Keithley 7999-5 Service manual

Model 7999-5

RS-232 Relay Controller

Instruction Manual

Contains Operating and Servicing Information

W ARRANTY

Keithley Instruments, Inc. warrants this product to be free from defects in material and workmanship for a
period of 1 year from date of shipment.

Keithley Instruments, Inc. warrants the following items for 90 days from the date of shipment: probes, cables,
rechargeable batteries, diskettes, and documentation.

During the warranty period, we will, at our option, either repair or replace any product that proves to be defec­tive.

To exercise this warranty, write or call your local Keithley representative, or contact Keithley headquarters in
Cleveland, Ohio. You will be given prompt assistance and return instructions. Send the product, transportation
prepaid, to the indicated service facility . Repairs will be made and the product returned, transportation prepaid.
Repaired or replaced products are warranted for the balance of the original warranty period, or at least 90 days.

LIMIT A TION OF W ARRANTY

This warranty does not apply to defects resulting from product modification without Keithley’s express written
consent, or misuse of any product or part. This warranty also does not apply to fuses, software, non-recharge­able batteries, damage from battery leakage, or problems arising from normal wear or failure to follow instruc­tions.

THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUD­ING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR USE.
THE REMEDIES PROVIDED HEREIN ARE BUYER’S SOLE AND EXCLUSIVE REMEDIES.

NEITHER KEITHLEY INSTRUMENTS, INC. NOR ANY OF ITS EMPLOYEES SHALL BE LIABLE FOR
ANY DIRECT , INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF
THE USE OF ITS INSTRUMENTS AND SOFTWARE EVEN IF KEITHLEY INSTRUMENTS, INC., HAS
BEEN ADVISED IN ADVANCE OF THE POSSIBILITY OF SUCH DAMAGES. SUCH EXCLUDED DAM­AGES SHALL INCLUDE, BUT ARE NOT LIMITED TO: COSTS OF REMOVAL AND INSTALLATION,
LOSSES SUSTAINED AS THE RESULT OF INJURY TO ANY PERSON, OR DAMAGE TO PROP­ERTY.ERTY.

Keithley Instruments, Inc.

BELGIUM: Keithley Instruments B.V.
CHINA: Keithley Instruments China
FRANCE: Keithley Instruments Sarl
GERMANY: Keithley Instruments GmbH
GREAT BRITAIN: Keithley Instruments Ltd
INDIA: Keithley Instruments GmbH
ITALY: Keithley Instruments s.r.l.
NETHERLANDS: Keithley Instruments B.V.
SWITZERLAND: Keithley Instruments SA
TAIWAN: Keithley Instruments Taiwan

• 28775 Aurora Road • Cleveland, OH 44139 • 440-248-0400 • Fax: [phone] • http://www.k eithley.com

Bergensesteenweg 709 • B-1600 Sint-Pieters-Leeuw • 02/363 00 40 • Fax: [phone]

Yuan Chen Xin Building, Room 705 • 12 Yumin Road, Dewai, Madian • Beijing 100029 • 8610-62022886 • Fax: [phone]

B.P. 60 • 3, allée des Garays • 91122 Palaiseau Cédex • 01 64 53 20 20 • Fax: [phone]

Landsberger Strasse 65 • D-82110 Germering • 089/84 93 07-40 • Fax: [phone]

The Minster • 58 Portman Road • Reading, Berkshire RG30 1EA • 0118-9 57 56 66 • Fax: [phone]
Flat 2B, WILOCRISSA • 14, Rest House Crescent • Bangalore 560 001 • 91-80-509-1320/21 • Fax: [phone]
Viale S. Gimignano, 38 • 20146 Milano • 02/48 30 30 08 • Fax: [phone]
Postbus 559 • 4200 AN Gorinchem • 0183-635333 • Fax: [phone]
Kriesbachstrasse 4 • 8600 Dübendorf • 01-821 94 44 • Fax: [phone]

1 Fl. 85 Po Ai Street • Hsinchu, Taiwan, R.O.C. • 886-3572-9077• Fax: [phone]

10/99

Model 7999-5 16-Channel RS-232 Relay Controller

Instruction Manual

©1998, Keithley Instruments, Inc.

All rights reserved.

Cleveland, Ohio, U.S.A.

Second Printing, December 1999

Document Number: 7999-5-901-01 Rev. B

Manual Print History

The print history shown below lists the printing dates of all Revisions and Addenda created
for this manual. The Revision Le vel letter increases alphabetically as the manual under goes sub­sequent updates. Addenda, which are released between Revisions, contain important change in­formation that the user should incorporate immediately into the manual. Addenda are numbered
sequentially . When a new Re vision is created, all Addenda associated with the previous Re vision
of the manual are incorporated into the new Revision of the manual. Each ne w Revision includes
a revised copy of this print history page.

Revision A (Document Number 7999-5-901-01).....................................................November 1999

Revision B (Document Number 7999-5-901-01)..................................................... December 1999

All Keithley product names are trademarks or registered trademarks of Keithley Instruments, Inc.
Other brand names are trademarks or registered trademarks of their respective holders.

Safety Precautions

The following safety precautions should be observed before using this product and any associated in­strumentation. Although some instruments and accessories would normally be used with non-hazardous
voltages, there are situations where hazardous conditions may be present.

This product is intended for use by qualified personnel who recognize shock hazards and are familiar
with the safety precautions required to avoid possible injury. Read the operating information carefully
before using the product.

The types of product users are:

Responsible body

ensuring that the equipment is operated within its specifications and operating limits, and for ensuring
that operators are adequately trained.

Operators

and proper use of the instrument. They must be protected from electric shock and contact with hazardous
live circuits.

Maintenance personnel

setting the line voltage or replacing consumable materials. Maintenance procedures are described in the
manual. The procedures explicitly state if the operator may perform them. Otherwise, they should be
performed only by service personnel.

Service personnel

ucts. Only properly trained service personnel may perform installation and service procedures.
Exercise extreme caution when a shock hazard is present. Lethal voltage may be present on cable con-

nector jacks or test fixtures. The American National Standards Institute (ANSI) states that a shock haz­ard exists when voltage lev els greater than 30V RMS, 42.4V peak, or 60VDC are present.

practice is to expect that hazardous voltage is present in any unknown circuit before measuring.

Users of this product must be protected from electric shock at all times. The responsible body must en­sure that users are prevented access and/or insulated from every connection point. In some cases, con­nections must be exposed to potential human contact. Product users in these circumstances must be
trained to protect themselves from the risk of electric shock. If the circuit is capable of operating at or
above 1000 volts,

As described in the International Electrotechnical Commission (IEC) Standard IEC 664, digital multi­meter measuring circuits (e.g., Keithley Models 175A, 199, 2000, 2001, 2002, and 2010) are Installation
Category II. All other instruments’ signal terminals are Installation Category I and must not be connect­ed to mains.

Do not connect switching cards directly to unlimited power circuits. They are intended to be used with
impedance limited sources. NEVER connect switching cards directly to AC mains. When connecting
sources to switching cards, install protective devices to limit fault current and voltage to the card.

Before operating an instrument, make sure the line cord is connected to a properly grounded power re­ceptacle. Inspect the connecting cables, test leads, and jumpers for possible wear, cracks, or breaks be­fore each use.

For maximum safety, do not touch the product, test cables, or any other instruments while power is ap­plied to the circuit under test. ALWAYS remove power from the entire test system and discharge any
capacitors before: connecting or disconnecting cables or jumpers, installing or removing switching
cards, or making internal changes, such as installing or removing jumpers.

is the individual or group responsible for the use and maintenance of equipment, for

use the product for its intended function. They must be trained in electrical safety procedures

are trained to work on live circuits, and perform safe installations and repairs of prod-

no conductive part of the circuit may be exposed.

perform routine procedures on the product to keep it operating, for example,

A good safety

Do not touch any object that could provide a current path to the common side of the circuit under test or power
line (earth) ground. Alw ays make measurements with dry hands while standing on a dry, insulated surface ca­pable of withstanding the voltage being measured.

The instrument and accessories must be used in accordance with its specifications and operating instructions
or the safety of the equipment may be impaired.

Do not exceed the maximum signal levels of the instruments and accessories, as defined in the specifications
and operating information, and as shown on the instrument or test fixture panels, or switching card.

When fuses are used in a product, replace with same type and rating for continued protection against fire hazard.
Chassis connections must only be used as shield connections for measuring circuits, NOT as safety earth

ground connections.
If you are using a test fixture, keep the lid closed while power is applied to the device under test. Safe operation

requires the use of a lid interlock.

If a screw is present, connect it to safety earth ground using the wire recommended in the user documen­tation.

!

The symbol on an instrument indicates that the user should refer to the operating instructions located in
the manual.

The symbol on an instrument sho ws that it can source or measure 1000 volts or more, including the com­bined effect of normal and common mode voltages. Use standard safety precautions to av oid personal contact
with these voltages.

The

WARNING

read the associated information very carefully before performing the indicated procedure.

heading in a manual explains dangers that might result in personal injury or death. Always

The

CAUTION

invalidate the warranty.
Instrumentation and accessories shall not be connected to humans.
Before performing any maintenance, disconnect the line cord and all test cables.
To maintain protection from electric shock and fire, replacement components in mains circuits, including the

power transformer, test leads, and input jacks, must be purchased from Keithley Instruments. Standard fuses,
with applicable national safety approvals, may be used if the rating and type are the same. Other components
that are not safety related may be purchased from other suppliers as long as they are equivalent to the original
component. (Note that selected parts should be purchased only through Keithley Instruments to maintain ac­curacy and functionality of the product.) If you are unsure about the applicability of a replacement component,
call a Keithley Instruments office for information.

To clean an instrument, use a damp cloth or mild, water based cleaner. Clean the exterior of the instrument
only. Do not apply cleaner directly to the instrument or allow liquids to enter or spill on the instrument. Prod­ucts that consist of a circuit board with no case or chassis (e.g., data acquisition board for installation into a
computer) should never require cleaning if handled according to instructions. If the board becomes contami­nated and operation is affected, the board should be returned to the factory for proper cleaning/servicing.

heading in a manual explains hazards that could damage the instrument. Such damage may

Rev. 10/99

Model 7999-5 Specifications

OUTPUTS: 16 open collector relay control lines, each capable of 300mA max. sink current. Coil suppression diodes included.
OUTPUT SATURATION VOLTAGE: 0.18V typ. @ 300mA.
MAXIMUM RELAYPOWER VOLTAGE: 28V DC (user supplied).
CONNECTORS: Two 10-position quick disconnect terminal blocks.
UPPER CONNECTOR: Relay power, relay common, relay control outputs 1–8.
LOWER CONNECTOR: Relay power, relay common, relay control outputs 9–16.

The relay common of the upper and lower connectors is internally connected together to chassis ground.
The relay power inputs of the upper and lower connectors are separate, allowing two different coil voltages to be used for each bank.

GENERAL

INTERFACE: RS-232 control (9600 baud, 8 data, 1 stop). Response terminator selectable (CR, LF, CRLF, LFCR).
ENVIRONMENT: Operating: 0° to 40°C, up to 35°C <80% RH. Storage: –25° to 65°C.
POWER CONSUMPTION: 7.3W.
WARRANTY: 1 year.
EMC: Conforms with European Union Directive 89/336/EEC, FCC part 15 class B.
SAFETY:Conforms with European Union Directive 73/23/EEC.
DIMENSIONS: 109mm long × 112mm wide × 59mm deep (4.3˝ × 4.4˝ × 2.3˝).
ACCESSORIES SUPPLIED: AC/DC power adapter (100–120VAC/ 220–240VAC, 50 or 60Hz) with line cord, user and service manual, two terminal

block mating connectors (part no. CS-846-1).

Specifications subject to change without notice.

T able of Contents

1 General Information

Introduction ................................................................................ 1-2

Feature overview ........................................................................ 1-2

Warranty information ................................................................. 1-2

Manual addenda ......................................................................... 1-2

Safety symbols and terms .......................................................... 1-3

Specifications ............................................................................. 1-3

Unpacking and inspection .......................................................... 1-3

Inspection for damage ......................................................... 1-3

Handling precautions .......................................................... 1-3

Shipment contents ............................................................... 1-4

Instruction manual .............................................................. 1-4

Repacking for shipment ...................................................... 1-4

Connections ................................................................................ 1-4

2 Connections

Introduction ................................................................................ 2-2

Handling precautions ................................................................. 2-2

Configuration ............................................................................. 2-3

Layout ................................................................................. 2-3

Connections ................................................................................ 2-4

RS-232 connection .............................................................. 2-4

Power connector .................................................................. 2-5

Quick disconnect connections ............................................. 2-5

3 Operation

Introduction ................................................................................ 3-2

Maximum voltage and current considerations ........................... 3-2

Operation (RS-232) .................................................................... 3-2

Sending and receiving data ................................................. 3-2

Termination characters ........................................................ 3-2

RS-232 command set .......................................................... 3-4

Command interpretation ..................................................... 3-5

Typical connection scheme ................................................. 3-7

4 Service Information

Introduction ................................................................................ 4-2

Handling and cleaning precautions ............................................ 4-2

Handling precautions .......................................................... 4-2

Card and connector cleaning ............................................... 4-2

Replacing components ................................................................ 4-3

Replacement parts ............................................................... 4-3

Replacement precautions ..................................................... 4-3

Soldering considerations ..................................................... 4-3

Disassembly ........................................................................ 4-3

Performance verification ............................................................. 4-4

Environmental conditions .................................................... 4-4

Recommended equipment ................................................... 4-4

Output saturation voltage verification procedure ................ 4-5

5 Replaceable Parts

Introduction ................................................................................ 5-2

Parts list ...................................................................................... 5-2

Ordering information .................................................................. 5-2

Factory service ............................................................................ 5-2

Component layout ...................................................................... 5-2

List of Illustrations

2 Connections

Figure 2-1 General layout ........................................................................ 2-3

Figure 2-2 RS-232 interface connector .................................................... 2-4

Figure 2-3 Relay control connector pinouts ............................................ 2-6

3 Operation

Figure 3-1 Jumper location ...................................................................... 3-3

Figure 3-2 Typical connection scheme .................................................... 3-7

4 Service Information

Figure 4-1 Output saturation voltage test connections ............................ 4-5

List of T ables

2 Connections

Table 2-1 RS-232 connector terminals ................................................... 2-4

Table 2-2 Upper relay connector pinouts ............................................... 2-5

Table 2-3 Lower relay connector pinouts ............................................... 2-6

3 Operation

Table 3-1 Jumper positions—termination characters ............................. 3-3

Table 3-2 Command set .......................................................................... 3-4

Table 3-3 Sample command interpretation ............................................ 3-6

4 Service Information

Table 4-1 Recommended verification equipment ................................... 4-4

5 Replaceable Parts

Table 5-1 Parts list—electronic components .......................................... 5-3

Table 5-2 Parts list—mechanical parts ................................................... 5-4

1

General Information

1-2 General Information

Introduction

This section contains general information about the Model 7999-5 16-channel RS-232 relay
controller. The information is organized as follows:

• Feature overview

• Warranty information

• Manual addenda

• Safety symbols and terms

• Specifications

• Unpacking and inspection

• Connections

If you have any questions after reviewing this information, please contact your local
Keithley representative or call a Keithley Applications Engineer at 1-800-348-3735 (U.S. and
Canada only). Worldwide phone numbers are listed at the front of this manual.

Feature overview

The Model 7999-5 is a 16-channel open collector relay controller with the following
features:

• 16 open-collector relay control lines

• Quick-disconnect terminal block type connectors (mating connectors supplied)

• Coil suppression diodes

W arranty information

Warranty information is located at the front of this instruction manual. Should your Model
7999-5 require warranty service, contact the Keithley representative or authorized repair facil­ity in your area for further information. When returning the relay controller for repair, be sure
to fill out and include the service form at the back of this manual to provide the repair facility
with the necessary information.

Manual addenda

Any improvements or changes concerning the relay controller or manual will be explained
in an addendum included with the manual. Be sure to note these changes and incorporate them
into the manual.

Safety symbols and terms

The following symbols and terms may be found on the relay controller or used in this

manual.

The symbol indicates that the user should refer to the operating instructions located in

!

the manual.

General Information 1-3

The

symbol

safety precautions to avoid personal contact with these voltages.

The

WARNING

injury or death. Always read the associated information very carefully before performing the
indicated procedure.

The

CAUTION

controller. Such damage may invalidate the warranty.

shows that high voltage may be present on the terminal(s). Use standard

heading used in this manual explains dangers that might result in personal

heading used in this manual explains hazards that could damage the relay

Specifications

Full Model 7999-5 specifications are included at the front of this manual.

Unpacking and inspection

Inspection for damage

The Model 7999-5 is packaged in a re-sealable, anti-static bag to protect it from damage due
to static discharge and from contamination that could degrade its performance. Before remov­ing the relay controller from the bag, observe the precautions on handling discussed below.

Handling precautions

• Always grasp the relay controller by the covers. Do not touch board surfaces or
components.

• After removing the relay controller from its anti-static bag, inspect it for any obvious
signs of physical damage. Report any such damage to the shipping agent immediately.

• When the relay controller is not installed and connected, keep the relay controller in its
anti-static bag, and store it in the original packing carton.