Choosing the Right Industrial Digital I/O Module for Your Digital Outp... https://www.ni.com/en-us/innovations/white-papers/06/choosing-the-ri...

Updated Feb 4, 2020

Digital output sensors as well as actuators driven by digital signals are very popular in the industry. One can find a digital output sensor
for practically any type of variable (temperature, flow, pressure, speed and more) with their digital output signal represented in multiple
formats. In this document we first classify Digital Output Sensors based on their output signal and circuit interface, and then point out
the critical parameters that should be taken into account when selecting a Digital I/O Module1 for your application.

Introduction to Digital Output Sensors

Classification of Digital Output Sensor Based on:
Characteristic of the Signal Driving the Sensor Output
Sinking vs. Sourcing Outputs
2-Wire and 3-Wire Sensors
Electronic Component Used to Implement the Sensor’s Output
Selecting the Right Industrial Digital I/O Module for Your Digital Output Sensors
Example of Digital Output Sensors

Digital Output Sensor is a sensor that will produce only two values in its output, either On or Off, as opposed to an Analog Output
Sensor which produces a continuously varying output value over its entire range. The simplest example of a digital sensor is the touch
switch. A typical touch switch is an open circuit with infinite resistance when it is not pressed and a short circuit with zero resistance
when it is pressed.

Whenever interfacing the digital output sensor it is important to take into account some key factors that will determine the compatibility
of the sensor with the data acquisition device. Throughout this document we will present these key factors and provide an easy way to
select the appropriated data acquisition device for your application.

Digital Output Sensors can be classified based on the following parameters:

1. Characteristic of the Signal Driving the Sensor’s Output

2. Sinking vs. Sourcing Outputs

3. 2-Wire and 3-Wire Sensors

4. Electronic Component Used to Implement the Sensor’s Output

Technological development has brought a variety of complex digital output sensors to the market. Nowadays, you can find sensors that
produce trains of transitions between the On and Off state, with these types of sensors the frequency characteristic or even the shape
of the pulse trains convey the sensor’s measurement, making it possible to implement continuous measurement.

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Figure 1 shows a classification of digital output sensors based on signal characteristics driving its output. As can be seen in the chart,
45 % of the digital output sensors are based on the on-off state of the digital line, 35 % of the sensors are based on the frequency of the
signal and 12 % as based on the duty cycle of the output frequency 2 .

Figure 1 – Digital Output Sensors – Characteristic Conveying Measurement2

The signal characteristic conveying the sensor’s measurement is the first parameter to be considered when selecting an industrial
digital I/O module. This is important to decide whether you need counters on your digital I/O module.

Browse industrial static DIO devices

Browse counter/timer devices

Sinking and Sourcing are terms used to define the control of direct current flow in a load.

Sinking Device: provides a path for the current to ground and is not responsible for powering the device. Terms used to describe
sinking devices include NPN, Open Collector, Normally High, and IEC Negative Logic.
Sourcing Device: A sourcing device provides the power or a positive potential. Sourcing devices 'push' the current through the
load. Terms used to describe sourcing devices include PNP, Open Emitter, Normally Low, and IEC Positive Logic.

The concept of Sourcing and Sinking is independent of the component (ex.: transistor, mechanical relay and etc...) that implements the
operation. This concept applies to any DC circuitry; the component that is implementing the circuitry may vary.

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Figure 2 - Sinking Output Sensors.

Figure 3 - Sourcing Output Sensors.

The third type classification is important in order to define the relationship between current and voltage in the sensor’s On state and Off
state. A sensor can be classified as a 2-wire or 3-wire device as follows:

2-Wire Sensors: They are connected in series with the device that is acquiring the data.

Figure 4 – 2 Wire Sensors

When the sensor is not activated, it must draw a minimum operating current normally referred to as off-state leakage current, which in
some cases are also called by the sensors manufacturers as residual current. This current is necessary in order to keep the sensor
electronics working. The residual current is not a problem if the sensor is connected directly to another load other then the data
acquisition device, for example in industrial environment is not unusual to have these 2-wire sensors directly connected to motors and
similar devices, which have a low impedance.

Residual current is a problem for the system if the sensor requires a residual current higher then what the digital I/O module has been
designed to sustain. In this case the digital I/O module might incorrectly detect an On state because the current being drawn is higher
then it expects to provide. Most 2-wire sensors in the industry have an off-state leakage current or residual current no higher then

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1.7 mA.

Similar to the Off state, there is also a minimum current required to sustain the On state of a sensor, called the minimum holding
current. Typically this current ranges from 3 mA to 20 mA. The sensor will not operate correctly if the digital I/O module cannot sink or
source this current.

3-wire Sensors: 3-wire sensors derive their power from a excitation terminal and not directly through the digital output line, they
are also called by some manufacturers as line-powered sensors.

Figure 5 – 3-wire Sensors

The operating current these devices pull from the digital I/O module is called burden current and it is typically in the neighborhood of
20 mA. Important to notice this current is provided by the excitation terminal.

There are three electronic components that typically drive the output of a signal output sensor:

Mechanical Relay;
Transistor;
Bilateral FET Devices:
Mechanical Relay: A Mechanical relay is an electromechanical device that closes contacts to complete a circuit or opens contacts to
interrupt a circuit. It is a device that can handle current load at high voltages.

Since they are relatively slow devices when compared against solid state relays, they are normally used by sensors where the state of
the line is the characteristic of the signal driving output. These devices are subject to contact wear and resistance build up. Their
contact life depends on the load current as well as the frequency of operation. They can sometimes produce erratic results due to
contact bounce when connected to counters and digital I/O modules.

Transistor: is a solid-state device designed to control DC current. Transistors are most commonly found in low DC powered sensors as
the output switch. There are two types of transistors - NPN and PNP.

Figure 6 shows a NPN (Current Sink) Open Collector Transistor

Figure 6 – Sensor NPN Output.

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Bilateral FET Device: Many photosensors in the market have an output implemented in an architecture called bilateral FET output
which can be seen in Figure 7. This architecture has many advantages but the most important one is the fact that interfaces directly to
TTL and CMOS circuits, additionally they show:

Low off-state leakage current;

Fast response time;
FET stands for Field Effect Transistor and is supposed to become the most popular output for digital output sensors because of its
operating characteristics, being near to the ideal model.

Figure 7 - Sensor with Bilateral FET Device Output

In order to select the Digital I/O module one should answer the three following questions:

What is the characteristic of the digital signal that conveys the sensosurement? This has been discussed in the section on
"Characteristic of the Signal Driving the Sensor’s Output" in this document.
Based on this answer make reference to Table-A to check the group of Digital I/O modules that would be appropriate for your
application.

Is the sensor output a sinking or sourcing output?

Table-A again provide a classification of the NI boards based on sinking and sourcing capabilities, so if your sensor has a sinking output
you want to select a board with a sourcing input and vice-versa.

What is the component that implements the output of my device?

At this point might need to consider the off-state leakage current as well as the minimum holding current for On state.

Compare specs of the sensors with the specs of the data acquisition devices in Table-B in order to select the most appropriate device
for your sensor. Besides the voltage levels, one should still observe the two important following conditions which are sometimes
overlooked:

1. Off-State leakage current (sensor) < Maximum Input Current at Low State (Board)
2. Minimum holding current (sensor) < Maximum Input Current at High State (Board)

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Timed-Based
Sensors Digital I/O
Type of
NI Board On-Off (State) (Frequency, Module Input # Channels
Isolation
Duty-Cycle, Type
etc.)

NI 6601 — √ Sinking — 4 CTR

NI 6602/6608 — √ Sinking — 8 CTR

NI 6624 — √ Sinking Ch-Ch 8 CTR

24 DIO 1
NI 6501 √ √* Sinking/Sourcing —
CTR

NI 6509 √ — Sinking/Sourcing — 96 DIO

NI 6514 √ — Sourcing Bank 32 DI 32 DO

NI 6515 √ — Sinking Bank 32 DI 32 DO

NI 6518 √ — Sourcing Bank 16 DI 16 DO

NI 6519 √ — Sinking Bank 16 DI 16 DO

NI 6520/6521 √ — Sinking/Sourcing Ch-Ch 8 DI 8 DO

8 DI 8 DO 1
NI 6525 √ √* Sinking/Sourcing Ch-Ch
CTR

NI 6528 √ — Sinking/Sourcing Ch-Ch 24 DI 24 DO

Table - A
(* The USB-6501 and USB-6525 have one event counter)

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Voltage Input Current Input

Maximum
Input Logic Low Input Logic High
NI Board Switching
Voltage (VIL) Voltage (HIL) Max Input Max Input
Capacity
Current Current
(low) (high)
Min Max Min Max

Supply
-0.3 0.8
NI 6601 2 VDC +0.3 -10 µA 200 µA 4 mA
VDC VDC
VDC

Supply
NI -0.3 0.8
2 VDC +0.3 -10 µA 200 µA 4 mA
6602/6608 VDC VDC
VDC

0.8 3.2 48
NI 6624 — 0.1 mA 10 mA 200 mA
VDC VDC VDC

-0.3 0.8 5.8

NI 6501 2 VDC — — ±8 mA
VDC VDC VDC

0.8
NI 6509 0 VDC 2 VDC VCC -91.0 µA 91.0 µA ±24 mA
VDC

±4 ±11 ±30 12.5

NI 6514 0 VDC 4.5 mA/line 350 mA
VDC VDC VDC mA/line

±4 ±11 ±30 12.5

NI 6515 0 VDC 4.5 mA/line 500 mA
VDC VDC VDC mA/line

±4 ±11 ±30 12.5

NI 6518 0 VDC 4.5 mA/line 350 mA
VDC VDC VDC mA/line

±4 ±11 ±30 12.5

NI 6519 0 VDC 4.5 mA/line 500 mA
VDC VDC VDC mA/line

NI ±4 ±11 ±30 4.5 12.5

0 VDC 2A
6520/6521 VDC VDC VDC mA/channel mA/channel

-60 3.2 60 3.0 3.0

NI 6525 1 VDC 500 mA
VDC VDC VDC mA/channel mA/channel

-60 3.2 60
NI 6528 1 VDC 1.5 mA 2 mA 150 mA
VDC VDC VDC

Table - B

Type of Measurement: Flow Measurement

Manufacturer: Gems Sensors
Digital Output type: Frequency

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Type of Measurement: Acceleration (ADXL202, ±2 g Dual Axis Accelerometer)

Manufacturer: Analog Devices
Digital Output Type: Duty-Cycle (TTL, CMOS compatible)

Type of Measurement: Position Switch (Mechanical Relay)

Manufacturer: Schmersal
Digital Output Type: ON-OFF output.

Other Manufacturers of Digital Output Sensors include

· Omega
· Omron
· Encoder Products Co.
· US. Sensors
· Sensotec
· Watlow
· PCB Piezotronics
· Weed Instrument

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· Measurement Specialities
· Celesco
· Endevco
· Macro Sensors
· Transducer Techniques Inc.

1
Throughout this document 'Digital I/O Module' is used to describe the data acquisition device that is connected to the Digital Output
Sensor.

2 Kirianaki, Yurish, Shpak, Deynega. Data Acquisition and Signal Processing for Smart Sensors, 2002 [ISBN 0-470-84317-9].

Related Links:
Buy Digital I/O Modules for Your Sensor
Data Acquisition Hardware Selection

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