ICP DAS USA ZT-257 Series User manual

ZT-257x DIO Data Concentrator
Quick Start Guide
Warranty
All products manufactured by ICP DAS are under warranty regarding
defective materials for a period of one year, beginning from the date of
delivery to the original purchaser.
Warning
ICP DAS assumes no liability for any damage resulting from the use of
this product. ICP DAS reserves the right to change this user manual at
any time without notice. The information furnished by ICP DAS is
believed to be accurate and reliable. However, no responsibility is
assumed by ICP DAS for its use, nor for any infringements of patents or
other rights of third parties resulting from its use.
Copyright
Copyright © 2016 by ICP DAS. All rights are reserved.
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Names are used for identification purposes only and may be registered
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Technology Support
If you have any problems, please feel free to contact us via
email at [email protected]m

Table of Contents
1Introduction to the ZigBee DIO Data Concentrator.................... 1
2Parameters ...................................................................................... 4
2.1 An Overview of the Configuration Procedure..................................................4
2.2 Basic Configuration .....................................................................................................5
3ZT Series Module Settings............................................................ 12
3.1 Configuring the ZT-20xx-IOG Module ............................................................. 13
3.1.1. Connecting to the ZT-20xx-IOG Module (RUN).......................................... 15
3.1.2. Connecting to the ZT-20xx-IOG Module (INIT)........................................... 17
3.1.3. Hardware Settings for the ZT-20xx-IOG Module........................................ 19
3.1.4. Software Settings for the ZT-20xx-IOG Module.......................................... 23
3.2 Configuring the ZT-257x Module....................................................................... 25
4Technical Support ......................................................................... 28
5Appendix........................................................................................ 29
5.1 Advanced functions: DIO Channel Offset........................................................ 29
5.2 Advanced functions: Status Detection Schemes in Wireless
Environments ............................................................................................................. 33
5.2.1. The Check-Router-Alive function ....................................................................... 33
5.2.2. The Safe Value function.......................................................................................... 36
5.3 Modbus Register........................................................................................................ 39
5.3.1. 01 (0x01) Read Coils ................................................................................................ 39
5.3.2. 02 (0x02) Read Discrete Inputs ........................................................................... 41
5.3.3. 05 (0x05) Write Single Coil ................................................................................... 43
5.3.4. 15 (0x0F) Write Multiple Coils ............................................................................. 45
5.4 LED Status Indicator Definitions.......................................................................... 47

ICP DAS, ZT-257x DIO Data Concentrator Quick Start Guide, v1.0 Page 1
Copyright © 2016, by ICP DAS Co., LTD. All Rights Reserved
1Introduction to the ZigBee DIO Data
Concentrator
Overview of the Functions
ZT-257x series modules contain a built-in ZigBee DIO data concentrator function. This function
can be used to automatically retrieve the status of a remote DIO channel via a ZigBee wireless
network, and then temporarily save the data to the corresponding Modbus register. After the
data has been stored, it means that the remote PAC is able to read the data once, and then,
using the Modbus protocol, write the data to multiple DIO channels on remote ZigBee
modules connected to the ZT-257x module via the Ethernet, RS-232, or RS-485 interface.
The ZigBee DIO data concentrator function can be used to easily establish communication
between a Zigbee wireless network and the Ethernet, meaning that the distributed DIO data
can be integrated, allowing a remote monitoring system to be quickly implemented.
The ZigBee DIO data concentrator supports a maximum of 280 digital channels and a
maximum of 32 ZT-2000-IOG series modules. Using the ZigBee DIO data concentrator allows
the architecture of a system to be simplified, while simultaneously expanding system flexibility
and reducing the traffic load on an Ethernet and ZigBee wireless network, thereby improving
system performance.
I/O Exchange via the ZT-IOG ZigBee Network
ZT-2055-IOG
(8 DI + 8
DO)
ZT-2060-IOG
(6 DI + 4
DO)
ZT-2053-IOG
(14 DI)
ZT-2043-IOG
(14 DO)
ZT-2570 / ZT-2571
(280 CH Digital I/O Concentrator)
MODBUS RTU
MODBUS TCP
RS-232/RS-485
Ethernet

ICP DAS, ZT-257x DIO Data Concentrator Quick Start Guide, v1.0 Page 2
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Overview of the ZT-257x Series
The ZT-2570 and ZT-2571 series modules are small-sized wireless ZigBee converters based on
the IEEE802.15.4 standard that allow devices based on the RS-232, RS-485 and Ethernet
interfaces to be integrated into a personal area ZigBee network. In addition, the transmission
frequency can be adjusted in the range from 2405 MHz to 2480 MHz, separated into 5 MHz
sectors, providing 16 channels and 16384 PAN IDs (i.e., Pan ID, 0x0000 to 0x3FFF).
The ZT ZigBee series of products conform to the ZigBee 2007 (ZigBee Pro) specifications
developed by the ZigBee Alliance for a suite of high-level communication protocols using
small, low-power digital radio modules. Only one ZigBee Host, e.g., a ZT-2570 module, can be
used in a single ZigBee network. This module is known as the “ZigBee Coordinator”, and is
used to manage the network initialization and routing. In addition, up to 255 ZigBee Slave
devices can be used in a single ZigBee network. Each of these devices is defined as a “ZigBee
Router”, and can be used to receive or forward data to or from a nearby node.
Further information related to the ZT-2570 (Host, ZigBee Coordinator) and the ZT-2571 (Slave,
ZigBee Router) series of converters can be found at:
http://www.icpdas.com/root/product/solutions/industrial_wireless_communication/
wireless_solutions/zt-2570.html

ICP DAS, ZT-257x DIO Data Concentrator Quick Start Guide, v1.0 Page 3
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Overview of the ZT-2000-IOG Series
The ZT-2000-IOG series is a range of active wireless I/O modules developed by ICP DAS that
can be configured to operate as either a ZigBee Coordinator or a ZigBee Router by adjusting
the DIP/Rotary switch, while also being able to automatically provide updates related to the
status of the I/O channels. In addition, ICP DAS also provides a user-friendly GUI configuration
utility that allows users to perform advanced functions designed to meet the various needs of
customized applications.
More information related to the ZT-20xx-IOG series of I/O modules (ZigBee Coordinator/
Router) can be found at:
http://www.icpdas.com/root/product/solutions/industrial_wireless_communication/
wireless_solutions/wireless_selection.html#e
Documents providing more details about these devices can be downloaded from:
http://ftp.icpdas.com/pub/cd/usbcd/napdos/zigbee/zt_series/document/

ICP DAS, ZT-257x DIO Data Concentrator Quick Start Guide, v1.0 Page 4
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2Parameters
2.1 An Overview of the Configuration Procedure
When using the ZT-257x module as a ZigBee DIO data concentrator, the following
configuration procedure should be performed:
①Create a ZigBee wireless connection between the ZT-257x module and a remote
ZT-20xx-IOG module. See Section 2.2 –(1) to (5) for more details.
②Specify the method to determine the conditions for how the status of the DIO channels
will be updated. See Section 2.2 –(6) to (7) for more details.
③Specify the protection mechanism that should be activated if the ZigBee wireless
communication is interrupted. See Section 2.2 –(8) to (9) for more details. Note that this
function is not essential to be enabled, but could be especially useful as it helps to
protect the module should an error occur or if communication is lost.
④Set the mapping between the DIO channels (ZT-20xx-IOG) and the Modbus register(s).
See Section 2.2 –(10) to (11) for more details.

ICP DAS, ZT-257x DIO Data Concentrator Quick Start Guide, v1.0 Page 5
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2.2 Basic Configuration
The main parameters used to perform the configuration procedure for the ZT-20xx-IOG and
ZT-257x modules described in Section 2.1 are listed below. For more information related to
each parameter, refer to the Sections indicated.
Configuration Parameters
Details
ZT-20xx-IOG
ZT-257x
Pan ID
➀
Section 2.2-(1)
Section 3.1.4
Section 3.2
Node ID
Section 2.2-(2)
Section 3.1.3 (DIP Switch 4-8)
Encryption
Section 2.2-(3)
Section 3.1.3 (DIP Switch 3)
RF Channel
Section 2.2-(4)
Section 3.1.3 (Rotary Switch)
RF Power
Section 2.2-(5)
Section 3.1.4
Trigger Mode
➁
Section 2.2-(6)
Section 3.1.3 (DIP Switch 2)
Refresh Interval
Section 2.2-(7)
Section 3.1.4
Check-Router-Alive
➂
Section 2.2-(8)
Section 3.1.4
Safe Value
Section 2.2-(9)
Section 3.1.4
Channel Offset (DI/DO)
➃
Section 2.2-(10)
Section 3.1.4
Modbus Slave ID
Section 2.2-(11)
N/A
1. Pan ID: (Overview)
-This parameter is used to configure the Pan ID, which is the group ID for the ZigBee
network, and must be the same for all modules that exist in the same ZigBee
network. The valid value range is from 0x0000 to 0x3FFF.
-The factory default Pan ID for a ZT-20xx-IOG module is 0x0000, but will be set to
0x3FFFF when operating in INIT mode.
-Normally, ZigBee network groups can be separated by adjusting the RF Channel
without setting the Pan ID. See the RF Channel section (4) below for more details.

ICP DAS, ZT-257x DIO Data Concentrator Quick Start Guide, v1.0 Page 6
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2. Node ID: (Overview)
-This parameter is used to configure the Node ID, which is the identification number
for the module, and must be unique within a single ZigBee network.
-The Node ID for the ZigBee Coordinator is fixed to 0x0000, whereas the Node
ID for ZigBee Router can be configured in the range from 0x0001 to 0xFFF7.
-Up to 32 Node IDs can be configured for a ZT-20xx-IOG module in the range from
0x0000 to 0x001F. However, if the module is set to INIT mode, the Node ID will be
set to 0x0020.
-One of the devices in a single ZT-IOG network must be assigned as the ZigBee
Coordinator (0x0000), and must be always powered on or else the IOG system will
not function correctly.
3. Encryption: (Overview)
-This parameter is used to switch support for the AES 128-bit encryption algorithm
either ON or OFF.
-When using the ZT-20xx-IOG module, this function can be set using the rotary
switch. When using the ZT-257x module, this function can be configured using
software.
-When using the ZT-20xx-IOG module as a ZigBee Router, data encryption function
will passively be performed.
4. RF Channel: (Overview)
-This parameter is used to configure the radio-frequency channel, and all modules
must be set to the same frequency if they are connected to the same ZigBee
network, as indicated in the following table.
Channel
0x00
0x01
0x02
……
0x0E
0x0F
Frequency (MHz)
2405
2410
2415
……
2475
2480

ICP DAS, ZT-257x DIO Data Concentrator Quick Start Guide, v1.0 Page 7
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Determining which Wi-Fi channels are available:
Use a Smartphone (or PC) App such as Wi-Fi Analyzer to analyze the wireless
network environment, scan which WLAN frequency bands (e.g., Wi-Fi) are being
used for the Wi-Fi channels in the local vicinity. For example:
As illustrated in the screenshot from Wi-Fi Analyzer below, several Wi-Fi signals
are being used for specific Wi-Fi channels (i.e., channels 1, 6, and 11).
Determining which ZigBee channels do not overlap with the available Wi-Fi
channels:
By referring to the corresponding Wi-Fi and ZigBee channel table below, based on
the IEEE802.15.4 standard, the ZigBee transmission frequency can be adjusted in the
range from 2405 MHz to 2480 MHz, separated into 5 MHz sectors, providing 16
channels. In the table below, it can be determined that ZigBee channels 4, 9, E, and F
and Wi-Fi channels 1, 6, and 11 do not overlap. In this case, RF channels 4, 9, E, and
F can be selected.

ICP DAS, ZT-257x DIO Data Concentrator Quick Start Guide, v1.0 Page 8
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‧Comparison between RF Channel frequencies and ZigBee (802.15.4)
and WLAN (IEEE 802.11b/IEEE 802.11g) bands





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5. RF Power: (Overview)
-This parameter is used to configure the strength of the radio frequency signal, as
indicated in the following table.
Code (Hex.)
Description
0x0F
Typical maximum output
0x08
Meets CE/FCC certification
0x00
Typical minimum output
※Be aware that any adjustment of this parameter is based purely on individual
circumstances. ICP DAS cannot guarantee that the CE/FCC certification will be
applicable if this parameter is adjusted, nor does ICP DAS assume any liability
derived from the illegal adjustment of this parameter.
6. Trigger Mode: (Overview)
-This parameter is used to modify the trigger type and logic for the DIO channels,
including both the Level and the Pulse trigger modes.
-Refer to the user manual for the ZT-20xx-IOG module for more details. Select the
Level Mode option when using the ZigBee DIO data concentrator function.
7. Refresh Interval: (Overview)
-This parameter is used to modify the time interval between I/O channel updates (in
seconds).
-When the DIO state changes from Low to High, one time unit is required for the
updated data to be synchronized.
-When the DIO state changes from High to Low, two time units are required for the
updated data to be synchronized.

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8. Check-Router-Alive: (Overview)
-This parameter is used to monitor the status of the connection so that the wireless
module can determine whether the module is connected or disconnected. See
Section 5.2 Advanced functions: Status Detection Schemes in Wireless Environments
for more details.
-This parameter is only applicable to the ZT-2570 (Host, ZigBee Coordinator) module,
or when a ZT-20xx-IOG series module is acting as the ZigBee Coordinator (i.e., when
the Node ID = 0x0000).
9. Safe Value: (Overview)
-This parameter is used to configure the Safe value for a DO channel. If a module is
disconnected for the specified time, the status of the DO channel will be set to the
Safe value. See Section 5.2 Advanced functions: Status Detection Schemes in
Wireless Environments for more details.
-This parameter is only applicable to the ZT-2571 (Slave, ZigBee Router) module, or
when a ZT-20xx-IOG series module is acting as the ZigBee Router.
See item 2. Node ID above for more details.
10. Channel Offset (DI/DO): (Overview)
-This parameter is used to configure the I/O mapping between the DIO channels on
a ZT-20xx-IOG module and the Modbus register on the ZT-257x module. See
Section 5.1 Advanced functions: DIO Channel Offset for more details.
-This parameter is only applicable to ZT-20xx-IOG series modules.

ICP DAS, ZT-257x DIO Data Concentrator Quick Start Guide, v1.0 Page 11
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11. Modbus Slave ID: (Overview)
-This parameter is used to configure the Modbus Slave ID for a ZT-257x module.
When using a ZT-257x module as a ZigBee DIO data concentrator, the module
allows the external host (or controller) to read data from or write data to the
ZT-20xx-IOG DIO module using the Modbus protocol. Consequently, a Modbus ID
must be assigned to the ZT-257x module.

ICP DAS, ZT-257x DIO Data Concentrator Quick Start Guide, v1.0 Page 12
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3ZT Series Module Settings
When using the ZT-257x module as a data concentrator, the first task that must be
performed is to establish a ZigBee network between the ZT-257x module and the remote
ZT-20xx-IOG module so that the physical DIO channel data can be automatically and
correctly sent to the Modbus Register on the ZT-257x module. For more details about
configuring the ZT-257x module, follow the instructions below.
Establish a ZigBee
connection
Configure the ZT-2570 (1)
and the ZT-20xx-IOG (INIT)
Connect to a ZT-20xx-IOG
Configure the ZT-20xx-IOG
(via the ZT-2570)
Configure the ZT-2570 (2)
and the ZT-20xx-IOG (RUN)
Create a connection to the
ZT-20xx-IOG
Establish a ZigBee
connection
Configure the ZT-2570
first
Establish a ZigBee
connection
Using for the first time
Connect to a ZT-20xx-IOG
Configure the
ZT-20xx-IOG (RUN)
(via the ZT-2570)
For maintenance
(ZT-20xx-IOG: Online)
Configure the
ZT-20xx-IOG (RUN)
(via the ZT-2570)
For maintenance
(ZT-20xx-IOG: Offline)
The data concentrator and
the IOG begin working
Section 3.1.2
Section 3.1.1
Section 3.1.1
Section 3.1.1
Section 3.2

ICP DAS, ZT-257x DIO Data Concentrator Quick Start Guide, v1.0 Page 13
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3.1 Configuring the ZT-20xx-IOG Module
Establishing ZigBee Wireless Communication
As the ZT-20xx-IOG module has no physical communication port, a ZigBee wireless
connection needs to be established using the ZigBee convertor (e.g., ZT-2570, ZT-2550, or
ZT-USBC) in order to configure the ZT-IOG module via wireless communications.
There are three main parameters that need to be configured are shown below.
Parameters
ZT-20xx-IOG
ZT-2550/
ZT-2570
ZT-USBC
Value
(1) Pan ID
Set via software
Set via software
Set to the same value
(2) Node ID
Set via DIP Switch
Set via software
Set to a unique value
(3) RF Channel
Set via Rotary Switch
Set via software
Set to the same value
-The Node ID and RF Channel for the ZT-20xx-IOG module are set using either the DIP or
the Rotary switch. See Section 3.1.3 Hardware Settings for the ZT-20xx-IOG Module for
details of how to create a ZigBee wireless connection.
-The Pan ID for the ZT-20xx-IOG module is set remotely using software and cannot be
adjusted using an external hardware switch. There are two methods of creating a
connection between the ZT-2570 module and the ZT-20xx-IOG module:
①If the Pan ID is known: Set the ZT-20xx-IOG module to RUN mode, and then configure
it remotely via wireless communication using a ZT-2570 module.
②If the Pan ID is unknown: Set the ZT-20xx-IOG module to INIT mode, and then
configure it remotely via wireless communication using a ZT-2570 module.
※See Section 3.1.4 Software Settings for the ZT-20xx-IOG Module for more details.

ICP DAS, ZT-257x DIO Data Concentrator Quick Start Guide, v1.0 Page 14
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DIP Switch = 1
Configure the ZT-2570
Using the ZT-2570
Factory default
ZT-20xx-IOG
Has the Pan ID been
changed?
Refer to the
Default settings in
Section 3.1.1
ZT-20xx-IOG
(Set to RUN)
Refer to the
INIT Settings in
Section 3.1.2
YES
NO
Is the Pan ID
known?
YES
NO
Target setting: ZT-20xx-IOG
Connect to a ZT-20xx-IOG
Configure the ZT-20xx-IOG
ZT-20xx-IOG
(Set to RUN)
ZT-20xx-IOG
(Set to INIT)
The Pan ID
is Unknown
The Pan ID
is known

ICP DAS, ZT-257x DIO Data Concentrator Quick Start Guide, v1.0 Page 15
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3.1.1. Connecting to the ZT-20xx-IOG Module (RUN)
Step1 Configure the ZT-2570 module to establish a common ZigBee network
with the ZT-20xx-IOG module
①See Section 3.2 Configuring the ZT-257x Module for details of how to configure the
ZT-2570 module. In order to create a connection between the ZT-2570 module and the
ZT-20xx-IOG module, configure the ZT-2570 module using the settings indicated in the
table below.
②After completing the configuration, set the DIP switch on the ZT-2570 module to the
“ZBRUN”position, and then reboot the module.
Parameter
ZT-20xx-IOG
ZT-2550
ZT-2570
ZT-USBC
RUN
Pan ID
(ZigBee Group ID)
User-defined
(Default: 0x0000)
Set to the same ID as the
ZT-20xx-IOG
Node ID (*)
ZigBee Router
ZigBee Coordinator
Set using DIP switches 4-8.
The Node ID can be set a value in
the range of 0x0001 to 0x001F
(see item 4 in Section 3.1.3 -
Hardware Settings of for the
ZT-20xx-IOG Module for more
information regarding the positions
of DIP Switches 4-8)
0x0000
RF Channel (*)
Set using the Rotary switch (0 - F)
Set to the same frequency as
the ZT-20xx-IOG
Application Mode (*)
Level Mode
Level
Mode/Transparent
Mode
N/A
Data Format
N/A
None, 8, 1
Baud Rate
N/A
115200 bps
Note that the Pan ID must be the same for all modules that exist in the same ZigBee network.
(*): See item2 in step 2 below.

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Step2 Configure the ZT-20xx-IOG module via the ZT-2570 module
①Set the DIP switch on the ZT-20xx-IOG module to the “RUN” position (i.e., move DIP
switch 1 to the OFF position).
②Configure the ZT-20xx-IOG module, and then adjust the hardware switches based on
the Node ID, RF Frequency and Application Mode settings indicated in the table above.
See Section 3.1.3 Hardware Settings for the ZT-20xx-IOG Module for details of how to
adjust the ZT-20xx-IOG module.
③Reboot the ZT-20xx-IOG module and wait until a connection is established.
④See Section 3.1.4 Software Settings for the ZT-20xx-IOG Module for details of how to
configure the I/O mapping for the ZT-20xx-IOG module.
Example:
Set the ZT-20xx-IOG module to “RUN”mode (i.e., move DIP switch 1 to the OFF position) to
remotely connect to the ZT-2570 module. The relevant settings are provided in the table
below.
ZT-20xx-IOG
ZT-2570
Config. Mode
DIP1
OFF
Pan ID
0x0000
Application Mode
DIP2
OFF
Application Mode
Level Mode/Transparent Mode
Encryption
DIP3
OFF
Encryption
Disabled
Node ID
DIP4
OFF
Node ID
0x0000 (ZigBee Coordinator)
DIP5
OFF
RF Channel
0x00
DIP6
OFF
Data Format
None, 8, 1
DIP7
OFF
Baud Rate
115200 bps
DIP8
ON
RF Channel
Rotary
0

ICP DAS, ZT-257x DIO Data Concentrator Quick Start Guide, v1.0 Page 17
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3.1.2. Connecting to the ZT-20xx-IOG Module (INIT)
Step1 Configure the ZT-2570 module to establish a common ZigBee network
with the ZT-20xx-IOG module
①In order to create a connection between the ZT-2570 module and the ZT-20xx-IOG
module, configure the ZT-2570 module using the settings indicated in the table below.
See Section 3.2 Configuring the ZT-257x Module for details of how to configure the
ZT-2570 module.
②After completing the configuration, set the DIP switch on the ZT-2570 module to the
ZBRUN position, and then reboot the module.
Parameter
ZT-20xx-IOG
ZT-2550
ZT-2570
ZT-USBC
INIT
Pan ID
(ZigBee Group ID)
0x3FFF
Set to the same ID as the
ZT-20xx-IOG
Node ID (*)
ZigBee Router
ZigBee Coordinator
0x0020
0x0000
RF Channel (*)
Set using the Rotary switch (0 - F)
Set to the same frequency as
the ZT-20xx-IOG
Application Mode (*)
Level Mode
Transparent Mode
N/A
Data Format
N/A
None, 8, 1
Baud Rate
N/A
115200 bps
Note that the Pan ID must be the same for all modules that exist in the same ZigBee network.
(*): See item2 in step 2 below.
Step2 Configure the ZT-20xx-IOG module via the ZT-2570 module
①Set the DIP switch on the ZT-20xx-IOG module to the “INIT” position (i.e., move DIP
switch 1 to the ON position).
②Configure the ZT-20xx-IOG module, and then adjust the hardware switches based on the
Node ID, RF Frequency and Application Mode settings indicated in the table above.
See Section 3.1.3 Hardware Settings for the ZT-20xx-IOG Module for details of how to
adjust the ZT-20xx-IOG module.

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③Reboot the ZT-20xx-IOG module and wait until a connection is established.
④See Section 3.1.4 Software Settings for the ZT-20xx-IOG Module for details of how to
configure the I/O mapping for the ZT-20xx-IOG module.
Example:
Set the ZT-20xx-IOG module to “INIT”mode (i.e., move DIP switch 1 to the ON position) to
remotely connect to the ZT-2570 module. The relevant settings are provided in the table
below.
ZT-20xx-IOG
ZT-2570
Config. Mode
DIP1
ON
Pan ID
0x3FFF
Application Mode
DIP2
OFF
Application Mode
Transparent Mode
Encryption
DIP3
OFF
Encryption
Disabled
Node ID
DIP4
OFF
Node ID
0x0000 (ZigBee Coordinator)
DIP5
OFF
RF Channel
0x00
DIP6
OFF
Data Format
None, 8, 1
DIP7
OFF
Baud Rate
115200 bps
DIP8
ON
RF Channel
Rotary
0