Wired is inconvenient, wireless is unreliable. What if you could combine the best of both worlds?
We present ZigBee-Modbus-R1 a unique device designed to solve this very problem. It's a hybrid relay that simultaneously supports both the wired Modbus RTU interface and the wireless ZigBee network. This allows you to create truly flexible and fault-tolerant control systems.
Key Features:
Flexible Installation: Use the ZigBee wireless protocol where running cables is impossible or not cost-effective.
Industrial Reliability: Rely on the time-tested Modbus wired protocol for mission-critical parts of your system where stability is paramount.
Maximum Fault Tolerance (Failover): Activate both interfaces simultaneously. In case of a failure on one network (e.g., a cable break or strong radio interference), the device remains controllable via the second network, ensuring uninterrupted operation.
A unique approach to simultaneous ZigBee and Modbus protocol support, providing control from multiple networks and status conversion between protocols.
Device will attempt to connect to the ZigBee network after turning on (24VDC power should be connected). Short press on reset button resets device. Long press on reset button (about 4 seconds) until the LED starts flashing performs a complete reset of ZigBee settings. The default Modbus settings are: ID 66, baudrate 9600, and 'no parity'. To change these parameters, the device must be connected to a Zigbee network, and the values must be updated through Zigbee parameters.
Project is built using:
esp-idf-v5.3.2 (for Linux)
Export path:
cd esp-idf
. ./export.sh
Go to directory:
cd zigbee\zigbee_modbus\zigbee_modbus_relay
Commads:
idf.py set-target esp32c6
idf.py build
Binary files and addresses:
bootloader.bin 0x0
partition-table.bin 0x8000
zigbee_modbu_relay.bin 0x10000
ESP32 device flashing:
Download Flash Download Tools
Connect device to PC via USB while holding the programming button
Run flash_download_tool.exe and select the following values
- ChipType = ESP32-C6
- WorkMode = Develop
- LoadMode = USB
- Tick the checkboxes
- Choose binary files and set the addresses
- Select correct COM port as detected by the OS
- Click ERASE button, to erase ESP32-C6 memory
- Click START button, to upload the firmware
WARNING
Intermittent ZigBee Initialization Failure on Cold Boot
There is a known, hard-to-reproduce issue where the ZigBee stack may fail to initialize on a cold boot (i.e., when power is first connected). This occurs intermittently, approximately once in every 50 power cycles.
Workaround: A simple power cycle (unplugging and replugging the device) or a manual reset resolves the issue.
We can provide the PCB design files to those who are interested. Please reach out and let us know. Your feedback is important, as it helps us understand our community and who we're collaborating with.