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Sealevel eI/O-170E

The Sealevel eI/O-170E is the module to use when utilization comes from motor current, because it is the only one with analog inputs. It has 8 analog inputs and 2 dry-contact opto inputs.

Power: 9–30VDC on the side terminal, or PoE on the eI/O-170PoE · Default IP: 192.168.42.253 · Protocol: Modbus TCP

Hardware​

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

Terminal Reference​

Sealevel eI/O-170E terminal reference — analog inputs, opto-inputs, solid-state relays and LEDs

TerminalFunctionModbus
Analog 1–8Analog infunc: 4 input registers 0–7, int16, 0–4095 counts
Analog GAnalog ground (both G are common)—
Opto 1 / CDry contact infunc: 2 discrete input 0
Opto 2 / CDry contact infunc: 2 discrete input 1
SSR 1, SSR 2Solid-state outputsNot used by MachineMetrics
PWR / ACTPower on / Modbus activity—
  • Default IP is 192.168.42.253. Change it with SeaMAX Ethernet Config.
  • Analog inputs can pair as four differential channels (1–2, 3–4, 5–6, 7–8). MachineMetrics wiring is single-ended to G.
  • Each Opto input has its own C. Opto and C are internally biased — never apply external voltage to them.
  • Power: side terminal, 9–30VDC on the eI/O-170E, or 802.3af PoE on the eI/O-170PoE.

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

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

  1. Select module in device list
  2. Enter new static IP address (from your IT team)
    • Example: 192.168.1.101
  3. Enter subnet mask: 255.255.255.0
  4. Enter gateway (if required)
  5. Click "Apply Changes"
  6. Module will reboot with new IP

Step 4: Verify Connection

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

Wiring Patterns​

Three patterns cover almost every Sealevel install. Each one includes the adapter script that reads it.

These diagrams are samples

The schematics on this page are reference wiring, drawn from the manufacturer datasheets. They are not a wiring diagram for your machine. Verify every connection against the machine's own electrical prints before you install, and confirm terminal labels and the Modbus map against the unit in front of you — they vary by firmware revision.

Analog Current Transducer to the Analog Inputs​

Sealevel analog current transducer wiring — CT clamped on one phase, output to Analog 1 and Analog G

  • Clamp the CT around one phase conductor between the drive and the motor. Never around the full cable or more than one conductor.
  • Orient the CT arrow toward the load.
  • Range switch (20 / 40 / 60A): choose the lowest range above the motor's normal running current. Output is 10V × amps ÷ range, so at 10A the 20A range reads 5.0V, the 40A range 2.5V and the 60A range 1.7V. If the output pins at 10V while cutting, step up a range. For motors above 60A use an SC-651-R2 (50/100/150A) or an SC-651-200.
  • Configure the channel for 0–10V single-ended. Analog inputs have no overvoltage clamp — never land a 24V signal on one.
  • Run 2-conductor shielded twisted pair, 18–22 AWG. Land the drain at Analog G only. Route away from motor leads and the VFD output.
  • Scaling: 4096 counts = 10V, so divide counts by 409.6. Idle should read under 1.5V, and a typical ACTIVE threshold is 1.0–1.5V.
  • The SC-651 is average-responding and rated for 50/60Hz. On a VFD output the reading is approximate — good enough for run/idle, not for power measurement.

Adapter script

version: 2
unit-id: 1

registers:
  spindle-raw:
    address: 0 # Analog 1 -> input register 0
    func: 4 # Read Input Registers
    type: int16 # Raw ADC counts (0-4095)

variables:
  # 4096 counts = 10V, so counts / 409.6 gives volts.
  ct-voltage-int:
    - source: spindle-raw / 409.6

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

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

data-items:
  - execution
  - ct-voltage

Dry Contacts to the Opto Inputs​

Sealevel dry contact wiring — voltage-free contacts to Opto 1 and Opto 2 with their own commons

  • Opto 1 and Opto 2 are dry-contact inputs, each with its own C terminal. The module supplies the sensing current, about 12mA through 330Ω. Opto n shorted to its C reads 1.
  • The source must be voltage-free and isolated: spare N.O. relay contacts, limit switches, or a CT switch output.
  • Never apply external voltage to Opto or C. A voltage signal such as a 24V stack light has to drive an interposing relay coil first — see Interposing Relays.
  • Use contacts rated for low-level switching (gold-flashed or bifurcated). Power contacts may not pass 12mA reliably.
  • Solid-state CT switch outputs can be polarity-sensitive. Confirm S1/S2 orientation against the CT datasheet.
  • Two discrete inputs only. If you need more, use a WISE-4050.

Adapter script

version: 2
unit-id: 1

coils:
  in-cycle:
    address: 0 # Opto 1 -> discrete input 0
    func: 2 # Read Discrete Inputs
  part-pulse:
    address: 1 # Opto 2 -> discrete input 1
    func: 2

variables:
  execution:
    - source: in-cycle
    - off-delay: 10
    - state:
        - ACTIVE: this
        - READY: true

  part-count:
    - source: part-pulse
    - rising-edge
    - count

data-items:
  - execution
  - part-count

Interposing Relays for Voltage Signals​

Sealevel interposing relay wiring — 120VAC and 24VDC coils in parallel with existing loads, N.O. contacts to Opto inputs

  • Any signal that carries voltage needs a relay on Sealevel — 24VDC (PNP or NPN), 24VAC or 120VAC. The Opto inputs accept contacts only.
  • Match the coil voltage to the circuit, and wire the coil in parallel with the existing load so it follows the output exactly.
  • DC coils need a flyback diode, cathode to +. AC coils need RC or varistor suppression. Interface relays with built-in suppression satisfy both.
  • Use a low-level (gold) N.O. contact, wired Opto n → its own C.
  • Confirm the added coil current stays within the PLC or CNC output rating.
  • Piggyback option: parallel a coil across A1/A2 of a contactor that already marks the event — a coolant pump, or a spare M-code relay.

Adapter script

The relay contact lands on an Opto input, so the script reads it as a dry contact. Only the hardware differs from Dry Contacts.

version: 2
unit-id: 1

coils:
  green-light:
    address: 0 # CR1 N.O. -> Opto 1 (120VAC lamp circuit)
    func: 2
  m-code-pulse:
    address: 1 # CR2 N.O. -> Opto 2 (24VDC PNP output)
    func: 2

variables:
  execution:
    - source: green-light
    - off-delay: 10
    - state:
        - ACTIVE: this
        - READY: true

  part-count:
    - source: m-code-pulse
    - rising-edge
    - count

data-items:
  - execution
  - part-count

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

The MachineMetrics standard is the Greystone SC-651-R1.

  • Input: 0–20 / 40 / 60A AC, selected with the L / M / H switch on the unit
  • Output: 0–10VDC, proportional to current
  • Scaling: 10V × amps ÷ range — at 10A the 20A range reads 5.0V, the 40A range 2.5V and the 60A range 1.7V
  • Self-powered: No external supply needed
  • Response: Average-responding, rated 50/60Hz. On a VFD output the reading is approximate — good enough for run/idle, not for power measurement

For motors drawing more than 60A, use an SC-651-R2 (50/100/150A) or an SC-651-200. Other 0–10V clamp CTs work the same way — NK Technologies AT Series, CR Magnetics CR5410, Veris H Series — but check the range, because a fixed-range CT cannot be tuned to the motor the way the SC-651 can.

Wiring to eI/O-170:

The CT + output goes to an analog input and − to Analog G. See Analog Current Transducer to the Analog Inputs for the diagram, the range-selection rule and the adapter script.

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: Nothing external — the Opto input supplies its own sensing current
  • 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:

The switch output is a dry contact, so it wires straight between Opto 1 and its own C — exactly like any other contact. See Dry Contacts to the Opto Inputs for the diagram and the adapter script.

⚠️ Do not add an external supply. The Opto input sources its own 12mA. Solid-state switch outputs can be polarity-sensitive, so confirm S1/S2 orientation against the CT datasheet.

Use Cases:

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

Installing a Current Transducer​

Greystone SC-651-R1 current sensor — the MachineMetrics standard analog CT, a clamp-style sensor with a 0-10VDC output, an L/M/H range selector for 20/40/60A, and a two-terminal output block

AC current transducer overview — monitors AC motor current and outputs proportional DC voltage; common applications include spindle drives, axis drives, and work conveyors

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

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

FANUC spindle drive inside electrical cabinet with CT clamped around one phase conductor — left: spindle drive identified; right: CT clamped on U/V/W phase wire with callout

CT installed on FANUC spindle drive power cables — sensor secured at the base of the drive unit

Step 4: Wire CT Output

Current Transducer Wiring Diagram

What good CT data looks like in MachineMetrics:

MachineMetrics sensor view — Sensor 1 analog CT waveform showing current spikes during each spindle cycle, with V-Threshold line visible at the bottom

Modbus 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)
  • Adapter Scripts — worked scripts for every pattern above
  • WISE — the alternative module, for more discrete inputs or fast counting
  • Troubleshooting — connection and signal problems