WirelessHART TP400W Manual

TP400
HART
Position Transmitter
Wireless
OPERATION, MAINTENANCE AND
INSTRUCTION MANUAL
TM
TP400WME

web: www.smar.com/contactus.asp
www.smar.com
Specifications and information are subject to change without notice.
Up-to-date address information is available on our website.
sma
r

Introduction
III
NOTE
This manual is compatible with version 7.XX, where 7 indicates software version and XX software release. The
indication 7.XX means that this manual is compatible with any release of software version 7.
Waiver of responsibility
The contents of this manual abides by the hardware and software used on the current equipmen
t
version. Eventually there may occur divergencies between this manual and the equipment. The
information from this document are periodically reviewed and the necessary or identified corrections
will be included in the following editions. Suggestions for their improvement are welcome.
Warning
For more objectivity and clarity, this manual does not contain all the detailed information on the
product and, in addition, it does not cover every possible mounting, operation or maintenance
cases.
Before installing and utilizing the equipment, check if the model of the acquired equipment complies
with the technical requirements for the application. This checking is the user’s responsibility.
If the user needs more information, or on the event of specific problems not specified or treated in
this manual, the information should be sought from Smar. Furthermore, the user recognizes that the
contents of this manual by no means modify past or present agreements, confirmation or judicial
relationship, in whole or in part.
All of Smar’s obligation result from the purchasing agreement signed between the parties, which
includes the complete and sole valid warranty term. Contractual clauses related to the warranty are
not limited nor extended by virtue of the technical information contained in this manual.
Only qualified personnel are allowed to participate in the activities of mounting, electrical connection,
startup and maintenance of the equipment. Qualified personnel are understood to be the persons
familiar with the mounting, electrical connection, startup and operation of the equipment or othe
r
similar apparatus that are technically fit for their work. Smar provides specific training to instruct and
qualify such professionals. However, each country must comply with the local safety procedures,
legal provisions and regulations for the mounting and operation of electrical installations, as well as
with the laws and regulations on classified areas, such as intrinsic safety, explosion proof, increased
safety and instrumented safety systems, among others.
The user is responsible for the incorrect or inadequate handling of equipments run with pneumati
c
or hydraulic pressure or, still, subject to corrosive, aggressive or combustible products, since thei
r
utilization may cause severe bodily harm and/or material damages.
The field equipment referred to in this manual, when acquired for classified or hazardous areas, has
its certification void when having its parts replaced or interchanged without functional and approval
tests by Smar or any of Smar authorized dealers, which are the competent companies for certifying
that the equipment in its entirety meets the applicable standards and regulations. The same is true
when converting the equipment of a communication protocol to another. In this case, it is necessar
y
sending the equipment to Smar or any of its authorized dealer. Moreover, the certificates are
different and the user is responsible for their correct use.
Always respect the instructions provided in the Manual. Smar is not responsible for any losses
and/or damages resulting from the inadequate use of its equipments. It is the user’s responsibility to
know and apply the safety practices in his country.

TP400 WirelessHARTTM - Operation, Maintenance and Instructions Manual
IV
TABLE OF CONTENTS
SECTION 1 - INSTALLATION.......................................................................................................1.1
GENERAL..................................................................................................................................1.1
INSTALLATION PROCEDURE..................................................................................................1.1
ANTENNA ROTATION...............................................................................................................1.6
HOUSING ROTATION...............................................................................................................1.7
MAINTENANCE PORT ..............................................................................................................1.8
LINEAR ROTARY AND LINEAR MAGNET................................................................................1.9
CENTRALIZER DEVICE OF LINEAR MAGNET........................................................................1.9
REMOTE SENSOR POSITION..................................................................................................1.9
INSTALLATION IN HAZARDOUS AREAS...............................................................................1.11
INTRINSICALLY SAFE ............................................................................................................1.11
SECTION 2 - OPERATION............................................................................................................2.1
FUNCTIONAL DESCRIPTION - POSITION SENSOR...............................................................2.1
FUNCTIONAL DESCRIPTION - ELECTRONICS.......................................................................2.1
LOCAL ADJUSTMENT...............................................................................................................2.3
WRITE PROTECTION ...............................................................................................................2.4
FUNCTIONAL DESCRIPTION - DISPLAY (LCD) ......................................................................2.5
SECTION 3 - MAINTENANCE.......................................................................................................3.1
GENERAL..................................................................................................................................3.1
DIAGNOSTIC WITH DISPLAY...................................................................................................3.1
DISASSEMBLY PROCEDURE ..................................................................................................3.1
ASSEMBLY PROCEDURE ........................................................................................................3.3
TROUBLESHOOTING ...............................................................................................................3.4
EXPLODED VIEW......................................................................................................................3.5
ACCESSORIES AND SPARE PARTS.......................................................................................3.5
RETURNING MATERIALS.........................................................................................................3.7
SECTION 4 - TECHNICAL CHARACTERISTICS.........................................................................4.1
ORDERING CODE.....................................................................................................................4.3
APPENDIX A – SRF – SERVICE REQUEST FORM.................................................................................. A.1
APPEDIX B – BATTERY SAFETY DATASHEET ...................................................................................... B.1

Introduction
V
INTRODUCTION
WirelessHART Technology Overview
The WirelessHART technology is based on a wireless mesh network communication protocol used in
process automation applications. It adds wireless capabilities to the HART protocol, while maintaining
compatibility with existing HART devices, commands and already known and used tools.
WirelessHART network
Basically, a WirelessHART network, defined in the HART specifications, consists of a host, a
WirelessHART Gateway and one or more field devices and/or WirelessHART adapters. Together they
compose a mesh network where the host and devices can communicate.
Host
The host, usually connected to the control network, is a workstation in which, e.g., can be installed a
HumanMachine Interface application,whichallows an operatorto interact withtheprocess. Throughthe
WirelessHART Gateway (DF100), the host can gather data from devices connected to the
WirelessHART network. The host communicates with the WirelessHART Gateway (DF100) using a
communication protocol, for example, HSE, H1, Profibus or Modbus.
WirelessHART Gateway (DF100)
It is a "translator" equipment. Thus it convertsdata fromthehost totheWirelessHART protocol, used by
the devices connected to the WirelessHART network, and converts datafrom thedevices to the host. In
general, the WirelessHART Gateway (DF100) incorporates the features of Network Manager and
Access Point. Roughly, the access point can be understoodas the WirelessHART radio installed at the
gateway to communicate with devices connected to the wireless network.
Security Manager
The Security Manager is an application usually embedded in the WirelessHART Gateway (DF100).
Allowed only one Network Manager in a WirelessHART network, but the same Security Manager can
serve several WirelessHART networks.
Its main function is to create, store and manage security keys (encryption and authentication) for which
the devices have network access and monitor the status of network security.

TP400 WirelessHARTTM - Operation, Maintenance and Instructions Manual
VI
Network Manager
The Network Manager is an application that can be embedded in the WirelessHART Gateway. On a
WirelessHART network is only allowed to have one Network Manager. Among its responsibilities, the
Network Manager distributes network identity (advertisement) publishing its existence, manages and
authenticates the addition (joining) of devices to the network. It also distributes individual securitykeys
(static or rotating) to the devices to ensure secure communication between it and the devices. The
Network Manager assigns communication band to the devices already connected to the network that
requested services to it, as well as manages the routes between the devices on the mesh network.
Specifically about the joining process of a WirelessHART device to the network, the Network Manager
validatesthe NetworkID andthe Join Keyattributes whichare configuredin the WirelessHART Gateway
and WirelessHART devices.
The Network ID identifies a WirelessHART network in unique way. It is an unsigned integer attribute
and must be configured on the WirelessHART Gateway and all WirelessHART devices. Considering a
WirelessHART network installed in a plant, the permitted values for the Network ID ranges from 0 (hex
0x0000) to 32767 (0x7FFF hexadecimal).
The Join Key is a security key used to encrypt joining requests from WirelessHART devices that receive
the advertisement with the Network Id identical to theirs. It may be single or eachWirelessHART device
may be configured with an individual Join Key. In the first case, the WirelessHART Gateway and all
WirelessHART devices must be configured with the same Join Key. In the secondcase, which provides
higher communication security level, (a) must be configured in the WirelessHART Gateway a list with
individual Join Keys, i.e., a key for each WirelessHART device, and (b) you must configure each
WirelessHART device with its individual Join Key. The Join Key is a hexadecimal string of 16 bytes.
There is no restriction to the hexadecimal value of each byte. The table below shows examples of some
join keys.
JOIN KEYS 16-BYTE HEXADECIMAL STRING
00000000000000000000000000000000 0x00, 0x00, 0x00, 0x00, 0x00, 0x00, 0x00, 0x00,
0x00, 0x00, 0x00, 0x00, 0x00, 0x00, 0x00, 0x00
00000000000000000000000000000302 0x00, 0x00, 0x00, 0x00, 0x00, 0x00, 0x00, 0x00,
0x00, 0x00, 0x00, 0x00, 0x00, 0x00, 0x03, 0x02
00000000FFFFFFFF0000000000000000 0x00, 0x00, 0x00, 0x00, 0xFF, 0xFF, 0xFF, 0xFF,
0x00, 0x00, 0x00, 0x00, 0x00, 0x00, 0x00, 0x00
550000000000000000000000000000AA 0x55, 0x00, 0x00, 0x00, 0x00, 0x00, 0x00, 0x00,
0x00, 0x00, 0x00, 0x00, 0x00, 0x00, 0x00, 0xAA
WirelessHART device
The WirelessHART field device is the device that connects to the process, being able to receive and/or
transmit data on the WirelessHART network. It is a WirelessHART router (repeater) by nature, i.e., it is
able to retransmit messages to/from other devices on the WirelessHART network.
WirelessHART Adapter
It is a bridge-type device, because it is able to provide data of HART + 4 to 20mA field device, legacy, to
the host via WirelessHART. The adapter uses HART FSK standard communication, wired, to access
data from HART field devices. And the adapter also uses the WirelessHART communication to provide
data of the field device to the host. The adapter thus enables a HART field device to work on
WirelessHART network.
Planning a WirelessHART network
The planning of a WirelessHART network is a task that is very similar to the activities that currently we
perform with conventional wired devices. Furthermore, due to the simplicity of a mesh WirelessHART
network, is exempt, in general, detailed field surveys, which are usually needed when we plan networks
based on other wireless technologies.
Basically, a WirelessHART network involves planning, design, installation and commissioning phases.
Planning
This phase requires the execution of the following steps:

Introduction
VII
Scope definition
Clearly define the scope of the network. Answer the question: whydo we need the wireless network?To
monitor process variables or to implement a non-critical control? The answer to this question will
facilitate the understanding between the team members responsible for the network and determine one
or more process units in the plant. For each process unit, allocate a gateway with unique and specific
Network ID. Outline the main field devices.
Identify potential sources of interference
Are there radio communications or otherwirelessnetworksinthe plant? What protocols andfrequencies
do they use? Use high power? Although unlikely, given the robustness of the radios used by the
WirelessHART technology, prior knowledge of the answers to these questions may identify potential
sources of interference and to indicate the taking of preventive and/or limiting actions even before
installation. For example, you can select a frequencychannelas unavailable,adding it to theblack list of
frequencies that is under the WirelessHART Network Manager control.
Integration with the host
The gateway connects the WirelessHART field devices to the host system. Plan what devices and what
data are needed. Also, the stations or applications which will process the data have to be clearly
defined. From this set, among the protocols in the system, define which one will be used for integration
with the host and with the existing tools for configuring the devices. After defining the protocol for
integration, the user has to choose the gateway on the market that best meets yourrequirements. Smar
offers the Gateway DF100 that supports Modbus/TCP/HSE.
Project
In the project phase, it is recommended the adoption of the practices below. Although conservative,
these practices ensure robustness and scalability to the network.
oDefine the Network ID that will be used for all devices in the process unit;
oDefine if the Join Key will be common to all devices or individual and dedicated ;
oDefine the policy to be used for the definition of devices (Long) Tags;
oUse a scale drawing of the process unit;
oPlace the gateway in a strategic position in the process unit ;
oPlan networks with at least five devices;
oInstall at least five devices within the gateway coverage area;
oEnsure that 25 % of the devices are within the gateway coverage area;
Gateway coverage area

TP400 WirelessHARTTM - Operation, Maintenance and Instructions Manual
VIII
oReposition the gateway as needed ;
oCheck the coverage area of each device;
oEnsure that each device has three neighbors within its coverage area;
WirelessHART devices vicinity
oPlace the repeaters as needed.
Installation
As mentioned before, WirelessHART devices should be connected to the process and configured the
same way as conventional wired HART devices. Handheld terminalscan be usednormally. Justbe sure
of having it properly uploaded with the latest DD files of the devices. However, it is known that the
WirelessHART devices have characteristics inherent to the technology. Because of this, it is
recommended the adoption of practices mentioned below for positioning the gateway and devices.
oInstall the gateway and the devices so that their antennas are vertical;
oEnsure that the antennas are at 0.5 m minimum distance of large obstacles or surfaces ;
oEnsure that the antennas of gateway and repeaters are 2 m above most obstacles within their
coverage areas;
Gateway and repeater 2m above the obstacles

Introduction
IX
oIf there are high devices, does not exceed 45° viewing angles between them;
Device’s viewing angle
oMake sure that the gateway is integrated to the host system as planned.
Commissioning on Bench
Commissioning consists on testing the device and verifying its configuration data. The TP400
WirelessHART can be commissioned either before or after installation. The commissioning of the
device in bench before its installation using CONF401, HPC401 or any DD-based configurator, e.g.
Smar AssetView, ensures that all transmitters’ components are working properly.
To turn on/off the repeater use the terminal SW1 (ON/OFF), as shown in Figure 1.7.
To connect the handheld to the device, use the communication terminals "CN1 and CN2" on the
terminal block. See Figure 1.7.
Commission the devices and gateway.
WirelessHART devices commissioning
a. Install and power the gateway (DF100)
b. If not specified by the client at time of order, the Network ID and Join Key values of gateway and
devices will be the factory defaultvalues. Note: It isstrongly recommendedthat both bechanged!To
change these parameters install the gateway and all network devices following the steps below.
Once the network is fully operational it will be more practical to change them.
c. The devices configuration must be done individually, starting with thosenearest to the gateway and
further to the most distant so that communication is established correctly.
d. Always install the device with the antenna in thevertical direction.None WirelessHART device must
be located at the highest point of the plant, preventing it to work as possible lightning rod;
e. Turn on the device by the switch at left of the displayand waitfor its connection to the network (this
time can vary from 2 to 20 minutes depending on the network size). The device status on the
network can be verified on display, maintenance port or gateway.

TP400 WirelessHARTTM - Operation, Maintenance and Instructions Manual
X
ATTENTION
If the device was not purchased with the gateway, i.e.thegatewayalreadyhas values ofNetworkID and
Join Key different from the default values, it is necessaryto set these parameters in the device so that it
properly connects to the network: first configure Network ID and then Join Key, restarting the device
after settings.
f. Once these steps are performed for all network devices and theyare connected properly, it is time
to change the values of Network ID and Join Key from factory following the instructions at the end of
step "e" (if not changed yet). Network ID can be any number between 0 and 32767 which identifies
the network among others. Join Keyis a key of 32 hexadecimal characters (0-9 and AF) that works
as a key so the devices can have access to the configured network.
g. Configure the LongTAG parameter that identifies the device on the network.
h. Check if the device engineering units are in accordance with those required by the process.
i. Configure the parameters of the burst mode to publish measurements and status desired:
Burst Message: up to 3 messages with commands and different times can be configured;
Minimum Time : is the time for publication of the variables;
Maximum Time: must be greater than the minimum time and is only used in trigger mode (check
the operation of the trigger mode in the device manual if you want to receive the monitoring
variables only when there is any change on their values);
Command: HART command that sends the variables desired by user (e.g. , the command 3
sends values of PV, SV, TV and QV, when available);
Burst Mode: Once all parameters have been configured, activate Burst mode.
Acquisition based on Burst time parameter that reduces the consumption of the device to
perform only one acquisition immediately before the burst transmission. If this parameter is
disabled, the device will execute an acquisition every two seconds, regardless of the Burst
Minimum Time.
j. After some time negotiating with the gateway, the device will start publishing the configured
command at a minimum time rate configured. The ACK icon is shown on the display (if available)
when the device enters in Burst Mode and the icon F(t) blinks on the moment that the command
burst is sent.
ATTENTION
The Burst mode configurations remain even after the shutdown of the device, i.e., when it is turned on,
the device connects to the network automatically in Burst mode with the same time and command
configured. The higher the refresh rate, the lower the lifetime of the battery and vice versa. Configure a
refresh rate that allows the device to last few years.
k. After the general network configuration, wait a period of about 1 hour for the network starts to
operate 100% optimized.
ATTENTION
There is a battery estimated lifetime parameter that indicates the expected duration in days of the
device. This parameter is recalculated every 60 minutes and its value should only become valid after
two or three hours of operation of the device on the network (time required for consumption
optimization). When this value is near the end, the user will receive a warningin thedevice statusand in
the display (when available). When you replace the Battery Module (Smar code 400-1209) youhave to
configure the replacement via configurator that will restart the counting of the estimated lifetime for the
new module.
ATTENTION
Do not discard the Module of Batteries in regular trash. Use a proper disposal for batteries or chemical
waste.