About Brainboxes
Brainboxes Industrial Serial Networking Solutions
Brainboxes is a trusted UK manufacturer of industrial data connectivity products, specializing in Ethernet-to-serial converters, remote I/O modules, and managed Ethernet switches that enable legacy serial-port devices to integrate seamlessly into modern TCP/IP Ethernet networks. Founded to bridge the massive installed base of RS-232, RS-422, and RS-485 industrial equipment (PLCs, barcode scanners, weighing scales, legacy HVAC controllers, industrial printers) with Industry 4.0 and IIoT (Industrial Internet of Things) network architectures, Brainboxes has become the de facto standard for serial-device networking in factories, utilities, and critical-infrastructure operations worldwide.
The flagship ES Series Ethernet-to-Serial device servers convert Ethernet TCP/IP traffic transparently to RS-232, RS-422, or RS-485 serial signals without requiring device-side software modifications. Model ES-511 offers a single serial port (switchable between RS-232, RS-422, or RS-485 modes) with -40°C to +80°C industrial operating temperature, +5 to +30 VDC dual-input power with reverse-polarity protection, and removable screw terminal blocks for industrial-grade wiring. The two-port ES-522 extends this to dual serial ports with the same rugged specifications. For applications requiring galvanic isolation (protecting sensitive equipment from ground loops and voltage spikes), the ES-551 Isolated variant offers complete electrical isolation between the device, Ethernet port, serial port, and power supply—critical for safety-critical systems, high-noise manufacturing floors, and multi-site networked installations.
All Brainboxes converters feature Serial Port Tunneling technology, allowing TCP/IP replacement of serial cable runs over any distance—enabling remote monitoring of equipment in field locations, offshore platforms, or across geographically dispersed facilities without custom serial cabling or repeaters. The devices support standard Modbus RTU/TCP, DNP3, and manufacturer-proprietary serial protocols (HART, Profibus, etc.) transparently; firmware acts as a simple pass-through bridge rather than a protocol interpreter, ensuring compatibility with virtually every industrial device ever built with RS-232, RS-422, or RS-485 interfaces.
Installation is minimal: screw terminals accept industrial-grade 18 AWG to 12 AWG wire, power supply is wide-input (5–30 VDC), and DIN-rail mounting enables compact placement in standard electrical cabinets. Optional web-based configuration UI (accessible via browser, no special software) allows setting baud rate, parity, flow-control, and Modbus mode without device reprogramming. Firmware updates are delivered via Ethernet OTA (over-the-air) or USB, and optional remote-management integration (via MQTT or Brainboxes cloud dashboard) enables fleet monitoring across hundreds of converters.
Whether deploying IIoT data collection from a factory floor's legacy barcode scanners and production counters, implementing remote SCADA monitoring of wastewater treatment plants' PLCs across multiple sites, or networking industrial printers and card-access systems in a large facility, Brainboxes serial converters provide proven, cost-effective, maintenance-free integration of decades-old serial equipment into modern IP networks. ChatMRO's industrial database surfaces the exact Brainboxes device server model (1-port, 2-port, isolated, or non-isolated) and serial-mode configuration required for your legacy equipment—simply describe the devices you need to network (PLC brand/model, baud rate, RS-232 vs. RS-485, isolation requirement), and our AI delivers matched converters with real-time pricing and availability from verified industrial-networking distributors.
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Tell us the legacy equipment you need to network (brand, RS-232/422/485 mode, baud rate), how many serial ports, and whether galvanic isolation is required.
Frequently asked questions
How does Brainboxes' Ethernet-to-serial converter work, and do I need to modify my legacy devices?
Brainboxes converters act as a transparent Ethernet-to-serial bridge: your legacy device (PLC, printer, scale) remains unchanged, still sending/receiving serial data over RS-232/422/485. The converter intercepts this serial traffic, re-encapsulates it as TCP/IP Ethernet packets, and forwards it to your Ethernet network. Your network-side software (SCADA, monitoring dashboard, or custom app) connects to the converter's TCP port as if it were a direct serial connection.
What's the difference between ES-511, ES-522, and ES-551?
ES-511 is a single-port non-isolated converter; ES-522 adds a second serial port; ES-551 is identical to ES-511 but includes galvanic isolation between the device, Ethernet, serial port, and power supply, protecting against ground-loop noise and voltage spikes on industrial floors.
When do I need galvanic isolation (ES-551), and when is non-isolated (ES-511) sufficient?
Isolation is essential when your legacy device is in a high-noise industrial environment (electric motor drives, welding equipment, large HVAC compressors nearby) or when the device is grounded to equipment that might experience voltage spikes. For office environments, clean factory zones, or single-site installations with well-behaved power supplies, non-isolated converters suffice.
Can Brainboxes converters handle high baud rates (38.4 kbps, 115.2 kbps)?
Yes—Brainboxes converters support standard industrial baud rates from 1200 to 115,200 bps, with full protocol support (no parity, odd parity, even parity, 7-bit, 8-bit, 1 stop bit, 2 stop bits) configurable per port.
How many legacy devices can I network with a single Brainboxes converter?
Each physical serial port on the converter supports one legacy device. For example, ES-511 (1 port) networks 1 device; ES-522 (2 ports) networks 2 devices. To network 10 devices, you'd deploy 5 ES-511 converters or 5 ES-522 converters, each on the same Ethernet network.