Bridge Legacy Machinery to Real-Time Cloud Intelligence
The IIOTCore Node v2.2 is an industrial-grade edge gateway and data logger engineered to seamlessly bridge legacy industrial equipment, PLCs, and sensors with modern cloud analytics, SCADA, and private on-premise infrastructure.
This revision introduces a widened 9–24V DC wide-range power input with built-in reverse-polarity and overvoltage safeguards, an external TFT display header, high-performance isolated RS-485 Modbus RTU, 4G LTE multi-WAN with automatic 3G/2G fallback, Wi-Fi, BLE, and integrated GNSS positioning.
32 Field Devices
Per single Node gatewayEdge Processing
Parsing, anomaly & alertsMicroSD Buffer
Zero data loss on outages9–24V DC Protected
DIN-rail & wall mount
Hardware Highlights:
- Power Input: 9–24V DC terminal block (Max continuous 26.4V DC, reverse polarity safeguarded).
- Connectivity: 4G LTE (3G/2G fallback), RJ45 10 Mbps Ethernet, Wi-Fi 802.11b/g/n, BLE.
- Integrated GNSS: Real-time asset location tagging and geofencing.
- Offline Continuity: Built-in MicroSD card slot for offline buffering during internet dropouts.
- Display Option: Onboard TFT header for optional external status and parameter display.
Target Industry Solutions & Use Cases
The IIOTCore Node v2.2 solves high-cost operational bottlenecks across brownfield factories, renewable power, cold storage, smart cities, and heavy motor drive infrastructure.
Factory Retrofit
Brownfield ManufacturingMarket Problem
~98M automation assets installed since 1996 run reliably for 10–20+ years but lack data connectivity. Full replacement is capital-intensive and risky.
IIOTCore Solution
Isolated RS-485 / Modbus RTU bridges legacy serial PLCs & drives, while Modbus TCP handles Ethernet gear. Up to 32 machines per node delivers 30–50% less downtime at 10–30% lower cost than rip-and-replace.
Lead with: Downtime reduction & zero rip-and-replaceSolar Power Plants
Unified Inverter LoggingMarket Problem
Inverters speak differing protocols (Modbus, SunSpec, CAN, vendor APIs). OEM-native loggers lock plants to single brands, preventing expansion.
IIOTCore Solution
One gateway aggregates mixed-brand string and central inverters. Built-in GNSS + 4G caters to remote off-grid farms. Edge anomaly algorithms detect string faults before losing a day's energy yield.
Lead with: Multi-brand fleet aggregation & off-grid 4G/GNSSCold Chain & FMCG
Data Logger & Compliance AlertsMarket Problem
WHO estimates 40% perishable food loss due to equipment failure (62% temperature excursions). Non-tamper-proof logs cause severe FSSAI / HACCP audit failures.
IIOTCore Solution
Local millisecond threshold breach alerting without waiting for cloud round-trips. MicroSD buffer creates immutable audit logs. 4G + GNSS tracks refrigerated transit trucks and cold rooms, cutting spoilage 34–52%.
Lead with: Local alerting + tamper-proof HACCP logsSmart Street Lighting
CCMS Fleet & Feeder Pillar MonitoringMarket Problem
Municipalities struggle with fragile CCMS units where backend cloud outages cause total loss of fault visibility, leading to withheld contractor payments and dark roads.
IIOTCore Solution
Deployed at feeder pillars to aggregate multiple poles. Built-in GNSS tags exact pole/pillar GPS coordinates. Edge logic maintains local schedules, dimming, burn-hours, and power metering even during server outages.
Lead with: Fault visibility even when backend is downVFD Fleet Monitoring
Predictive Maintenance & Motor HealthMarket Problem
Capacitor degradation from thermal stress causes catastrophic VFD breakdowns costing $5,000–$30,000+ per drive in emergency replacement and lost manufacturing output.
IIOTCore Solution
Polls existing drive registers directly over RS-485 Modbus (speed, torque, voltage, DC bus ripple, thermal levels) with zero hardware changes to the drive. One node monitors an entire VFD bank.
Lead with: Predictive maintenance & zero new sensorsIIOTCore Cloud & On-Premise Dashboard
Every IIOTCore Node connects seamlessly to a unified single pane of glass, giving operational managers, maintenance engineers, and executives total real-time control.
Live & Historical Views
High-resolution real-time telemetry streaming, interactive waveform analysis, and multi-year historical trend comparisons for every deployed node.
Threshold & Anomaly Alerts
Instant automated SMS, WhatsApp, and email notifications triggered the millisecond an edge anomaly or threshold deviation occurs on site.
Multi-Site Unified View
One centralized login managing multiple factories, decentralized solar plants, cold logistics fleets, and municipal smart lighting zones across regions.
Audit-Ready Compliance
Exportable, tamper-evident PDF/CSV logs structured specifically for statutory audits including FSSAI, HACCP, ISO 50001, and O&M service reviews.
Fleet-Wide Rollout
Scales effortlessly from a single proof-of-concept pilot node to hundreds of edge gateways with centralized Over-The-Air (OTA) firmware deployment.
Strict Data Sovereignty
Fully supports deployment in air-gapped on-premise servers, enterprise private clouds, or hybrid cloud configurations to guarantee domestic data residency.
Technical Specifications Matrix
Full hardware, electrical, network, protocol, and mechanical specifications for the IIOTCore Node v2.2.
Hardware & Interfaces
| Enclosure | Compact industrial enclosure, DIN-rail mountable |
|---|---|
| Display Header | TFT header for optional external display connection |
| Ethernet Port | 1× RJ45, 10 Mbps (Auto MDI/MDIX) |
| Serial Interface | RS-485 via isolated terminal block (A / B / GND) |
| Modbus Support | Modbus RTU (Master and Slave mode) |
| Local Storage | 1× MicroSD card slot for offline buffering & log retention |
| Status Indicators | PWRLANSTAT |
Power Specification
| Input Voltage | 9–24V DC (wide-range terminal block input) |
|---|---|
| Max Continuous Voltage | 26.4V DC (do not exceed) |
| Maximum Current | ~1.2A (all communication modules active) |
| Polarity Protection | Reverse polarity protection on terminal block |
| Overvoltage Protection | Overvoltage safeguard on terminal block |
| Device Capacity | Up to 32 connected field devices per node |
Wireless & Protocols
| Cellular | 4G LTE (primary), automatic 3G/2G fallback |
|---|---|
| Positioning | Integrated GNSS — asset location tagging & geofencing |
| Wi-Fi | IEEE 802.11 b/g/n — local access, diagnostics, OTA updates |
| Bluetooth | BLE — proximity sensor coupling, wireless diagnostics |
| Industrial Protocols | Modbus RTU (Master/Slave, RS-485); Modbus TCP/IP |
| Cloud Protocols | MQTT, REST API, HTTP/HTTPS with TLS/SSL encryption |
Dimensions & Compliance
| Overall Dimensions | 118.30 mm × 92.00 mm × 48.55 mm (H × W × D) |
|---|---|
| DIN-Rail Engagement | 23.20 mm depth |
| Mounting Options | DIN-rail mount or wall mount — convertible clip system |
| Terminal Block Pitch | 8.00 mm |
| Design & Origin | Domestically designed & assembled — Origin: India |
| Certification | CE Marked |
Deploy IIOTCore Node in Your Facility
Need partner enablement sheets, pricing models, custom protocol register maps, or an on-site pilot demonstration? Reach out to the Techseal Solutions Industrial IoT team today.
