LON Communication

In recent inquiries, we have received requests for a radio communication circuit board for LON bus systems, with a required communication distance of approximately 200 meters and installation in industrial environments such as wagons and fixed stations.

This article explains:

  • What LON communication is
  • What an .xif file is
  • The challenges of making LON wireless
  • Key technical questions that must be clarified
  • Possible solution approaches

What Is LON Communication?

Local Operating Network (LON) is a distributed control networking protocol widely used in:

  • Building automation
  • Sistemi ferroviari
  • Industrial control
  • HVAC systems
  • Vehicle control applications

LON is primarily designed for:

  • Real-time control data
  • Sensor and actuator communication
  • Distributed automation networks

It is not designed for high-bandwidth data like video transmission.

Is LON a Wireless Protocol?

NO.

LON is traditionally a wired fieldbus system, commonly using physical layers such as:

  • TP/FT-10 (twisted pair free topology)
  • Power line
  • Fibra (in some cases)

When customers ask for a “LON radio communication board,” what they usually mean is:

A wireless bridge that connects two LON segments over RF.

This is technically called:

  • Wireless LON bridge
  • LON over RF
  • LON wireless extender

The key challenge is that the wireless link must behave as a transparent extension of the LON bus.

What Is an .xif File in LON Systems?

In many LON projects, customers mention the .xif file.

An .xif (External Interface File) defines:

  • Network variables (NVs)
  • Input/output variables
  • Configuration properties
  • Device interface structure

It is used by LON network management tools to understand how a node behaves.

Important clarification:

  • If you are building a LON node device, you must provide an .xif file.
  • If you are building a transparent wireless bridge, no .xif modification is required.

For most wireless extension projects, the goal is to keep the existing LON structure unchanged.

Key Technical Questions Before Designing a Wireless LON Solution

When evaluating a 200m wireless LON system, the following questions must be clarified:

1. Is 200 meters Line-of-Sight (LOS)?

  • Or are there metal wagons, edifici, or machinery between nodes?
  • Industrial environments significantly affect RF performance.

2. What LON Physical Layer Is Used?

  • TP/FT-10?
  • Another variant?

3. Is Real-Time Control Required?

LON systems are often used in control applications.
Latency and packet reliability are critical.

4. What Type of Data Is Transmitted?

  • Small sensor and control data only?
  • Any large payload?
  • Any video? (Typically not applicable for LON.)

5. Environmental Requirements

  • Intervallo di temperatura?
  • Vibrazione?
  • EMC requirements?

These parameters determine whether the project is feasible and what wireless technology is appropriate.

Possible Technical Approaches

Based on typical industrial scenarios, there are two main approaches:

Opzione 1: LON + LoRa

Adatto per:

  • Low data rate
  • Non-real-time monitoring
  • Long-distance, low-power applications

Not ideal for:

  • Fast control loops
  • Strict real-time industrial control

Opzione 2: LON + IP Broadband Wireless Bridge (Recommended for Industrial Use)

In this approach:

LON → LON-to-Ethernet conversion → IP wireless transceiver → remote side → Ethernet-to-LON conversion

Vantaggi:

  • Stable broadband communication
  • Bassa latenza
  • Industrial reliability
  • 200m+ easily achievable
  • Suitable for complex industrial environments

This solution keeps the LON protocol intact and acts as a transparent bridge.

Common Misunderstanding: Designing a “LON RF Board” From Scratch

Designing a native wireless LON board with full protocol support requires:

  • LON-certified stack implementation
  • Neuron chip integration
  • Full compatibility with existing LON management tools

This significantly increases development complexity and cost.

In most industrial retrofitting scenarios, UN transparent wireless bridge approach is more practical and reliable.

Conclusione

When considering wireless LON communication over 200 metri, it is essential to:

  • Clearly define physical environment conditions
  • Understand whether real-time control is required
  • Determine if the goal is a wireless node or a transparent bridge
  • Evaluate RF interference and obstacles

A properly engineered wireless bridge solution can extend existing LON networks without modifying .xif files or disrupting system architecture.

If you are evaluating a similar project, feel free to share:

  • Your LON physical layer type
  • Required distance and environment
  • Data characteristics
  • Installation conditions

With clear technical parameters, a reliable solution can be designed.

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