SEALEVEL DIO-32.PCI Input Digital Interface User Manual

DIO-32.PCI
User Manual
8004

Introduction

Overview
The DIO-32.PCI digital I/O interface provides 16 optically isolated inputs and 16 reed relay outputs. The inputs (rated for 10-30V) protect the PC and other sensitive equipment from spikes and ground loop current that can be generated in industrial environments, while the outputs provide high quality, long life, low current (10 Watt maximum), dry contact switch closures. Reed relays are well suited for low current applications. The relays are normally open and close when energized.

The DIO-32.PCI is designed to be used with a variety of Operating Systems including Windows 98/NT/ME/2000/XP, Linux, and DOS. The SeaI/O API (Application Programmer Interface) provides a variety of useful high-level function calls implemented as a Windows dynamic link library (DLL) and as a Linux kernel module and library. In addition to the API, SeaI/O includes sample code and utilities to simplify software development.

Other Sealevel PCI Digital I/O Products

Model No.

| Part No.|

Description

---|---|---
PIO-24.PCI| (P/N 8008)| – 24 TTL Inputs/Outputs
PIO-32.PCI| (P/N 8010)| – 32 TTL Inputs/Outputs
PIO-48.PCI| (P/N 8005)| – 48 TTL Inputs/Outputs
PIO-96.PCI| (P/N 8009)| – 96 TTL Inputs/Outputs
DIO-16.PCI| (P/N 8002)| – 8 Reed Relay Outputs/8 Opto-isolated Inputs
REL-16.PCI| (P/N 8003)| – 16 Reed Relay Outputs
ISO-16.PCI| (P/N 8006)| – 16 Opto-isolated Inputs
REL-32.PCI| (P/N 8007)| – 32 Reed Relay Outputs
PLC-16.PCI| (P/N 8011)| – 8 Form C Relay Outputs/8 Opto-isolated Inputs

Before You Get Started

What’s Included
The DIO-32.PCI is shipped with the following items. If any of these items are missing or damaged, please contact Sealevel for replacement.

• Item# 8004H – DIO-32.PCI Adapter
• Item# CA165 – DB-78 Male to DB-37 Male and DB-37 Female V-cable

Advisory Conventions

Warning
The highest level of importance is used to stress a condition where damage could result to the product, or the user could suffer serious injury.

Important
The middle level of importance is used to highlight information that might not seem obvious or a situation that could cause the product to fail.

Note
The lowest level of importance is used to provide background information, additional tips, or other non-critical facts that will not affect the use of the product.

Optional Items
Depending upon your application, you are likely to find one or more of the following items useful for interfacing the DIO-32.PCI to real-world signals. All items can be purchased from our website (www.sealevel.com.) or by calling 864-843-4343.

• DB-37 Male to DB-37 Female Extension Cable (Item# CA112)
  This cable provides a 6’ extension to the CA165. It has one DB37 Male connector and one DB37 female connector.

• DB-37 Male/Female Terminal Block (Item# TB02)
  Break out serial and digital connectors to screw terminals for easy field connection. The TB02 terminal block is designed with both DB37 male and female connectors, therefore; it can be used with any DB37 board regardless of the board’s port gender.

• Cable and Terminal Block Kit (Item# KT101)
  The KT101 includes the TB02 terminal block and CA112 cable. To fully connect the DIO-32.PCI two KT101 kits will be required.

Software Installation

Operating System Installation
For Windows Users
This section contains helpful information pertaining to the installation of supported Sealevel Systems, Inc. software packages. First, the process of acquiring the software is discussed. Next, the installation is detailed in a step-by-step guide for Windows and Linux operating systems. Refer to the SeaIO Software Overview page.

1. Sealevel software for Windows and Linux operating systems is available at these links:
   • Software for Windows
   • Software for Linux

2. Choose the link for the desired software package and click on the ‘Download File’ link to download the current driver.

3. Proceed to the Manual Software Installation guide for your operating system.

SeaI/O software can also be downloaded from the 8004H-product webpage: DIO-32.PCI Product Page

Other Operating Systems
Refer to the appropriate section of Serial Utilities Software.

LINUX INSTALLATION
Refer to Linux Archives – Sealevel. This link contains valuable information on installing your serial adapter in the various Linux releases. Also included is a series of files explaining proper Linux syntax and typical Linux serial implementations.
For additional software support, please call Sealevel Systems’ Technical Support, at 864-843-4343. Our technical support is free and available from 8:00 AM-5 PM Eastern Time, Monday through Friday. For email support contact: support@sealevel.com.

Hardware Installation

The adapter can be installed in any 5V PCI expansion slot.
Do not install the Adapter in the machine until the software has been fully installed.

1. Turn off PC power. Disconnect the power cord.
2. Remove the PC case cover.
3. Locate an available 5V PCI slot and remove the blank metal slot cover.
4. Gently insert the PCI adapter into the slot. Make sure that the adapter is seated properly.
5. After the adapter has been installed, the cables should be routed thru the opening in the bracket. This bracket also features a strain relief function that should be used to prevent unexpected cable removal.
6. Replace the screw you removed for the blank and use it to secure the adapter into the slot. (This is required to ensure FCC Part 15 compliance.)
7. Replace the cover.
8. Connect the power cord Installation is finished.

Programming the DIO-32.PCI

Sealevel’s SeaI/O software is provided to assist in the development of reliable applications for the Sealevel Systems family of digital I/O adapters. The software also includes driver functions for use in accessing the I/O as well as helpful samples and utilities.

Programming for Windows
The SeaI/O API (Application Programmer Interface) provides a variety of useful high-level function calls implemented in a Windows dynamic link library (DLL). The API is defined in the help file (Start/Programs/SeaIO/SeaIO Help) under “Application Programmers Interface”. This help file also includes detailed information dealing with the installation/removal of the software and information about latency, logic states, and device configuration.
For C language programmers we recommend using the API to access the REL-16.PCI. If you are programming in Visual Basic, using the ActiveX control included with SeaI/O is advised.

Samples and Utilities
A variety of sample programs and utilities (both executable and source code) is included with SeaI/O. Further documentation on these samples can be found by selecting “Start/Programs/SeaI/O/Sample Application Description”. Information about where the files are physically stored on your disk is also included in this same file.

Programming for Linux
SeaI/O for Linux consists of two major parts: a kernel module and a library. The kernel module is a simple IO pass-through device, allowing the library to handle the more sophisticated functions provided to SeaI/O users. It is provided in a ‘tarball’ format and can easily be compiled and included in the kernel build.

Digital I/O Interface
The DIO-32.PCI provides four parallel input/output (I/O) ports. The ports are organized as ports A, B, C, and D. Port A and B are input ports interfaced to optically isolated inputs, while ports C and D are reed relay output ports. Assuming an I/O address of 300 Hex the following table shows the Port Addresses.

Base Address

| Hex| Decimal|

Mode

---|---|---|---
Port A Address| 300| 768| Optically Isolated Input Port
Port B Address| 301| 769
Port C Address| 302| 770| Reed Relay Output Port
Port D Address| 303| 771

Input Ports
Ports A and B are 8-bit input ports connected to optically isolated input sensors. Each sensor can be used to interface a voltage input and then sense whether the voltage is on or off. Each sensor is isolated (with respect to a common ground) from every other sensor and also isolated with respect to the host PC ground. This means that signals such as low-level AC line voltage, motor servo voltage, and control relay signals can be ‘sensed’, or read by the PC, without the risk of damage due to ground loops or ground faults.

Each sensor input pair has a current limiting resistor that is used to limit the input current to the optoisolator. The optoisolator has two ‘back-to-back’ diodes internally. This allows AC or DC signals to be sensed, regardless of polarity. When the applied voltage is high enough to cause the led in the optoisolator to turn on, the output of the optoisolator goes low (0 volts), and the signal is read as a low logic level (binary 0) by the PC. When the input signal is too low to turn on the optoisolator, the output goes high, and the port bit is read by the PC as a high logic level (binary 1).

The input impedance of each isolated input is approximately 560 ohms (factory default). The optoisolator requires approximately 3mA to turn on. The maximum input current is 50mA. There are two things to consider when selecting the input resistor. The first is turn-on the voltage for the circuit to sense, and the second is the maximum input voltage. Maximum input voltage must not provide too much power to the input resistor and must also not overdrive the optoisolator input current specification. The following formulas apply:
Turn on Voltage = diode drop + (turn on current) x (resistance) [Ex: 1.1 + (.003) x R] Input Current = ((input voltage)-1.1V) / (resistor value)
Maximum voltage = 1.1 + square root of (.25(resistor value))

The following table shows common input resistors and the ranges associated with each.

Input Resistor| Turn-On| Input Range| Max Input|

Max Current

---|---|---|---|---
220WΩ| 1.8V| 1.8 – 7.0V| 8.5V| 27mA
560WΩ| 2.8V| 2.8 – 10.6V| 12.9V| 20mA
1KWΩ| 4.1V| 4.1 – 13.8V| 16.9V| 15mA
2.2KWΩ| 7.7V| 7.7 – 20.0V| 24.5V| 10mA
3.3KWΩ| 10.0V| 10.0 – 24.0V| 30.0V| 9mA
4.7KWΩ| 15.2V| 15.2 – 28.0V| 35.0V| 7mA

The turn-off voltage for all resistors is less than 1V.
Increasing the input resistor accordingly can increase the maximum input voltage. Because socketed DIP resistors are utilized, they can easily be replaced with a different value. Sealevel can do this, if necessary.
The input circuits are not intended for monitoring 120-volt AC circuits. In addition to being too high a voltage for the circuits, it is dangerous to have that high a voltage on the card.

Input Ports Pin Assignments (DB-37 Female)
Inputs are interfaced via the DB-37 female connector on the supplied CA165 cable.

Port A Bit

| Port A Pins| Port B Bit|

Port B Pins

---|---|---|---
0| 18,37| 0| 10,29
1| 17,36| 1| 9, 28
2| 16,35| 2| 8,27
3| 15,34| 3| 7,26
4| 14,33| 4| 6,25
5| 13,32| 5| 5,24
6| 12,31| 6| 4,23
7| 11,30| 7| 3,22
Ground| 2,20,21| |
+12 Volts| 1| |
+5 Volts| 19| |

The CA165 cable input pinout is not compatible with the 3093 ISA digital I/O board. If you are upgrading from the 3093 and wish to preserve existing infrastructure wiring, order the CA378 cable.

Output Ports (Reed Relay)
Reed relays provide very high quality, long life, low current (10 Watt maximum), and dry contact switch closures.
Reed relays are not suited for high current applications and can be destroyed by inductive load switching, where a spark occurs across the contacts internally. The relays are normally open and close when energized.

Output Ports (Reed Relay) Pin Assignments (DB-37 Male)
Outputs are interfaced via the DB-37 male connector on the supplied CA165 cable.

Port C Bit

| Relay| Port C Pins| Port D Bit| Relay|

Port D Pins

---|---|---|---|---|---
0| K16| 2,20| 0| K8| 10,28
1| K15| 3,21| 1| K7| 11,29
2| K14| 4,22| 2| K6| 12,30
3| K13| 5,23| 3| K5| 13,31
4| K12| 6,24| 4| K4| 14,32
5| K11| 7,25| 5| K3| 15,33
6| K10| 8,26| 6| K2| 16,34
7| K9| 9,27| 7| K1| 17,35
Ground| 18,36,37| | | |
+ 5 Volts| 19| | | |
+ 12 Volts| 1| | | |

DB-78 Female Pin Assignments (Card Edge Connector)

Bit

| Port A Pins| Port B Pins| Port C Pins|

Port D Pins

---|---|---|---|---
0| 55,74| 47,66| 2,20| 10,28
1| 54,73| 46,65| 3,21| 11,29
2| 53,72| 45,64| 4,22| 12,30
3| 52,71| 44,63| 5,23| 13,31
4| 51,70| 43,62| 6,24| 14,32
5| 50,69| 42,61| 7,25| 15,33
6| 49,68| 41,60| 8,26| 16,34
7| 48,67| 40,59| 9,27| 17,35
GND| 39,57,58| 18,36,37
+12V| 38| 1
+5V| 56| 19

Direct Hardware Control
In systems where the user’s program has direct access to the hardware (DOS) the tables that follow give the mapping and functions that the DIO-32.PCI provides.

Function Available

| Port| Address Hex|

Port Type

---|---|---|---
RD| A| Base + 0| Optically Isolated Input Port
RD| B| Base + 1
RD/WR| C| Base + 2| Reed Relay Output Port
RD/WR| D| Base + 3

RD = Read, RD/WR = Read or Write

Reading the Inputs
The inputs are active Low. If no voltage is applied across one of the differential inputs, it returns a one on that bit. If an AC or DC voltage is applied, it returns a zero on that bit.

Reading the Outputs
The relay ports return the ones that complement the value that is currently being used to drive the relays.

Writing the Outputs
The output ports are the only ports that can be written. The relays are on a standard DIO-32.PCI is normally open. To close a relay one must be written to the appropriate bit.

Register Description
All ports are set to input after reset or power-up.

Address

| | Mode| D7| D6| D5| D4| D3| D2| D1|

D0

---|---|---|---|---|---|---|---|---|---|---
Base+0| Input Port A| RD| PAD7| PAD6| PAD5| PAD4| PAD3| PAD2| PAD1| PAD0
Base+1| Input Port B| RD| PBD7| PBD6| PBD5| PBD4| PBD3| PBD2| PBD1| PBD0
Base+2| Output Port C| RD/WR| PCD7| PCD6| PCD5| PCD4| PCD3| PCD2| PCD1| PCD0
Base+3| Output Port D| RD/WR| PDD7| PDD6| PDD5| PDD4| PDD3| PDD2| PDD1| PDD0
Base+4| | RD| 0| 0| 0| 0| 0| 0| 0| 0
Base+5| Interrupt Status| RD/WR| IQRA| TRUST| 0| 0| 0| 0| IRC1| IRC0

Interrupt Control
When enabled, interrupts are generated on Port A bit D0.

IRC0
IRC1| Interrupt mode select, see table below
Interrupt mode select, see table below

Interrupt Mode Select Table
The interrupt source is Base+0 bit D0. When selecting the Interrupt Type, always disable interrupts prior to changing or setting states. This will help prevent inadvertent or unexpected interrupts from occurring.

IRC1

| IRC0|

Interrupt Type

---|---|---
0| 0| Low Level
0| 1| High Level
1| 0| Falling Edge
1| 1| Rising Edge

When using the High and Low Level interrupts, an interrupt occurs when input D0 changes to either a High or Low state. This will cause the computer to remain in an interrupt state until the input state changes.

Interrupt Read
Reading the Interrupt Status port (Base+5) clears any interrupt pending.

Optional 3093 Migration Cable (CA378)
On the 3093 ISA digital I/O board, the input pins #1 and #19 are reversed from the standard CA165 cable that ships standard with the 8004H. If you are upgrading from a 3093 ISA board to an 8004H PCI board and wish to preserve existing infrastructure wiring, order the CA378 cable and use it in place of the standard CA165 cable.

CA378 Input Pin Assignments (DB-37 Female)
Inputs are interfaced via the DB-37 female connector on the optional CA378 cable.

Port A Bit| Port A Pins| Port B Bit|

Port B Pins

---|---|---|---
0| 18,37| 0| 10,29
1| 17,36| 1| 9, 28
2| 16,35| 2| 8,27
3| 15,34| 3| 7,26
4| 14,33| 4| 6,25
5| 13,32| 5| 5,24
6| 12,31| 6| 4,23
7| 11,30| 7| 3,22
Ground| 2,20,21| |
+12 Volts| 19| |
+5 Volts| 1| |

The CA378 cable is designed specifically for customers upgrading from a 3093 ISA board to the 8004 PCI board. If you are not upgrading from the 3093 board, use the standard CA165 cable that ships with the 8004 PCI digital I/O board.

CA378 Output Pin Assignments (DB-37 Male)
Outputs are interfaced via the DB-37 male connector on the optional CA378 cable.

Port C Bit

| Relay| Port C Pins| Port D Bit| Relay|

Port D Pins

---|---|---|---|---|---
0| K16| 2,20| 0| K8| 10,28
1| K15| 3,21| 1| K7| 11,29
2| K14| 4,22| 2| K6| 12,30
3| K13| 5,23| 3| K5| 13,31
4| K12| 6,24| 4| K4| 14,32
5| K11| 7,25| 5| K3| 15,33
6| K10| 8,26| 6| K2| 16,34
7| K9| 9,27| 7| K1| 17,35
Ground| 18,36,37| | | |
+ 5 Volts| 19| | | |
+ 12 Volts| 1| | | |

Electrical Characteristics

Features

• 2 sets of SPST relays with each having 8 relays
• 2 eight-bit input ports
• DB-37 Male connector for relay outputs
• DB-37 Female connector for optically isolated inputs
• Highly reliable 10 VA DIP reed relays
• Multiple adapters can reside in the same computer

Specifications

Input Ports

Output Relays

Contact Max Power Rating| 10W| |
---|---|---|---
Contact Voltage Maximum| 100 VDC/VAC| |
Contact Current Maximum| .5A AC/DC RMS| |
Contact Resistance, Initial| .15 W| |
Rated Life| 200 Million Closures (Low Load)| 100 Million Closures (Maximum Load)|
Contact Speed| Operate – .5mS| Release – .5mS| Bounce – .5 mS
Maximum Operating Speed| 600 Hz| |

Environmental Specifications

Specification

| Operating|

Storage

---|---|---
Temperature Range| 0º to 70º C| -50º to 105º C

Manufacturing
All Sealevel Systems Printed Circuit boards are built to UL 94V0 rating and are 100% electrically tested.
These printed circuit boards are solder masks over bare copper or solder mask over tin nickel.

Power Requirements

Physical Dimensions

Example Circuits

Appendix A – Troubleshooting

Sealevel Software is supplied with the Sealevel Systems adapter and will be used in the troubleshooting procedures. By using this software and following these simple steps, the most common problems can be eliminated without the need to call Technical Support.

1. Install the software first. After installing the software then proceed to add the hardware. This places the required installation files in the correct locations.
2. Read this manual thoroughly before attempting to install the adapter in your system.
3. Use Device Manager under Windows to verify proper installation.
4. Use the SeaI/O Control Panel applet or the Device Manager’s property page for card identification and configuration.

If these steps do not solve your problem, please call Sealevel Systems’ Technical Support, at 864-843-4343. Our technical support is free and available from 8:00 AM-5 PM Eastern Time, Monday through Friday. For email support contactsupport@sealevel.com:.

Appendix B – How To Get Assistance

Please refer to Appendix A — Troubleshooting Guide prior to calling Technical Support.
Begin by reading through the Trouble Shooting Guide in Appendix A. If assistance is still needed, please see below.
When calling for technical assistance, please have your user manual and current adapter settings. If possible, please have the adapter installed in a computer ready to run diagnostics.
Sealevel Systems provides an FAQ section on its website. Please refer to this to answer many common questions.
This section can be found at http://www.sealevel.com/faq.asp.
Sealevel Systems maintains a web page on the Internet. Our home page address is www.sealevel.com. The latest software updates and newest manuals are available via our
website.
Technical support is available Monday to Friday from 8:00 a.m. to 5:00 p.m. eastern time.
Technical support can be reached at 864-843-4343.

RETURN AUTHORIZATION MUST BE OBTAINED FROM SEALEVEL SYSTEMS BEFORE RETURNED MERCHANDISE WILL BE ACCEPTED. AUTHORIZATION CAN BE OBTAINED BY CALLING SEALEVEL SYSTEMS AND REQUESTING A RETURN MERCHANDISE AUTHORIZATION (RMA) NUMBER.

Appendix C – Silk Screen – 8004 PCB

Appendix D – Compliance Notices

Federal Communications Commission (FCC) Statement
This equipment has been tested and found to comply with the limits for Class A digital devices, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in such case the user will be required to correct the interference at the user’s expense.

EMC Directive Statement
Products bearing the CE Label fulfill the requirements of the EMC directive (89/336/EEC) and of the low-voltage directive (73/23/EEC) issued by the European Commission. To obey these directives, the following European standards must be met:

• 55022 Class A – “Limits and methods of measurement of radio interference characteristics of information technology equipment”
• 55024 – “Information technology equipment Immunity characteristics Limits and methods of measurement”.

This is a Class A Product. In a domestic environment, this product may cause radio interference in which case the user may be required to take adequate measures to prevent or correct the interference.

Always use the cabling provided with this product if possible. If no cable is provided or if an alternate cable is required, use high-quality shielded cabling to maintain compliance with FCC/EMC directives.

Warranty

Sealevel’s commitment to providing the best I/O solutions is reflected in the Lifetime Warranty that is standard on all Sealevel manufactured I/O products. We are able to offer this warranty due to our control of manufacturing quality and the historically high reliability of our products in the field. Sealevel products are designed and manufactured at its Liberty, South Carolina facility, allowing direct control over product development, production, burn- in, and testing. Sealevel achieved ISO-9001:2015 certification in 2018.

Warranty Policy
Sealevel Systems, Inc. (hereafter “Sealevel”) warrants that the Product shall conform to and perform in accordance with published technical specifications and shall be free of defects in materials and workmanship for the warranty period. In the event of failure, Sealevel will repair or replace the product at Sealevel’s sole discretion. Failures resulting from misapplication or misuse of the Product, failure to adhere to any specifications or instructions, or failure resulting from neglect, abuse, accidents, or acts of nature are not covered under this warranty.

Warranty service may be obtained by delivering the Product to Sealevel and providing proof of purchase. The customer agrees to insure the Product or assume the risk of loss or damage in transit, to prepay shipping charges to Sealevel, and to use the original shipping container or equivalent. The warranty is valid only for the original purchaser and is not transferable.
This warranty applies to Sealevel manufactured Products. Products purchased through Sealevel but manufactured by a third party will retain the original manufacturer’s warranty.

Non-Warranty Repair/Retest
Products returned due to damage or misuse and Products retested with no problem found are subject to repair/retest charges. A purchase order or credit card number and authorization must be provided in order to obtain an RMA (Return Merchandise Authorization) number prior to returning the Product.

How to obtain an RMA (Return Merchandise Authorization)
If you need to return a product for warranty or non-warranty repair, you must first obtain an RMA number.
Please contact Sealevel Systems, Inc. Technical Support for assistance:

Available Monday – Friday, 8:00 AM to 5:00 PM EST
Phone _ 864-843-4343
Email: support@sealevel.com

Trademarks
Sealevel Systems, Incorporated acknowledges that all trademarks referenced in this manual are the service mark, trademark, or registered trademark of the respective company.

References

• Sealevel - I/O & Computing Products, Engineering and Manufacturing
• FAQs - Sealevel
• Sealevel - I/O & Computing Products, Engineering and Manufacturing
• PCI 16 Reed Relay Output/16 Isolated Input Digital Interface (10-30V) - Sealevel
• Linux - Sealevel
• SeaIO Software Overview - Sealevel
• Software: SeaIO Classic - Linux - Sealevel
• Software: SeaIO Classic V5 - Windows - Sealevel

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