National Instruments 779640-01 User manual

USER GUIDE AND SPECIFICATIONS
NI USB-6525
This user guide describes how to use the National Instruments USB-6525
data acquisition (DAQ) device.
Introduction
The NI USB-6525 is a full-speed USB 2.0 device that provides
eight ±60 VDC channel-to-channel isolated digital inputs (DI),
eight 60 VDC/30 Vrms channel-to-channel isolated solid-state relay (SSR)
outputs, and a 32-bit counter.
Figure 1. USB-6525 Top View
1 USB Cable Strain Relief
1

USB-6525 User Guide and Specifications 2 ni.com
Figure 2. USB-6525 Back View
Installing Software
Software support for the USB-6525 for Windows 2000/XP is provided by
NI-DAQmx.
The NI-DAQmx CD contains example programs that you can use to get
started programming with the USB-6525. Refer to the NI-DAQmx for USB
Devices Getting Started Guide, that shipped with your device and is also
accessible from Start»All Programs»National Instruments»NI-DAQ
for more information.
Note For information about non-Windows operating system support, refer to ni.com/
info and enter rddqld.
Hardware
The block diagram in Figure 3 shows key functional components of the
USB-6525.
Figure 3. USB-6525 Block Diagram
P0.<0..7>A/B
P1.<0..7>+/–
Digital I/O Terminal Block
Vbus
Full-Speed USB Interface
USB
SSRs
P0
P1
USB Microcontroller
Current-
Limiting
Isolated
Inputs

©National Instruments Corporation 3 USB-6525 User Guide and Specifications
Refer to the Safety Guidelines section of this document for important safety
information.
Setting Up Hardware
Complete the following steps to set up the hardware:
1. Install combicon screw terminal blocks by inserting them into the
combicon jacks.
Note The USB-6525 kit ships with signal labels. You can apply the signal labels on the
screw terminal blocks for easy signal identification.
2. Refer to Table 1 and Figure 4 for label orientation and affix provided
signal labels to the screw terminal blocks. Insert the screw terminal
blocks into their respective matching combicon jacks. Refer to
Figure 4 for more information about signal label orientation.
Figure 4. Signal Label Application Diagram
3. Connect the wiring to the appropriate screw terminals.
1 Overlay Label with Pin Orientation Guides
2 Combicon Jack
3 Screw Terminal Blocks
4 Signal Labels
4
3
3
2
1
4

USB-6525 User Guide and Specifications 4 ni.com
I/O Connector
The USB-6525 device ships with two detachable terminal blocks for digital
signals. Each individual terminal accepts a wire gauge between
16 AWG–28 AWG.
Table 1. Digital Terminal Assignments
Module Terminal Signal Module Terminal Signal
1P0.0A 17 P1.0+
2P0.0B 18 P1.0–
3P0.1A 19 P1.1+
4P0.1B 20 P1.1–
5P0.2A 21 P1.2+
6P0.2B 22 P1.2–
7P0.3A 23 P1.3+
8P0.3B 24 P1.3–
9P0.4A 25 P1.4+
10 P0.4B 26 P1.4–
11 P0.5A 27 P1.5+
12 P0.5B 28 P1.5–
13 P0.6A 29 P1.6+
14 P0.6B 30 P1.6–
15 P0.7A 31 P1.7+/PFI 0+
16 P0.7B 32 P1.7–/PFI 0–

©National Instruments Corporation 5 USB-6525 User Guide and Specifications
Signal Descriptions
Table 2 describes the signals available on the I/O connectors.
Features
The NI 6525 features digital filtering, change detection, programmable
power-up output states, and a watchdog timer.
Digital Filtering
Use the digital filter option available on the NI 6525 input lines to eliminate
glitches on input data. When used with change detection, filtering can also
reduce the number of changes to examine and process.
You can configure the digital input channels to pass through a digital filter,
and you can program the filter interval the filter uses. The filter blocks
pulses that are shorter than half of the specified filter interval and passes
pulses that are longer than the specified interval. Intermediate-length
pulses—pulses longer than half of the interval but less than the
interval—may or may not pass the filter.
The filter operates on the inputs from the optocouplers. The optocouplers
turn on faster than they turn off, passing rising edges faster than falling
Table 2. Signal Descriptions
Signal Name Direction Description
P0.<0..7>A/B Output Solid-state relay 60 VDC/30 Vrms (42.4 Vpk) output
P1.<0..6>+/– Input ±60 VDC digital input.
P1.<0..6>+ corresponds to the positive input terminal.
P1.<0..6>– corresponds to the negative input terminal.
P1.7+/– or PFI 0+/– Input This channel is configurable as either a digital input or
an event counter.
Digital Input Signal—±60 VDC digital input.
P1.7+ corresponds to the positive input terminal.
P1.7– corresponds to the negative input terminal.
CTR—As a counter, this signal can be used as an event
counter input source.
PFI 0+ corresponds to the positive counter terminal.
PFI 0– corresponds to the negative counter terminal.

USB-6525 User Guide and Specifications 6 ni.com
edges. The optocouplers can therefore subtract up to 150 μs from a low
pulse.
Table 3 lists the pulse widths guaranteed to be passed and blocked.
You can enable filtering on as many input lines as is necessary for your
application. All filtered lines share the same timing interval, which ranges
from 120 μs to 2600 ms.
Internally, the filter uses two clocks: the sample clock and the filter clock.
The sample clock has a 40 μs period1. The filter clock is generated by a
counter and has a period equal to one half of the specified timing interval.
The input signal is sampled on each rising edge of the sample clock, which
is every 40 μs1. A change in the input signal is recognized only if it
maintains its new state for at least two consecutive rising edges of the filter
clock.
The filter clock is programmable and allows you to control how long a
pulse must last to be recognized. The sample clock provides a fast sample
rate to ensure that input pulses remain constant between filter clocks.
Table 3. NI 6525 Digital Filtering
Filter Interval
Pulse Width Passed Pulse Width Blocked
Low Pulse High Pulse Low Pulse High Pulse
tinterval tinterval + 150 μs tinterval tinterval/2 (tinterval/2) – 150 μs
1 The accuracy of the sample clock is ±1.5%.

©National Instruments Corporation 7 USB-6525 User Guide and Specifications
Digital Filtering Example
Figure 5 shows a filter configuration with a tinterval filter interval
(tinterval/2 filter clock).
Figure 5. Digital Filtering Example
In periods A and B, the filter blocks the glitches because the external signal
does not remain steadily high from one rising edge of the filter clock to the
next. In period C, the filter passes the transition because the external signal
remains steadily high. Depending on when the transition occurs, the filter
may require up to two filter clocks—one full filter interval—to pass a
transition. The figure shows a rising (0 to 1) transition. The same filtering
applies to falling (1 to 0) transitions.
Change Detection
You can program the NI 6525 to send an interrupt when a change occurs on
any input line.
The NI 6525 can monitor changes on selected input lines or on all input
lines. It can monitor for rising edges (0 to 1), falling edges (1 to 0), or both.
When an input change occurs, the NI 6525 generates an interrupt, and the
NI-DAQ driver then notifies the software.
Note Excessive change detections can affect system performance. Use digital filtering to
minimize the effects of noisy input lines.
The NI 6525 sends a change detection when any one of the changes occurs,
but it does not report which line changed or if the line was rising or falling.
After a change, you can read the input lines to determine the current line
states. The maximum rate of change detection is determined by the
software response time, which varies from system to system.
HHHHH
HLLHH
HLLHH
A
B
C
Sample Clock
External
Signal
Sampled
Filtered
Signal
External
Signal
Filter
Clock

USB-6525 User Guide and Specifications 8 ni.com
An overflow bit indicates that an additional rising or falling edge has been
detected before the software could process the previous change.
Refer to the software documentation for information about how to set up
and implement the change detection.
Change Detection Example
Table 4 shows a change detection example for six bits of one port.
This example assumes the following line connections:
• Bits 7, 6, 5, and 4 are connected to data lines from a four-bit TTL
output device. The NI 6525 detects any change in the input data so you
can read the new data value.
• Bit 1 is connected to a limit sensor. The NI 6525 detects rising edges
on the sensor, which correspond to over-limit conditions.
• Bit 0 is connected to a switch. The software can react to any switch
closure, which is represented by a falling edge. If the switch closure is
noisy, enable digital filtering for this line.
In this example, the NI 6525 reports rising edges only on bit 1, falling edges
only on bit 0, and rising and falling edges on bits 7, 6, 5, and 4. The NI 6525
reports no changes for bits 3 and 2. After receiving notification of a change,
you can read the port to determine the current values of all eight lines. You
cannot read the state of any lines that are configured for change detection
until the change detection interrupt occurs.
Table 4. Change Detection Example
Bit
76543210
Changes to detect — —
Enable rising-edge
detection
yes yes yes yes no no yes no
Enable falling-edge
detection
yes yes yes yes no no no yes

©National Instruments Corporation 9 USB-6525 User Guide and Specifications
Programmable Power-Up Output States
The default power-up state of the digital output lines is logic low, which
opens the solid-state relays. The lines on output ports are user-configurable
for logic high (closed relay) or logic low (open relay). User-configurable
power-up states are useful for ensuring that the NI 6525 powers up in a
known state.
To use MAX (recommended) to program the power-up states, select
the device and click the Properties button. Refer to the software
documentation for information about how to program the power-up states
using NI-DAQ with LabVIEW or other National Instruments application
development environments (ADEs).
Watchdog Timer
The watchdog timer is a software configurable feature used to set critical
outputs to safe states in the event of a software failure, a system crash, or
any other loss of communication between the application and the NI 6525.
When the watchdog timer is enabled, if the NI 6525 does not receive a
watchdog reset software command within the time specified for the
watchdog timer, the outputs go to a user-defined safe state and remain in
that state until the watchdog timer is disarmed by the application and new
values are written, the NI 6525 is reset, or the computer is restarted. The
expiration signal that indicates an expired watchdog will continue to assert
until the watchdog is disarmed. After the watchdog timer expires, the
NI 6525 ignores any writes until the watchdog timer is disarmed.
You can set the watchdog timer timeout period to specify the amount of
time that must elapse before the watchdog timer expires. The counter on the
watchdog timer is configurable up to (232 – 1) × 40 μs1before it expires.
Digital I/O
USB-6525 has eight channel-to-channel optically isolated inputs,
P1.<0..7>, and eight channel-to-channel optically isolated solid-state relay
outputs, P0.<0..7>. P1.7/PFI 0 can also function as a 32-bit counter. Refer
to the Event Counter section for more information about the counter.
Optically Isolated Inputs
The USB-6525 provides eight channels of isolated digital inputs. These
inputs consist of an optocoupler, a depletion-mode MOSFET-based
current-limiting circuit, and Schottky diode.
1 The accuracy of the sample clock is ±1.5%.

USB-6525 User Guide and Specifications 10 ni.com
Each channel has its own positive and negative terminals. The input range
on the channels is –60 VDC to +60 VDC.
Sensing DC Voltages
The USB-6525 detects a wide range of DC signals, from TTL-like logic
levels to DC power supply levels up to 60 V.
Applying a DC voltage of at least 3.2 V across two input terminals registers
logic high. Applying no voltage or a voltage difference of 1 V or less
registers logic low. DC voltages between 1 V and 3.2 V may not register a
consistent or usable value.
Signal Connection Example
Figure 6 shows signal connections for a power supply and load connected
to an isolated input.
Figure 6. Connecting a Power Supply and Load to the Isolated Input
Caution Use twisted-pair field wiring to reduce EMC noise.
In Figure 6, the USB-6525 is sensing a powered load that is connected to
the power supply through a switch.
Note Power supplies must be within the USB-6525 device range. Refer to the
Specifications section for information about these ranges.
When the switch is open, no current flows through the load and no voltage
is applied to the load or to the USB-6525 input. The digital logic of the
USB-6525 then registers a logic low for the channel. When the switch is
Isolation
Digital
Logic
Computer
Ground
USB-6525
P1.x+
P1.x–
MOSFET-Based
Current-Limiting
Circuitry
Schottky
Load
+
_
Twisted-Pair
Wiring
Vcc
Vsupply

©National Instruments Corporation 11 USB-6525 User Guide and Specifications
closed, current flows through both the load and the USB-6525 optocoupler,
and the USB-6525 registers a logic high for the channel.
Solid-State Relay (SSR) Outputs
You can connect loads to the USB-6525. Connect the load to one of the
leads of the power source. Connect either the P0.xA or the P0.xB terminal
to the load and the other terminal to the other lead of the AC or DC power
source. Figure 7 shows a possible configuration where the load is
connected to the P0.xB terminal and the DC or AC power source.
Figure 7. Connecting a Load to the USB-6525
Caution Use twisted-pair field wiring to reduce EMC noise.
Power-On and Power-Off Conditions
The default power-on state of the solid-state relays is open. By default, the
solid-state relays remain open when the chassis and the USB-6525 device
are powered off.
Protecting Inductive Loads
When inductive loads are connected to the USB-6525 SSR outputs, a large
counter-electromotive force may occur at switching time because of the
energy stored in the inductive load. These flyback voltages can damage the
SSR outputs and/or the external power supply.
Limit flyback voltages at your inductive load by installing one of the
following:
• For DC loads—Install a flyback diode within 18 in. of the load.
• For AC loads—Install a metal oxide varistor (MOV) rated for 30 Vrms
or slightly higher.
+
_
or
AC
USB-6525
P0.xA
P0.xBLoad
Twisted-Pair
Wiring

USB-6525 User Guide and Specifications 12 ni.com
Figures 8 and 9 show examples of using an external flyback diode to
protect DC inductive loads and an MOV to protect AC inductive loads,
respectively.
Figure 8. Contact Protection for DC Inductive Loads
Figure 9. Contact Protection for AC Inductive Loads
Inductive
Load
USB-6525
Flyback Diode for
DC Inductive Loads
VDC
+
–
P0.xA
P0.xB
Inductive
Load
USB-6525
MOV for AC
Inductive Loads
VAC
P0.xA
P0.xB

©National Instruments Corporation 13 USB-6525 User Guide and Specifications
Using the USB-6525 as a TTL Output Device
Figure 10 shows a signal connection example for a TTL-level application
with an external supply voltage of +5 V.
Figure 10. TTL Device Signal Connection Example
When the SSR is open, a small amount of current flows through RLand the
output voltage is close to 5 V, a logic high. When the SSR is closed, current
flows through RLand the output voltage is close to 0 V, a logic low.
Choose an RLvalue small enough to provide the necessary source current
but large enough to reduce sink current and to avoid consuming
unnecessary power. Many TTL-level applications use an RLvalue of 5 kΩ.
Event Counter
You can configure PFI 0 (an alias to P1.7) as the source for a 32-bit counter.
In this mode, the device counts low to high transitions on P1.7. The counter
can be armed and disarmed and the count can be read or reset through
software. For more information about event timing requirements, refer to
the Specifications section. Refer to your software documentation for more
information about counter programming techniques.
VOUT
RL= 5 kΩ
Isolated
Ground
To External
+5 V Supply
P0.xA
P0.xB
USB-6525

USB-6525 User Guide and Specifications 14 ni.com
Specifications
The following specifications are typical at 25 °C, unless otherwise noted.
Isolated Inputs
Number of input channels.......................8, ch-ch isolated
Input voltage range .................................–60 VDC to 60 VDC
Input current ...........................................3.0 mA/channel max
Minimum pulse-width
for change detection................................200 μs
Propagation delay ...................................65 μs, typical
Solid-State Relay Outputs
Number of output channels.....................8, ch-ch isolated
Relay type ...............................................Normally open solid-state
relay (SSR)
Switching voltage ...................................60 VDC/30 Vrms max
Switching current (per channel)..............500 mA max, full operation
temperature range
Switching rate (90% duty cycle) ............5 operations per second
Relay open time ......................................60 μs typ
Relay close time......................................1.2 ms typ
On resistance...........................................550 mΩmax
Off state leakage .....................................0.6 μA typ
Counter
Number of counters ................................1 (P1.7 can be configured
as a counter)
Level Min Max
Input low voltage –60 VDC 1 VDC
Input high voltage 3.2 VDC 60 VDC

©National Instruments Corporation 15 USB-6525 User Guide and Specifications
Resolution .............................................. 32 bits
Counter measurements........................... Rising edge counting
Maximum input frequency..................... 5 KHz
Minimum high pulse width .................... 20 μs
Minimum low pulse width ..................... 180 μs
Bus Interface
USB specification .................................. USB 2.0 full-speed (12 Mb/s)
Power Requirements
USB
Input voltage ................................... 4.5 to 5.25 VDC in
configured state
Active current ................................. 150 mA max
Suspend current............................... 350 μA typ
Physical Characteristics
Dimensions
Without connectors ......................... 6.35 cm ×8.51 cm ×2.31 cm
(2.50 in. ×3.35 in. ×0.91 in.)
With connectors .............................. 8.18 cm ×8.51 cm ×2.31 cm
(3.22 in. ×3.35 in. ×0.91 in.)
I/O connectors ........................................ USB series B receptacle,
(2) 16 position (screw terminal)
plug headers
Screw-terminal wiring............................ 16 to 28 AWG copper conductor
wire with 10 mm (0.39 in.) of
insulation stripped from the end
Torque for screw terminals .................... 0.22 – 0.25 N · m
(2.0 – 2.2 lb · in.)
Weight
With connectors .............................. Approx. 87 g (3.1 oz)
Without connectors ......................... Approx. 64 g (2.3 oz)

USB-6525 User Guide and Specifications 16 ni.com
Safety
Standards
This product meets the requirements of the following standards of safety
for electrical equipment for measurement, control, and laboratory use:
• IEC 61010-1, EN 61010-1
• UL 61010-1, CSA 61010-1
Note For UL and other safety certifications, refer to the product label or the Online
Product Certification section.
Isolation
Channel-to-channel.................................60 VDC continuous
Channel-to-earth ground.........................60 VDC continuous
Withstand................................................60 VDC continuous
Caution Do not use this module for connection to signals or for measurements within
Measurement Categories II, III, or IV.
Hazardous Locations
The USB-6525 is not certified for use in hazardous locations.
Environmental
The USB-6525 device is intended for indoor use only.
Operating temperature
(IEC 60068-2-1 and IEC 60068-2-2)......0 to 55 °C
Operating humidity
(IEC 60068-2-56) ...................................10 to 90% RH, noncondensing
Maximum altitude...................................2,000 m (at 25 °C ambient
temperature)
Storage temperature
(IEC 60068-2-1 and IEC 60068-2-2)......–40 to 85 °C
Storage humidity
(IEC 60068-2-56) ...................................5 to 90% RH, noncondensing
Pollution Degree (IEC 60664) ................2

©National Instruments Corporation 17 USB-6525 User Guide and Specifications
Electromagnetic Compatibility
This product meets the requirements of the following EMC standards for
electrical equipment for measurement, control, and laboratory use:
• EN 61326 (IEC 61326): Class A emissions; Basic immunity
• EN 55011 (CISPR 11): Group 1, Class A emissions
• AS/NZS CISPR 11: Group 1, Class A emissions
• FCC 47 CFR Part 15B: Class A emissions
• ICES-001: Class A emissions
Note For the standards applied to assess the EMC of this product, refer to the Online
Product Certification section.
Note For EMC compliance, operate this product according to the documentation.
CE Compliance
This product meets the essential requirements of applicable European
Directives as follows:
• 2006/95/EC; Low-Voltage Directive (safety)
• 2004/108/EC; Electromagnetic Compatibility Directive (EMC)
Online Product Certification
Refer to the product Declaration of Conformity (DoC) for additional
regulatory compliance information. To obtain product certifications and
the DoC for this product, visit ni.com/certification, search by model
number or product line, and click the appropriate link in the Certification
column.
Environmental Management
NI is committed to designing and manufacturing products in an
environmentally responsible manner. NI recognizes that eliminating
certain hazardous substances from our products is beneficial to the
environment and to NI customers.
For additional environmental information, refer to the NI and the
Environment Web page at ni.com/environment. This page contains the
environmental regulations and directives with which NI complies, as well
as other environmental information not included in this document.

USB-6525 User Guide and Specifications 18 ni.com
Waste Electrical and Electronic Equipment (WEEE)
EU Customers At the end of their life cycle, all products must be sent to a WEEE recycling
center. For more information about WEEE recycling centers and National Instruments
WEEE initiatives, visit ni.com/environment/weee.htm.
Safety Guidelines
Caution Operate the hardware only as described in these operating instructions.
The following section contains important safety information that you must
follow when installing and using the USB-6525.
Do not operate the USB-6525 in a manner not specified in this document.
Misuse of the device can result in a hazard. You can compromise the safety
protection built into the device if the device is damaged in any way. If the
device is damaged, contact National Instruments for repair.
Do not substitute parts or modify the device except as described in this
document. Use the device only with the chassis, modules, accessories, and
cables specified in the installation instructions. You must have all covers
and filler panels installed during operation of the device.
Do not operate the device in an explosive atmosphere or where there may
be flammable gases or fumes. If you must operate the device in such an
environment, it must be in a suitably rated enclosure.
If you need to clean the device, use a dry cloth. Make sure that the device
is completely dry and free from contaminants before returning it to service.
Operate the device only at or below Pollution Degree 2. Pollution is foreign
matter in a solid, liquid, or gaseous state that can reduce dielectric strength
or surface resistivity. The following is a description of pollution degrees:
• Pollution Degree 1 means no pollution or only dry, nonconductive
pollution occurs. The pollution has no influence.
• Pollution Degree 2 means that only nonconductive pollution occurs in
most cases. Occasionally, however, a temporary conductivity caused
by condensation must be expected.
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(For information about China RoHS compliance, go to ni.com/environment/rohs_china.)

©National Instruments Corporation 19 USB-6525 User Guide and Specifications
• Pollution Degree 3 means that conductive pollution occurs, or dry,
nonconductive pollution occurs that becomes conductive due to
condensation.
You must insulate signal connections for the maximum voltage for which
the device is rated. Do not exceed the maximum ratings for the device. Do
not install wiring while the device is live with electrical signals. Do not
remove or add connector blocks when power is connected to the system.
Avoid contact between your body and the connector block signal when hot
swapping modules. Remove power from signal lines before connecting
them to or disconnecting them from the device.
Operate the device at or below the Measurement Category I1. Measurement
circuits are subjected to working voltages2and transient stresses
(overvoltage) from the circuit to which they are connected during
measurement or test. Measurement categories establish standard impulse
withstand voltage levels that commonly occur in electrical distribution
systems. The following is a description of measurement categories:
• Measurement Category I is for measurements performed on circuits
not directly connected to the electrical distribution system referred to
as MAINS3voltage. This category is for measurements of voltages
from specially protected secondary circuits. Such voltage
measurements include signal levels, special equipment, limited-energy
parts of equipment, circuits powered by regulated low-voltage sources,
and electronics.
• Measurement Category II is for measurements performed on circuits
directly connected to the electrical distribution system. This category
refers to local-level electrical distribution, such as that provided by a
standard wall outlet (for example, 115 V for U.S. or 230 V for Europe).
Examples of Measurement Category II are measurements performed
on household appliances, portable tools, and similar USB devices.
• Measurement Category III is for measurements performed in the
building installation at the distribution level. This category refers to
measurements on hard-wired equipment such as equipment in fixed
installations, distribution boards, and circuit breakers. Other examples
are wiring, including cables, bus-bars, junction boxes, switches,
socket-outlets in the fixed installation, and stationary motors with
permanent connections to fixed installations.
• Measurement Category IV is for measurements performed at the
primary electrical supply installation (<1,000 V). Examples include
1 Measurement Category as defined in electrical safety standard IEC 61010-1. Measurement Category is also referred to as
Installation Category.
2 Working Voltage is the highest rms value of an AC or DC voltage that can occur across any particular insulation.
3 MAINS is defined as a hazardous live electrical supply system that powers equipment. Suitably rated measuring circuits may
be connected to the MAINS for measuring purposes.

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electricity meters and measurements on primary overcurrent
protection devices and on ripple control units.
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