Best practices for integrating embeNET with existing infrastructure

Why integration is critical in industrial environments

Many industrial systems were designed decades ago. They still rely on wired PLCs, SCADA platforms or fieldbus networks. These solutions work well, but they lack flexibility. Adding wireless communication is no longer just a convenience – it’s a strategic upgrade.

embeNET, a wireless mesh networking solution, allows modernisation without replacing your entire infrastructure. To succeed, integration needs to be precise, thoughtful and tailored to the conditions of each site.

Understand the existing system before deployment

Start by reviewing how your infrastructure works today. Every plant or facility is different, but a few key questions apply everywhere:

• What protocols are in use? (Modbus RTU, Modbus TCP, OPC UA, Profinet?)
  
• Where is the control logic processed – in PLCs or remote servers?
  
• Are there real-time requirements or latency-sensitive processes?
  
• How are sensors connected and powered?
  

Understanding these layers helps define how and where embeNET can be added without disrupting the existing workflow.

Define the role of embeNET in your system

embeNET works best when it extends existing systems – not replaces them. Use it where wiring is expensive, flexibility is required, or retrofitting is complex. Typical roles include:

• adding new sensors in hard-to-reach areas,
  
• connecting mobile assets like trolleys or forklifts,
  
• linking remote panels or temporary installations,
  
• enabling condition monitoring without major rewiring.
  

The idea is to fill the gaps using embeNET while keeping the backbone intact.

Use a gateway that speaks both languages

The gateway is the heart of the integration. It connects the embeNET mesh with the legacy wired infrastructure. It translates between different protocols, bridges data models, and buffers mismatched update rates.

Choose a gateway that supports:

• standard industrial protocols on both ends,
  
• configurable mapping of inputs and outputs,
  
• secure remote updates and diagnostics,
  
• scalable integration (support for multiple nodes and topics).
  

Gateways must be compatible not just at the physical level (e.g. RS-485, Ethernet), but also at the data structure level.

Align timing and data formats

Legacy systems often work on fixed cycles. They expect regular polling or fixed packet sizes. embeNET is more dynamic – it can report data on change, on schedule, or on request.

To avoid mismatch:

• use buffers if the SCADA system is slower than the node,
  
• normalize units and data types (e.g. integers vs floats),
  
• convert messages to the expected format before forwarding.
  

Matching expectations avoids false alarms, dropped messages or data loss.

Plan for power and signal quality

Wireless integration sounds simple – but only works well if the environment is ready. Think about:

• electromagnetic noise from motors or inverters,
  
• physical barriers like steel walls or high racks,
  
• node placement and antenna orientation,
  
• interference from nearby networks.
  

Site surveys and test deployments are essential before going live. Even the best mesh network needs clean signal paths and reliable power.

Combine embeNET with edge logic where needed

Not all data needs to go to the cloud or SCADA. In many cases, adding local logic improves responsiveness. Examples:

• local alarms triggered by thresholds,
  
• buffer logs when the server is offline,
  
• local control of lighting or HVAC.
  

This kind of distributed intelligence improves resilience and reduces latency.

Work in phases – not all at once

Integration works best when it’s gradual. Start small. Add a few nodes, link them to a gateway, and connect to the PLC or SCADA. Observe how they behave, adjust the configuration, then expand.

This approach helps detect issues early. It also reduces the risk of downtime in critical areas.

Partner with solution providers

Integrating wireless mesh into legacy infrastructure requires both experience and context. Elsta Elektronika and Embetech offer support in designing and deploying mixed systems. Their teams understand the limits of old platforms and the power of new ones.

Working with a trusted partner saves time, reduces risk, and ensures that your investment in embeNET is effective from day one.

Move forward without starting over

You don’t have to choose between modern and old. With embeNET, you can extend your current system – making it more flexible, scalable and ready for the next decade.

Wireless mesh isn’t about replacing cables. It’s about creating networks that adapt. And with the right plan, it fits naturally into what you already have.