WirelessHART MACTek Bullet WirelessHART 110100 User manual

DM1101010UAB
Copyright 2009-2010
MACTek®Corporation
Bullet™ WirelessHART®Adapter – Model 110100
User Manual

DM1101010UAB
Copyright 2009-2010
LIMITED WARRANTY
Bullet™
WirelessHart®Adapter
MACTek®Corporation warrants this interface and all its component against defects in
materials or workmanship for a period of one year from the date of purchase. This warranty only extends
to the original consumer of this product.
If the Interface or a component does not function because of defects in material or workmanship
during the warranty period, MACTek will either repair the defective product or replace it with a new or
remanufactured functionally equivalent product of equal value. The original consumer must send proof
of purchase along with the defective product as provided below. To obtain service under this warranty,
first call the MACTek Support Center to obtain a Return Merchandise Authorization (RMA) number
from MACTek; then deliver the product, shipment pre-paid, to MACTek addressed as follows:
MACTek Engineering Dept.
Attn: RMA # ___________________
2112 Case Parkway South #1
Twinsburg, OH 44087
USA
Call the MACTek Support Center at [phone] to obtain an RMA number, or for further
product or service information under this warranty.
MACTek has no obligation to repair or replace any defective product that has been subject to
misuse, neglect, accident, or abuse, or subject to alteration or repair by persons other than MACTek or
its authorized repair agents. This warranty does not cover normal wear and tear.
REPAIR OR REPLACEMENT AS PROVIDED UNDER THIS WARRANTY IS THE SOLE
AND EXCLUSIVE REMEDY OF THE CONSUMER. MACTek SHALL NOT BE LIABLE FOR
ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES OR FOR BREACH OF ANY EXPRESS OR
IMPLIED WARRANTY ON THIS PRODUCT. EXCEPT TO THE EXTENT PROHIBITED BY
APPLICABLE LAW, MACTek SPECIFICALLY DISCLAIMS ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
Some state or countries do not allow limitations on how long an implied warranty lasts, so the
above limitation may not apply to you. In addition, some states or countries do not allow the exclusion
or limitation of incidental or consequential damages, so the above limitation may not apply to you.
This warranty gives you specific legal rights, you may also have other rights which vary from state
to state and country to country.
No terms in any purchase order or other sales agreement shall alter or replace the terms
contained in this Limited Warranty.
WirelessHART®and HART® are registered trademarks of the HART Communication Foundation.
MACTek® is a registered trademark and Bullet™ is a trademark of MACTek Corp

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Table of Contents
1. OVERVIEW......................................................................................................................5
Basic Operation..................................................................................................................... 6
Typical Usage........................................................................................................................ 6
Power.................................................................................................................................... 7
Loop Powered Mode................................................................................................................ 7
Direct Powered Mode............................................................................................................... 8
External Power Source Mode .................................................................................................. 8
2. CONFIGURATION.............................................................................................................9
Bench Top Configuration ...................................................................................................... 9
Quick Setup........................................................................................................................... 9
HART Dynamic Variables .......................................................................................................11
Configure Power Mode (method)............................................................................................11
Adapter Power ........................................................................................................................11
Join Device to Network (method)............................................................................................13
Network ID..............................................................................................................................13
Join Key..................................................................................................................................13
HART Polling Address ............................................................................................................14
HART Master Mode ................................................................................................................14
HART Retry Count..................................................................................................................15
HART Number of Response Preambles .................................................................................15
Write Protect ...........................................................................................................................15
Sub-Device Time Synchronization..........................................................................................15
Sub-Device Scan on Power-up...............................................................................................15
Scan Start Address.................................................................................................................16
Scan Stop Address .................................................................................................................16
Scan for Sub-Devices (method)..............................................................................................16
Automatic Burst Mode Configuration.......................................................................................16
Factory Reset..........................................................................................................................16
Alerts................................................................................................................................... 18
ALERT – Direct Power Out of Range......................................................................................18
ALERT – Loop Power Out of Range.......................................................................................19
ALERT – Temperature Out of Range......................................................................................19
ALERT – Power Mode Misconfigured.....................................................................................19
ALERT – Watchdog Reset......................................................................................................20
ALERT – Stack Overflow ........................................................................................................20
ALERT – Duplicate HART Master Detected............................................................................20
ALERT – HART Devices Count Exceeded..............................................................................21
ALERT – HART Sub-Device Lost............................................................................................21
ALERT – Burst Packets are Being Dropped ...........................................................................21
ALERT – Field Device Power Control.....................................................................................22
ALERT – Wireless Capacity Denied........................................................................................22
ALERT – Burst Message Configuration Issue.........................................................................23
ALERT – Wired Device in Burst Mode ....................................................................................23
ALERT – Bullet Failed to Join the Network.............................................................................23
ALERT – Radio Malfunction....................................................................................................24
ALERT – Variable Simulation..................................................................................................24
HART DD Menu Tree.......................................................................................................... 25
3. INSTALLATION...............................................................................................................26
Antenna Positioning............................................................................................................ 26
Typical Installation............................................................................................................... 26
Bullet as a Standalone WirelessHART Router........................................................................27
Bullet with a 4-20mA Analog Transmitter (non-HART)............................................................27
Bullet with a 4-20mA HART Transmitter .................................................................................27
FIGURE 1: Configuration #1 ...................................................................................................28
FIGURE 2: Configuration #2 ..................................................................................................28
Bullet with HART Devices in Multi-Drop Mode........................................................................28
Bullet with a 4-20mA Transmitter with Battery Powered Operation.........................................29
Bullet installation to Field Device.............................................................................................29

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5. TROUBLESHOOTING......................................................................................................31
Does Not Detect Wired-HART Sub-Devices....................................................................... 31
Cannot Connect to the WirelessHART Network................................................................. 31
Resetting the Bullet............................................................................................................. 31
Soft Reset – Via DD................................................................................................................31
Soft Reset – Via Power connections.......................................................................................31
Hard Reset..............................................................................................................................31
6.0 CERTIFICATES AND APPROVALS..................................................................................32
Telecommunication Compliance......................................................................................... 32
FCC and IC.............................................................................................................................32
European Union Directives .....................................................................................................32

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1. Overview
The Bullet enables existing wired HART field devices to communicate with host
applications by means of WirelessHART™ technology. The Bullet is installed
permanently by screwing it directly into an available spare port of HART field device, or
using a short, right angle elbow conduit. Other installation options are possible anywhere
on the loop using a junction box or T-fitting. A wired HART field device retrofitted with a
Bullet communicates its PV over the existing wiring to DCS and simultaneously
communicates diagnostic and alarm data over the WirelessHART network to process
management, asset management and engineering applications. The Bullet has options
for power scavenging or local/direct power. The Bullet when powered by the current
loop saves users the long term cost of battery maintenance, replacement and disposal
programs. The Bullet Local/Direct power option can be used when the field device is
powered either by a power supply or an external battery/solar system. In the case of
external battery power, the Bullet provides battery power management by cycling the
field device power and taking periodic readings.
Typical Use Cases
•Upgrade legacy wired HART analog only field devices with WirelessHART
communication capability to enable 24/7 monitoring of alarms and diagnostic
information
•1-Port WA is the preferred housing for explosion proof conduit applications
•Low cost / low risk means to test and evaluate WirelessHART networks in a plant
•Substitute for multiplexers or legacy DCS upgrade to HART enabled IO.
•External Battery powered wireless remote I/O data collection
Features
•HART 7.1 Registered with HCF = fully HART compliant for communication reliability
when the WirelessHART test suite is available
•Loop powered – no batteries or other power sources required
•Connects directly to HART field device and optionally anywhere on the 4-20 mA
control loop
•MACTek patent pending StepVolt™ technology sets insertion voltage in steps from 1
to 2.5 volts to optimize trade off between available loop power and Wireless
communication bandwidth
•Direct Power option when local DC power is available: system power, external
battery/solar system
oInternal 250 ohm loop current sense resistor provided, configurable by
WirelessHART command.
oIn Direct Power mode, can switch field device on/off to take periodic readings
to save power.
•Multidrop support for up to 6 devices
•300 meters open air range

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Basic Operation
The Bullet WirelessHART Adapter allows legacy wired-HART devices to be connected to
a WirelessHART network. This allows remote access to diagnostic data, digital process
variables, and alarm data stored inside HART devices.
The Bullet has both a wireless interface to communicate with the WirelessHART network
and a wired-HART interface which is connected to a traditional 4-20mA current loop.
The Bullet communicates as a wired-HART master to connected HART devices on the
loop, and can transmit and receive HART data from these connected HART devices to
the WirelessHART network. The Bullet also supports being configured like a wired-
HART slave device, so traditional HART configuration tools (such as HART Field
Communicators and PCs with HART modems) can be used to configure the Bullet.
In WirelessHART terminology, any wired-HART devices that can be communicated with
from a WirelessHART Adapter is known as a sub-device. A single Bullet WirelessHART
Adapter can support up to six wired-HART sub-devices connected to it. The
WirelessHART Gateway maintains a list of all of the devices in the WirelessHART
network, including sub-devices connected to WirelessHART Adapters. Host applications
that communicate with the WirelessHART gateway can communicate directly with the
wired-HART sub-device, and the WirelessHART gateway and WirelessHART Adapter
will transparently handle the message translation.
WirelessHART supports publishing of data from devices to the WirelessHART Gateway
on a periodic basis. This is called “burst mode” in HART terms, but is much more
advanced than the “burst mode” traditionally supported by HART devices. Data can be
burst based on an update time or when the specified process value causes a trigger that
has been configured to trip - such as when the process value rises above a certain point.
When the Bullet is configured in burst mode, it supports all of these advanced modes on
behalf of any wired-HART sub-devices that are connected. Burst mode is also very
useful to publish device status data (such as malfunctions or alarms) to the Gateway on
a periodic basis or immediately when a critical event occurs.
Typical Usage
In most network configurations, the Bullet will be used in conjunction with a wired-HART
sub-device and will be configured to publish process data and device status data from
the sub-device to the WirelessHART network on a periodic basis (such as every 8
seconds or every minute, etc).
The Bullet adds several features to make this typical usage mode very easy to configure,
such as the Automatic Sub-Device detection and Automatic Burst mode configuration.

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Power
The Bullet WirelessHART Adapter has been designed to be extremely power efficient
and flexible to allow for a wide variety of installation options.
Loop Powered Mode
The Bullet can be wired in series with devices on a 4-20mA loop and be powered from
the loop. The Bullet utilizes MACTek’s patent pending StepVolt™ technology, to allow
the user to set this insertion voltage drop between 1.0 – 2.5 Volts, in 0.5 Volt increments.
StepVolt™ allows users to select the best insertion voltage drop for their application.
The higher the voltage drop setting used, the more WirelessHART messages the Bullet
will be able to transmit and receive.
In applications where there is very little voltage overhead in the loop, such as
transmitters on very long cable runs or with IS barriers, StepVolt™ allows the selection
of a low insertion voltage drop. However in a number of applications there is plenty of
voltage overhead on the loop to allow for a high voltage insertion drop from the Bullet.
A concern with a loop powered WirelessHART Adapter is being able to operate under
worst case conditions since very little power is available to be used by the Adapter at low
loop current conditions. The Bullet is designed to operate at the worst case operating
conditions at all power settings and will respond to Wired or WirelessHART commands.
The Bullet will operate as specified with reliable communications even under the
following conditions:
- Loop current of 3.2mA and 1.0V insertion voltage drop
- Temperature Extremes (-40C to +85C)
- Worst Case wired-HART communication on the loop. Constant wired-HART
communication addressed to the Adapter and the Adapter responding to every
command.
- Every WirelessHART timeslot filled and transmitting
Note: On power-up, the voltage drop will be set to 1.0V until the Bullet has finished
initialization. At this point, it will change the voltage drop to the value specified.
NOTE: The Bullet cannot control the loop current, if connected in loop-powered mode
there must be something controlling the loop current, such as a 4-20mA transmitter.
StepVolt™ Benefits
The benefit to using a high StepVolt™ setting is that the Bullet will be able to support a
much higher amount of WirelessHART packets per second. Even if the particular device
attached to the Bullet is configured for a very low update rate, being able to support a
high amount of WirelessHART packets per second helps the overall WirelessHART
network operation.

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WirelessHART is a mesh network – each node in the network will route messages on
behalf of other nodes in the network. This is done to expand the overall range of the
network and also for the data reliability of the network by forming multiple redundant
paths. By setting the Bullet to a high StepVolt™ setting, more WirelessHART packets
can be routed through the Bullet for other nodes in the network.
Another consideration from a WirelessHART network standpoint is that many devices in
a WirelessHART network are battery powered and all wireless transmissions performed
by these devices impact their battery life. The more WirelessHART devices that a
battery powered node has to route messages for, the shorter its overall battery life is.
The Bullet is different – since it is loop powered it can support wireless messages
indefinitely without any concerns of battery life. By placing MACTek Bullet’s at key
locations in a WirelessHART network, such as places that route messages for other
WirelessHART nodes, this routing function can be offloaded from battery powered nodes
to the Bullet and help to preserve their battery life of the battery powered nodes.
StepVolt Setting WirelessHART Packets per Second
1.0 V 5.79
1.5 V 12.65
2.0V 19.66
2.5V 26.66
Note: The value shown in WirelessHART Packets per second column is the value
reported back in HART Command 777. These values are preliminary and subject to
change.
Recommendation: Plan on using the highest StepVolt™ setting possible to help the
overall WirelessHART network performance.
Direct Powered Mode
In direct powered mode, the Bullet can be powered by an external DC supply.
The DIRECT POWER connections are DIRECT POWER, black lead wire, to the positive
potential and the RETURN, white lead wire, to the negative terminal of the external DC
source. The voltage range of this input is 7VDC to 32VDC.
External Power Source Mode
The Bullet can be powered by an external DC power source such as; battery, solar panel
and control power to the Field device.

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2. Configuration
This section contains information on configuration that should be performed prior to
installation of the Bullet in the field.
Initial configuration is performed through the use of a HART Device Descriptor (DD) for
the Bullet over the wired-HART connection. Once connected to the WirelessHART
network, configuration changes can be made using the DD over either the wired-HART
interface or the WirelessHART interface.
Bench Top Configuration
Power the Bullet. This can be performed by connecting the bench power supply positive
terminal to the “Direct Power” input wire and the power supply negative terminal to the
“Return” wire.
Connect HART communicator or HART modem to the Bullet. Connect one lead of the
HART modem to the “Return” wire of the Bullet and the other lead of the HART modem
to the “HART“ wire of the Bullet. The HART signal connection is polarity independent.
NOTE: By default, the Bullet is at HART polling address 15.
NOTE: By default, all WirelessHART Adapters are configured as a primary HART
master. The HART communicator used to configure the Bullet should be configured in
Secondary HART master mode.
Wire Color Description
Green / Yellow Internal Earth Ground
Black Direct Power
Red Loop Power
White Return
Yellow HART
Ground Screw External Earth Ground
Quick Setup
Connect into the device using the DD.
Set the HART Tags for the Bullet:
1. From the Main DD screen, select Configure… (In Simatic PDM, select
Configure… from the Device menu at the top of the screen).
2. Select Manual Setup… Bullet Information…
3. Enter in the HART Tag
4. Enter in the HART Long Tag
5. Transfer the updated information to the Bullet by clicking on the “Send” or
“Transfer” button

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Set the Power Configuration for the Bullet:
1. From the Main DD screen, select Configure… (In Simatic PDM, select
Configure… from the Device menu at the top of the screen).
2. Select Guided Setup…
3. Select Configure Power Mode…
4. Follow the on screen instructions and select the proper power configuration for
the application.
Configure Burst settings
1. From the Main DD screen, select Configure… (In Simatic PDM, select
Configure… from the Device menu at the top of the screen).
2. Select Manual Setup… Burst Settings…
3. Set the Automatic Burst Mode to the desired update rate (recommended) or set
this to disabled.
4. If not using the Automatic Burst Mode, manually set the burst mode configuration
for each Burst Message. Note: Sub-devices must be detected before configuring
the manual Burst Mode configuration.
5. Transfer the updated information to the Bullet by clicking on the “Send” or
“Transfer” button
Configure WirelessHART Network settings
1. From the Main DD screen, select Configure… (In Simatic PDM, select
Configure… from the Device menu at the top of the screen).
2. Select Guided Setup…
3. Select Join Device to Network…
4. Follow the on screen instructions and enter in the WirelessHART Network ID and
join key
5. After accepting the settings, the Bullet will attempt to join the network
Monitoring WirelessHART Network join status
1. From the Main DD screen, select Service Tools… (In Simatic PDM, select
Service Tools… from the Device menu at the top of the screen).
2. Select Communications… Wireless Status…
3. Monitor the progress of the WirelessHART join. If “Join Failed” under Join Status
becomes set, check the Network ID and Join Key that were used to see that they
are correct.
At this point, the Bullet is ready to be installed and commissioned in the field.