Digital I/O

Digital I/O & Modbus TCP Connectivity Guide

Overview

What is I/O Connectivity?

I/O (Input/Output) connectivity is used when we need to connect machines that do not have Ethernet or a communication protocol available. This is typically our approach for older machines that predate modern networked controls.

How It Works:

MachineMetrics uses a piece of hardware (typically a Sealevel or WISE device) installed in the machine's electrical cabinet. This hardware module connects to electrical signals from the machine to monitor activity and production.

Our Standard Approach:

Utilization Signal (Machine Activity):
- Install a current transducer (CT) on a cable drawing current
- Typically attached to the spindle motor cable
- Detects when the machine is running vs. idle by monitoring motor current
Part Count Signal:
- Capture a signal that indicates when a part is complete
- Lathes: Often use bar feed signal
- Mills: Often use fixture clamp signal or pallet changer
- Other machines: Part eject, part counter relay, etc.

The hardware module reads these electrical signals and sends the data to MachineMetrics over your network using Modbus TCP protocol.

When to Use I/O

Use I/O connectivity when:

Machine does not support modern protocols (FOCAS, MTConnect, OPC-UA)
Older legacy equipment (pre-2000 machines)
Simple machine tools without networked controls
Non-CNC machines (press brakes, injection molding, grinders, assembly equipment)
Equipment with accessible electrical signals but no data interface

Key Technical Concepts

Understanding these terms will help as you configure I/O connectivity:

Wet Contact: Signal provides its own voltage source (e.g., 24VDC output from PLC)
Dry Contact: Simple switch closure, requires external voltage source
Current Transducer (CT): Sensor that outputs proportional voltage or current based on AC motor current
Optically Isolated: Electrical isolation between input and system ground (3000VDC+ typical)
Modbus TCP: Industry-standard digital protocol for reading/writing data over Ethernet

Current I/O Hardware

Sealevel eI/O-170E / eI/O-170PoE

MachineMetrics' exclusive I/O solution for all new installations. We sell and support only this model.

Sealevel eI/O-170 Module

Sealevel eI/O-170 Ethernet I/O Module - A compact DIN-rail mounted device with digital inputs and outputs for connecting to machine signals. This module communicates via Modbus TCP and is commonly used for monitoring machine utilization through current transducers and capturing part counts from machine signals.

Specifications

Analog Inputs (8 channels):

Voltage Ranges: 0-5V, 0-10V, ±5V, ±10V (software configurable)
Resolution: 12-bit (4096 counts, 0.00244V per count at 10V range)
Input Impedance: 100kΩ
Channels: 8 single-ended OR 4 differential
Typical Use: Current transducers (analog 0-10V CT models)

Digital Inputs (2 channels - Opto 1 & Opto 2):

Type: Dry contact sensing (internally powered)
Isolation: 1000VDC optical isolation
Source Current: 12mA max
Wiring: Connect switch/contact between input and common terminal
⚠️ CRITICAL: These inputs SOURCE current. DO NOT apply external voltage.

Power Options

Standard Model (eI/O-170E):

Power: 9-30VDC, 3W typical
Screw terminals on side of unit
Use 24VDC shop power

Power over Ethernet (eI/O-170PoE):

IEEE 802.3af-2003 PoE (Class 0)
No separate power supply needed
Single cable for power and data
Requires PoE switch or injector

Physical Specifications

Size: 4.5" L × 3.5" W × 1.3" H
Mounting: DIN rail clip included (35mm rail)
Terminals: 3.5mm removable screw terminals
Status LEDs:
- Power (Green): Lights when powered
- Act (Green): Blinks during Modbus TCP activity
Operating Temp: -40°C to 70°C

Purchasing

Order from: shop.machinemetrics.com
MachineMetrics provides pre-configured units
Full technical support included

Advantech WISE-4050

Preferred wireless I/O solution that customers source directly from Advantech or distributors.

Advantech WISE-4050/LAN I/O Module

Advantech WISE-4050/LAN Ethernet I/O Module - Wired version with 4 digital inputs. The module features terminal connections for easy wiring and supports Modbus TCP communication. This is the LAN (wired Ethernet) variant; a wireless WiFi version (WISE-4050) is also available.

Specifications

Model: WISE-4050 (Wireless) or WISE-4050/LAN (Wired Ethernet)

Digital Inputs (4 channels):

Type: Optically isolated
Voltage Range: 10-50VDC
Isolation: 3000VDC (optical)
Wet Contact Compatible: Yes (10-50VDC)
Dry Contact Compatible: Yes (requires external power)

Wireless Specifications (WISE-4050)

WiFi:

Standard: IEEE 802.11 b/g/n
Frequency: 2.4 GHz
Range: Up to 150m (line of sight)
Security: WEP, WPA, WPA2-PSK
Modes: Infrastructure or AP mode

Network Configuration

Default Settings:

Wireless AP Mode: SSID "WISE-4050-XXXXXX" (last 6 of MAC)
Default IP: 10.0.0.1 (AP mode) or DHCP (Infrastructure mode)
Default Login: root / 00000000 (8 zeros)
Modbus Port: 502
Web Interface: http://[IP-address]

Sourcing WISE-4050

Purchase Options:

Direct from Advantech: www.advantech.com
Distributors: DigiKey, Mouser, Newark, Arrow
Typical Price: $150-250 USD

Part Numbers:

WISE-4050: Wireless version
WISE-4050/LAN: Wired Ethernet version

Additional Items Required for Wireless WISE-4050:

Antenna extension cable (customer must purchase)
- Type: RP-SMA or compatible with WISE-4050 antenna connector
- Length: 1-3 feet recommended
- Features: Look for cables with magnetic base antenna for easy mounting
- Connects module inside cabinet to antenna outside cabinet
Installation requirement: Hole must be drilled in electrical cabinet for external antenna mounting

Note: Wireless WISE-4050 requires antenna to be mounted externally to the electrical cabinet for proper WiFi signal reception. See Installation section for details.

Retired Hardware

LabJack T4/T7 (Hardwired)

⚠️ RETIRED: No longer sold by MachineMetrics. Existing installations fully supported.

If you already have these modules, they will continue to work with full MachineMetrics support. Analog voltage-based (0-40VDC) configuration.

LabJack U3 (Wireless)

⚠️ RETIRED: No longer sold by MachineMetrics. Existing installations fully supported.

Use Advantech WISE-4050 for new wireless installations.

Understanding Current Transducers

Types of Current Transducers

There are two types of CTs for different applications:

1. Analog Output CT (0-10VDC)

For use with Sealevel eI/O-170 Analog Inputs

Specifications:

Input: 0-100A AC (or 0-200A for larger motors)
Output: 0-10VDC (proportional analog voltage)
Example: 50A motor current = 5VDC output
Self-powered: No external power needed

Common Models:

NK Technologies AT Series
CR Magnetics CR5410
Veris H Series

Wiring to eI/O-170:

CT (+) output → AN1 terminal
CT (-) output → AG terminal (analog ground)

Use Cases:

Spindle motor monitoring (main utilization signal)
Live tooling head monitoring
Axis drive monitoring (Z-axis, etc.)
Any motor-driven activity detection

2. Dry Contact Output CT (Switch Closure)

For use with Sealevel eI/O-170 Digital Inputs (Opto 1 & Opto 2)

Specifications:

Input: 0-100A AC (adjustable setpoint)
Output: Dry contact closure when current exceeds setpoint
Requires: External voltage source for switch sensing
Adjustable Trip Point: Set threshold for switch activation

Common Models:

NK Technologies AS2 Series
Veris H800 Series with switch output

Wiring to eI/O-170 Digital Input:

External 24VDC (+) → One side of CT switch output
Other side of CT switch → Opto 1 terminal
COM terminal → External 24VDC (-)

Use Cases:

Simple on/off detection (machine running or not)
When analog resolution not needed
Cost-effective solution

Installing a Current Transducer

Step 1: Identify Motor to Monitor

Usually spindle motor drive
Could be live tooling head
Could be axis drive (Z-axis for lathes)
For multi-spindle: CT on each spindle

Step 2: Access Motor Power Wires

Open electrical cabinet
Find motor drive or contactor
Identify three phase wires (L1, L2, L3)

Step 3: Install CT

Clamp CT around ONE phase wire only (any of the three)
Arrow on CT should point toward motor
Secure CT so it doesn't vibrate loose
Do not clamp around multiple wires
Do not clamp around insulated cable bundle (individual wire only)

Step 4: Wire CT Output

Analog CT: Connect to AN1 and AG terminals
Dry Contact CT: Connect through external 24VDC to Opto 1

Current Transducer Wiring Diagram

Signal Selection Strategy

Utilization Signals

Goal: Determine if machine is ACTIVE or IDLE.

Preferred Methods (in order):

Current Transducer on Spindle (Most Reliable)
- Analog CT: Monitors actual motor current
- Set low threshold (1.0-1.5V) for low-speed detection
- Works on almost any spindle-driven equipment
Green Stack Light (If Accurate)
- Wet contact: 24VDC when machine running
- Simple and reliable
- Verify it accurately reflects in-cycle state
PLC Output "In Cycle" (If Available)
- Dedicated signal from PLC
- Most accurate when available
- May be labeled "Auto Mode", "Cycle Active", etc.

Part Count Signals

Goal: Detect when a part has been completed.

Preferred Methods (in order):

Part Count Relay (Ideal)
- Dedicated relay triggered by M-code in program
- Pulses briefly after each part
- Most reliable method
Pallet Changer Signal (Mills with Pallets)
- Signal when pallet changes
- Each pallet change = parts completed
- Monitor "Pallet Index Complete" or similar
Barfeeder Pulse (Lathes with Barfeeders)
- Signal when barfeeder advances
- Each advance = new part started
- May need logic: count on part eject, not bar advance
Part Ejector/Unloader
- Signal from part handling equipment
- Part catcher, conveyor, or robot
- May need combination logic (ejector AND auto mode)
Coolant Pump Pulse (Last Resort)
- ⚠️ Use only when other methods not available
- Requires two M-code pulses (on, off, on, off)
- Must use min-delta and max-delta for timing verification
- Can cause excessive coolant pump wear
- Requires program modifications

Sealevel eI/O-170 Installation

Physical Installation

Step 1: Mount Module

Install on 35mm DIN rail in electrical cabinet
Keep away from high-voltage lines (>240VAC)
Accessible location for wiring
Protected from coolant and chips

Step 2: Power Connection

Standard Model (eI/O-170E):

24VDC (+) → V+ terminal (side of module)
24VDC (-) → V- terminal

PoE Model (eI/O-170PoE):

Connect CAT5/CAT6 ethernet cable
PoE provides power automatically via ethernet

Step 3: Network Connection

Connect ethernet cable to RJ45 port
Connect to network switch
Module communicates with Edge device over network

Network Configuration

Sealevel Module Configuration

Sealevel I/O Module with terminal connections - The module features multiple digital input and output terminals for wiring machine signals. Note the clear terminal labeling and the RJ45 Ethernet port for network connectivity. This view shows the actual connection points where you'll wire current transducers, part count signals, and other machine I/O.

Step 1: Download SeaMAX Software

Visit: https://www.sealevel.com/software-seamax-windows
Download SeaMAX Suite for Windows
Install as administrator

Step 2: Discover Module

Launch "Ethernet Config" utility (Start → All Programs → Sealevel Systems → SeaMAX → Ethernet Configuration Tool)
Click "Search for SeaI/O Devices"
Modules on network will appear
Default IP: 192.168.42.253

Step 3: Configure Static IP

Select module in device list
Enter new static IP address (from your IT team)
- Example: 192.168.1.101
Enter subnet mask: 255.255.255.0
Enter gateway (if required)
Click "Apply Changes"
Module will reboot with new IP

Step 4: Verify Connection

Ping module from Edge device or computer
Launch MaxSSD utility (Start → All Programs → Sealevel Systems → SeaMAX → MaxSSD Configuration Utility)
Select "Ethernet" from COM Port dropdown
Select module IP from list
Click "Get SeaIO Module Settings"
Module information should display

Terminal Wiring

Analog Inputs (for CTs):

AN1 - Analog Input 1 (address 0, e.g., main spindle CT)
AN2 - Analog Input 2 (address 1, e.g., live tooling CT)
AN3 - Analog Input 3 (address 2, e.g., Z-axis CT)
AN4 - Analog Input 4 (address 3)
AN5 - Analog Input 5 (address 4)
AN6 - Analog Input 6 (address 5)
AN7 - Analog Input 7 (address 6)
AN8 - Analog Input 8 (address 7)
AG  - Analog Ground (common for all analog inputs)

Digital Inputs (Opto 1 & Opto 2):

Opto 1 - Digital Input 0 (dry contact sensing)
Opto 2 - Digital Input 1 (dry contact sensing)
COM    - Common for digital inputs

⚠️ CRITICAL: Digital inputs are internally powered (source 12mA). Connect switch/relay contacts between Opto terminal and COM. DO NOT apply external voltage to these inputs.

Example: Dry Contact Relay Wiring to Opto 1:

External 24VDC (+) → One side of relay N.O. contact
Other side of relay contact → Opto 1 terminal
COM terminal → External 24VDC (-)

WISE-4050 Installation & Configuration

Advantech WISE-4050/LAN I/O Module

Advantech WISE-4050/LAN Ethernet I/O Module - A versatile wireless/wired I/O module with multiple digital inputs and outputs. This compact module supports both WiFi (WISE-4050) and Ethernet (WISE-4050/LAN) connectivity, making it ideal for machines where running cables is difficult. The module communicates via Modbus TCP and features indicator LEDs for easy status monitoring. Image shows the wired LAN version.

Physical Installation

Step 1: Mount Module

Snap onto 35mm DIN rail
Mount inside electrical cabinet for protection

Step 2: Antenna Mounting (Wireless WISE-4050 Only)

IMPORTANT: For wireless WISE-4050 modules, the antenna must be mounted externally to the electrical cabinet for proper WiFi signal reception.

WiFi Antenna Extension Cable

WiFi antenna extension cable with RP-SMA connector - Required for wireless WISE-4050 installations. The extension cable connects the WISE-4050 module inside the electrical cabinet to the antenna mounted outside the cabinet. The cable features spring-coiled sections for flexibility and a magnetic base antenna for easy external mounting.

Antenna Installation Requirements:

Drill Hole in Cabinet
- A hole must be drilled in the electrical cabinet wall
- Size: Appropriate for antenna connector/cable (typically 1/2" to 3/4")
- Location: Choose a location with clear line-of-sight to WiFi access points
- Coordinate with machine owner/electrician before drilling
Antenna Extension Cable Required
- Customer must purchase an antenna extension cable
- Cable connects WISE-4050 module (inside cabinet) to antenna (outside cabinet)
- Cable type: RP-SMA or compatible with WISE-4050 antenna connector
- Recommended length: 1-3 feet (minimize signal loss)
- Features: Magnetic base antenna for easy mounting
Mount Antenna Externally
- Route extension cable through drilled hole
- Attach antenna to outside of cabinet (magnetic base works well on metal cabinets)
- Secure antenna in position with appropriate mounting hardware
- Ensure antenna has clear path for WiFi signals

Note: The WISE-4050/LAN (wired Ethernet version) does not require antenna mounting. Simply connect an Ethernet cable to the module's RJ45 port.

Step 3: Power Connection

24VDC (+) → V+ terminal
24VDC (-) → V- terminal

DIP Switch Configuration

Before wiring signals to the WISE-4050, you must configure the DIP switches on the back of the module to set the input type (wet contact or dry contact) for each digital input channel.

WISE-4050 DIP Switch Configuration Table

WISE-4050 DIP Switch Configuration - The module has three switches (SW1, SW2, SW3) on the back that control operation mode and input types. SW2 configures channels DI0-3, and SW3 configures channels DI4-7. Set to ON for dry contact or OFF for wet contact.

DIP Switch Functions:

Switch	Description	Position	ON (Default)	OFF
SW1	Operation Mode	P1	Normal Mode	Initial Mode
		P2	N/A	N/A
SW2	DI Type (Ch0-3)	P1	Dry Contact	Wet Contact
		P2	Dry Contact	Wet Contact
SW3	DI Type (Ch4-7)	P1	Dry Contact	Wet Contact
		P2	Dry Contact	Wet Contact

Understanding Contact Types:

Wet Contact (Switch OFF)

Machine provides voltage on the signal wire
Example: Machine outputs 24VDC when signal is active
Common for: Stack lights, relay outputs, PLC outputs with power
Wiring: Connect signal wire to DI terminal, no external power needed

Dry Contact (Switch ON - Default)

Machine provides contact closure only (no voltage)
Requires external power supply
Common for: Relay contacts, switch contacts, mechanical contacts
Wiring: Connect external 24VDC (+) to one side of contact, other side to DI terminal

Configuration Examples:

Example 1: All Wet Contacts (Stack Lights)

Machine outputs 24VDC on all signals
Set SW2 P1, P2 = OFF (channels DI0-3)
Set SW3 P1, P2 = OFF (channels DI4-7)

Example 2: All Dry Contacts (Relay Contacts)

Machine has relay contacts only
Set SW2 P1, P2 = ON (channels DI0-3) - Default
Set SW3 P1, P2 = ON (channels DI4-7) - Default
Provide external 24VDC power

Example 3: Mixed Configuration

DI0-3: Wet contacts (stack lights)
DI4-7: Dry contacts (relay contacts)
Set SW2 P1, P2 = OFF (wet contact for DI0-3)
Set SW3 P1, P2 = ON (dry contact for DI4-7)

Important Notes:

⚠️ POWER OFF the WISE-4050 before changing DIP switch settings. Changing switches while powered can damage the module.

⚠️ MATCH SIGNAL TYPE to switch setting. Applying 24VDC to an input configured for dry contact can damage the module.

Step 4: Wire Signal Connections

After configuring DIP switches, wire your machine signals according to the contact type selected.

WiFi Configuration (Wireless Model)

Initial Setup - Connect to WISE AP:

Power on WISE-4050
- Module creates its own WiFi network on first boot
- SSID: WISE-4050-XXXXXX (last 6 digits of MAC address)
- No password required initially
Connect Computer to WISE WiFi
- Use laptop or tablet
- Connect to WISE-4050-XXXXXX WiFi network
- Computer will receive IP via DHCP
Access Web Interface
- Open web browser
- Navigate to: http://10.0.0.1
- Login: root
- Password: 00000000 (8 zeros)

[Recommended Image]: Screenshot of WISE-4050 web interface login and configuration page

Configure for Your Shop WiFi (Infrastructure Mode):

Change to Infrastructure Mode
- In web interface, go to: Network → WLAN → Mode
- Select: Infrastructure
- Click Submit
Select Your WiFi Network
- Go to: Network → WLAN → Infrastructure Settings
- SSID: Enter your shop WiFi network name
- Security: Select security type (WPA2-PSK recommended)
- Password: Enter your WiFi password
- Click Submit
Configure Static IP (Recommended)
- Go to: Network → LAN → Ethernet/WLAN IP Configuration
- Uncheck Enable DHCP
- IP Address: Enter static IP (from IT team)
  - Example: 192.168.1.150
- Subnet Mask: 255.255.255.0
- Gateway: Your network gateway
- Click Submit
Set Modbus Unit ID
- Go to: I/O Status → Modbus Address
- Unit ID: Set to 1 (or as required)
- Click Submit
Reboot Module
- Go to: Maintenance → System → Reboot
- Click Reboot
- Module will restart and connect to your WiFi
Verify Connection
- Reconnect computer to your shop WiFi
- Navigate to new IP address: http://192.168.1.150 (your configured IP)
- Should see WISE web interface
- Verify WiFi signal strength in web interface

Important Security Settings:

Change Default Password
- Go to: Maintenance → Account
- Change password from default 00000000
- Use strong password
- Document password for future access

WISE-4050/LAN Configuration (Wired Model)

Connect ethernet cable to RJ45 port
Access web interface at default IP: http://10.0.0.1
Login: root / 00000000
Configure static IP as described above
Set Modbus Unit ID to 1

Terminal Wiring Examples

IMPORTANT: Ensure DIP switches are configured correctly BEFORE wiring signals. See DIP Switch Configuration section above.

Wet Contact Wiring (DIP Switch OFF)

Use when machine provides voltage on signal wire (e.g., stack lights, PLC outputs with power):

Green Light (+24VDC) → DI0+ terminal
Green Light (0V/GND) → COM terminal

Yellow Light (+24VDC) → DI1+ terminal
Yellow Light (0V/GND) → COM terminal

Part Signal (+24VDC) → DI2+ terminal
Part Signal (0V/GND) → COM terminal

DIP Switch Setting: SW2 OFF (for DI0-3)

Dry Contact Wiring (DIP Switch ON - Default)

Use when machine provides contact closure only (e.g., relay contacts, mechanical switches):

External 24VDC (+) → DI0+ terminal
Relay Contact (NO) → DI0- terminal
Relay Contact (COM) → COM terminal

External 24VDC (+) → DI1+ terminal
Switch Contact → DI1- terminal
Switch Contact → COM terminal

DIP Switch Setting: SW2 ON (for DI0-3) - This is the default setting

Mixed Contact Example

DI0-3 configured for wet contacts (stack lights):

DIP Switch SW2: OFF
Green Light (24VDC) → DI0+
Yellow Light (24VDC) → DI1+
Red Light (24VDC) → DI2+
All grounds → COM

DI4-7 configured for dry contacts (relay):

DIP Switch SW3: ON (default)
External 24VDC (+) → DI4+
Relay contact → Between DI4- and COM

WISE High-Frequency Counter Mode (Advanced)

For applications requiring RPM tracking or high-frequency pulse counting (e.g., conveyor speed, encoder pulses, production counters), we recommend using a WISE unit (either wireless or wired) configured in counter mode.

When to Use Counter Mode

Common use cases:

RPM monitoring: Spindle speed from encoder pulses
Conveyor speed: Tracking belt or chain speed from proximity sensors
High-speed part counting: Fast production lines with high pulse rates
Encoder tracking: Position or speed from rotary encoders
Frequency measurement: Any signal above 10 Hz

Why WISE for High-Frequency?

Standard digital inputs sample too slowly for fast pulses
Counter mode accumulates pulses in hardware (no missed counts)
Can handle frequencies up to several kHz
Polling adapter reads total count, not individual pulses

Configuring WISE Input as Counter

Step 1: Access WISE Web Interface

Navigate to WISE IP address in browser: http://192.168.1.150 (your configured IP)
Login: root / your password
Go to: I/O Status → Digital Input Configuration

Step 2: Set Input Mode to Counter

Select the input channel (DI0, DI1, DI2, or DI3)
Mode: Change from "Digital Input" to "Counter"
Counter Type: Select "Frequency Counter" or "Pulse Counter"
Click Submit and Reboot the module

Note: Once an input is set to counter mode, it accumulates pulses continuously. The adapter script reads the current count value and calculates the difference since the last reading.

How Counter Mode Works

Normal Digital Input Mode:

Adapter reads: true or false (on/off state)
High-speed pulses may be missed between reads
Limited to ~10 Hz sampling frequency

Counter Mode:

Adapter reads: Current accumulated count (integer)
WISE hardware counts every pulse (no missed counts)
Adapter calculates: count_difference = current_count - previous_count
Supports frequencies up to several kHz

Polling Frequency:

Use resample parameter in variables for precise sampling control
For RPM: resample: 5 (5-second sampling) is usually sufficient
For real-time counting: Use resample: 0.5 or resample: 1 (500ms or 1-second sampling)
More accurate and reliable than global scan-interval

Recommended: Place resample in the variable pipeline (e.g., after value-increase-diff) for best results.

WISE Counter Register Addresses

When using counter mode, WISE modules expose counter values as Modbus holding registers:

Digital Input	Counter Register Address	Function Code	Type
DI0	40019	3 (Read Holding Registers)	int16
DI1	40020	3	int16
DI2	40021	3	int16
DI3	40022	3	int16

Important: Counter mode changes the input from a boolean coil to a 16-bit register. The digital input coil remains available separately for reading the current state.

Sample Script: RPM Calculation from Encoder

Hardware Setup:

WISE-4050 or WISE-4050/LAN
DI0: Encoder pulse output (configured as counter in WISE web interface)
Encoder: 60 pulses per revolution (PPR)
Resample interval: 5 seconds

Configuration:

version: 2
unit-id: 1

registers:
  encoder-count:
    address: 40019  # DI0 counter register
    type: int16

variables:
  # Track count increase (pulses since last reading)
  pulse-diff:
    - source: encoder-count
    - value-increase-diff  # Returns difference from last reading
    - resample: 5  # Sample counter every 5 seconds
  
  # Calculate RPM from pulse difference
  # Formula: RPM = (pulses / PPR) * (60 / resample_interval)
  # With 60 PPR and 5-second resample: RPM = (pulses / 60) * (60 / 5)
  # Simplified: RPM = pulses / 5
  spindle-rpm:
    - source: pulse-diff / 5
    - expression: round(this, 0)  # Round to whole number
  
  # Optional: Execution state from RPM
  execution:
    - source: spindle-rpm > 100  # Active if RPM > 100
    - state:
        - ACTIVE: this
        - READY: true

data-items:
  - spindle-rpm
  - encoder-count
  - execution

Key Points:

resample: 5 in the variable pipeline samples the counter value every 5 seconds
More accurate and reliable than using scan-interval
value-increase-diff returns the count increase since last reading
RPM formula depends on PPR (pulses per revolution) and resample interval
encoder-count is cumulative and will roll over at max int16 (32,767)
Roll-over is handled automatically by value-increase-diff
Register address 40019 is for DI0 counter

Note: The resample parameter goes in the variables section, not on the register definition.

Sample Script: High-Speed Part Counting

Hardware Setup:

WISE-4050
DI1: Part sensor configured as counter in WISE web interface
Part sensor pulses once per part
Resample interval: 1 second

Configuration:

version: 2
unit-id: 1

registers:
  parts-counter:
    address: 40020  # DI1 counter register
    type: int16

variables:
  # Extract count difference and accumulate
  part-count:
    - source: parts-counter
    - value-increase-diff  # Get new parts since last poll
    - resample: 1  # Sample counter every 1 second
    - count  # Accumulate into total
  
  # Calculate parts per minute (production rate)
  parts-per-minute:
    - source: parts-counter
    - value-increase-diff
    - resample: 1  # Sample counter every 1 second
    - expression: this * 60  # Scale 1-second reading to per-minute
  
  # Execution based on production activity
  execution:
    - source: parts-per-minute > 5  # Active if producing
    - off-delay: 30  # Hold for 30 seconds
    - state:
        - ACTIVE: this
        - READY: true

data-items:
  - part-count
  - parts-per-minute
  - parts-counter
  - execution

Key Points:

Counter mode ensures no pulses are missed on fast production lines
resample: 1 in the variable pipeline samples the counter value every 1 second
More accurate and reliable than using scan-interval
value-increase-diff gets new parts since last reading
count operation accumulates differences into running total
Scale to per-minute by multiplying by 60 / resample_interval
Register address 40020 is for DI1 counter
Counter will roll over at 32,767 (handled automatically)

Note: The resample parameter goes in the variables section, not on the register definition.

RPM Calculation Reference

General RPM Formula:

RPM = (pulses_per_scan / pulses_per_revolution) * (60 / scan_interval_seconds)

Example Calculations:

PPR	Scan Interval	Pulses Counted	RPM Calculation
60	5 seconds	300	(300/60) * (60/5) = 60 RPM
1	5 seconds	50	(50/1) * (60/5) = 600 RPM
100	1 second	50	(50/100) * (60/1) = 30 RPM
360	5 seconds	1800	(1800/360) * (60/5) = 60 RPM

Simplified Formulas for Common Configurations:

# 60 PPR, 5-second resample:
pulse-diff:
  - source: encoder-count
  - value-increase-diff
  - resample: 5
spindle-rpm:
  - source: pulse-diff / 5

# 1 PPR (1 pulse per revolution), 5-second resample:
pulse-diff:
  - source: encoder-count
  - value-increase-diff
  - resample: 5
spindle-rpm:
  - source: pulse-diff * 12

# 100 PPR, 1-second resample:
pulse-diff:
  - source: encoder-count
  - value-increase-diff
  - resample: 1
spindle-rpm:
  - source: pulse-diff * 0.6

# 360 PPR, 5-second resample:
pulse-diff:
  - source: encoder-count
  - value-increase-diff
  - resample: 5
spindle-rpm:
  - source: pulse-diff / 30

Complete Working Example: WISE High-Frequency Counter

This is a real-world configuration using a WISE unit with DI0 configured as a counter.

Hardware Setup:

WISE-4050 or WISE-4050/LAN
DI0: High-frequency pulse input (configured as counter in WISE web interface)
DI0 also used for execution state detection

Basic Counter Configuration:

version: 2
unit-id: 1

coils:
  di0:
    address: 1  # Digital input state (still available)

registers:
  counter1:
    address: 40019  # DI0 counter register
    type: int16  # 16-bit signed integer

variables:
  execution:
    - source: di0  # Use digital input state
    - resample: 0.1  # Sample every 100ms for fast response
    - state:
        - ACTIVE: this
        - INTERRUPTED: true

data-items:
  - di0  # Current input state
  - execution  # Derived state
  - counter1  # Counter value

With RPM Calculation:

version: 2
unit-id: 1

coils:
  di0:
    address: 1

registers:
  counter1:
    address: 40019
    type: int16

variables:
  # Calculate pulses since last reading
  pulse-diff:
    - source: counter1
    - value-increase-diff
    - resample: 5  # Sample counter every 5 seconds
  
  # Calculate RPM (assuming 60 pulses per revolution)
  # Formula: (pulses / 60 PPR) * (60 seconds / 5 second resample)
  # Simplified: pulses / 5
  spindle-rpm:
    - source: pulse-diff / 5
    - expression: round(this, 0)
  
  # Execution from RPM threshold
  execution:
    - source: spindle-rpm > 100
    - state:
        - ACTIVE: this
        - READY: true

data-items:
  - di0
  - execution
  - counter1
  - spindle-rpm

Key Points:

Counter register is at address 40019 for DI0
Counter is int16 type (range: -32,768 to 32,767)
Digital input coil remains available at address 1
resample in variables controls sampling frequency for each data point
Both the counter value and input state are output

Note: The resample parameter goes in the variables section, not on registers or at the global level.

Counter Roll-Over Handling

Since the counter is int16, it will roll over at:

Maximum: 32,767
Rolls to: -32,768

The value-increase-diff operation handles this roll-over automatically, so your counts remain accurate even after roll-over occurs.

Troubleshooting Counter Mode

Counter not incrementing:

Verify input is configured as counter in WISE web interface
Check signal wiring and voltage (should be 10-50VDC for wet contact)
Test signal with multimeter or oscilloscope
Ensure signal frequency is within WISE specifications

Incorrect RPM or count:

Verify PPR (pulses per revolution) for your encoder
Check scan interval matches script configuration
Confirm register address matches DI channel
Test with known RPM source for calibration

Counter resets unexpectedly:

Check WISE power supply stability
Verify network connectivity (dropped connections can cause resets)
Review WISE system logs in web interface

Modbus TCP Addressing

Sealevel eI/O-170 Address Map

Analog Inputs:

AN1 → Register 0 (function 4, type int16)
AN2 → Register 1 (function 4, type int16)
AN3 → Register 2 (function 4, type int16)
AN4 → Register 3 (function 4, type int16)
AN5 → Register 4 (function 4, type int16)
AN6 → Register 5 (function 4, type int16)
AN7 → Register 6 (function 4, type int16)
AN8 → Register 7 (function 4, type int16)

Digital Inputs (Opto 1 & Opto 2):

Opto 1 → Coil 0 (function 2 - Read Discrete Inputs)
Opto 2 → Coil 1 (function 2 - Read Discrete Inputs)

WISE-4050 Address Map

Digital Inputs:

DI0 → Coil 0 (function 2 - Read Discrete Inputs)
DI1 → Coil 1 (function 2 - Read Discrete Inputs)
DI2 → Coil 2 (function 2 - Read Discrete Inputs)
DI3 → Coil 3 (function 2 - Read Discrete Inputs)

Data Types

Sealevel eI/O-170:

Analog Inputs: int16 (0-4095 raw counts)
Digital Inputs: Boolean (coils)

WISE-4050:

Digital Inputs: Boolean (coils)

Comprehensive Adapter Script Examples

Reference Documentation:

Adapter Scripts Guide: https://developers.machinemetrics.com/docs/adapter-scripts/intro
Available Operations: https://developers.machinemetrics.com/docs/adapter-scripts/operations

Example 1: CT for Execution (Main Spindle)

Hardware: Sealevel eI/O-170E

AN1: Main spindle CT (analog 0-10V model)

Configuration:

version: 2
unit-id: 1

registers:
  spindle-raw:
    address: 0 # AN1
    func: 4 # Read Input Registers
    type: int16 # Raw ADC counts (0-4095)

variables:
  # Convert raw ADC counts to voltage (0-10V range)
  # 4096 counts = 10V, so divide by 409.6 to get voltage
  ct-voltage-int:
    - source: spindle-raw / 409.6 # Intermediate voltage (0.0 to 10.0 VDC)

  # Create cleaned version for data output (reduces noise/database load)
  ct-voltage:
    - source: ct-voltage-int
    - resample: 0.5 # Sample every 500ms
    - min-delta: 0.1 # Only report changes >0.1V

  # Execution based on voltage threshold with off-delay
  execution:
    - source: ct-voltage-int > 1.15 # 1.15V threshold
    - off-delay: 10 # 10 second off-delay (prevents flicker)
    - state:
        - ACTIVE: this
        - READY: true

data-items:
  - execution
  - ct-voltage # Send cleaned voltage value for trending

Key Points:

Raw ADC is 0-4095 (12-bit)
Divide by 409.6 to convert to 0-10V
Create intermediate variable (ct-voltage-int) for threshold logic
Create cleaned variable (ct-voltage) with resample and min-delta for data output
Use cleaned version in data-items to reduce database load
1.15V threshold catches low-speed operations
10-second off-delay prevents flicker during rapid start/stop

Example 2: Multiple CTs (Main Spindle + Live Tooling + Z-Axis)

Hardware: Sealevel eI/O-170E

AN1: Main spindle CT
AN2: Live tooling head CT
AN3: Z-axis drive CT
Opto 1: Part eject signal (dry contact)

Configuration:

version: 2
unit-id: 1

registers:
  main-spindle-raw:
    address: 0 # AN1
    func: 4
    type: int16

  live-tool-raw:
    address: 1 # AN2
    func: 4
    type: int16

  z-axis-raw:
    address: 2 # AN3
    func: 4
    type: int16

coils:
  part-eject:
    address: 0 # Opto 1
    func: 2 # Read Discrete Inputs

variables:
  # Convert all CTs to voltage (intermediate)
  main-spindle-voltage-int:
    - source: main-spindle-raw / 409.6

  live-tool-voltage-int:
    - source: live-tool-raw / 409.6

  z-axis-voltage-int:
    - source: z-axis-raw / 409.6

  # Create cleaned versions for data output
  main-spindle-voltage:
    - source: main-spindle-voltage-int
    - resample: 0.5
    - min-delta: 0.1

  live-tool-voltage:
    - source: live-tool-voltage-int
    - resample: 0.5
    - min-delta: 0.1

  z-axis-voltage:
    - source: z-axis-voltage-int
    - resample: 0.5
    - min-delta: 0.1

  # Machine active if ANY spindle/axis has current
  execution:
    - source: main-spindle-voltage-int > 1.0 or live-tool-voltage-int > 1.0 or z-axis-voltage-int > 0.8
    - off-delay: 10
    - state:
        - ACTIVE: this
        - READY: true

  # Part count on eject signal
  part-count:
    - source: part-eject
    - rising-edge
    - count

data-items:
  - execution
  - part-count
  - main-spindle-voltage
  - live-tool-voltage
  - z-axis-voltage

Key Points:

Monitors three different motors/drives
Uses OR logic: active if any has current
Lower threshold for Z-axis (0.8V) as it draws less current
Intermediate variables (-int suffix) for threshold logic
Cleaned variables with resample/min-delta for data output
Separate voltage values for analysis/trending

Example 3: Stack Lights + Dry Contact Part Count

Hardware: WISE-4050

DI0: Green light (24VDC wet contact)
DI1: Yellow light (24VDC wet contact)
DI2: Part count relay (dry contact with external 24VDC)
DI3: Red light (24VDC wet contact)

Machine Behavior:

Green ON + Yellow OFF = In cycle (ACTIVE)
Green ON + Yellow ON = Operator stop (INTERRUPTED)
Red ON = Alarm (INTERRUPTED)
All OFF = Idle (READY)

Configuration:

version: 2
unit-id: 1

coils:
  green-light:
    address: 0 # DI0
    func: 2 # Read Discrete Inputs
  yellow-light:
    address: 1 # DI1
    func: 2
  part-relay:
    address: 2 # DI2
    func: 2
  red-light:
    address: 3 # DI3
    func: 2

variables:
  # Complex execution state from light combination
  execution:
    - state:
        - INTERRUPTED: red-light # Alarm
        - INTERRUPTED: green-light and yellow-light # Op-stop
        - ACTIVE: green-light and yellow-light == false # In cycle
        - READY: true # Idle

  # Part counter
  part-count:
    - source: part-relay
    - rising-edge
    - count

data-items:
  - execution
  - part-count
  - green-light
  - yellow-light
  - red-light

Key Points:

Order matters in state: (first match wins)
Check alarm and op-stop before checking active
Use == false instead of not for clarity
Send individual light states for diagnostics

Example 4: Pallet Changer on Mill

Hardware: WISE-4050

DI0: Pallet index complete signal
DI1: Auto mode signal
DI2: Spindle running (from CT with dry contact output)

Configuration:

version: 2
unit-id: 1

coils:
  pallet-index:
    address: 0 # DI0
    func: 2 # Read Discrete Inputs
  auto-mode:
    address: 1 # DI1
    func: 2
  spindle:
    address: 2 # DI2
    func: 2

variables:
  # Active when spindle running
  execution:
    - source: spindle
    - off-delay: 10
    - state:
        - ACTIVE: this
        - READY: true

  # Count parts on pallet change (only in auto mode)
  part-count:
    - source: pallet-index and auto-mode # Both must be true
    - rising-edge
    - count

data-items:
  - execution
  - part-count
  - auto-mode

Key Points:

Use and operator for combination logic
Pallet index only counts in auto mode
Prevents false counts during manual pallet changes

Example 5: Barfeeder Pulse on Lathe

Hardware: Sealevel eI/O-170E

AN1: Main spindle CT
Opto 1: Barfeeder advance complete signal

Configuration:

version: 2
unit-id: 1

registers:
  spindle-raw:
    address: 0 # AN1
    func: 4
    type: int16

coils:
  barfeed-pulse:
    address: 0 # Opto 1
    func: 2 # Read Discrete Inputs

variables:
  # Spindle monitoring (intermediate conversion)
  spindle-voltage-int:
    - source: spindle-raw / 409.6

  # Cleaned version for data output
  spindle-voltage:
    - source: spindle-voltage-int
    - resample: 0.5
    - min-delta: 0.1

  execution:
    - source: spindle-voltage-int > 1.0
    - off-delay: 10
    - state:
        - ACTIVE: this
        - READY: true

  # Count on barfeed advance (new part started)
  part-count:
    - source: barfeed-pulse
    - rising-edge
    - count

data-items:
  - execution
  - part-count
  - spindle-voltage

Key Points:

Barfeed advance indicates new part cycle starting
Each bar advance = 1 part (adjust if multiple parts per bar)
May need to count on part eject instead depending on machine

Example 6: Coolant Pulse Method (Last Resort)

Hardware: Sealevel eI/O-170E

AN1: Spindle CT
Opto 1: Coolant pump contactor (dry contact)

⚠️ WARNING: Use this method only when other part counting methods are not available. Requires program modifications and uses 2 pulses.

M-Code in Part Program:

M08          ; Coolant ON (pulse 1)
G04 P0.5     ; Wait 0.5 seconds
M09          ; Coolant OFF
G04 P0.5     ; Wait 0.5 seconds
M08          ; Coolant ON (pulse 2)
G04 P0.5     ; Wait 0.5 seconds
M09          ; Coolant OFF
M30          ; Program end

Configuration:

version: 2
unit-id: 1

registers:
  spindle-raw:
    address: 0 # AN1
    func: 4
    type: int16

coils:
  coolant-raw:
    address: 0 # Opto 1
    func: 2 # Read Discrete Inputs

variables:
  # Spindle monitoring (intermediate conversion)
  spindle-voltage-int:
    - source: spindle-raw / 409.6

  # Cleaned version for data output
  spindle-voltage:
    - source: spindle-voltage-int
    - resample: 0.5
    - min-delta: 0.1

  execution:
    - source: spindle-voltage-int > 1.0
    - off-delay: 10
    - state:
        - ACTIVE: this
        - READY: true

  # Filter coolant signal to verify pulse duration
  coolant-filtered:
    - source: coolant-raw
    - min-delta: 0.4 # Must be on for at least 0.4 seconds
    - max-delta: 0.7 # Must be on for no more than 0.7 seconds

  # Count on filtered coolant signal (2 pulses = 1 part)
  pulse-count:
    - source: coolant-filtered
    - rising-edge
    - count

  # Divide pulse count by 2 to get part count
  part-count:
    - source: pulse-count / 2

data-items:
  - execution
  - part-count
  - spindle-voltage

Key Points:

min-delta and max-delta verify pulse duration (0.4-0.7 sec)
Prevents false counts from normal coolant operation
Two pulses required per part (divide count by 2)
Adds wear to coolant pump (use sparingly)
Requires modification of all part programs

Example 7: Auto Mode Filtering

Hardware: WISE-4050

DI0: Auto mode signal
DI1: Part ejector signal
DI2: Green light

Problem: Part ejector can be triggered manually during setup. Only count parts in auto mode.

Configuration:

version: 2
unit-id: 1

coils:
  auto-mode:
    address: 0 # DI0
    func: 2 # Read Discrete Inputs
  part-ejector:
    address: 1 # DI1
    func: 2
  green-light:
    address: 2 # DI2
    func: 2

variables:
  # Execution from green light
  execution:
    - source: green-light
    - state:
        - ACTIVE: this
        - READY: true

  # Part count ONLY when in auto mode (using AND logic)
  part-count:
    - source: part-ejector and auto-mode # Both must be true
    - rising-edge
    - count

data-items:
  - execution
  - part-count
  - auto-mode

Key Points:

Use and operator to combine conditions
Prevents false counts during manual operation
Common requirement for automated equipment

Example 8: Injection Molding Machine

Hardware: WISE-4050

DI0: Mold closed (wet contact)
DI1: Auto mode (wet contact)
DI2: Injection in progress
DI3: Alarm

Configuration:

version: 2
unit-id: 1

coils:
  mold-closed:
    address: 0
    func: 2 # Read Discrete Inputs
  auto-mode:
    address: 1
    func: 2
  injection:
    address: 2
    func: 2
  alarm:
    address: 3
    func: 2

variables:
  # Execution state
  execution:
    - state:
        - INTERRUPTED: alarm
        - ACTIVE: injection and auto-mode
        - READY: true

  # Count parts on mold closing (only in auto)
  part-count:
    - source: mold-closed and auto-mode # Both must be true
    - rising-edge
    - count

data-items:
  - execution
  - part-count
  - auto-mode
  - alarm

Machine-Specific Integrations

Haas CNC Machines (Pre 2001)

Recommended Configuration:

Hardware: Sealevel eI/O-170E
AN1: Spindle CT (analog 0-10V)
Opto 1: Part count relay or coolant contactor

Adapter Script:

version: 2
unit-id: 1

registers:
  spindle-raw:
    address: 0 # AN1
    func: 4
    type: int16

coils:
  part-signal:
    address: 0
    func: 2 # Read Discrete Inputs

variables:
  # Spindle monitoring (intermediate conversion)
  spindle-voltage-int:
    - source: spindle-raw / 409.6

  # Cleaned version for data output
  spindle-voltage:
    - source: spindle-voltage-int
    - resample: 0.5
    - min-delta: 0.1

  execution:
    - source: spindle-voltage-int > 1.15
    - off-delay: 10
    - state:
        - ACTIVE: this
        - READY: true

  part-count:
    - source: part-signal
    - rising-edge
    - count

data-items:
  - execution
  - part-count
  - spindle-voltage

Citizen/Miyano Lathes

Recommended Configuration:

Hardware: Sealevel eI/O-170E
AN1: Main spindle CT
AN2: Sub spindle CT (if applicable)
Opto 1: Work count relay

Adapter Script:

version: 2
unit-id: 1

registers:
  main-spindle-raw:
    address: 0 # AN1
    func: 4
    type: int16

  sub-spindle-raw:
    address: 1 # AN2
    func: 4
    type: int16

coils:
  work-count:
    address: 0
    func: 2 # Read Discrete Inputs

variables:
  # Convert CTs to voltage (intermediate)
  main-voltage-int:
    - source: main-spindle-raw / 409.6

  sub-voltage-int:
    - source: sub-spindle-raw / 409.6

  # Cleaned versions for data output
  main-voltage:
    - source: main-voltage-int
    - resample: 0.5
    - min-delta: 0.1

  sub-voltage:
    - source: sub-voltage-int
    - resample: 0.5
    - min-delta: 0.1

  # Active if either spindle running
  execution:
    - source: main-voltage-int > 1.0 or sub-voltage-int > 1.0
    - off-delay: 10
    - state:
        - ACTIVE: this
        - READY: true

  part-count:
    - source: work-count
    - rising-edge
    - count

data-items:
  - execution
  - part-count
  - main-voltage
  - sub-voltage

Troubleshooting

Cannot Connect to Module

Diagnostic Steps:

Check Power
- Sealevel: Power LED green?
- WISE: Power LED on?
- Measure voltage at terminals: 24VDC ±10%
Check Network
- Cable fully seated in RJ45?
- Link lights blinking?
- Try different cable or switch port
Check IP Address
- Sealevel default: 192.168.42.253
- WISE default: 10.0.0.1 or DHCP
- Is computer on same subnet?
Ping Module
- Open command prompt
- ping 192.168.42.253 (or module IP)
- Should receive replies

Signal Not Detected

Diagnostic Steps:

Measure Voltage
- Use multimeter
- Measure between input terminal and common
- Should read signal voltage when active
- Should read near 0V when inactive
Check Wiring
- Terminals tight?
- Correct polarity?
- Any broken wires?
Verify Modbus Address
- Sealevel: AI0=register 0, Opto 1=coil 0
- WISE: DI0=coil 0, DI1=coil 1, etc.
Test with Configuration Tool
- Sealevel: Use MaxSSD utility
- WISE: Use web interface diagnostics
- Confirm signal reaches module

Current Transducer (CT) State Detection Issues

Current transducers measure electrical current to determine machine state (Active/Idle). Use this systematic approach to diagnose and resolve CT-related issues.

CT Troubleshooting Timeline View

Common Symptoms:

Machine shows Idle while physically running
Machine shows Active while physically idle
Erratic switching between Active and Idle states
Machine state never changes

⚠️ CRITICAL PRINCIPLE: When a machine is completely idle (spindle off, no motors running), the CT voltage should be very low (typically 0.5V - 1.5V). If you see high voltage during idle, the CT is in the wrong location or measuring the wrong circuit.

Understanding CT Switch Positions

Most analog CTs (0-10V output) have three switch positions that determine the current measurement range:

Switch Position	Current Range	When to Use
1 (Low)	0-50A	Small motors, low-power equipment
2 (Medium)	0-100A	Most spindle motors, typical CNC equipment
3 (High)	0-200A	Large motors, high-power machines

How to Choose: Check the motor nameplate for rated current, then select the switch position that covers that range. Too low = CT maxes out; too high = poor signal separation.

Diagnostic Steps:

Review Current Configuration
- Navigate to Machines → [Machine] → Settings → Data Collection
- Document current threshold value and off-delay setting
Observe CT Behavior in Timeline
- Go to Machine → Timeline view and enable Live Mode
- Add "CT Converted Voltage - Raw" data item to timeline
- Watch the signal for several minutes while machine cycles
Verify Physical Installation

Checkpoint	✅ Correct	❌ Incorrect
Clamp closure	Fully closed, no gap	Gap visible between halves
Cable type	Single conductor only	Multiple wires or cable bundle
Location	Spindle motor or main power	General building power
Interference	18"+ from VFDs/transformers	Adjacent to high-voltage equipment

Perform Live Testing (Most Critical Step)

Stand at the machine and observe CT voltage during these states:

Test A: Machine Completely Idle

Spindle OFF, no motors running
Record idle voltage range (should be < 2.0V)
If higher: CT is on wrong circuit or switch position too high

Test B: Spindle Running (Not Cutting)

Start machine, activate spindle at normal speed
Record active voltage range

Test C: Production (Cutting)

Load part and begin cutting operation
Record cutting voltage range

Calculate Optimal Threshold

Optimal Threshold = (Max Idle Voltage + Min Active Voltage) / 2

Example:

Idle range: 0.8V to 1.5V (Max = 1.5V)
Active range: 3.2V to 5.0V (Min = 3.2V)
Calculation: (1.5 + 3.2) / 2 = 2.35V
Set threshold to 2.3V or 2.5V

⚠️ Important: You need at least 0.5V separation between max idle and min active.

Update Adapter Script Configuration

Navigate to Machines → [Machine] → Settings → Data Collection and update your adapter script:

variables:
  # Intermediate variable for logic (not output)
  ct-voltage-int:
    - source: spindle-raw / 409.6 # SeaLevel conversion

  # Cleaned variable for data output
  ct-voltage:
    - source: ct-voltage-int
    - resample: 0.5 # Sample every 0.5 seconds
    - min-delta: 0.1 # Only send if changed by 0.1V

  # Execution state based on threshold
  execution:
    - source: ct-voltage-int > 2.5 # Your calculated threshold
    - off-delay: 90 # Optional delay in seconds
    - state:
        - ACTIVE: this
        - READY: true

data-items:
  - execution
  - ct-voltage # Output cleaned variable only

⚠️ CRITICAL Variable Naming:

Always use TWO variables for CT voltage
Intermediate variable (ct-voltage-int): Used for threshold logic, never include in data-items
Cleaned variable (ct-voltage): Uses resample and min-delta to reduce noise, safe for data-items
This prevents database overload from noisy analog signals

Common CT Issues & Quick Solutions:

No voltage signal (flat line at 0V)

Check physical connections at IO module
Verify Modbus register address in script
Test with multimeter or swap CT

Constant high voltage (even when machine is off)

Turn machine off at breaker - CT should drop to ~0V
If signal persists, CT is on wrong circuit
Relocate to machine-specific circuit (spindle motor)
Ensure only single conductor in CT clamp
Check CT switch position - try higher range setting

Extreme noise / erratic signal

Move CT 18"+ away from VFDs and transformers
Reroute CT cable away from high-voltage runs
Verify cable shielding is intact

Typical Voltage Ranges (Quick Reference):

Machine State	Typical Voltage	Diagnosis
Completely Off (breaker off)	0V - 0.2V	No current flowing
Idle / Standby	0.5V - 1.5V	✅ Normal baseline
⚠️ High Idle (PROBLEM)	2.5V - 4.0V	❌ Wrong circuit or multiple conductors
Spindle Running (no load)	2.5V - 4.0V	Clear increase from idle
Cutting / Under Load	3.5V - 5.0V	Peak activity

When to Contact Support:

No voltage signal despite verified connections
CT signal doesn't correlate with machine behavior
Overlapping idle/active voltage ranges after relocating CT
Adapter script changes don't take effect

Include: Machine name, Timeline screenshots showing CT voltage, documented voltage ranges, photos of CT installation, and current adapter script.

False Part Counts

Solutions:

Add Auto Mode Logic

part-count:
  - source: part-signal and auto-mode
  - rising-edge
  - count

Add Pulse Duration Verification (for coolant method)

filtered-signal:
  - source: raw-signal
  - min-delta: 0.4
  - max-delta: 0.7

Use Correct Edge Detection
- Try rising-edge vs falling-edge
- Depends on signal behavior

Best Practices

Planning:

Study machine operation before selecting signals
Review electrical schematics
Test signals under various conditions
Document everything

Current Transducers:

Use analog 0-10V CTs for Sealevel eI/O-170 analog inputs
Use dry contact CTs for Sealevel eI/O-170 digital inputs (Opto 1/2)
Clamp around ONE phase only
Secure CT to prevent vibration
Set low threshold (1.0-1.5V) for low-speed detection

Wiring:

Use 18-22 AWG stranded wire
Label all wires clearly
Keep wiring neat and organized
For Sealevel digital inputs: DO NOT apply external voltage (internally powered)

Electrical Safety:

Never apply >50VDC to any input
Use relays for AC voltages
Verify voltage with multimeter
Follow lockout/tagout procedures
Work with qualified electricians

Configuration:

Start with simple adapter scripts
Test incrementally
Use descriptive variable names
CRITICAL: Never output raw analog values in data-items
- Create intermediate variable for logic (e.g., ct-voltage-int)
- Create cleaned variable with resample and min-delta for output
- Only output cleaned variables to reduce noise and database load
Reference: https://developers.machinemetrics.com/docs/adapter-scripts/intro
Keep backup of working configurations

Part Counting:

Prefer dedicated part count relay
Use pallet changer signal when available
Use barfeeder pulse when applicable
Coolant pulse method is last resort only

Additional Resources

MachineMetrics Developer Documentation:

Adapter Scripts Introduction: https://developers.machinemetrics.com/docs/adapter-scripts/intro
Available Operations: https://developers.machinemetrics.com/docs/adapter-scripts/operations

Sealevel Resources:

SeaMAX Software Download: https://www.sealevel.com/software-seamax-windows
eI/O-170 Product Page: https://www.sealevel.com
Technical Support: (864) 843-4343 or support@sealevel.com

Advantech Resources:

WISE-4050 Product Page: https://www.advantech.com
WISE-4050 User Manual (see provided PDF)
Technical Support: www.advantech.com/support

Purchasing:

Sealevel eI/O-170: Order from shop.machinemetrics.com
WISE-4050: Customer-sourced from Advantech or distributors
Current Transducers: NK Technologies, CR Magnetics, Veris

Getting Help

Before Contacting Support

Gather this information:

Hardware Details
- Module model (eI/O-170E or WISE-4050)
- Module IP address
- Can you ping the module?
Machine Details
- Make, model, year
- What signals are you monitoring?
Signal Information
- What is each input connected to?
- Voltage measurements with multimeter
- Wet or dry contact?
- For CTs: Analog or dry contact output?
Adapter Script
- Current script (copy/paste)
- What behavior are you seeing vs. expecting?

Contact Options

MachineMetrics Support:

Email: support@machinemetrics.com
Include all information above
Attach photos of wiring
Include complete adapter script

For Sealevel Hardware:

Sealevel Support: (864) 843-4343
Email: support@sealevel.com
Hardware-specific questions

For WISE Hardware:

Advantech Support: www.advantech.com/support
Hardware configuration questions

Ready to connect your machine with I/O?

Choose hardware: Sealevel eI/O-170 (wired/PoE) or WISE-4050 (wireless)
Identify signals: CT for execution, appropriate part count method
Install module and wire signals
Configure network (static IP)
Create Modbus TCP adapter script
Test and refine

Questions? Contact support@machinemetrics.com

Digital I/O & Modbus TCP Connectivity Guide​

Overview​

What is I/O Connectivity?​

When to Use I/O​

Key Technical Concepts​

Current I/O Hardware​

Sealevel eI/O-170E / eI/O-170PoE​

Advantech WISE-4050​

Retired Hardware​

LabJack T4/T7 (Hardwired)​

LabJack U3 (Wireless)​

Understanding Current Transducers​

Types of Current Transducers​

Installing a Current Transducer​

Signal Selection Strategy​

Utilization Signals​

Part Count Signals​

Sealevel eI/O-170 Installation​

Physical Installation​

Network Configuration​

Terminal Wiring​

WISE-4050 Installation & Configuration​

Physical Installation​

DIP Switch Configuration​

WiFi Configuration (Wireless Model)​

WISE-4050/LAN Configuration (Wired Model)​

Terminal Wiring Examples​

WISE High-Frequency Counter Mode (Advanced)​

Modbus TCP Addressing​

Sealevel eI/O-170 Address Map​

WISE-4050 Address Map​

Data Types​

Comprehensive Adapter Script Examples​

Example 1: CT for Execution (Main Spindle)​

Example 2: Multiple CTs (Main Spindle + Live Tooling + Z-Axis)​

Example 3: Stack Lights + Dry Contact Part Count​

Example 4: Pallet Changer on Mill​

Example 5: Barfeeder Pulse on Lathe​

Example 6: Coolant Pulse Method (Last Resort)​

Example 7: Auto Mode Filtering​

Example 8: Injection Molding Machine​

Machine-Specific Integrations​

Haas CNC Machines (Pre 2001)​

Citizen/Miyano Lathes​

Troubleshooting​

Cannot Connect to Module​

Signal Not Detected​

Current Transducer (CT) State Detection Issues​

False Part Counts​

Best Practices​

Additional Resources​

Getting Help​

Before Contacting Support​

Contact Options​

Digital I/O & Modbus TCP Connectivity Guide

Overview

What is I/O Connectivity?

When to Use I/O

Key Technical Concepts

Current I/O Hardware

Sealevel eI/O-170E / eI/O-170PoE

Advantech WISE-4050

Retired Hardware

LabJack T4/T7 (Hardwired)

LabJack U3 (Wireless)

Understanding Current Transducers

Types of Current Transducers

Installing a Current Transducer

Signal Selection Strategy

Utilization Signals

Part Count Signals

Sealevel eI/O-170 Installation

Physical Installation

Network Configuration

Terminal Wiring

WISE-4050 Installation & Configuration

Physical Installation

DIP Switch Configuration

WiFi Configuration (Wireless Model)

WISE-4050/LAN Configuration (Wired Model)

Terminal Wiring Examples

WISE High-Frequency Counter Mode (Advanced)

Modbus TCP Addressing

Sealevel eI/O-170 Address Map

WISE-4050 Address Map

Data Types

Comprehensive Adapter Script Examples

Example 1: CT for Execution (Main Spindle)

Example 2: Multiple CTs (Main Spindle + Live Tooling + Z-Axis)

Example 3: Stack Lights + Dry Contact Part Count

Example 4: Pallet Changer on Mill

Example 5: Barfeeder Pulse on Lathe

Example 6: Coolant Pulse Method (Last Resort)

Example 7: Auto Mode Filtering

Example 8: Injection Molding Machine

Machine-Specific Integrations

Haas CNC Machines (Pre 2001)

Citizen/Miyano Lathes

Troubleshooting

Cannot Connect to Module

Signal Not Detected

Current Transducer (CT) State Detection Issues

False Part Counts

Best Practices

Additional Resources

Getting Help

Before Contacting Support

Contact Options