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

Technical Description
Sealevel Systems PLC-16.PCI Page 9
Optional Terminal Block Kit KT108
The third option for termination of the PLC-16.PCI is the KT108 Terminal Block Kit, which features the CA185
(HD44 M/F) and the TB08 Terminal Block adapter. This adapter groups the common connections of the
PLC-16.PCI into groups of four. The following is the silkscreen for the TB08. Note that the connections are
labeled for ease in wiring and troubleshooting:

Technical Description
Sealevel Systems PLC-16.PCI Page 10
Direct Hardware Control
In systems where the user’s program has direct access to the hardware (i.e. DOS) the table below gives the mapping
and functions that the PLC-16.PCI provides.
R = Read
W = Write
R/W = Read or Write
Function Available Port Address Hex Address Decimal Port Type
R A 300 (Base + 0) 768 Input Port (Opto Input)
B 301(Base + 1) 769 Not Used
R/W C 302 (Base + 2) 770 Output Port (Reed Relays)
D 303 (Base + 3) 771 Not Used
FINDPCI.EXE is a utility used in the DOS environment to identify resources that have been assigned to the adapter
by the BIOS. It is found on the supplied Sealevel Software CD in the \software\seaio\Other\DOS directory. It will
display resources for each detected Sealevel Systems card in the system. These settings are also stored in the file
PCI.INI, located in the same directory as FINDPCI.EXE.
Each system motherboard organizes its physical PCI slots according to the current PCI specification. There is not a
fixed order or number of slots for each motherboard.
To determine which resources correspond to which PCI card, you may want to add the cards one at a time and run
FINDPCI.EXE after each card is added. Each PCI slot will have a corresponding BUS, DEVICE, and FUNCTION
number. These numbers uniquely identify that slot when running these DOS utilities. Note the slot data for each
card that you install.
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 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 PLC-16.PCI are normally open.
To close a relay a one must be written to the appropriate bit.

Technical Description
Sealevel Systems PLC-16.PCI Page 11
Register Description
Address Mode D7 D6 D5 D4 D3 D2 D1 D0
Base+0 RD/WR PAD7 PAD6 PAD5 PAD4 PAD3 PAD2 PAD1 PAD0
Base+1 RD {0} {0} {0} {0} {0} {0} {0} {0}
Base+2 RD/WR PCD7 PCD6 PCD5 PCD4 PCD3 PCD2 PCD1 PCD0
Base+3 RD {0} {0} {0} {0} {0} {0} {0} {0}
Base+4 RD {0} {0} {0} {0} {0} {0} {0} {0}
Base+5 RD/WR IRQEN IRQST {0} {0} {0} {0} IRC1 IRC0
Base+6 RD {0} {0} {0} {0} {0} {0} {0} {0}
Base+7 RD {0} {0} {0} {0} {0} {0} {0} {0}
Note: When selecting the Interrupt Mode, always disable interrupts prior to changing or setting states. This will
help prevent inadvertent or un-expected interrupts from occurring. When using the high and low level interrupts, a
change in state of the input must occur before the interrupt can be cleared. The device providing the input to Base
+0, bit D0 must do this.
PAD0-7 = Port A (Base+0) Input port.
PCD0-7 = Port C (Base+2) Output port.
IRC0-1= Interrupt Mode select (Base+5)
IRC1 IRC0 Interrupt Type
0 0 Low Level
0 1 High Level
1 0 Falling Edge
1 1 Rising Edge
IRQEN = enable interrupts (Base+5)
0 = disabled
1 = enabled (disabled after reset or power up).
IRQST = interrupt status (Base+5)
1 = interrupt pending (reading the bit clears interrupt).

Specifications
Sealevel Systems PLC-16.PCI Page 12
Specifications
Environmental Specifications
Specification Operating Storage
Temperature
Range
0º to 70º C
(32º to 158º F)
-50º to 105º C
(-58º to 221º F)
Humidity Range 10 to 90% R.H.
Non-Condensing
10 to 90% R.H.
Non-Condensing
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 Consumption
Supply line +5 VDC
Rating 380mA
Physical Dimensions
Board Length 4.90 inches (12.446m.)
Board Height including Goldfingers 4.20 inches (10.668m.)
Board Height excluding Goldfingers 3.575 inches (9.842 cm.)
Board Weight 3.2 ounces (90.71g)

Appendix A - Troubleshooting
Sealevel Systems PLC-16.PCI Page 13
Appendix A - Troubleshooting
Sealevel Software is supplied with the Sealevel Systems adapter and may be used in the troubleshooting procedures.
Using this software and following these simple steps can eliminate most common problems without the need to call
Technical Support.
1. Identify all I/O adapters currently installed in your system. This includes your on-board serial ports,
controller cards, sound cards etc. The I/O addresses used by these adapters, as well as the IRQ (if any)
should be identified.
2. Configure your Sealevel Systems adapter so that there is no conflict with currently installed adapters. No
two adapters can occupy the same I/O address.
3. Make sure the Sealevel Systems adapter is using a unique IRQ. While the Sealevel Systems adapter does
allow the sharing of IRQs, many other adapters (i.e. SCSI adapters & on-board serial ports) do not. The
IRQ is typically selected by the BIOS or Operating system. Some BIOS setup software will allow changing
the IRQ, but others do not. Another method of changing assigned resources is to try changing PCI slots.
This will typically cause the BIOS or OS to reassign the resources.
4. Make sure the Sealevel Systems adapter is securely installed in a motherboard slot.

Appendix B - How To Get Assistance
Sealevel Systems PLC-16.PCI Page 14
Appendix B - How To Get Assistance
Please refer to Troubleshooting Guide prior to calling Technical Support.
1. Begin by reading through the Trouble Shooting Guide in Appendix A. If assistance is still needed
please see below.
2. 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.
3. 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.
4. Sealevel Systems maintains a web page on the Internet. Our home page address is
http://www.sealevel.com. The latest software updates, and newest manuals are available via our web
site.
5. 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.

Appendix C - Silk-Screen
Sealevel Systems PLC-16.PCI Page 15
Appendix C - Silk-Screen
4.2"
4.9"

Appendix D - Compliance Notices
Sealevel Systems PLC-16.PCI Page 16
Appendix D - Compliance Notices
Federal Communications Commission Statement
FCC - This equipment has been tested and found to comply with the limits for Class A digital device, 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 users 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:
EN55022 Class A - “Limits and methods of measurement of radio interference characteristics of
information technology equipment”
EN55024 – “Information technology equipment Immunity characteristics Limits and methods of
measurement”.
EN60950 (IEC950) - “Safety of information technology equipment, including electrical business
equipment”
Warning
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 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 Systems PLC-16.PCI Page 17
Warranty
Sealevel's commitment to providing the best I/O solutions is reflected in the Lifetime
Warranty that is standard on all Sealevel manufactured 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 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 life. 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 or abuse are not covered under this warranty.
Warranty service is obtained by delivering the Product to Sealevel and providing proof of purchase. Return
authorization must be obtained from Sealevel Systems before returned merchandise will be accepted.
Authorization is obtained by calling Sealevel Systems and requesting a Return Merchandise Authorization
(RMA) number. 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. Warranty is valid only
for original purchaser and is not transferable.
Sealevel Systems assumes no liability for any damages, lost profits, lost savings or any other incidental or
consequential damage resulting from the use, misuse of, or inability to use this product. Sealevel Systems will not
be liable for any claim made by any other related party.
This warranty applies to Sealevel manufactured Product. Product purchased through Sealevel but manufactured by a
third party will retain the original manufacturer's warranty.
Sealevel Systems, Incorporated
155 Technology Place
P.O. Box 830
Liberty, SC 29657 USA
[phone] FAX: [phone]
www.sealevel.com
email: [email protected]
Technical Support is available from 8 a.m. to 5 p.m. Eastern time.
Monday - Friday
Trademarks
Sealevel Systems, Incorporated acknowledges that all trademarks referenced in this manual are the service mark,
trademark, or registered trademark of the respective company.
PLC-16.PCI is a trademark of Sealevel Systems, Incorporated.