SeaLevel PLC-16.PCI User manual

PLC-16.PCI
Users Manual
Part # 8011
Sealevel Systems, Inc. Telephone: [phone]
155 Technology Place Fax: [phone]
Liberty, SC 29657 USA www.sealevel.com

Contents
INTRODUCTION .......................................................................................................................................................1
OVERVIEW .....................................................................................................................................................................1
WHAT’S INCLUDED ........................................................................................................................................................1
OPTIONAL CABLES/ACCESSORIES ..................................................................................................................................1
INSTALLATION ........................................................................................................................................................2
WINDOWS 98/ME/NT/2000/XP INSTALLATION .............................................................................................................2
LINUX INSTALLATION.....................................................................................................................................................2
PHYSICAL INSTALLATION ...............................................................................................................................................3
TECHNICAL DESCRIPTION ..................................................................................................................................4
FEATURES ......................................................................................................................................................................4
DIGITAL INPUTS .............................................................................................................................................................4
RELAY OUTPUTS ............................................................................................................................................................4
DIGITAL INPUT PORT......................................................................................................................................................5
OUTPUT PORT (RELAY) ..................................................................................................................................................6
PORT PIN ASSIGNMENTS.................................................................................................................................................7
HD44 PIN ASSIGNMENTS ...............................................................................................................................................7
OPTIONAL CABLE CA184 PIN ASSIGNMENTS.................................................................................................................8
OPTIONAL TERMINAL BLOCK KIT KT108 ......................................................................................................................9
DIRECT HARDWARE CONTROL .....................................................................................................................................10
READING THE INPUTS ...................................................................................................................................................10
READING THE OUTPUTS................................................................................................................................................10
WRITING THE OUTPUTS:...............................................................................................................................................10
REGISTER DESCRIPTION ...............................................................................................................................................11
SPECIFICATIONS ...................................................................................................................................................12
ENVIRONMENTAL SPECIFICATIONS...............................................................................................................................12
MANUFACTURING ........................................................................................................................................................12
POWER CONSUMPTION .................................................................................................................................................12
PHYSICAL DIMENSIONS ................................................................................................................................................12
APPENDIX A - TROUBLESHOOTING ................................................................................................................13
APPENDIX B - HOW TO GET ASSISTANCE .....................................................................................................14
APPENDIX C - SILK-SCREEN ..............................................................................................................................15
APPENDIX D - COMPLIANCE NOTICES...........................................................................................................16
FEDERAL COMMUNICATIONS COMMISSION STATEMENT ..............................................................................................16
EMC DIRECTIVE STATEMENT ......................................................................................................................................16
WARRANTY .............................................................................................................................................................17
© Revision December 9, 2003
Sealevel Systems, Incorporated. All rights reserved.

Introduction
Sealevel Systems PLC-16.PCI Page 1
Introduction
Overview
The PLC-16.PCI provides 8 Form C relays that can switch and carry 2A loads making it suitable for latching
power, data or other electronic signals for control applications. 8 optically isolated inputs are also provided to allow
monitoring of off board switch closures, relays or for any other general purpose monitoring needs. The
PLC-16.PCI is optimized for 24V DC/AC usage.
What’s Included
The PLC-16.PCI is shipped with the following items. If any of these items is missing or damaged, contact the
supplier.
•PLC-16.PCI Adapter
•Sealevel SeaIO Software CD
Optional Cables/Accessories
KT108 – Includes CA185, HD44 M/F Cable and TB08, PLC type Terminal Block.
KT109 – Includes CA184, HD44 to (2) DB37 M/F Cable and (2) TB02, 37 pin Terminal Blocks

Installation
Sealevel Systems PLC-16.PCI Page 2
Installation
Windows 98/ME/NT/2000/XP Installation
Do not install the Adapter in the machine until the software has been fully installed.
1. Start Windows.
2. Insert the Sealevel Systems CD in to your CD drive.
3. If ‘Auto-Start’ is enabled for this drive the software will automatically launch. Otherwise, point your
browser to the ‘Index.htm’ on the root of the CD
4. Select ‘Install Software’.
5. Select the part number for your adapter from the listing.
6. Select ‘Windows 98/ME/NT/2000/XP’ the setup file will automatically detect the operating environment
and install the proper components. Next (depending on the OS version) select the ‘Run from current
location’ or ‘Open’ option. Follow the information presented on the screens that follow. 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 available to remove SeaIO files and 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.
Linux Installation
Note: You need to have "root" privileges to install the software and drivers.
1. Login as "root".
2. Mount the CDROM by typing:
mount -t iso9660 /dev/hdc /cdrom
Note Your cdrom may not be /dev/hdc it could be /dev/hda, /dev/hdb, /dev/hdd, or if you have a SCSI drive
/dev/sda, /dev/sdb, /dev/sdc, etc. You may mount the CDROM to any location, the /cdrom is just a common
example.
3. Next change to the directory where you mounted the CDROM:
Ex. cd /cdrom/software/SeaIO/Other/linux
Note: The syntax is case sensitive.
4. Copy seaio .tar.gz to your home directory by typing:
cp seaio .tar.gz ~
5. Change to your home directory by typing:
cd

Installation
Sealevel Systems PLC-16.PCI Page 3
6. Unmount the drive and then Unzip and Untar the drivers and software by typing:
umount /cdrom
tar -xvzf seaio .tar.gz
7. Change to the SeaIO directory by typing:
cd SeaIO
8. Now compile and prepare the drivers for use:
make install
9. With the system off and unplugged, install your SeaIO PCI card.
10. Plug system back in and boot Linux.
Login as "root".
11. Load the driver by typing:
SeaIO -load
The driver has enabled the card and is ready to use, and you now have the option to run a test utility on it. Skip to
section "Using the test software" if you wish to do so at this time.
To set up Linux to automatically load the driver; refer to a Linux manual concerning your specific distribution for
help.
Physical 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. Install cable (CA165).
7. Replace the cover.
8. Connect the power cord.
Installation is finished.
.

Technical Description
Sealevel Systems PLC-16.PCI Page 4
Technical Description
The PLC-16.PCI provides two parallel input/output (I/O) ports. The ports are organized as ports A, B, C, and D.
Port A is an input port interfaced to optically isolated inputs, while port C is the relay output port.
Features
Digital Inputs
•Number of inputs: Eight.
•Type: Non-polarized, optically isolated from each other and from the computer.
•Voltage Range: 5 to 24V DC or AC.
Relay Outputs
•Number of outputs: Eight.
•Contact Rating: 2A carry current, bifurcated, gold clad, silver palladium.
•Contact Arrangement: SPDT (Single Pole Double Throw) Form C.
•Contact Resistance: Initial 100 milliohms maximum.
•Contact Life: mechanical: 10 million operations minimum.
•Contact Life: electrical: 5 million operations minimum at full load.
•Operating Time: 2 milliseconds maximum.
•Release Time: 1 milliseconds maximum.

Technical Description
Sealevel Systems PLC-16.PCI Page 5
Digital Input Port
Port A is an 8 bit input port 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 (1K ohm) that is used to limit the input current to the opto-
isolator. A current path is required to ‘turn-on’ the sensor.
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 1K ohms. The opto-isolator requires approximately 3 mA to turn on.
The maximum input current is 60 mA. Adding additional resistors to the input current limiting resistor can increase
the voltage to be sensed. Two things to consider when selecting additional input resistance:
1. Turn on voltage for the circuit to sense.
2. The maximum input voltage. Maximum input voltage must not provide too much power to the input
resistor, and must not overdrive the opto-isolator input current specification. The following formulas apply:
Turn on current: 3 mA
Isolator diode drop: 1.1 V
Resistor power Max: 1 W
Turn on Voltage = diode drop + (turn on current) x (resistance)
Or:
1.1 + (.003) x R
Maximum voltage = square root of (resistor value)
The input circuits are not for monitoring 120-volt AC circuits.
1 K Ohm
1 Watt
Voltage input (5-24V)
Ground Reference
User Installable Capicator
1K
+5VDC
Ground

Technical Description
Sealevel Systems PLC-16.PCI Page 6
Output Port (Relay)
The PLC-16.PCI provides 8 Form C (SPDT) Electro-mechanical relays. These relays have three connections;
Normally Open (NO), Normally Closed (NC) and a Common. The relays are all de-energized at power-on. Data to
the relays is latched by a write to the base+2 address. On/off status of the relays can be read back by a read at the
base+2 address.
The above is a schematic representation of the Output Bit D0. The NC contact would be Pin 1 on the HD44, N0
would be Pin 31 and the Common would be Pin 16.
+5 V
2
5
4
1
3
HD-44
1
16
31
Output Bit D0

Technical Description
Sealevel Systems PLC-16.PCI Page 7
Port Pin Assignments
The PLC-16.PCI has several different cable and terminal block options. The card itself has a high-density 44-pin
connector (HD44), unlike many competitive products. This allows both poles (NO/NC) of the Form C relay to be
accessed as well as each input of the optically isolated input circuit to be represented as a unique pin on the
connector. The following table shows the correlation between pins on the HD44 and their specific function.
HD44 Pin Assignments
Input:
Port A Bit P1
D0 9,10
D1 11,12
D2 13,14
D3 23,24
D4 25,26
D5 27,28
D6 29,30
D7 40,41
Output:
Port C Bit Normally Closed Common Normally Open
D0 (K1) 1 16 31
D1 (K2) 2 17 32
D2 (K3) 3 18 33
D3 (K4) 4 34 35
D4 (K5) 5 19 36
D5 (K6) 6 20 37
D6 (K7) 7 21 38
D7 (K8) 8 22 39

Technical Description
Sealevel Systems PLC-16.PCI Page 8
Optional Cable CA184 Pin Assignments
In our continuing effort to make our products more easily integrated into systems that may have previously used our
I/O interface products, the CA184 was created. This cable mimics several of the pin-out options found on Sealevel’s
PCI and ISA legacy products and provides a direct connection to Sealevel’s TB02, 37 pin Terminal Block. The
following table shows the correlation between pins on the CA184 option cable connectors and their specific
function.
Input: DB37 Female
Port A Bit Input
D0 3,22
D1 4,23
D2 5,24
D3 6,25
D4 7,26
D5 8.27
D6 9,28
D7 10,29
Output: DB37 Male
Port C Bit Normally Closed Common Normally Open
D0 (K1) 1 2 3
D1 (K2) 4 5 6
D2 (K3) 7 8 9
D3 (K4) 10 11 12
D4 (K5) 22 23 24
D5 (K6) 25 26 27
D6 (K7) 28 29 30
D7 (K8) 31 32 33