case of failure.
6. Service and Warranty
ProSoft Technology provides a 2-year standard warranty for the ANC-100E, covering defects in materials, workmanship, and protocol conversion performance. For critical applications (e.g., power plants), the ProSoft Essential Support Plan extends coverage to 3 years, including:
24/7 technical support (1-hour response time for communication outages).
Annual remote configuration verification (via web interface).
Expedited replacement (48-hour delivery of a loaner module during repairs).
Customers also gain free access to resources:
Application notes (e.g., “ANC-100E for Water Treatment Sensors”).
Video tutorials (web configuration, troubleshooting).
A user community for sharing best practices (e.g., integrating with specific PLC models).
For out-of-warranty repairs, ProSoft offers a flat-rate service ($150 per module) that restores the ANC-100E to factory specs—including firmware updates and full functionality testing—with a 6-month warranty on repairs.
