Wireless Serial Converters for Industrial Automation
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A common problem in many factories is simple to understand but difficult to solve on-site: the PLC, controller, energy meter, weigh indicator, data logger or remote field device has a serial port, but the control room is far away. Pulling a new RS-485 or RS-232 cable may be expensive, unsafe, time-consuming or physically impossible.
This is where wireless serial converters become useful.
Instead of running long serial cables across machines, panels, utilities or shop floors, a wireless serial converter helps transmit RS-232 / RS-422 / RS-485 data over RF, Zigbee or WiFi depending on the model and application.
For buyers, the main question is not only “Which converter is cheaper?” The real question is:
Which wireless serial converter will work reliably with my distance, communication interface, baud rate, power supply, PLC/SCADA system and site environment?
For Radical TechMart buyers comparing ATC-871 / ATC-873 / ATC-875, ATC-3200 and ATC-2000WF, this guide explains how to select the right model for actual industrial use.
What are Wireless Serial Converters?
A wireless serial converter is a communication device that converts wired serial communication such as RS-232, RS-422 or RS-485 into a wireless communication path.
In simple words, it acts like a bridge between a serial device and a wireless network.
For example:
- RS-485 device to RF link
- RS-232 controller to wireless receiver
- RS-485 Modbus meter to SCADA system
- Serial machine data to WiFi network
- PLC serial port to remote HMI or monitoring software
These converters are commonly used when serial communication is required but cable laying is difficult, costly or impractical.
Why Wireless Serial Communication Matters in Actual Plant Conditions
In actual plant conditions, communication problems usually appear during commissioning or maintenance.
A machine may be installed far from the control room. A weighbridge may be located outdoors. A utility meter may be inside a remote panel. A PLC may need to exchange data with another controller across a production area.
If communication wiring is not planned properly, the site team may face:
- Long cable routing delays
- RS-485 signal drop or noise issues
- Extra cable tray and conduit cost
- Difficulty in connecting moving or rotating equipment
- Outdoor cable damage
- Grounding and electrical noise problems
- Downtime during cable replacement
- Weak communication between PLC, SCADA, HMI or data logger
A wireless serial converter can reduce these problems when selected correctly. But wrong selection can create new problems like poor range, unstable data transfer, wrong interface matching or software compatibility issues.
How Wireless Serial Converters Work
A wireless serial converter receives data from a wired serial port such as RS-232, RS-422 or RS-485. It then transmits that data using a wireless medium such as RF, Zigbee or WiFi.
At the receiving end, another converter or network device converts the signal back into a usable serial or network communication format.
A typical communication path may look like this:
PLC / Meter / Controller → RS-485 / RS-232 Port → Wireless Serial Converter → RF / Zigbee / WiFi Link → SCADA / HMI / PC / Remote Device
The important point is that the converter must match:
- The serial interface
- Communication speed
- Wireless technology
- Distance requirement
- Power supply
- Software or network requirement
- Site environment
Types of Wireless Serial Converters in this Category
1. Serial to RF Converter – ATC-871 / ATC-873 / ATC-875
The ATC-871 / ATC-873 / ATC-875 type is suitable when a serial signal needs to be transmitted wirelessly using RF communication. This is useful where the user wants a dedicated wireless serial link instead of depending on factory WiFi.
Technical points to note:
- Interface: RS-232 / RS-422 / RS-485
- Carrier frequency: 433 MHz
- Field interface: Radio frequency
- Channels: Up to 8 channels
- Transmission rate: 1.2 kbps to 38.4 kbps
- Indication LED: Sending data red / receiving data green
- Transmission distance options: 300 m, 500 m, 800 m, 2000 m at 9.6 kbps
- Power supply: 9–24 VDC external adaptor supply
Where it is commonly used:
- Remote RS-485 meter communication
- PLC-to-PLC low-speed serial communication
- Utility monitoring panels
- Machine data transfer where cable routing is difficult
- Outdoor or semi-outdoor equipment communication
- Factory automation points requiring wireless serial link
2. RS-232 / RS-422 / RS-485 to Zigbee Converter – ATC-3200
The ATC-3200 is suitable when a serial device needs to communicate using Zigbee-based wireless transmission. This type is useful for applications where low-power wireless networking and short-to-medium range device communication are required.
Technical points to note:
- Interface: RS-232 / RS-422 / RS-485
- Wireless standard: IEEE 802.15.4 compliant
- Typical receiver sensitivity: 102 dBm
- Transmission rate: Typical throughput rate 250 kbps
- Indication LED: Sending data red / receiving data green
- Wireless band: Globally available 2.4 GHz ISM band
- Power supply: 9–24 VDC external adaptor supply
Where it is commonly used:
- Wireless sensor or controller networking
- Remote data acquisition points
- Automation panels where short-distance wireless communication is preferred
- Machine monitoring systems
- Energy monitoring or utility data collection
- OEM automation projects requiring wireless device communication
3. WiFi to Serial Converter – ATC-2000WF
The ATC-2000WF is suitable when a serial device needs to connect into a WiFi or Ethernet-style network environment. This model is useful when plant data needs to move from a serial device to PC software, virtual COM port software, monitoring systems or network-based applications.
Technical points to note:
- Interface: Compatible with EIA RS-232C and RS-485 standard
- Supported wireless modes: Ad-hoc, infrastructure and pseudo IBSS mode support
- Transmission rate: Auto-negotiating 10/100 Mbps Ethernet
- Software support: Vports software and other virtual serial port software
- Indication LED: Sending data red / receiving data green
- Distance: 1000 feet in open environment
- Power supply: 9–24 VDC external adaptor supply
Where it is commonly used:
- Serial device connection to PC software
- RS-485 device monitoring over WiFi
- Data logging and remote parameter monitoring
- SCADA or HMI network integration
- Utility meter or controller communication
- Retrofit automation where serial cabling is difficult
Quick Comparison: ATC-871 / 873 / 875 vs ATC-3200 vs ATC-2000WF
| Model | Wireless Type | Serial Interface | Best Use Case | Selection Caution |
|---|---|---|---|---|
| ATC-871 / ATC-873 / ATC-875 | RF, 433 MHz | RS-232 / RS-422 / RS-485 | Dedicated wireless serial link over distance | Confirm distance, baud rate and matching receiver setup |
| ATC-3200 | Zigbee, 2.4 GHz ISM | RS-232 / RS-422 / RS-485 | Zigbee-based wireless serial networking | Confirm Zigbee suitability and interference condition |
| ATC-2000WF | WiFi / network-based | RS-232C / RS-485 | Serial device connection to WiFi, PC software or network | Confirm WiFi strength, IP setup and virtual COM software compatibility |
Key Selection Factors for Wireless Serial Converters
1. Serial Interface Type
First confirm whether the field device has:
- RS-232
- RS-422
- RS-485
This is the first selection point. A wrong interface selection means the converter may not communicate with the field device at all.
RS-232 is generally point-to-point. RS-485 is commonly used for multi-drop industrial communication. RS-422 is used in selected full-duplex communication applications.
2. Wireless Technology
Choose the wireless type based on application:
- RF converter: Better for dedicated serial wireless link
- Zigbee converter: Better for low-power device networking
- WiFi converter: Better when serial data needs to connect with network or PC software
Do not select wireless technology only by availability. Select it based on plant layout, communication requirement and system architecture.
3. Distance Requirement
Distance is not only the number written in the specification. Actual distance depends on:
- Line of sight
- Walls and machinery
- Electrical noise
- Antenna position
- Cable and panel location
- Outdoor or indoor environment
- Baud rate and data stability requirement
For example, an open-environment distance will not always be achieved inside a factory full of machines, panels and metal structures.
4. Baud Rate and Data Load
Check the baud rate of the connected device. Some serial devices use 9600 bps, while others may use higher speeds.
If the converter supports the required interface but not the required data speed, communication can become unstable.
5. Power Supply
Most industrial panels commonly use 24 VDC instrumentation power. The models discussed here use 9–24 VDC external adaptor supply, so confirm the available panel power and adaptor requirement before purchase.
6. PLC / SCADA / HMI Compatibility
Before selecting the converter, check:
- Does the PLC communicate on RS-232, RS-485 or RS-422?
- Is the protocol Modbus RTU or another serial protocol?
- Does SCADA need a COM port or IP-based connection?
- Is virtual COM software required?
- Is the system master-slave or peer-to-peer?
Wireless serial conversion should not disturb the protocol structure.
7. Site Environment
Industrial wireless communication can be affected by:
- Metal panels
- Motor drives
- VFD electrical noise
- Welding machines
- Heavy machinery
- Thick walls
- Long distance between buildings
- Outdoor weather exposure
Always check installation conditions before finalizing the model.
Common Applications of Wireless Serial Converters
Wireless serial converters are commonly used in:
- PLC to remote device communication
- SCADA data collection from remote RS-485 devices
- HMI communication with serial controllers
- Wireless utility meter monitoring
- Weighbridge and weighing system communication
- Boiler, compressor and pump room monitoring
- Water treatment plant remote panels
- Packaging and production machine data transfer
- OEM machine communication
- Retrofitting old serial devices into modern monitoring systems
Common Mistakes to Avoid
| Mistake | Why It Creates Problems |
|---|---|
| Selecting only by wireless range | Real factory range may be lower because of walls, panels and machines |
| Ignoring interface type | RS-232, RS-422 and RS-485 are not interchangeable without correct conversion |
| Not checking baud rate | Communication may fail or become unstable |
| Assuming WiFi is always better | WiFi depends on network strength, security and IP configuration |
| Using RF without confirming both-end setup | Wireless link needs proper transmitter-receiver planning |
| Not checking protocol requirement | Converter handles communication path, but protocol compatibility must still be confirmed |
| Ignoring power supply | Wrong supply voltage can delay installation |
| Not checking software support | PC or SCADA software may need virtual COM port support |
Do This, Not That
| Do This | Not This |
|---|---|
| Confirm RS-232 / RS-422 / RS-485 interface before ordering | Assume all serial ports are the same |
| Select RF, Zigbee or WiFi based on actual application | Select only by model number |
| Check baud rate and communication protocol | Focus only on wireless distance |
| Test signal strength at installation location | Assume open-distance range applies inside factory |
| Confirm PLC, HMI, SCADA or PC software compatibility | Install first and troubleshoot later |
| Check power supply availability in panel | Forget adaptor and site wiring requirement |
Quick Selection Checklist
Before selecting a wireless serial converter, confirm these points:
- What is the field interface — RS-232, RS-422 or RS-485?
- What is the communication protocol — Modbus RTU or another serial protocol?
- What baud rate is required?
- What distance is required between devices?
- Is the communication point-to-point or network-based?
- Is RF, Zigbee or WiFi better for the application?
- Is 9–24 VDC power available near the installation point?
- Does the system need virtual COM port software?
- Will the converter connect to PLC, SCADA, HMI, PC or another controller?
- Are there obstacles, electrical noise or metal structures between communication points?
Product Selection Guide
Choose ATC-871 / ATC-873 / ATC-875 when:
- You need serial to RF communication
- Your device uses RS-232 / RS-422 / RS-485
- You need a dedicated wireless serial link
- The application is not dependent on plant WiFi
- Distance and line-of-sight planning can be done properly
This model family is useful for plant-level serial communication where cable laying is difficult and RF transmission is preferred.-
Choose ATC-3200 when:
- You need Zigbee-based wireless communication
- Your system supports RS-232 / RS-422 / RS-485 interface
- You want 2.4 GHz ISM band communication
- The application involves device networking or low-power wireless communication
- The installation can support Zigbee communication conditions
This model makes sense where Zigbee communication fits the automation architecture.
Choose ATC-2000WF when:
- You need WiFi to serial communication
- You want RS-232C / RS-485 devices to communicate through network-based software
- PC monitoring or virtual COM software is required
- Existing network infrastructure is available
- The application needs serial device access over WiFi or Ethernet-style communication
This model is better when the user wants serial data to move into software or network-based monitoring systems.
Specifications to Confirm Before Purchase
Before finalizing any wireless serial converter, confirm:
- Serial interface: RS-232 / RS-422 / RS-485
- Wireless type: RF / Zigbee / WiFi
- Baud rate requirement
- Transmission distance
- Indoor or outdoor installation condition
- Power supply requirement
- Antenna and mounting position
- Protocol compatibility
- PLC / SCADA / HMI compatibility
- Virtual COM software requirement
- Master-slave communication logic
- Site electrical noise condition
- Number of devices in communication network
- Datasheet and wiring diagram
- Availability, pricing and delivery timeline
Specifications may vary depending on model and manufacturer. Please confirm the datasheet before final selection.
Why Buy Wireless Serial Converters from Radical TechMart?
At Radical TechMart, the focus is not only to supply the product, but to help customers select the right communication device for the right application.
For wireless serial converters, proper selection matters because one wrong assumption can create communication failure during commissioning. A purchase team may compare price, but the maintenance and automation team will face the result of wrong selection.
Radical TechMart can support buyers with:
- Wireless serial converter selection
- RS-232 / RS-485 / RS-422 communication product guidance
- PLC, HMI and SCADA communication requirement discussion
- Product availability and pricing support
- Datasheet and technical inquiry support
- Support for OEMs, panel builders, factories and system integrators
Final Thoughts
Wireless serial converters are useful when industrial communication needs to move beyond cable limitations. But they should not be selected casually.
The correct model depends on the interface, wireless method, distance, baud rate, protocol, power supply and control system compatibility.
For a simple RF serial link, ATC-871 / ATC-873 / ATC-875 may be suitable. For Zigbee-based serial networking, ATC-3200 can be considered. For WiFi or network-based serial communication, ATC-2000WF is the better direction.
In industrial applications, the right communication product is not selected only by price or model number. It is selected by understanding the device, the signal, the distance, the environment and the final control requirement.
FAQs
1. What is a wireless serial converter?
A wireless serial converter is a device that converts RS-232, RS-422 or RS-485 serial communication into wireless communication using RF, Zigbee or WiFi.
2. Which wireless serial converter is suitable for RS-485 communication?
It depends on the wireless method required. ATC-871 / ATC-873 / ATC-875 can be used for RF-based serial communication, ATC-3200 for Zigbee-based serial communication, and ATC-2000WF for WiFi to serial communication.
3. Can wireless serial converters connect with PLC and SCADA?
Yes, they can be used with PLC and SCADA systems if the serial interface, baud rate, communication protocol and software configuration are compatible.
4. What is the difference between RF and WiFi serial converters?
RF serial converters are generally used for dedicated wireless serial links. WiFi serial converters are used when serial devices need to connect through WiFi or network-based software.
5. Is ATC-2000WF suitable for virtual COM port applications?
ATC-2000WF supports virtual serial port software, making it suitable for applications where PC software needs to communicate with serial devices over a network.
6. What should be checked before buying a wireless serial converter?
Check serial interface, baud rate, wireless range, protocol, power supply, site environment, PLC/SCADA compatibility and datasheet before purchase.
7. Can wireless serial converters be used for Modbus RTU?
Yes, they can be used for Modbus RTU communication if the converter supports the required serial interface and baud rate, and the wireless link is stable enough for the application.
8. Which is better: RF, Zigbee or WiFi?
There is no single best option. RF is useful for dedicated wireless serial links, Zigbee is useful for device networking, and WiFi is useful when serial data needs to connect with network or PC software.