SeaLevel DIO-32.104 User manual

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© Sealevel Systems, Inc. 3730H Manual | SL9020H12/2022
DIO-32.104
User Manual | 3730H

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© Sealevel Systems, Inc. 3730H Manual | SL9020H12/2022
Contents
CONTENTS...........................................................................................................................................................2
INTRODUCTION ................................................................................................................................................... 3
BEFORE YOU GET STARTED ...............................................................................................................................4
CARD SETUP ........................................................................................................................................................6
SOFTWARE INSTALLATION ................................................................................................................................7
PHYSICAL INSTALLATION................................................................................................................................10
PROGRAMMING THE DIO-32.104.....................................................................................................................11
ELECTRICAL CHARACTERISTICS.....................................................................................................................16
SPECIFICATIONS ...............................................................................................................................................17
EXAMPLE CIRCUITS ..........................................................................................................................................19
APPENDIX A – TROUBLESHOOTING................................................................................................................20
APPENDIX B – HOW TO GET ASSISTANCE .....................................................................................................21
APPENDIX C – SILK SCREEN – 3730H PCB ....................................................................................................22
APPENDIX D – COMPLIANCE NOTICES ..........................................................................................................23
WARRANTY ........................................................................................................................................................24

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© Sealevel Systems, Inc. 3730H Manual | SL9020H12/2022
Introduction
The DIO-32.104 is a PC/104 form factor adapter that provides 16 reed relays that can switch power, data,
or other electronic signals for control applications and 16 optically isolated inputs to allow monitoring of
off board switch closures, relays or for any other general purpose monitoring needs. The inputs (rated for
3-13V) 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-32.104 is designed to be used with a variety of Operating Systems including Windows, Linux, and
DOS. The SeaI/O API (Application Programmer Interface) included in the software available for the DIO-
32.104 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-48.PC104 (P/N 3701) - 48 Channel TTL
DIO-104.REL (P/N 3710) - 16 Reed Relay Outputs
DIO-104.OPTO (P/N 3720) - 16 Optically Isolated Inputs

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© Sealevel Systems, Inc. 3730H Manual | SL9020H12/2022
Before You Get Started
What’s Included
The DIO-32.104 is shipped with the following items. If any of these items are missing or damaged, please
contact Sealevel for replacement.
•DIO-32.104 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 DIO-32.104 to real-world signals. All items can be purchased from our website
(www.sealevel.com) or by calling 864-843-4343.
40-Pin IDC to DB-37 Male 6” Ribbon Cable (Part Number CA110)
For compatibility with other Sealevel digital I/O devices, the CA110 connects to the 40-pin
header connector on the DIO-32.104 and provides a DB-37 Male connector. The CA110 is
typically used for the relay output side of the DIO-32.104.
40-Pin IDC to DB-37 Female 8” Ribbon Cable (Part Number CA211)
The CA211 connects to the 40-pin header connector on the DIO-32.104 and provides a DB-
37 Female connector. The CA211 is typically used for the isolated input side of the DIO-
32.104.
DB-37 Male to DB-37 Female 6’ Cable - (Part Number CA112)
This cable extends the DB-37 connector on the 6” ribbon cable, part number CA110, to six
feet and is pinned one-to-one.
DB-37 Male/Female Terminal Block (Part Number TB02-KT)
Break out serial and digital connectors to 37 screw terminals for easy field connection. The
TB02 terminal block is designed with both DB-37 male and female connectors, therefore; it
can be used with any DB-37 board regardless of the board's port gender.
Cable and Terminal Block Kit (Part Number KT101)
For convenient and easier ordering, the KT101 includes the TB02-KT terminal block and
CA112 cable in a single kit.

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© Sealevel Systems, Inc. 3730H Manual | SL9020H12/2022
Card Setup
Address Selection
The DIO-32.104 contains several jumper straps for each port that must be set for proper operation.
The DIO-32.104 occupies 4 consecutive I/O locations. The DIP-switch (S1) is used to set the base address
for these locations. 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. To maintain
compatibility with other Sealevel Systems I/O adapters, the actual port addresses are found at
BaseAddress+2 (Relays K1-K8) and BaseAddress+3 (Relays K9-K16).
Address Binary Switch Settings
A9 A8 A7 A6 A5 A4 A3 A2
1 2 3 4 5 6 7 8
100-103 01 0000 00xx On Off On On On On On On
104-107 01 0000 01xx On Off On On On On On Off
200-204 10 0000 00xx Off On On On On On On On
280-283 10 1000 00xx Off On Off On On On On On
284-287 10 1000 01xx Off On Off On On On On Off
2EC-2EF 10 1110 11xx Off On Off Off Off On Off Off
300-303 11 0000 00xx Off Off On On On On On On
320-323 11 0010 00xx Off Off On On Off On On On
388-38B 11 1000 10xx Off Off Off On On On Off On
3A0-3A3 11 1010 00xx Off Off Off On Off On On On
3A4-3A7 11 1010 01xx Off Off Off On Off On On Off
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 XX 11 0000 00XX where X = a non-selectable address bit.
1 2 3 4 5 6 7
ON
OFF
A9 A2
8
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. 3730H Manual | SL9020H12/2022
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 legacy driver download and installation instructions.
1. Begin by locating, selecting, and installing the correct software from the Sealevel software driver
database.
2. Select the Part Number (#3730H) for your adapter from the listing.
3. Select ‘Download Now’ for the SeaIO Classic for Windows. The setup file will automatically detect
the operating environment and install the proper components. Next (depending on your browser)
select the ‘Run this program from its 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.
4. If installing in NT, skip to step 13. ‘Windows NT Card Installation.’
5. Go to the “Add New Hardware Wizard” in the Control Panel.
6. When the Wizard asks if you want Windows to search for the new hardware, choose “No, I want to
select the hardware from a list.”
7. Scroll through the list of categorized hardware and select ‘SeaIO Devices.’ If this is the first SeaIO
device you may need to select ‘Other Devices’ and ‘Sealevel Systems, Inc.’ instead of ‘SeaIO
Devices.’
8. Click “Next.”
9. Select the card model and press “Next.”
10. The Wizard will guide you through a few more informational prompts; continue to click “Next” until
it is completed.
11. Your card’s resource assignments may be adjusted through the Device Manager (if, for instance,
you need to change the I/O port address Windows assigned when you installed the card).
12. Windows software installation is complete
13. Windows NT Card Installation: After accomplishing steps 1 – 3, 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.

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© Sealevel Systems, Inc. 3730H Manual | SL9020H12/2022
Linux Installation
You MUST have “root” privileges to install the software and drivers.
The syntax is case sensitive.
Users can obtain a README file included in the SeaIO Linux package which contains important
installation and configuration instructions that makes the Linux installation more user friendly.
1. Begin by locating, selecting, and installing the correct software from the Sealevel software driver
database.
2. Select the Part Number (P/N: 3730H) for your adapter from the listing.
3. Select ‘Download Now’ for the version of SeaIO Classic for Linux.
4. Copy seaio.tar.gz to your home directory by typing:
cp seaio.tar.gz ~
5. Change to your home directory by typing:
cd
6. Unzip and Untar the drivers and software by typing:
tar -xvzf seaio.tar.gz
7. Change to the SeaIO directory by typing:
cd seaio
8. User must download and compile a Linux kernel source.
9. Now compile and prepare the drivers for use by typing:
make install
10. Using your favorite text editor, edit the /etc/seaio.conf
11. Within the quote marks, insert
cardtype=0xYourSeaIOcardType io=0xCardBaseAddress

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Linux Installation, Continued
YourSeaIOcardType = Model Number of your SeaIO Card.
CardBaseAddress = What base address you have your SeaIO card addressed at.
12. Save the file and exit your editor.
13. With the system off and unplugged, install your SeaIO PCI card (See Physical Installation).
14. Plug system back in and boot Linux. Login as "root".
15. Load the SeaIO driver by typing:
seaioload
16. The driver has enabled the card and is ready to use.
To set up Linux to automatically load the driver; refer to a Linux manual concerning your specific distribution
for help.
For additional software support, please call Sealevel Systems’ Technical Support, [phone]. Our
technical support is free and available from 8:00 AM - 5:00 PM Eastern Time, Monday through Friday. For
email support contact: [e-mail].

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© Sealevel Systems, Inc. 3730H Manual | SL9020H12/2022
Physical Installation
Extreme care should be taken when installing the DIO-32.104 to avoid causing damage to the connectors.
After the adapter is installed, connect your I/O cables to the P1 (relays) and P2 (inputs) header connectors.
Please note these headers are keyed so that pin 1 of the cable matches pin 1 of the connector. Refer to
Card Setup for information on setting the address before inserting the DIO-32.104 onto the stack.
Do not install the Adapter in the machine until the software has been fully installed.
1. Turn off power. Disconnect the power cord.
2. Remove the case cover (if applicable).
3. Gently insert the DIO-32.104 connector noting proper key orientation of the expansion connector
on a PC/104 compatible card. The DIO-32.104 adapter is keyed per the current PC/104
Specification. This will aid in preventing the adapter from being inserted incorrectly.
4. Mounting hardware (nylon stand-offs and screws) is provided to ensure a good mechanical
connection. Retain any mounting hardware not used to allow for future expansion.
5. The cables provided are keyed and can be installed before or after the adapter is inserted in the
stack.
6. Replace the cover.
7. Connect the power cord and power up the machine.
The DIO-32.104 is now ready for use.
3rd Party Software
For the most up to date information on third party software support, please visit:
https://www.sealevel.com/support/3rd-party-software-support/.

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© Sealevel Systems, Inc. 3730H Manual | SL9020H12/2022
Programming the DIO-32.104
Sealevel’s SeaI/O software is available to assist in the development of reliable applications for the Sealevel
Systems family of digital I/O adapters. Included in the SeaI/O software 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 DIO-32.104. 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 in the SeaI/O
software. Further documentation on these samples can be found by selecting
“Start/Programs/SeaIO/Sample Application Description.” Information about where the files are included in
the software.
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-32.104 provides four parallel input/output (I/O) ports. The ports are organized as ports A, B, C, and
D. Ports 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

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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 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 signal is high enough to cause the opto-isolator to turn-on, the
output of the opto-isolator goes low (0 volts), and the port bit 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))
The following table shows common input resistors and the ranges associated with each.
Input Resistor Turn-On Input Range Max Input Max Current
220W 1.8V 1.8 – 7.0V 8.5V 27mA
560W 2.8V 2.8 – 10.6V 12.9V 20mA
1KW 4.1V 4.1 – 13.8V 16.9V 15mA
2.2KW 7.7V 7.7 – 20.0V 24.5V 10mA
3.3KW 10.0V 10.0 – 24.0V 30.0V 9mA
4.7KW 15.2V 15.2 – 28.0V 35.0V 7mA
The turn-off voltage for all resistors is less than 1V.

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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, if necessary can do this.
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 Pin Assignments (P2)
Port A Bit P2 DB-37 Port B Bit P2 DB-37
0
36 18
35 37
0
20 29
19 10
1
34 17
33 36
1
18 28
17 9
2
32 16
31 35
2
16 27
15 8
3
30 15
29 34
3
14 26
13 7
4
28 14
27 33
4
12 25
11 6
5
26 13
25 32
5
10 24
9 5
6
24 12
23 31
6
8 23
7 4
7
22 11
21 30
7
6 22
5 3
Ground
4 21
3 2
2 20
+ 12 Volts 1 1
+ 5 Volts 37 19

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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 (of sufficient magnitude, covered above) is applied it returns a zero on that
bit.
Function Available Port Address Hex
R A Base + 0
R B Base + 1
R = Read
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.

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Output Pin Assignments (P1)
Port C Bit Relay P1 DB-37 Port D Bit Relay P1 DB-37
0 K1
2 20
3 2
0 K9
18 28
19 10
1 K2
4 21
5 3
1 K10
20 29
21 11
2 K3
6 22
7 4
2 K11
22 30
23 12
3 K4
8 23
9 5
3 K12
24 31
25 13
4 K5
10 24
11 6
4 K13
26 32
27 14
5 K6
12 25
13 7
5 K14
28 33
29 15
6 K7
14 26
15 8
6 K15
30 34
31 16
7 K8
16 27
17 9
7 K16
32 35
33 17
Ground
34 36
35 18
36 37
+ 5 Volts 37 19
+ 12 Volts 1 1
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-32.104 are normally
open. To close a relay a one must be written to the appropriate bit.

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Electrical Characteristics
Features
•2 sets SPST relays with each having 8 relays
•2 eight bit input ports
•Selectable I/O port addressing from 100H - 3FFH
•Highly reliable 10 VA DIP reed relays
•Multiple adapters can reside in same computer
•All address, data and control signals are TTL compatible

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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 10 W
Contact Voltage Maximum 100 VDC/VAC
Contact Current Maximum .5A AC/DC RMS
Contact Resistance, Initial .15 Ω
Rated Life Low Load: 200 million closures
Maximum Load: 100 million closures
Contact Speed
Operate: .5mS
Release: .5mS
Bounce: .5 mS
Maximum Operating Speed 600 Hz
Temperature Range
Operating 0°C – 70°C
Storage -50°C – 105°C
Power Consumption
Supply line +5 VDC +12VDC
Rating 285 mA (Optional)

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Specifications, Continued
Physical Dimensions
PCB Length 3.6” (9.0 cm)
PCB Height 3.8” (9.6 cm)
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
Input Circuit
Output Circuit

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© Sealevel Systems, Inc. 3730H Manual | SL9020H12/2022
Appendix A – Troubleshooting
The adapter should provide years of trouble-free service. However, in the event that device appears to not
be functioning incorrectly, the following tips can eliminate most common problems 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 SeaIO Control Panel applet or the Device Manager’s property page for card identification
and configuration.
5. Always use the Sealevel Systems diagnostic software when troubleshooting a problem. This will
eliminate any software issues from the equation.
If these steps do not solve your problem, please call Sealevel Systems’ Technical Support, [phone].
Our technical support is free and available from 8:00 A.M.- 5:00 P.M. Eastern Time Monday through Friday.
For email support contact [e-mail].