TI Designs: TIDA-010044

NAMUR PLC Digital Input With Fault Protection and

Diagnostics Reference Design

Description Features
The NAMUR proximity sensor is widely used in • 1.6-mA threshold, 0.4-mA hysteresis
industrial control when a special requirement on • 0.2-mA open circuit, 6-mA short-circuit threshold
maximum energy is to be fulfilled by the sensor. This • 8.2-V open-circuit voltage, 8.2-mA short-circuit
in turn dictates special requirements on the PLC digital current
input designed to interface with such sensor with
regard to accuracy, and reliability. This reference • Extensive diagnostics
design is a full front-end of a digital input compatible • Fault protection
with NAMUR sensors. The design demonstrates • Power and data isolation
achieving reliability through redundancy, fault
protection, and extensive diagnostic features in a • Redundant components for higher reliability
compact footprint.
Applications
Resources • PLC NAMUR Digital Input Module
• NAMUR Isolation Barrier
TIDA-010044 Design Folder
LM2901AV-Q1 Product Folder
TL431LI Product Folder
TVS3301 Product Folder
LM25019 Product Folder
TLV760 Product Folder
ISO7340FC Product Folder

ASK Our E2E™ Experts

24 VIN

REF
NAMUR
Sensor 8.2 VOUT I V Short
Error

NAMUR in

Status/
5V
Failure

spacer

An IMPORTANT NOTICE at the end of this TI reference design addresses authorized use, intellectual property matters and other
important disclaimers and information.

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1 System Description
The NAMUR proximity sensor is widely used in industrial control when a special requirement on maximum
energy is to be fulfilled by the sensor. This in turn dictates special requirements on the PLC digital input
designed to interface with such sensor with regard to accuracy, and reliability.
NAMUR sensors and their interfaces (digital input or amplifiers) have to comply with the NAMUR
standard(EN 60947-5-6:2000 or IEC 60947-5-6).
NAMUR abbreviation stands for the German term "Normenarbeitsgemeinschaft für Meß- und
Regelungstechnik in der Chemischen Industrie" which translates to "Association for Standardization of
Measurement and Control Engineering in the Chemical Industry"
TIDA-010044 is a NAMUR PLC digital input module reference design lillustrating the common
performance requirements and shows how to enhance reliability of the module by adding diagnostics and
protection features.

1.1 Key System Specifications

The TIDA-010044 system specifications in Table 1 represent the common set of parameters required by a
NAMUR PLC digital input module. On top comes the extensive diagnostic features required to implement
a high-reliability module.

Table 1. Key System Specifications

PARAMETER SPECIFICATIONS
Number of Inputs 1
Input type NAMUR compatible
ON-state current 2.1 mA
OFF-state current 1.2 mA
Hysteresis 0.4 mA
Output impedance 1 kΩ
Maximum input voltage 24 V, –24 V
Short-circuit current 8.2 mA
Short-circuit threshold 6 mA
Broken wire threshold 0.4 mA
Short-to-supply+ threshold 8.5 V
Short-to-supply– threshold -6 V
Isolated 12-V supply fault threshold 7V
24-V supply range 18 V to 36 V
Operating temperature range –40 ºC to 80ºC
Diagnostic functions Sensor failure: wire break and short circuit
Short to supply: forward or reverse short to supply
Isolated supply failure

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2 System Overview
The NAMUR standard (EN 60947-5-6:2000) defines characteristics of proximity sensors and their
interfaces and digital inputs. Those sensors are acting as very low current switch representing the binary
states ON and OFF.
TIDA-010044 is a NAMUR PLC digital input module reference design showing one simple implementation
of such module. Figure 1 shows the block diagram of the reference design.

2.1 Block Diagram

Figure 1. TIDA-010044 Block Diagram

24 VIN

REF
NAMUR
Sensor 8.2 VOUT I V Short
Error

NAMUR in

Status/
Failure 5V

Isolated
Data Isolator Comparator
Power

V Voltage I Current Low-Pass

Limiter Limiter Filter

Refer to Section 2.4.3 for a detailed explanation of different parts of the block diagram.

2.2 Design Considerations

NAMUR digital input modules is basically a PLC digital input module that resolves low level current input
and fulfills the NAMUR standard as detailed in Section 2.4.2. In addition to fulfilling the I-V characteristics
of the standard, diagnostic features are essential for modern input modules. Sensor failures including
open and short-circuit conditions are detected by sensing the sensor current exceeding certain limits.
Short-to-supply errors are detected to prevent module damage due to miss-wiring. Isolated power supply
is also monitored to prevent wrong readings due to failed supply. It is important to have high reliability
module that fulfills the NAMUR standard even if one component failed, this might dictate selecting certain
components that fail in a certain way short or open, or adding redundant devices. Industrial temperature
range is essential for all components to achieve the specified operating temperature range.

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2.3 Highlighted Products

2.3.1 TVS3301
The TVS3301 device shunts up to 27 A of IEC 61000-4-5 fault current to protect systems from high-power
transients or lightning strikes. The device survives the common industrial signal line EMC requirement of
1-kV IEC 61000-4-5 open circuit voltage coupled through a 42-Ω impedance. The TVS3301 uses a
feedback mechanism to ensure precise flat clamping during a fault, keeping system exposure lower than
traditional TVS diodes. The tight voltage regulation allows designers to confidently select system
components with a lower voltage tolerance, lowering system costs and complexity without sacrificing
robustness. The TVS3301 has a ±33-V operating range to enable operation in systems that require
protection against reverse wiring conditions.
In addition, the TVS3301 is available in a small SON footprint designed for space constrained
applications, offering a significant size reduction compared to standard SMA and SMB packages. Low
device leakage and capacitance ensure a minimal effect on the protected line. To ensure robust protection
over the lifetime of the product, TI tests the TVS3301 against 5000 repetitive surge strikes at 125°C with
no shift in device performance.
The TVS3301 is part of TI’s Flat-Clamp family of surge devices. For a deeper look at the Flat-Clamp
family, refer to the Flat-Clamp Surge Protection Technology for Efficient System Protection white paper.

2.3.2 LM2901AV
The LM2901xx devices consist of four independent voltage comparators that are designed to operate from
a single power supply over a wide range of voltages. Operation from dual supplies also is possible, as
long as the difference between the two supplies is 2 V to 36 V, and VCC is at least 1.5 V more positive
than the input common-mode voltage. Current drain is independent of the supply voltage. The outputs can
be connected to other open-collector outputs to achieve wired-AND relationships. The LM2901AV device
is characterized for operation from –40°C to 125°C.

2.3.3 TL431LI
The TL431LI device is a three-terminal adjustable shunt regulator, with specified thermal stability over
applicable automotive, commercial, and military temperature ranges. The output voltage can be set to any
value from Vref(approximately 2.495 V) and 36 V, with two external resistors. These devices have a
typical output impedance of 0.3 Ω. Active output circuitry provides a very sharp turn-on characteristic,
making these devices excellent replacements for Zener diodes in many applications, such as onboard
regulation, adjustable power supplies, and switching power supplies. This device is a pin-to-pin alternative
to the industry standard TL431, with optimized Iref and IIdev performance. The lower Iref and IIdev values
enable designers to achieve higher system accuracy and lower leakage current.
The TL431LI device is offered in two grades, with initial tolerances (at 25°C) of 0.5% and 1%, for the B
and A grade, respectively. In addition, low output drift versus temperature ensures good stability over the
entire temperature range. The TL431LIAQ device is characterized for operation from –40°C to 125°C.

2.3.4 LM25019
The LM25019 is a 48-V, 100-mA synchronous step-down regulator with integrated high-side and low-side
MOSFETs. The constant on-time (COT) control scheme employed in the LM25019 requires no loop
compensation, provides excellent transient response, and enables very high step-down ratios. The on-time
varies inversely with the input voltage resulting in nearly constant frequency over the input voltage range.
A high-voltage start-up regulator provides bias power for internal operation of the IC and for integrated
gate drivers.
A peak current limit circuit protects against overload conditions. The undervoltage lockout (UVLO) circuit
allows the input undervoltage threshold and hysteresis to be independently programmed. Other protection
features include thermal shutdown and bias supply undervoltage lockout.

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2.3.5 TLV76050
The TLV760 is an integrated linear-voltage regulator featuring operation from an input as high as 30 V.
The TLV760 has a maximum dropout of 1.2 V at the full 100-mA load across operating temperature.
Standard packaging for the TLV760 is the 3-pin SOT-23 package.
The TLV760 is available in 3.3 V, 5 V, 12 V and 15 V. The SOT-23 packaging of the TLV760 series allows
the device to be used in space-constrained applications.
The TLV760 is designed to bias digital and analog circuits in applications that are subject to voltage
transients and spikes up to 30 V — for example, appliances and automation applications. The device has
robust internal thermal protection, which protects itself from potential damage caused by conditions like
short to ground, increases in ambient temperature, high load, or high dropout events.

2.3.6 ISO7340
The ISO734x family of devices provides galvanic isolation up to 3000 VRMS for 1 minute per UL 1577 and
4242 VPK per VDE V 0884-10. These devices have four isolated channels comprised of logic input and
output buffers separated by a silicon dioxide (SiO2) insulation barrier. The ISO7340x device has four
channels in forward direction. In case of input power or signal loss, the default output is 0.
Used in conjunction with isolated power supplies, these devices help prevent noise currents on a data bus
or other circuits from entering the local ground and interfering with or damaging sensitive circuitry. The
ISO734x device has integrated noise filter for harsh industrial environment where short noise pulses may
be present at the device input pins. The ISO734x device has TTL input thresholds and operates from 3-V
to 5.5-V supply levels. Through innovative chip design and layout techniques, electromagnetic
compatibility of the ISO734x family of devices has been significantly enhanced to enable system-level
ESD, EFT, surge, and emissions compliance.

2.4 System Design Theory

Details of the design flow of the NAMUR digital input reference design is explained in the following
sections. Starting from the NAMUR sensor and standard, we derive the required functions for the digital
input.

2.4.1 NAMUR Sensor

A field supply typically powers digital switches and proximity switches for industrial control systems. The
possibility of electrical arcs forming at the switch contacts, or the possibility of capacitive energy
accumulation in the sensors, make these types of switches unsuitable for hazardous areas with flammable
atmospheres.
a NAMUR output sensor is a type of sensor that is trying to circumvent this issue by representing the
switch states (ON and OFF) with two levels of resistance. The sensor is operated with a nominal operating
voltage of 8.2 V.
Figure 2 is a simple model of a NAMUR sensor.

Figure 2. NAMUR Sensor Model

I

Ith 1 NŸ

10 NŸ
8.2 V

R
ON Rth OFF
R = 1 NŸ R = 10 NŸ

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This resistive change results in a low-level current change (a few mAs), which a NAMUR input module
needs to detect. Common values of the threshold currents are below 1.2 mA for the off state and above
2.1 mA for the on state.

2.4.2 NAMUR Standard

The NAMUR standard (EN 60947-5-6:2000) defines characteristics of proximity sensors and their
interfaces and digital inputs. Those sensors are acting as very low current switches as described in the
previous section.
The NAMUR standard (EN 60947-5-6:2000) defines the valid operating regions of the NAMUR sensor as
Figure 3 shows. On top of the I-V curve, different impedance levels of the sensor are overlaid. The valid
ON-state operating region extends up to the load line equal to the ON-state resistance (for example up to
1 kΩ as a common case)

Figure 3. NAMUR Sensor Valid Operating Regions

Figure 4 represents the valid operating region mask for the NAMUR sensor interface (signal amplifier or
digital input). Any operating curve confined within the mask should fulfill the NAMUR standard. One valid
model of the digital input is shown on the diagram as thevinin equivalent of 8.2-V source in series with 1-
kΩ resistance. This model has the dotted load line extending from 8.2 V on the vertical axis to the 8.2 mA
on the horizontal access. The TIDA-010044 is designed to be equivalent to this model.

Figure 4. NAMUR Digital Input Valid Operating Region

V

14

12

10 1 NŸ

8
8.2 V

0
2 4 6 8 10 12 14 16 18 mA

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2.4.3 NAMUR Digital Input

The NAMUR input module is a special PLC digital input module that acts like a barrier and amplifier for a
NAMUR sensor. It delivers limited power (limited voltage and limited current) to the NAMUR sensor, and is
able to interpret the low-level output signal of the sensor to detect its state.
Figure 1 shows a simplified NAMUR digital input block diagram. A stable 8.2 V is derived from the 24-V
field supply, with a current limiter in place in case of a short circuit to supply. Analog comparators powered
from the 24-V supply convert the return current into voltage and filter for detection. Isolating the
comparator array outputs from the backplane protects the outputs in case of a surge or other harmful
event.
The NAMUR input module has to implement the following functions:
• Deliver a regulated 8.2-V output voltage at no load with a 1-kΩ source impedance.
• Limit the current in case of a short-circuit load to a current below 10 mA.
• Detect the off (below 1.2 mA of input current) and on (above 2.1 mA) state of the sensor.
• Detect sensor failure: short-circuit (close to current limit) and open-circuit (close to zero current) states.
• Detect short-to-supply error (forward and reverse)
• Protect against miswiring (short circuit to field supply, forward and reverse).
• Protect against surge events.
Many of these functions (detection and protection) are related to reliability. Section 2.4.4 will go into
details of how those functions are achieved.

2.4.4 Circuit Design

2.4.4.1 Shunt Regulator

The TL431 is used as shunt regulator to provide 8.2-V open circuit, it offers more flexibility compared to a
simple Zener diode. The TL431 is protected by two back-to-back diodes to prevent overcurrent in case of
short to positive or negative supply and to isolate the 12-V supply from the external terminals. Figure 5
shows a simplified shunt regulator circuit.

Figure 5. Shunt Regulator Circuit

VSUP 400 400

to NAMUR
Sensor
Power
Supply

TL431 500 100

VG

Vcomp

The 1-kΩ input impedance is split into 400 and 600 so that both pins have current limiter resistors.
Regulator is set to 8.5 V to account for the protection diode drop. This shows one benefit of using the
TL431 device as the regulated voltage can be set accurately to meet protection requirements.
The current from the supply is almost constant 10 mA over load range (0 to open circuit) as the simulation
results in Figure 6 show, the current is split between the load and the Zener.

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Figure 6. DC Operating Point Of Short-Circuit Case

The open load voltage is 8.2 V, as Figure 7 shows, and decreases with load. Note than open load voltage
is not equal to the Zener voltage.

Figure 7. DC Operating Point Of Open Circuit Case

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In the actual schematic, two TL431 devices are used to ensure the voltage limit is maintained in case one
of the devices fails open. The same applies for the protection back-to-back diodes which are duplicated.
The redundancy is increasing the level of reliability of the module and ensures output voltage is not
exceeded even in case of component failure.

2.4.4.2 Protection Against Short to Supply

As previously mentioned, the back-to-back diodes are preventing overcurrent in the TL431 device and
preventing overvoltage to reach the supply transformer. Apart from that maximum current in any
component (resistor or diode) should be maintained within the power rating of that component.
Simulation results in Figure 8 and Figure 9 show that maximum current occurs in case of short to supply
24 V or –24 V and does not exceed 27 mA. This is well below 0.5 W for the associated resistors. Rating
resistors of 1-W are selected, preferably carbon film resistors as they fail open.

Figure 8. DC Operating Point of Short to 24-V Supply Case

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Figure 9. DC Operating Point of Short to –24-V Supply Case

2.4.4.3 Isolated Supply

First choice of the isolated power supply is the secondary voltage level. From one side, a lower power-
supply level (close to 8.2 V) will reduce power dissipation in the limiting resistor. However, maintaining a
stable voltage over temperature range and various loading conditions will require a higher power-supply
level. A value of 12 V is optimal because it enables headroom with a low power requirement.
Based on the maximum current required from the 12 V source, less than 0.5 W source power is needed.
The chosen buck converter LM26019 is capable of delivering 100 mA on the primary side.
The TIDA-00129 design is adjusted to provide isolated 12-V output instead of 24 V by exchanging the
transformer with a custom 1:1.39 transformer from Wurth, and adjusting the feedback network accordingly.
For higher power requirement to service 2 or even 4 NAMUR input channels, the LM25019 or LM25017
can be used.

2.4.4.4 Status Comparator

Current in the sensor has to be converted into voltage and compared with reference levels to detect if the
current is below 1 mA or above 2 mA. ON and OFF state are shown respectively in Figure 10 and
Figure 11. A threshold current of approximately 1.6 mA and hysteresis detects the logic level and filters
input noise and bouncing. If using a 500-Ω conversion resistor, the threshold level is approximately 0.8 V
which requires almost rail-to-rail input comparator for proper operation.

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Figure 10. DC Operating Point for ON State

Figure 11. DC Operating Point for OFF State

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High power-supply voltage comparators make protection easier as 12 V appears at the input in case of
short to reverse 24-V supply. An open collector should ease the interface with the subsequent digital
stage. Lower offset comparator is required to achieve higher accuracy threshold levels, and rail-to-rail
input range is required to resolve the low threshold below 1 V. The LM2901AVQ device is chosen for the
comparator circuit as cost-effective low offset, 36-V comparator with near rail-to-rail input range.
The 12-V supply is only used to power the comparator, while the LDO generated 5 V is used as a
reference, and a supply for the pullup resistors of the comparator output stage.
As the input can reach high voltages in case of short to reverse supply, protection diodes are placed at the
comparator input to clamp input at the 12-V supply level. A 10-kΩ input impedance will keep the input
current in that case within few mAs, and hence protecting the input stage of the comparator.
Figure 12 shows the simulated transfer function of the status detection comparator circuit including the
hysteresis over temperature range –40ºC to 80ºC. The OFF state threshold is from 1.39 mA to 1.46 mA,
while the ON state threshold is well at 1.8 mA.

Figure 12. Status Output Simulation Curve

T
3.54 8.11m
Status Output Voltage

Load Current

1.77 4.31m

0.00 512.47u

0.00 4.00k 8.00k 12.00k 16.00k

Input resistance (ohms)

Note that NAMUR ON state is interpreted as logic '1' at Status output, However, the logic '1' is
represented as off LED after the isolator, and logic '0' is indicated as lit green LED.
For the basics of comparator design, view the Effective Application of Analog Comparators training, and TI
Precision Labs - Op Amps: Comparator Applications 1. For the details of designing an inverting amplifier
with hysteresis, see the Inverting Comparator With Hysteresis Circuit application note, and the
Comparator with Hysteresis Reference Design.

2.4.4.5 Fault Window Comparator

Apart from the input status (logic level), the circuit should detect sensor failures caused by short circuit
and open circuit (broken wire) conditions using a window comparator. The window comparator indicates
failure in case the input voltage is above or below certain thresholds. Failure is indicated as logic '0' at the
failure output. The failure LED is attached to the supply so LED is lit when fault is detected.
Figure 13 shows the simulated transfer function of the fault detection window comparator circuit over
temperature range –40ºC to 80ºC. The short state threshold is from 6.1 mA to 6.8 mA, while open circuit
or broken-wire state threshold is very close to 0.6 mA.

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Figure 13. Fault Output Simulation Curve

T
5.00 8.11m

Fault Output Voltage

Load Current
2.50 4.31m

0.00 512.47u

0.00 7.51k 15.00k

Load resistance (ohms)

For designing window comparators, check window comparator circuit application note, and window
comparator reference design.

2.4.4.6 Short-to-Supply Comparator

Whenever a short to supply or reverse supply occurs, the TL431 device turns on and the regulated voltage
VZ drops to about 2 V. This is used to detect the short to supply using a hysteresis comparator circuit. VZ
is scaled down and reference threshold is driven from the 5-V supply. The short to supply is indicated as
logic '0'. The short error LED is attached to the supply so LED is lit when short error is detected.
Figure 14 and Figure 15 show the simulation of voltage sweep of a supply shorted to the input terminals of
the digital input. As the figures show, the supply short is detected at 8.4 V for the positive supply, and –5
V to –5.5 V for the negative supply.

Figure 14. Short to Positive Supply Sweep Simulation Curve

T
8.74
ShortErr Output Voltage, and Vz

4.37

0.00

0.00 12.00 24.00

Input voltage (V)

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Figure 15. Short to Negative Supply Sweep Simulation Curve

T
8.66

ShortErr Output Voltage, and Vz

4.32

-25.62m

-24.00 -12.00 0.00

Input voltage (V)

For designing a non-inverting comparator with hysteresis, see the Non-Inverting Comparator With
Hysteresis Circuit application note. Feedback resistors can be adjusted to change the hysteresis window
to change the ShortErr circuit, it can work as the fault error, or make that error sticky so that power reset is
required to clear the error when it occurs, according to need.

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3 Hardware, Software, Testing Requirements, and Test Results

3.1 Required Hardware and Software

3.1.1 Hardware

The TIDA-010044 printed-circuit board (PCB) is two-layer, single-sided compact (7 × 3 cm2) board.
Figure 16 shows the component side with all connectors and jumpers annotated.

Figure 16. TIDA-010044 PCB Hardware - Top View

J1 D4 TP1 J2

Status LEDs J5 D15 J3 J4

Table 2 provides description of the board jumpers and connectors relevant to board testing.

Table 2. TIDA-10044 Jumpers and Connectors

COMPONENT DESCRIPTION
J1 24-V field supply connector. Note the polarity.
J2 NAMUR sensor connector. Note the polarity, positive terminal indicated by "POS(8.2 V)"
J3 5-V supply disconnect header:
Short with jumper for normal operation where 5 V LDO output is powering the circuit.
Disconnect to allow external 5-V supply, positive terminal is connected to the "5V" pin, and ground is connected to J4.
J4 Ground connector. Used as ground terminal when external 12-V or 5-V supply are connected. Note the requirements in
Section 3.2.1.
J5 6-pin digital output header:
5 V, and BP_GND pins must be connected to a 5-V supply for the isolator to work and status LEDs to operate.
Fail, Shrt, DIN (Status), Powfail are the status and diagnostics signals available for connection to back-end processor.
TP1 12-V supply test point. Use to prove the 12-V supply level. If external 12-V supply is to be enforced, disconnect 24-V
supply from J1, and connect the 12-V supply through TP1 and J4 (GND)
D4 12-V supply ON LED indicator
D15 5-V supply ON LED indicator
Status LEDs Status and diagnostics LEDS, requires 5-V supply connected through J5 to operate:
Green: Status LED
Orange: Sensor failure LED
Red: Short-to-supply LED
Blue: 12-V supply ON LED

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3.1.2 Software
There is no software required to test TIDA-010044, all functionality can be tested by monitoring the status
LEDs. Some performance parameters like threshold currents and voltages needs external multimeter in
addition to monitoring the LEDs.

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3.2 Testing and Results

This section describes the test setups used for testing TIDA-010044 functionality. Different tests requires
different powering schemes. Almost all tests can be carried out by only monitoring the status LEDs.

3.2.1 Normal Operation Test Setup

Figure 17 shows the test setup for normal operation. The 24-V supply is connected to J1, the 5-V
backplane supply is connected to J5, and a NAMUR proximity sensor is connected to J2, and J3 is
shorted with a jumper.
Pepperl+Fuchs NJ8-18GM-N, (106470) Induktiver Sensor (8 mm, 8 VDC, M18x1,5) is used for testing.

Figure 17. Normal Operation Test Setup

5-V Supply

+ í

í +

24-V Supply

í
NAMUR
Sensor

To test status operation, the metal plate is moved closer and away from the sensor. This is changing the
status green LED.
To test sensor failure operation, sensor is replaced by short circuit (Orange and Green LEDs on), or left
open (Orange LED on).
In all cases, the previously-mentioned current thresholds can be measured by adding an ammeter in
series with a potentiometer, and gradually changing the potentiometer from a high resistive value (like 15
kΩ), down to a low value (like 100 Ω) and record the current level when LED lights (Green and Orange)
change states. This is done in the reverse direction (low impedance to high impedance) to measure the
hysteresis.

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3.2.2 Power Fail Test Setup

Figure 18 shows the test setup for power failure test cases.
• For the 12-V failure test, the backplane 5-V supply is connected to J5, J1 is left unconnected, J3 is
shorted with a jumper, and the external 12-V supply is connected to TP1 and J4.
In this case, the external 12-V supply is swept from 12 V down to 5 V and the blue LED light is
monitored, the supply level at which LED turns off is the threshold for supply detection. The normal
operation of sensor input works as long as the blue LED light is ON.
• For the 5-V failure test, the backplane 5-V supply is connected to J5, 24-V supply is connected to J1,
J3 is not shorted, instead external 5-V supply is connected to 5V pin of J3 and J4.
In this case, the external 5-V supply is swept from 5 V down to 0 V, and output status LEDs are
monitored, when 5-V supply goes below failure level, all the LEDs turn off, and the sensor input
operation stops working. This indicates a 5-V supply failure.

Figure 18. Power Fail Test Setup

Isolated 5-V Supply 5-V Supply

í + + í

Isolated 12-V Supply

í
NAMUR
Sensor

3.2.3 Short-to-Supply Test Setup

Figure 19 shows the test setup for short to field supply error test cases. The 24-V supply is connected to
J1, the 5-V backplane supply is connected to J5, and J3 is shorted with a jumper. Instead of a NAMUR
sensor, an adjustable power supply is connected to J2 in forward or reverse direction.
In forward direction, the power supply voltage level is swept from 0 to 24 and the level at which ShortErr
LED is turning on is representing the short-to-positive supply threshold level. The green status LED is on
at that time.

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In reverse direction, the power supply voltage level is swept from 0 to 24 and the level at which ShortErr
LED is turning on is representing the short-to-negative supply threshold level. The green status LED is off
in this case.

Figure 19. Short-to-Supply Test Setup

5-V Supply

+ í

Forward or
Reverse

í +

í +
24-V Supply

24-V Supply

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3.2.4 Test Results

The TIDA-010044 implements extensive diagnostic functions, allowing identification of most of the failures
expected in the field for the NAMUR digital input module. As Table 3 shows, the 4 output signals are able
to specify the exact state of the module, either normal or failure state. This greatly reduces the time and
effort used to debug any of those failure states when they occur.
Looking at Table 3, TI recommends reversing the connection of the Powfail Blue LED, so that it is pulled-
up to the supply. This arrangement signals the power good as the blue LED, and the short to supply –24
V and 5-V supply fail can be distinguished.

Table 3. Diagnostic Outputs for Different Operating Conditions

CONDITION Status (DIN) Fault ShortErr Powfail
0 = Green 0 = Orange 0 = Red 1= Blue
Normal operation SW ON 0 1 1 0
SW OFF 1 1 1 0
Sensor failure Short 0 0 1 0
Open 1 0 1 0
Supply short –24-V supply 0 0 0 0
24-V supply 1 0 0 0
Power failure 12-V fail followsDIN followsDIN 0 1
5-V fail 0 0 0 0

Table 4 lists the measured values of the different tests for the normal case and failure conditions.
Measured values pretty much matches those of the target specification values in Table 1.

Table 4. Measured Voltage Thresholds for Operating Conditions

CONDITION MEASUREMENT
Normal operation SW ON threshold 1.77 mA
SW OFF threshold 1.48 mA
Sensor failure Short threshold 5.7 mA
Open threshold 0.59 mA
Supply short Negative supply short threshold -5-V (11.14 mA), -1-V (up)
Positive supply short threshold 8.6-V (0.4 mA)
Power failure 12-V iso supply fail threshold 6-V (down), 9-V (up)
5-V iso supply fail threshold 2.3-V (down), 3.8-V (up)
Open Circuit Voltage 8.18 V
Short Circuit Current 7.45 mA
Supply Current 5-V supply 6-7 mA, 8 mA (short)
24-V supply 12-13 mA, 15 mA (short)

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4 Design Files

4.1 Schematics
To download the schematics, see the design files at TIDA-010044.

4.2 Bill of Materials

To download the bill of materials (BOM), see the design files at TIDA-010044.

4.3 Layout Prints

To download the layer plots, see the design files at TIDA-010044.

4.4 Altium Project

To download the Altium Designer® project files, see the design files at TIDA-010044.

4.5 Gerber Files

To download the Gerber files, see the design files at TIDA-010044.

4.6 Assembly Drawings

To download the assembly drawings, see the design files at TIDA-010044.

4.7 Simulation Files

To download the simulation files, see the design files at TIDA-010044.

5 Related Documentation
1. Texas Instruments, TVS3301 33-V Bidirectional Flat-Clamp Surge Protection Device
2. Texas Instruments, LM339, LM239, LM139, LM2901 Quad Differential Comparators
3. Texas Instruments, TL43xLIx Programmable Shunt Regulator with Optimized Reference Current
4. Texas Instruments, LM25019 48V, 100mA Constant On-Time Synchronous Buck Regulator
5. Texas Instruments, TLV760 100-mA, 30-V, Fixed-Output, Linear-Voltage Regulator
6. Texas Instruments, ISO734x Robust EMC, Low Power, Quad-Channel Digital Isolators

5.1 Trademarks
E2E is a trademark of Texas Instruments.
Altium Designer is a registered trademark of Altium LLC or its affiliated companies.
All other trademarks are the property of their respective owners.

5.2 Third-Party Products Disclaimer

TI'S PUBLICATION OF INFORMATION REGARDING THIRD-PARTY PRODUCTS OR SERVICES DOES
NOT CONSTITUTE AN ENDORSEMENT REGARDING THE SUITABILITY OF SUCH PRODUCTS OR
SERVICES OR A WARRANTY, REPRESENTATION OR ENDORSEMENT OF SUCH PRODUCTS OR
SERVICES, EITHER ALONE OR IN COMBINATION WITH ANY TI PRODUCT OR SERVICE.

6 About the Author

AHMED NOEMAN is a system engineer at Texas Instruments Germany currently developing design
solutions for factory automation applications. Ahmed has many years of experience in analog and RF
design, AMS modeling, and verification, as well as application and system engineering in a wide range of
fields including RF transceivers, clocks and PLLs, memory systems. Ahmed received his BSC and MSEE
from Ain Shams University, Egypt.

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