Echelon 35100 ISA W/FTM-10 SMX LonWorks Network Card

Echelon 35100 ISA W/FTM-10 SMX LonWorks Network Card: Retrofit-Compatible Upgrade for Legacy LON Control Systems

The Echelon 35100 ISA W/FTM-10 SMX is a LonWorks-based ISA bus network interface card designed for integration into legacy industrial control systems that rely on the LON (Local Operating Network) communication protocol. Equipped with the FTM-10 SMX free topology media access controller, this card supports flexible network wiring topologies — including bus, star, and free topology configurations — making it an ideal retrofit solution for aging automation infrastructure where rewiring is not feasible.

As industrial facilities face increasing pressure to extend the operational life of existing control platforms while managing capital expenditure, the Echelon 35100 provides a proven, in-stock spare part solution that eliminates the need for full system replacement. With a 12-month warranty and pre-shipment functional testing, this unit is ready for direct installation into compatible ISA-slot host systems.

Upgrade Compatibility Table

Retrofit Planning for Existing Automation Systems

When planning a retrofit around the Echelon 35100 ISA W/FTM-10 SMX, engineers must account for the full scope of the LON network segment — not just the network interface card itself. In most legacy building automation and industrial control deployments, the 35100 card operates as the host-side network interface connecting a supervisory PC or SCADA workstation to a field-level LON segment populated by distributed I/O nodes, actuator controllers, and sensor modules.

A typical retrofit scenario begins with an audit of the existing LON segment. Field devices such as Echelon FT 3120 Smart Transceivers embedded in third-party controllers, or standalone Echelon i.LON 100 Internet Servers acting as LON-to-IP gateways, must be inventoried and their firmware versions confirmed. If the host workstation running the LNS network database is being upgraded or replaced, the LNS database backup must be completed before the 35100 card is removed, as the network topology, node addresses, and variable bindings are stored in the LNS database — not on the card itself.

Power supply integrity is a critical pre-installation check. The ISA bus slot must deliver stable +5 VDC and ±12 VDC rails within specification. In aging industrial PCs or embedded controllers, capacitor degradation in the power supply module can cause intermittent ISA bus errors that mimic a faulty network card. Before condemning the 35100, verify the host power supply output with a multimeter under load. If the host system uses a redundant power supply module or an external DIN-rail 24 VDC power supply for field device loops, confirm that the LON segment termination resistors and power conditioners are intact.

Terminal wiring on the LON segment side connects through the FTM-10 SMX transceiver’s two-wire twisted pair interface. When replacing the 35100, label and photograph all field wiring before disconnection. The TP/FT-10 free topology channel does not require polarity-sensitive wiring, but the termination resistors — typically a single 100-ohm terminator for free topology segments — must remain in place. If the segment previously used a LonWorks repeater or LON router to bridge multiple channels, confirm that the router’s channel configuration is not dependent on the host-side 35100 node address.

For facilities running Echelon LNS-based SCADA or BAS platforms, the replacement 35100 card must be re-commissioned using LonMaker or a compatible LNS-aware tool. The new card will present as an unconfigured network interface; the LNS database must be updated to associate the new card’s Neuron ID with the host application. This process typically takes 15–30 minutes in a well-documented system. If the original LNS database is unavailable, a full network re-commission may be required, which significantly extends downtime — making pre-replacement database backup a non-negotiable step.

In control cabinet upgrade projects where the host PC is being migrated from an ISA-based platform to a modern PCI or PCIe architecture, the Echelon 35100 may need to be paired with an ISA-to-PCI bridge card or the LON interface function may need to be migrated to an Echelon PCC-10 PCMCIA card or a USB-to-LON adapter such as the Echelon U10/U20 USB Network Interface. In such cases, the 35100 serves as the interim solution during the transition period, maintaining LON segment continuity while the new host platform is configured and validated offline.

I/O expansion during the retrofit should be planned carefully. Adding new LON nodes to an existing segment requires verifying that the segment’s node count does not exceed the FTM-10 channel capacity (127 nodes per channel). If expansion is required, a LON channel router or LON repeater must be introduced before the new nodes are commissioned. Signal isolation between the LON segment and other field bus networks — such as Modbus RTU or PROFIBUS DP — is typically handled by dedicated protocol gateways or signal isolators, which should be tested for compatibility with the upgraded LON segment configuration.

Downtime Control During System Migration

Minimizing downtime during a LON network interface card replacement requires a structured pre-outage preparation protocol. The single most impactful action is completing a full LNS database backup and exporting the network variable binding report before any hardware is touched. This document serves as the recovery baseline if commissioning encounters unexpected issues.

Where possible, the replacement Echelon 35100 should be bench-tested in a staging environment using a portable LON segment with at least one known-good LON node. This confirms that the replacement card is functional and that the host driver stack recognizes it correctly before the production system is taken offline. NINERMAS ships all units with a pre-shipment functional test certificate, reducing the risk of receiving a non-functional spare.

During the outage window, the sequence should follow: (1) place the LON-connected field devices in local/manual control mode where supported, (2) shut down the LNS host application gracefully, (3) power down the host PC, (4) swap the 35100 card, (5) power up and verify ISA bus recognition in the host BIOS, (6) launch the LNS application and re-associate the new card’s Neuron ID, (7) verify all network variable bindings are intact, and (8) return field devices to automatic control mode. This sequence, when followed in a well-documented system, typically achieves a total outage window of under two hours.

For systems where continuous operation is critical, consider deploying a parallel LON channel on a secondary 35100 card installed in a standby host PC. The standby host can be brought online rapidly if the primary host fails, provided both hosts share access to the same LNS database via a network-accessible LNS server. This architecture is particularly relevant in facilities where the LON network controls safety-critical functions such as fire suppression interfaces, access control interlocks, or emergency ventilation systems.

Original program logic stored in the LNS database is preserved across card replacements as long as the database is intact. The 35100 card itself does not store application logic — it functions purely as a network interface. This means that a card swap, when properly executed, carries no risk of program logic loss, provided the LNS database backup is current.

Retrofit Support FAQ

Q1: Is the Echelon 35100 ISA W/FTM-10 SMX a direct replacement for a failed unit of the same model?
Yes. The 35100 is a like-for-like replacement. After installation, the only required step is re-commissioning the card’s Neuron ID in the LNS database using LonMaker or a compatible tool. No firmware changes or hardware modifications are required. All network variable bindings and application logic remain in the LNS database and are unaffected by the card swap.

Q2: What commissioning tools are required after installation?
The Echelon LonMaker Integration Tool (version 3.2 or later) or any LNS-compatible network management application is required to re-associate the replacement card’s Neuron ID with the host application. NodeBuilder can also be used for low-level diagnostics. Ensure the LNS server service is running on the host PC before launching the commissioning tool.

Q3: How do I verify wiring compatibility before installation?
The FTM-10 SMX transceiver uses a two-wire TP/FT-10 interface. Confirm that the existing LON segment cable is twisted-pair (22 AWG recommended) and that a single 100-ohm termination resistor is present on the free topology segment. Polarity is not critical for TP/FT-10. Measure segment continuity and insulation resistance before connecting the replacement card to rule out cable faults that may have contributed to the original card failure.

Q4: What does the 12-month warranty cover, and what is the stock availability?
All Echelon 35100 ISA W/FTM-10 SMX units supplied by NINERMAS carry a 12-month warranty covering manufacturing defects and functional failures under normal operating conditions. Each unit undergoes a pre-shipment functional test. Stock is maintained for immediate dispatch; lead times for in-stock units are typically 3–7 business days depending on destination. For long-term spare parts programs or bulk procurement commitments, contact our team to discuss reserved stock arrangements and extended supply agreements.