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Relay Controllers

Wi-Fi Setup

Connecting the relay controller to Wi-Fi directly or via the HPzenAi gateway.

Connectivity Options​

HPzenAi relay controllers (XR/X series) can connect to the HPzenAi platform in three ways: via Wi-Fi directly (stand-alone mode), via RS485 to an HPzenAi gateway, or via SIM cellular (XR1, XR2, X1, X2 models). For sites with good Wi-Fi coverage, direct Wi-Fi mode is the simplest setup. For sites with multiple RS485 field devices or weak Wi-Fi, use RS485 via gateway. For remote sites without fixed internet, use SIM cellular. RF radio connectivity (XR1, XR3, X1, X3) is used to communicate with remote field devices rather than for cloud connectivity.

Option A — Direct Wi-Fi Setup (Stand-Alone Mode)​

In stand-alone Wi-Fi mode, the relay controller connects directly to your 2.4 GHz Wi-Fi router and communicates with the HPzenAi cloud without requiring a gateway.

Visual reference coming soon

Steps​

  • Power on the relay controller — the status LED will flash blue, indicating setup mode.
  • Open the HPzenAi app on your phone and ensure your phone is connected to the 2.4 GHz Wi-Fi network you want to use for the controller.
  • Go to Main Menu → Devices → Add Device → Relay Controller.
  • Select 'Wi-Fi' as the connection type.
  • The app will search for the controller's temporary hotspot (named HPzenAi-RC-XXXX).
  • Once found, the app connects to the hotspot and prompts you to select your 2.4 GHz Wi-Fi network.
  • Enter your Wi-Fi password and tap Confirm.
  • The controller joins your Wi-Fi network — the status LED turns solid green.
  • The controller appears in the app as a new device tile.

Guided Help Center

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Power on the relay controller.

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Option B — RS485 via Gateway​

In RS485 mode, the relay controller communicates with the HPzenAi gateway over a wired RS485 bus. The gateway handles Wi-Fi and cloud connectivity on behalf of the controller. This mode is preferred for multi-device installations and sites where the controller is too far from the Wi-Fi router.

Steps​

  • Ensure the HPzenAi gateway is already set up and online (solid green LED).
  • Wire the relay controller RS485 A terminal to the gateway RS485 A terminal.
  • Wire the relay controller RS485 B terminal to the gateway RS485 B terminal.
  • Use twisted-pair shielded cable for runs longer than 1 m.
  • Power on the relay controller — it will be discovered by the gateway automatically within 60 seconds.
  • In the app, go to Gateway → your gateway → and confirm the relay controller appears in the linked devices list.
  • Tap the relay controller tile to configure channel names, schedules, and automation.

Option C — SIM Cellular Fallback (XR1, XR2, X1, X2)​

SIM-enabled models automatically switch to cellular data when Wi-Fi is unavailable. This ensures continuous cloud connectivity on sites with intermittent Wi-Fi or for mobile deployments.

Steps​

  • Insert a nano-SIM card into the SIM slot on the side of the controller enclosure.
  • In the HPzenAi app, go to Device Settings → Network → Mobile Data.
  • Enter the APN (Access Point Name) provided by your SIM carrier.
  • Save and the controller will automatically use cellular data when Wi-Fi is unavailable.
  • The status LED shows a different colour pattern during cellular operation — refer to the LED guide in Device Settings.
  • Cellular data usage is minimal — the controller sends small status packets and schedule sync messages.

RF Radio Connectivity (XR1, XR3, X1, X3)​

The RF radio on XR1, XR3, X1, and X3 models is used to communicate with remote RF-enabled field devices and sensors that are out of Wi-Fi or RS485 cable range. It is not used for internet access — cloud connectivity is handled by Wi-Fi or SIM.

Steps​

  • Mount the RF antenna in an unobstructed location — outside the metal enclosure if possible.
  • In the app, go to Device Settings → RF → RF Channel and set the channel number.
  • Set the RF channel to the same number on all RF-enabled devices on the same site.
  • RF range is typically 200–500 m line-of-sight depending on obstructions.
  • For maximum range, mount the antenna vertically and away from metal structures.

Changing Wi-Fi Network​

Steps​

  • In the HPzenAi app, go to Device Settings → Network → Wi-Fi.
  • Tap Change Network.
  • The controller enters setup mode — the LED flashes blue.
  • Select the new 2.4 GHz network and enter the password.
  • Tap Confirm and wait for the LED to return to solid green.

Wi-Fi Quality Requirements​

Steps​

  • The relay controller requires a minimum Wi-Fi signal of −75 dBm for stable connectivity.
  • Use the HPzenAi app's Wi-Fi Signal Checker (Device Settings → Network → Signal Strength) to confirm signal quality at the installation location.
  • Only 2.4 GHz Wi-Fi networks are supported — 5 GHz networks are not compatible.
  • Place a Wi-Fi repeater or access point closer to the controller if signal is below −75 dBm.
  • Schedules stored on the controller continue to execute even if Wi-Fi is temporarily lost — only app visibility and schedule sync require connectivity.