Express Controls ZWP500 User manual

ZWP500™
Z-Wave Production Programmer & Tester
www.ExpressControls.com
February 2018 Bringing the Internet of Things (IoT) to Life 1
ZWP500™
Z-Wave Production Programmer & Test Platform
•Sigma Designs Z-Wave SoCs/Module Programmer
•FLASH & NVM Programmer
•Production Test Platform
•Firmware Validation Platform
•Programmable in Python or C
•SmartStart enabled with QRCode label printing
•Fully Customizable
•Validation Services Available
Overview
The ZWP500 is a robust and reliable programmer for the
Sigma Designs 500 series of Z-Wave modules. A high-
speed SPI bus interface programs the Z-Wave module in
seconds. The ZWP500 is designed to operate on the
factory production floor with a fanless design and push-
button operation. The Raspberry Pi Linux computer is
augmented with a PSoC5 microcontroller to provide the
most accurate and fastest programming times possible.
A Z-Wave module with a programmable RF attenuator
allows the ZWP500 to fully test the RF parameters of the
target DUT. A 1ppm accurate crystal calibrates every
device for optimal RF performance.
The Python API enables customizable production
programming and testing. Program each NVR with a
unique AES-128 Security S2 DSK pin code or other
custom fields. Set the LOCK bits to prevent unauthorized
access to the firmware. Have your team develop the test
code or let the experts at Express Controls do it for you.
Features
Sigma Designs 500 Series FLASH Programmer
- Standard Sigma 12 pin programming header
oSPI interface for programming
oUART interface for debug
- NVR and external NVM programming & test
- 1ppm Crystal RF Calibration
- SmartStart QRCode generation & printing
- Fanless protective enclosure
Production Test Platform
- Customizable Python interface
- Scanner interface for serial number or DSK
- Label printer interface for DSK
- Camera interface for LCD screen testing
Z-Wave ZM5202 Module onboard
- Programmable RF Attenuator with SMA
Python API
- Customizable Programming API or GUI
- Sample test scripts for production testing
Programmable Power Supply
- +2.0V to +4.5V 300mA
- Resolution 100uV, 100 uAmps
Raspberry Pi based controller
- 1.2GHz Quad ARM CPU running Linux
- 1GB RAM - 8GB FLASH microSD
- Ethernet, WiFi, HDMI and USB connectivity
- Control locally or remotely via VNC
Ordering information:
ZWP500-AU –Programmer/Tester (908Mhz US)
ZWP500-AE –Programmer/Tester (868Mhz EU)
ZWP500-AH –Programmer/Tester (921Mhz ANZ)
ZWP500-DV –DevKit Interface Board
ZWP500-SVC - ZWP500 Services & Customization
VIO
PC
ENET
SPI
TIMING
ENGINE
ARM
CPU
UART
2.0V-4.5V
PSoC5
ZWP500
RASPBERRY Pi3
ENET Quad ARM A7
1GB /8GB MEMORY
Raspian LINUX
ZM5x0x
SPI
UART
Atten SMA

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Z-Wave Production Programmer & Tester
www.ExpressControls.com
February 2018 Bringing the Internet of Things (IoT) to Life 2
Table of Contents
Overview .................................................................................................................................................................................5
Quick Start Guide....................................................................................................................................................................5
Typical ZWP500 Setup ...........................................................................................................................................................6
SmartStart QRCode Label Printer.......................................................................................................................................6
Hardware Connections............................................................................................................................................................7
Z-Wave Programming Cable...............................................................................................................................................7
Z-Wave Antenna..................................................................................................................................................................7
Sigma DevKit Interface Board –ZWP500-DV ........................................................................................................................7
Raspberry Pi............................................................................................................................................................................9
PSoC PlugIn Board ...........................................................................................................................................................10
Serial Port..........................................................................................................................................................................10
USB Ports..........................................................................................................................................................................10
HDMI Port..........................................................................................................................................................................10
Ethernet Port......................................................................................................................................................................10
WiFi Access.......................................................................................................................................................................10
Desktop Sharing with VNC................................................................................................................................................10
Source Code Control of Scripts.........................................................................................................................................10
Sigma 500 Series RF Calibration..........................................................................................................................................11
Tx Calibration.....................................................................................................................................................................11
Crystal Calibration .............................................................................................................................................................11
Programming.........................................................................................................................................................................11
Non-Volatile Register (NVR) Fields...................................................................................................................................11
Override Value !.............................................................................................................................................................12
Incrementing Value +.....................................................................................................................................................12
Check Value ?................................................................................................................................................................12
Random Value # ............................................................................................................................................................12
Scanner Value $ ............................................................................................................................................................12
Sigma Security S2 DSK.................................................................................................................................................12
Lock Bits.........................................................................................................................................................................13
Example [nvr] Section....................................................................................................................................................13
Non-volatile Memory (NVM)..............................................................................................................................................13
VIO Voltage & Current.......................................................................................................................................................13
FLASH File Preparation.....................................................................................................................................................13
CRC32 Calculation ........................................................................................................................................................13
Programmer Example Python Application.........................................................................................................................14
Product Validation.................................................................................................................................................................14

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Z-Wave Production Programmer & Tester
www.ExpressControls.com
February 2018 Bringing the Internet of Things (IoT) to Life 3
Product Validation Example Python Application ...............................................................................................................14
Production Testing ................................................................................................................................................................14
Production Testing Example Python Application...............................................................................................................14
Manufacturing Data Logging .............................................................................................................................................14
ZWP500 Interface .................................................................................................................................................................14
PSoC Commands..............................................................................................................................................................14
AcquireDUT ...................................................................................................................................................................15
Calibrate.........................................................................................................................................................................15
FirmwareUpdate ............................................................................................................................................................15
FlashDownload ..............................................................................................................................................................16
FlashErase.....................................................................................................................................................................16
FlashWrite......................................................................................................................................................................16
FlashRead 0xxxxx:0yyyyy..............................................................................................................................................17
FlashVerify.....................................................................................................................................................................17
FlashCRC.......................................................................................................................................................................17
GPIOGet ........................................................................................................................................................................17
GPIOSet PS...................................................................................................................................................................17
Help................................................................................................................................................................................18
I2CGet AA LL.................................................................................................................................................................18
I2CProbe........................................................................................................................................................................18
I2CSend AA DD…[p] .....................................................................................................................................................18
LEDSet RGB..................................................................................................................................................................19
NVMGet SSSSSS:EEEEEE ..........................................................................................................................................19
NVMSet AAAAAA=DD...................................................................................................................................................19
NVRGet..........................................................................................................................................................................20
NVRSet AA=DD.............................................................................................................................................................20
ResetDUT [0] .................................................................................................................................................................21
RFAttenuatorSet DD......................................................................................................................................................21
UARTGet........................................................................................................................................................................21
UARTInit BB...................................................................................................................................................................21
UARTSend DD… ...........................................................................................................................................................22
VIOSet............................................................................................................................................................................22
VIOGet...........................................................................................................................................................................22
ZWaveGet [TT] ..............................................................................................................................................................22
ZWaveSend DD… .........................................................................................................................................................22
Troubleshooting ....................................................................................................................................................................23
Firmware Update...................................................................................................................................................................23
Terminal Window Settings with PuTTY.................................................................................................................................23
Python sample application....................................................................................................................................................24

ZWP500™
Z-Wave Production Programmer & Tester
www.ExpressControls.com
February 2018 Bringing the Internet of Things (IoT) to Life 4
References............................................................................................................................................................................24
Warrantee & Copyright..........................................................................................................................................................24
Document History..................................................................................................................................................................25

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www.ExpressControls.com
February 2018 Bringing the Internet of Things (IoT) to Life 5
Overview
The ZWP500 is a production programmer for Z-Wave 500 series wireless RF modules. The ZWP500 programs Z-Wave
modules at their maximum programming speed bringing the typical programming time down under four seconds
compared to nearly 30 seconds with competing products. RF calibration is performed using the high accuracy 1ppm on-
board crystal. A fanless enclosure means the ZWP500 can be deployed on the factory floor without special packaging or
custom enclosures. The ZWP500 is a complete, high speed, robust production platform that can be customized to exactly
meet your requirements. Customization services are available from Express Controls team of experts.
In addition to being a fast production programmer, the ZWP500 is an ideal platform for testing Z-Wave devices. Product
testing on the factory floor to ensure every device is free of manufacturing defects requires an accurate, fast and robust
system. The ZWP500 utilizes the Linux based Raspberry Pi model 3 Quad Arm A7 processor which is then augmented
with the precise timing generators of a Cypress PSoC microcontroller and the RF capabilities of the on-board Z-Wave
module. A programmable power supply with current measurement capabilities enables rapid testing that the Device-
Under-Test (DUT) is free from gross production failures like power to ground shorts or missing power components. Either
Python or C programming languages can be used to develop a customized test program to fully verify every electronic
component of the DUT. Express Controls can write the test program for you or your team can develop it using the sample
code provided with the ZWP500 as a guide.
The ZWP500 is can be used for software validation to verify there are no bugs in each release of firmware. The full
power of high level programming languages like Python or C can be used to test every button press and Z-Wave
command class with each firmware revision. Push buttons can be activated with millisecond precision, DACs can
generate specific voltages or waveforms to trigger specific conditions, the power supply voltage can be varied to trigger
low-battery conditions as well as measure current to ensure the DUT battery lifetime will meet your specification. LCD
screens can be checked against reference images to verify every screen reacts properly to every button press. The power
of the RPi3 is completely at your disposal using the most advanced programming languages to fully test every aspect of
your product with every release.
Quick Start Guide
Unpack the ZWP500 which consists of the
following items:
1. ZWP500
2. Power Supply
The optional ZWP500-DV DevKit interface board
(shown here) is recommended for initial debug
and project development.
The following item must be supplied by you to
make a complete system:
1. Generic USB keyboard and mouse
2. Monitor with at least 1280x1024 resolution
and HDMI cable
3. Optional but recommended:
a. Sigma Designs Developers Board
ACC-ZDB5202-U2 (choose the one for your region)
Connect the ZWP500 to the keyboard, mouse and monitor. Connect the ribbon cable to the ZWP500-DV sample
developer kit interface board and plug the developer kit board into the interface board as shown. The developers kit board
is optional but is a good learning tool on how to use the ZWP500.
Connect the power supply into the ZWP500 and plug the power supply in. The ZWP500 should go thru the normal Linux
boot sequence and finally arrive at the ZWP500 desktop.

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February 2018 Bringing the Internet of Things (IoT) to Life 6
The icons on the left side of the
screen may be different.
Double click on the UserManual
icon to open the ZWP500 user
manual.
It is recommended to ALWAYS
double click on the SHUTDOWN
icon BEFORE powering the
ZWP500 off. This will cleanly
shut the file system down and
avoid corrupting the SD card of
the Raspberry Pi.
The PSOC icon opens a PuTTY
terminal window to communicate
directly with the PSoC. This can
be used to debug your own test
programs but is not used in normal operating modes.
Connect a Sigma Designs Development Board (not included) to the included DevKit interface board on J1. Click on the
SensorPIR icon and then press “?<enter>” to get a list of commands that can be run. See the Sigma DevKit Interface
section for more details.
Typical ZWP500 Setup
The ZWP500 does not come with all the items
required to build a complete programming and test
station. The ZWP500 is a complete Linux based
computer with a graphical user interface. Thus, a
keyboard, mouse and monitor are needed. The
RPi3 has an HDMI connector which is typically
connected to an inexpensive HDMI capable
monitor with at least 1280x800 resolution.
1910x1080p resolution is recommended. Any
generic keyboard and mouse will typically work.
They can be either wired for maximum reliability or
wireless for maximum flexibility.
A custom designed test jig is typically used to
connect to the ZWP500 and provide reliable and
easy connection to the DUT. Spring loaded pogo
posts are typically used to connect the 500 series
SPI bus to the ZWP500. Additional pins can
provide other capabilities to push button or
measure voltages. A 3D printed jig and clamp holds the DUT securely during programming and test.
SmartStart QRCode Label Printer
The ZWP500 has the ability to generate the required SmartStart QR Code labels for both the device and the package.
The QRCode requires customization to fit on the desired label but the sample SensorPIR project can be used as a guide.
Since each label is unique, the label MUST be immediately applied to the DUT to ensure the label matches values stored
within the DUT. Many types of printers are supported by the RPi including the popular Zebra printers. The Zebra GX430t

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Z-Wave Production Programmer & Tester
www.ExpressControls.com
February 2018 Bringing the Internet of Things (IoT) to Life 7
is recommended as it provides 300dpi resolution and yields a good quality image in permanent ink. The printer is plugged
into the USB port of the RPi and can be configured by using the browser to connect to the URL: localhost:631. More
information on working with printers can found on the Raspberry Pi or Linux web sites.
Hardware Connections
The ZWP500 uses the standard 12 pin Sigma Designs programming header. The Sigma ZDP03A has only a 10 pin
header and excludes the two UART pins but is otherwise pin compatible. Pins 2 and 5 are usually a no-connect on other
programmers but the ZWP500 uses these pins to connect to a DUT board with I2C GPIO expanders or other I2C devices
to enable complete control and measurement of the DUT. The cable should be less than 6 inches in length to ensure
reliable signal quality.
Z-Wave Programming Cable
Z-Wave Programming Cable - TOP view
VIO
1
2
I2C_SCL
NVM_CS_N
3
4
MOSI
I2C_SDA
5
6
MISO
GND
7
8
SCK
GND
9
10
RESET_N
RXD
11
12
TXD
Pin #
Signal Name
Description
1
VIO
Power for the DUT - programmable voltage from 2.0 to 4.5V at up to 300mA
2
I2C_SCL
Optional I2C SCL signal for controlling GPIO expanders/ADC/DACs on DUT test board
3
NVM_CS_N
Optional Chip Select signal to the Z-Wave module external NVM
4
MOSI
SPI MOSI signal
5
I2C_SDA
Optional I2C SDA signal
6
MISO
SPI MISO signal
7
GND
Ground (Vss) 0.0V
8
SCK
SPI Clock signal
9
GND
Ground (Vss) 0.0V
10
RESET_N
RESET_N pin of the Z-Wave module
11
RXD
Optional UART Receive Data (connect to the TXD of the Z-Wave module)
12
TXD
Optional UART Transmit Data (connect to RXD)
Z-Wave Antenna
An SMA connector on the side of the ZWP500 is typically connected to a 900MHz antenna to communicate with the DUT
over the Z-Wave radio. The SMA connector may be cabled to an RF shielded enclosure to limit the RF interference with
adjacent test stations or other Z-Wave networks.
Sigma DevKit Interface Board – ZWP500-DV

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Z-Wave Production Programmer & Tester
www.ExpressControls.com
February 2018 Bringing the Internet of Things (IoT) to Life 8
An interface board (ZWP500-DV DevKit) from the ZWP500 to
the Sigma ZDB5202 Developer Board is optional but highly
recommended for initial project development. Note that the
Sigma Developer Board is NOT included and must be
purchased separately (click on the links to purchase from
Digikey). The ZWP500-DV can be used to prototype the
programming and test environment of your product before the
hardware exists. The board can also be used as an example of
how to program and test a Z-Wave 500 series product using the
ZWP500. The SensorPIR project from the Sigma SDK is pre-
loaded on the ZWP500 and an icon to program and test it is on
the Desktop. Double click on the SensorPIR icon and a terminal
window comes up. Press “?<enter>” to get a list of commands
available by the programming and test program. The program is
written in Python and is in the /home/pi/examples/SensorPIR_test.py. Use the sample program to develop a customized
program/test suite or contract Express Controls to do it for you.
TBD –NOTE: Rev A ONLY supports the ZDB5202 Sigma Developer Board!!! The board is being updated to also support
the ZDB5101 and will be available soon.
Schematics for the ZWP500-DV DevKit board:

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February 2018 Bringing the Internet of Things (IoT) to Life 9
The DevKit board has two I2C GPIO expanders (PCAL9535A) at I2C address 20 and 21. These can be controlled using
the ZWP500 commands I2CSend and I2CGet. See the sample SensorPIR.py Python code for an example.
The PCAL chip command structure is the I2C Slave address, then a command byte which is a register address, then
optionally another data byte or two or perform an I2C read. See the PCAL9535A data sheet for more details.
•Command Byte definition:
•0x00 read port 0
•0x01 read port 1
•0x02 set the output value for port 0
•0x03 set the output value for port 1
•0x06 set the configuration for port 0, a 1 sets the pin to an input, 0 is an output
•0x07 set the configuration for port 1, a 1 sets the pin to an input, 0 is an output
Raspberry Pi
The brains of the ZWP500 are provided using the popular Raspberry Pi (RPi) embedded Linux computer. A plug-in board
is added to the RPi to provide high speed programming and measurement of the DUT. The RPi is a complete Linux
computer running the Raspian branch of the open source Linux operating system. A monitor and keyboard are typically

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February 2018 Bringing the Internet of Things (IoT) to Life 10
connected to the ZWP500 for full computer access (not included with the ZWP500). Most generic monitors with an HDMI
connection will work. Most generic wired or wireless USB keyboard and mouse will work with the RPi.
PSoC PlugIn Board
The RPi is augmented with a plug-in board that contains a Cypress PSoC System-On-Chip microprocessor. This
dedicated processor and its programmable hardware resources are used to program the DUT at the maximum speeds.
The PlugIn board also contains a ZM5202 Z-Wave chip and RF attenuators to enable complete testing of the DUT for
both functionality and RF performance. This board is integrated within the ZWP500 enclosure and should not be removed
or otherwise modified.
Serial Port
The PSoC PlugIn board is connected to the RPi via the 40 pin header on the RPi. The serial port on the header is the
primary communication method. The serial port /dev/ttyAMA0 operates at 921600 baud with 8 bits of data and 1 stop bit.
The UART connection is via the RPi expansion header on pins 8 and 10. The Raspberry Pi3 default has the “mini UART”
connected to the GPIOs and /dev/ttyAMA0 is connected to the on-board Bluetooth chip. The RPi has been configured to
swap the UARTs so that the /dev/ttyAMA0 UART is connected to the GPIOs (and thus the PSoC) and the mini UART is
connected to the Bluetooth chip which is normally not used but is still available.
USB Ports
Four USB 2.0 Type A connectors are present on the ZWP500. These USB ports support most generic USB devices like
keyboards, mouse, and memory sticks. The bar-code scanner and the label printer can be connected directly to these
USB ports.
HDMI Port
An HDMI port on the ZWP500 should be connected to a monitor to enable the user to interface with the software on the
ZWP500. The recommended resolution is 1280x1024 which is the default setting. The RPi supports many other
resolutions and most monitors will work. See the Raspberrypi.org site for details on configuring other resolutions.
Ethernet Port
An Ethernet RJ45 jack on the ZWP500 should be connected to a LAN which has access to the Internet. The ZWP500
requires a network connection to the internet to set the local time and date. Either a wired network connection or WiFi can
be used.
WiFi Access
The RPi3 has WiFi integrated onto the RPi3 board. WiFi can be configured using the network icon in the upper right
corner of the screen. See the Raspberrypi.org site for more details on configuring WiFi.
Desktop Sharing with VNC
The ZWP500 is configured with VNC for remote desktop access. Most VNC desktop applications will connect to the
ZWP500. The recommended application is TightVNC available from tightnvc.com. A password is required to log into the
ZWP500 with is “ExpressControls” (note the capitalization).
Source Code Control of Scripts
A common request is how and where to store the project specific custom coded scripts and how to deploy them across
multiple ZWP500 systems. The solution is to use git which is pre-installed on the RPi3. While any git server will work,
Express Controls recommends using BitBucket which provides a simple and free repository for small projects. Once the
account and a repository are created on BitBucket, you “clone” the repository onto the ZWP500. The table below gives a
few of the most commonly use git commands. See the online documentation of git for more details. Open a terminal