SeaLevel PIO-48 User manual

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© Sealevel Systems, Inc. 4030 Manual | SL9362 9/2021
PIO-48
User Manual | 4030

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© Sealevel Systems, Inc. 4030 Manual | SL9362 9/2021
Contents
CONTENTS............................................................................................................................................................................................................................2
INTRODUCTION...................................................................................................................................................................................................................3
BEFORE YOU GET STARTED..............................................................................................................................................................................................4
OPTIONAL ITEMS ................................................................................................................................................................................................................5
CARD SETUP........................................................................................................................................................................................................................8
INSTALLATION...................................................................................................................................................................................................................10
DIGITAL I/O INTERFACE ..................................................................................................................................................................................................12
PROGRAMMING THE PIO-48 .........................................................................................................................................................................................13
ELECTRICAL CHARACTERISTICS...................................................................................................................................................................................16
SPECIFICATIONS................................................................................................................................................................................................................17
EXAMPLE CIRCUITS .........................................................................................................................................................................................................18
APPENDIX A –TROUBLESHOOTING.............................................................................................................................................................................19
APPENDIX B –HOW TO GET ASSISTANCE..................................................................................................................................................................20
APPENDIX C–COMPLIANCE NOTICES.........................................................................................................................................................................21
WARRANTY........................................................................................................................................................................................................................22

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© Sealevel Systems, Inc. 4030 Manual | SL9362 9/2021
Introduction
Overview
The PIO-48 part number 4030 digital I/O interface provides 48 channels of buffered drive digital I/O
emulating 8255 mode zero. The PIO-48 can be utilized for a variety of control and automation applications
including control and monitoring of TTL devices (e.g., LEDs, small solenoids, small relays) and interfacing
to solid-state relay racks (SSRs) for high-power AC or DC loads.
The PIO-48’s 48 digital I/O channels are accessed via two 50-pin header connectors with industry-standard
pin out. Each header provides 24 bits of digital I/O divided into three eight-bit groups. Each eight-bit group
may be individually configured via software command as input or output to best match your application
requirements.
The PIO-48 is designed to be used with a variety of Operating Systems including Windows
98/NT/ME/2000/XP/7/8, Linux, and DOS. The SeaI/O API (Application Programmer Interface) included on
CD with the PIO-48 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 ISA Digital I/O Products
DIO-16
(P/N 3096)
-8 Reed Relay Outputs / 8 Opto-Isolated Inputs
ISO-16
(P/N 3094)
-16 Optically Isolated Inputs
REL-16
(P/N 3095)
-16 Reed Relay Outputs
DIO-32B
(P/N 3093)
-16 Reed Relay Outputs / 16 Opto-Isolated Inputs
REL-32
(P/N 3098)
-32 Switched Relay Outputs

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Before You Get Started
What’s Included
The PIO-48 is shipped with the following items. If any of these items is missing or damaged, please
contact Sealevel for replacement.
•PIO-48 Adapter
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.

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Optional Items
Depending upon your application, you are likely to find one or more of the following items useful for
interfacing the PIO-48 to real-world signals. All items can be purchased from our website
(http://www.sealevel.com) or by calling [phone].
For TTL applications:
•Terminal Block Kit - (Part Number KT107)
−Kit includes the TB07 screw terminal block and
CA167 ribbon cable for connecting one of the
PIO-48’s 50-pin header connectors to your I/O.
6” Snap track and DIN rail clips are included for
DIN rail mounting.
•IDC 50 to IDC 50 Pin 40" Ribbon Cable (Part Number CA167)
−Interfaces each of the PIO-48’s 50-pin header
connectors.
•Simulation/debug module (Part Number TA01)
−Module allows monitoring status of output pins
and controlling state of input pins. An LED
corresponding to each port bit illuminates to
indicate state. Eight position DIP-switches are
used to generate input status changes.

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Optional Items, Continued
For high-current, high-voltage applications:
•IDC 50 to IDC 50 Pin Ribbon Cable (Part Number CA167)
−40” cable connects the PIO-48 to solid-state
relay racks equipped with 50-pin header
interface.
•IDC 50 to IDC 50 Pin Ribbon Cable (Part Number CA135)
−40” cable connects the PIO-48 to solid-state
relay racks equipped with 50-pin edge
connector.
•Solid-State Relay Racks:
•Quad six position relay rack (Part Number PB24HQ)
−Relay rack can accept up to six QSSRs for a
total of 24 channels. Features a 50-pin header
connector for easy interface via 50-conductor
ribbon cables.
•Quad four position relay rack (Part Number PB16HQ)
−Relay rack can accept up to four QSSRs for a
total of 16 channels. Features a 50-pin header
connector for easy interface via 50-conductor
ribbon cables.
•Quad Solid-State Relay Modules:
•AC Input (Part Number IA5Q) - Provides 4 channels of discrete I/O interface to
monitor AC inputs up to 140V @ 10mA.
•DC Input (Part Number IB5Q) - Provides 4 channels of discrete I/O interface to
monitor DC inputs from 3.3V to 32V.
•AC Output (Part Number OA5Q) - Provides 4 channels of discrete I/O interface
to control AC outputs up to 140V @ 3A.
•DC Output (Part Number OB5Q) - Provides 4 channels of discrete I/O interface
to control DC outputs up to 60V @ 3A.
•Simulation/debug module (Part Number TA01)
−Module simulates the operation and load
characteristics of a standard 24-channel relay
rack. An LED corresponding to each port bit
illuminates to indicate state. Eight position DIP-
switches are used to generate input status
changes.

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Optional Items, Continued

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Card Setup
The PIO-48 contains several jumper straps for each port that must be set for proper operation.
Address Selection
The PIO-48 occupies 8 consecutive I/O locations. Dip-switch SW1 sets the base address for the PIO-48. Be
careful when selecting the base address as some selections conflict with existing PC ports. The following
table shows several examples that usually do not cause a conflict.
Address
Binary
Switch Settings
1
2
3
4
5
6
7
8
280-287
10 1000 0XXX
Off
On
Off
On
On
On
On
On
2A0-2A7
10 1010 0XXX
Off
On
Off
On
Off
On
On
On
2E8-2EF
10 1110 1XXX
Off
On
Off
Off
Off
On
Off
On
2F8-2FF
10 1111 1XXX
Off
On
Off
Off
Off
Off
Off
On
3E8-3EF
11 1110 1XXX
Off
Off
Off
Off
Off
On
Off
Off
300-307
11 0000 0XXX
Off
Off
On
On
On
On
On
Off
328-32F
11 0010 1XXX
Off
Off
On
On
Off
On
Off
On
3F8-3FF
11 1111 1XXX
Off
Off
Off
Off
Off
Off
Off
On
Address Selection Table
The following illustration shows the correlation between the DIP-switch setting and the address bits used
to determine the base address. In the example below, address 300 is selected as the base address. Address
300 in binary is 10 0000 XXX where X = a non-selectable address bit and address bit A9 is always a 1.
DIP-Switch Illustration
Setting the switch ‘On’ or ‘Closed’ corresponds to a ‘0’ in the address, while leaving it ‘Off’ or
‘Open’ corresponds to a ‘1’.

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© Sealevel Systems, Inc. 4030 Manual | SL9362 9/2021
Wait States
The PIO-48 has the option of inserting one 500 nS wait state for each access. This may be required on
certain machines with bus clocks in excess of 8 MHz. With the wide variety of machines available, no
concrete rules exist concerning wait states. If the PIO-48 does not seem to be responding properly, try
inserting a wait state.
To enable wait state insertion, set position 8 of the dip-switch to "ON". To disable wait states, set position
8 "OFF".
Interrupt Headers J5 and J6
The headers marked J5 and J6 allow the use of interrupts with the parallel ports. J5 selects IRQ2 through
IRQ7 for Port 1 (U9 and J1), while J6 selects the IRQ for Port 2 (U16 and J3).
IRQ Header E2
Optional Cable Connector P4
Discrete access to both sides of all relays is provided by attaching the optional cable (CA-108) to pin
header P4 with the colored edge of the ribbon cable attached to pin one. Removing all the jumpers
connecting row P1 to P2 places the A-side of each relay at the on-board DB-37 and the B-side at the
optional cable’s DB-37.

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© Sealevel Systems, Inc. 4030 Manual | SL9362 9/2021
Installation
Software Installation
Windows Operating System Installation
For Windows Users
Begin by locating, selecting, and installing the correct software from the Sealevel software driver database.
SeaI/O software can also be downloaded from the 4030-product webpage: ISA 48 Channel TTL Digital
Interface.
1. Select the Part Number for your adapter from the listing.
2. Select ‘SeaIO Classic for Windows V5.13.’ Select ‘Download Now.’The setup file will
automatically detect the operating environment and install the proper components. Follow
the information presented on the screens that follow.
3. A screen may appear with the declaration: “The publisher cannot be determined due to the
problems below: Authenticode signature not found.” Please select the ‘Yes’ button and
proceed with the installation. This declaration simply means that the Operating System is
not aware of the driver being loaded. It will not cause any harm to your system.
4. During setup, the user may specify installation directories and other preferred
configurations. This program also adds entries to the system registry that are necessary for
specifying the operating parameters for each driver. An uninstall option is also included to
remove all registry/INI file entries from the system.
Windows NT Card Installation: After accomplishing the above steps, bring up the Control Panel
and double-click on the SeaIO Devices icon. To install a new card, click “Add Port.” Repeat this
procedure for as many SeaIO cards as you wish to install.
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. SeaIO Classic for Linux V2.21 software can also be downloaded by following
the instructions above and selecting ‘SeaIO Classic for Linux V2.21’ on Step 2.
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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INSTALLATION, CONTINUED
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 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. Replace the screw. (This is required to ensure FCC Part 15 compliance.)
6. Replace the cover.
7. Connect the power cord
Installation is finished.

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Digital I/O Interface
The PIO-48’s 48 digital I/O channels are accessed via two industry-standard 50-pin header connectors.
Each header provides 24 bits of digital I/O divided into three eight-bit ports. Each port may be individually
configured via software command as input or output.
50-pin Header Connectors
You will need to install the bracket assembly and cables to the PIO-48 prior to installing it in the PC. The
PIO-48’s bracket features a unique cable clamp that provides a solid strain relief to prevent inadvertent
cable removal.
Both 50-pin connectors have the following pin out which is compatible with a wide variety of solid-state
relay racks:

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Programming the PIO-48
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. Included on the SeaI/O CD are 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 PIO-48. 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/SeaIO/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.
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 PIO-48 provides.
Reading the Inputs
The inputs are active true. If an input is driven high (2V to 5.25 V) it will read as a logical one, if driven low
(0V to 0.8V) it will read as a logical zero. If an input is not driven it will read as a one due to the 10K ohm
pull up resistors on each port.
Reading the Outputs
The value that is currently being used to drive the outputs will be returned.

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Programming the PIO-48, Continued
Presetting an Output Port
Each port has an output register associated with it. This register may be written and retains its value
whether the port is configured as an input or an output. To preset the value of an output port the program
should write to the port when it is configured as an input then configure it as an output.
Writing the Outputs
The outputs are active true. Writing a one (1) corresponds to 5V while writing a zero (0) corresponds to 0V,
at the output.
Register Description
Address
Mode
D7
D6
D5
D4
D3
D2
D1
D0
Base+0
Port A1
RD/WR
PA1D7
PA1D6
PA1D5
PA1D4
PA1D3
PA1D2
PA1D1
PA1D0
Base+1
Port B1
RD/WR
PB1D7
PB1D6
PB1D5
PB1D4
PB1D3
PB1D2
PB1D1
PB1D0
Base+2
Port C1
RD/WR
PC1D7
PC1D6
PC1D5
PC1D4
PC1D3
PC1D2
PC1D1
PC1D0
Base+3
CW Port 1
WR
CW1D7
0
0
CW1D4
CW1D3
CW1D2
CW1D1
CW1D0
Base+4
Port A2
RD/WR
PA2D7
PA2D6
PA2D5
PA2D4
PA2D3
PA2D2
PA2D1
PA2D0
Base+5
Port B2
RD/WR
PB2D7
PB2D6
PB2D5
PB2D4
PB2D3
PB2D2
PB2D1
PB2D0
Base+6
Port C2
RD/WR
PC2D7
PC2D6
PC2D5
PC2D4
PC2D3
PC2D2
PC2D1
PC2D0
Base+7
CW Port 2
WR
CW2D7
0
0
CW2D4
CW2D3
CW2D2
CW2D1
CW2D0

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Programming the PIO-48, Continued
I/O Control Word
Each port may be configured as either Input or Output. This is accomplished by writing the correct Control
Word (CW) to the proper register.
Control Word (X = 0)
Hex Value
Port Setup
7
6
5
4
3
2
1
0
A
B
C
1
X
X
0
0
X
0
0
80
Out
Out
Out
1
X
X
0
0
X
0
1
81
Out
Out
In
1
X
X
0
0
X
1
0
82
Out
In
Out
1
X
X
0
0
X
1
1
83
Out
In
In
1
X
X
0
1
X
0
0
88
Out
Out
In
1
X
X
0
1
X
0
1
89
Out
Out
In
1
X
X
0
1
X
1
0
8A
Out
In
In
1
X
X
0
1
X
1
1
8B
Out
In
In
1
X
X
1
0
X
0
0
90
In
Out
Out
1
X
X
1
0
X
0
1
91
In
Out
In
1
X
X
1
0
X
1
0
92
In
In
Out
1
X
X
1
0
X
1
1
93
In
In
In
1
X
X
1
1
X
0
0
98
In
Out
In
1
X
X
1
1
X
0
1
99
In
Out
In
1
X
X
1
1
X
1
0
9A
In
In
In
1
X
X
1
1
X
1
1
9B
In
In
In

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Electrical Characteristics
The PIO-48 uses 74LS245 octal bi-directional transceivers to provide TTL input/output capabilities. Each
bit is pulled to +5V through a 10K ohm pull-up resistor to ensure each bit is at a known state when not
driven.

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Specifications
Inputs
Logic High
Min 2VDC
Logic Low
Max 0.8VDC
Outputs
Logic High
Min 2VDC @ 15 mA
Logic Low
Max 0.5VDC @ 24 mA
Environmental Specifications
Specification
Operating
Storage
Temperature Range
0º to 70º C
-50º to 105º C
Power Consumption
Supply Line
+12VDC
+5 VDC
Rating
25 mA
200 mA
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.

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Example Circuits

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© Sealevel Systems, Inc. 4030 Manual | SL9362 9/2021
Appendix A –Troubleshooting
Following these simple steps can eliminate most common problems.
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 SeaIO 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: supp[email protected].

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© Sealevel Systems, Inc. 4030 Manual | SL9362 9/2021
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 web site. 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
web site.
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 [phone].
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.