XIO Module
Input / Output Controller for Plant Automation and Control

XIO industrial modules are designed and manufactured by MINDS to handle all digital and analog inputs and outputs for complete control of your asphalt/hotmix, emulsion, or modified bitumen plant. Build to last: deployed at hundreds of plants all over the world.


XIO - Multiple Inputs/Outputs Controller
XAF - Analog/pulse Interface
XEL - Logic Input Interface

" The quality and stability of the mix produced is incredible. I even had samples tested independently as it was almost unbelievable. All plant equipment is controlled on screen eliminating consoles, button and the likes. This allows for easier maintenance and operator training. The interface is user friendly and my operators had no difficulty at all getting used to it. MINDS accompanied us all the way giving us useful and pertinent insight into the control part of the design, saving a lot of time and errors. We bought another plant in 2010 and we stripped the old control system out without hesitation. "

Daniel Theoret Roxboro Excavation, QC

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XIO Module Highlights

Unique architecture

The XIO module is a multiple input/output controller used in our automation and control systems. This module is characterized by its unique architecture, compactness and robustness and uses a TCP/IP communication protocol over an Ethernet link. The XIO module is equipped with logic input and outputs, analog and frequency input-outputs, each type in a calculated proportion that just one type of module is needed to control an asphalt plant. Thus, a small application requires one or two XIOs. To increase capacity additional XIOs, all identical to the first one, can be added to increase the number of input-outputs. A very large plant with comprehensive automation can require six XIOs or more.

The advantages of this architecture are numerous:

  • Only one module is needed as a spare part
  • Guaranteed flexibility and extensibility
  • Simplified systematic wiring
  • Support and maintenance facilitated
  • Inherent generation of spare inputs and outputs
XIO module controller

Comparison with traditional architecture

In a traditional installation using a field network, electronic modules ensuring the input-outputs are specialized according to the type of signals: logic inputs, logic outputs, analog inputs, analog outputs, etc., this architecture multiplies the number and types of electronic modules (refer to Classical Architecture). With the XIO, only one standard device is necessary, having all the types of input-outputs onboard (refer to XIO Architecture). When the number of input-outputs is very important, the cost of the two solutions is similar, but on small and average installations, in an example of road construction plants, the architecture of XIO reduces costs and becomes more profitable. In all cases spare parts management is much easier with the XIO architecture.

classical architecture vs XIO architecture

XIO Technical Specifications

Main Features

  • Two (2) isolated analog outputs (six (6) with optional extension)
  • Four (4) isolated analog input (12 with option extension)
  • 32 scalable up to 56 logic outputs
  • 40 scalable up to 64 logic inputs (or analog inputs, individually configurable)
  • Six (6) quadrature/12 single optical encoder inputs
  • 2500 Vrms isolation (1 min)
  • Ethernet communication
  • DIN Rail mounting
  • Operating temperature: 0 to 50 °C (32 to 122°F)
  • Humidity: 5 to 95% non condensing
  • Storage temperature: -40 to 85°C (-40 to 185°F)
  • Dimensions mm (inches): 240 (9.4) x 105 (4.1) x 41 (1.6)

Analog Outputs

  • 12 bits, 0-10V, maximum load = 2kΩ
  • Differential nonlinearity (DNL) = +/- 0.5 LSB
  • Integral nonlinearity (INL) = +/- 3.5 LSB
  • Offset error = +/- 4 mV
  • Full scale error = +/- 2 LSB
  • Accuracy = 10V +/- 0.1%
  • Noise < 1ppm p-p (0.1Hz – 10Hz)
  • Short circuit protection by fuse (62.5mA)

Analog Inputs

  • 24 bits (NO MISSING CODE)
  • INL: 0.0012% of full scale
  • Measuring Scale: 0-20mV, 0-40 mV, 0-80 mV, 0-160 mV, 0-320 mV, 0-625 mV, 0-1.25 V, 0-2.5 V, 0-5 V, 0-10 V
  • Automatic calibration
  • Maximum common mode voltage = 50V (limited by ceramic capacitor)
  • Common mode rejection = 120dB
  • Normal mode rejection (60Hz or 50Hz) = 100dB
  • Input impedance : 400kΩ

Logic Outputs

  • Open drain output type
  • Short circuit protection: 0.9A
  • Over temperature protection
  • Short circuit and open load detection for each output
  • Over voltage protection

Logic Inputs (XEL interface connected)

  • 25ms switch debouncer
  • 24V input with 4V threshold

Non Isolated Analog Inputs (with XIE interface connected)

  • Possibility of 64 non-isolated current (4-20mA) inputs
  • 12 bits (NO MISSING CODE)
  • Integral Linearity Error = ±2 LSB
  • Differential Linearity Error = ±0.8 LSB
  • Offset Error = 10mV ±3 LSB
  • 2.5V Reference
    -Accuracy = 2.5V +/- 0.2%
    -Noise = 35μVrms (typ) (10Hz – 10kHz)
  • Maximum input voltage = 3.3V

Optical Encoder Inputs

  • Six (6) inputs over two (2) channels (quadrate decoder mode) or 12 inputs over one (1) channel
  • Digital glitch filter on each input
  • 16 bit counter
  • Configuration: counter mode/frequency mode
  • Accept all type of inputs (open drain, open emitter, totem pole, push pull)
  • Input current = 10mA

Main Board Components

  • CPU 66MHz, Coldfire 32bits with 1kbyte cache memory
  • 16 MB of SDRAM (32 bits)
  • 8 MB of FLASH (16 bits)
  • One (1) Ethernet port 100Mbits
  • One (1) RS232 Serial port
  • One (1) Real time clock
  • One (1) Reprogrammable FPGA
  • One (1) 3.3V 2A Power supply
  • One (1) 5V 2A Power supply
  • One (1) 1.5V 1.2A Power supply


  • Analog modules are isolated from one another
  • Isolation barrier = 2500Vrms


The board has two buses. The first is for CPU bus extensions where you can add a peripheral card like USB, touch screen monitor, mouse, RS-485, etc.

The second bus is a SPI type and has the ability for connecting two external cards providing two (2) analog outputs and four (4) analog inputs each. The electrical characteristics of those modules are the same as the one on the motherboard.

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