SeaLevel 8004H User manual

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© Sealevel Systems, Inc. 8004H Manual | SL9022H9/2021
DIO-32.PCI
User Manual | 8004H

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© Sealevel Systems, Inc. 8004H Manual | SL9022H9/2021
Contents
CONTENTS............................................................................................................................................................................................................................2
INTRODUCTION...................................................................................................................................................................................................................3
BEFORE YOU GET STARTED..............................................................................................................................................................................................4
SOFTWARE INSTALLATION ...............................................................................................................................................................................................5
HARDWARE INSTALLATION..............................................................................................................................................................................................6
PROGRAMMING THE DIO-32.PCI.....................................................................................................................................................................................7
ELECTRICAL CHARACTERISTICS...................................................................................................................................................................................16
SPECIFICATIONS................................................................................................................................................................................................................17
EXAMPLE CIRCUITS .........................................................................................................................................................................................................19
APPENDIX A – TROUBLESHOOTING.............................................................................................................................................................................20
APPENDIX B – HOW TO GET ASSISTANCE..................................................................................................................................................................21
APPENDIX C – SILK SCREEN – 8004 PCB .................................................................................................................................................................22
APPENDIX D – COMPLIANCE NOTICES........................................................................................................................................................................23
WARRANTY ........................................................................................................................................................................................................................24

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© Sealevel Systems, Inc. 8004H Manual | SL9022H9/2021
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) available on
Sealevel’s website 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

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© Sealevel Systems, Inc. 8004H Manual | SL9022H9/2021
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 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 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 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 [phone].
•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.

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© Sealevel Systems, Inc. 8004H Manual | SL9022H9/2021
Software Installation
Windows Installation
Do not install the Adapter in the machine until the software has been fully installed.
Only users running Windows 7 or newer should utilize these instructions for accessing and
installing the appropriate driver via Sealevel’s website. If you are utilizing an operating system
prior to Windows 7, please contact Sealevel by calling 864.843.4343 or emailing
[email protected] to receive access to the proper driver download and installation
instructions.
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 the 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, [phone]. Our
technical support is free and available from 8:00AM-5PM Eastern Time, Monday through Friday. For
email support contact: [e-mail].

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© Sealevel Systems, Inc. 8004H Manual | SL9022H9/2021
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 un-expected 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.

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© Sealevel Systems, Inc. 8004H Manual | SL9022H9/2021
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 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) are 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.

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© Sealevel Systems, Inc. 8004H Manual | SL9022H9/2021
PROGRAMMING THE DIO-32.PCI, CONTINUED
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
Port B Address
301
769
Optically Isolated Input Port
Port C Address
302
770
Port D Address
303
771
Reed Relay Output Port
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
opto-isolator. The opto-isolator 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 opto-isolator to turn-on, the output of the opto-isolator 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 opto-
isolator, 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 opto-
isolator 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 voltage for the circuit
to sense, and 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 opto-isolator 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))

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PROGRAMMING THE DIO-32.PCI, CONTINUED
The following table shows common input resistors and the ranges associated with each.
Input Resistor
Turn-On
Input Range
Max Input
Max Current
220Ω
1.8V
1.8 – 7.0V
8.5V
27mA
560Ω
2.8V
2.8 – 10.6V
12.9V
20mA
1KΩ
4.1V
4.1 – 13.8V
16.9V
15mA
2.2KΩ
7.7V
7.7 – 20.0V
24.5V
10mA
3.3KΩ
10.0V
10.0 – 24.0V
30.0V
9mA
4.7KΩ
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

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PROGRAMMING THE DIO-32.PCI, CONTINUED
The CA165 cable input pin out 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), 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

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PROGRAMMING THE DIO-32.PCI, CONTINUED
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.
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.
Function Available
Port
Address Hex
Port Type
RD
A
Base + 0
RD
B
Base + 1
Optically Isolated Input Port
RD/WR
C
Base + 2
RD/WR
D
Base + 3
Reed Relay Output Port

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PROGRAMMING THE DIO-32.PCI, CONTINUED
Reading the Outputs
The relay ports return the ones complement of 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 on a standard DIO-32.PCI are normally
open. To close a relay a 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
IRQEN
IRQST
0
0
0
0
IRC1
IRC0
Interrupt Control
When enabled, interrupts are generated on Port A bit D0.
IRQEN
Interrupt enable
1 = enabled
0 = disabled (0 on power up)
IRC0
IRC1
Interrupt mode select, see table below
Interrupt mode select, see table below

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PROGRAMMING THE DIO-32.PCI, CONTINUED
Interrupt Mode Select Table
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.
IRQST
(D0) Interrupt Status
1 = interrupt pending, 0 = none
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.

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PROGRAMMING THE DIO-32.PCI, CONTINUED
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.

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© Sealevel Systems, Inc. 8004H Manual | SL9022H9/2021
PROGRAMMING THE DIO-32.PCI, CONTINUED
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

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© Sealevel Systems, Inc. 8004H Manual | SL9022H9/2021
Electrical Characteristics
Features
•2 sets 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 same computer

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Specifications
Input Ports
Turn On Current 3mA
Isolator Diode Drop 1.1 VDC
Resistor Power Max .25 W
Maximum Input Range 3 – 13 VDC/VAC
Output Relays
Contact Max Power Rating 10W
Contact Voltage Maximum 100 VDC/VAC
Contact Current Maximum .5A AC/DC RMS
Contact Resistance, Initial .15 Ω
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 mask over bare copper or solder mask over tin nickel.
Power Requirements
Supply Line +5 VDC +12 VDC
Rating 450 mA (Optional Use)

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© Sealevel Systems, Inc. 8004H Manual | SL9022H9/2021
SPECIFICATIONS, CONTINUED
Physical Dimensions
PCB Length 6.0” (15.2 cm)
PCB Height including Goldfingers 4.2” (10.7 cm)

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© Sealevel Systems, Inc. 8004H Manual | SL9022H9/2021
Example Circuits
Input Circuit
Output Circuit

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© Sealevel Systems, Inc. 8004H Manual | SL9022H9/2021
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, most common problems can be
eliminated without the need to call Technical Support.
1. Install software first. After installing the software then proceed to adding 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, [phone].
Our technical support is free and available from 8:00AM-5PM Eastern Time, Monday through Friday. For
email support contact sup[email protected]:.