PXI-2510 Relay Replacement

The module uses electromechanical armature relays.

Note The module uses a custom lead length to meet safety standards. Trim leads to no more than 1 mm (0.04 inch) from the PCB. You also can use the spare relay included with the module at location K49.

Refer to the following for information about ordering replacement relays.

Relay Manufacturer Part Number

Tyco Electronics 5-1462039-8

Relay Kit Part Number

NI (10 relays) 781089-10

Disassemble the Module

  1. Ground yourself using a grounding strap or a ground connected to your PXI chassis.
    Note Properly grounding yourself prevents damage to your module from electrostatic discharge.
  2. Locate the relay you want to replace. Refer to the relay locations figures and tables.
  3. Remove the four screws that secure the mezzanine board to the base board. Do not remove the hex standoffs or the base board.
  4. Separate the mezzanine board from the base board.
Figure 1. Disassembling the Module

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  1. Screws
  2. Mezzanine Board
  3. Hex Standoff
  4. Base Board
Figure 2. Base Board Relay Locations

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Table 2. Base Board Relay Locations
Relay Name Reference Designator Relay Name Reference Designator Relay Name Reference Designator Relay Name Reference Designator
k0 K12 k7a K14 k14b K40 k22 K67
k0a K11 k7b K15 k15 K37 k22a K65
k0b K10 k8 K35 k15a K39 k22b K66
k1 K7 k8a K34 k15b K38 k23 K64
k1a K8 k8b K36 k16 K59 k23a K62
k1b K9 k9 K33 k16a K60 k23b K63
k2 K6 k9a K32 k16b K61 k24 K79
k2a K5 k9b K31 k17 K56 k24a K77
k2b K4 k10 K28 k17a K58 k24b K78
k3 K2 k10a K29 k17b K57 k25 K76
k3a K3 k10b K30 k18 K53 k25a K74
k3b K1 k11 K25 k18a K55 k25b K75
k4 K23 k11a K26 k18b K54 ka0busA K84
k4a K22 k11b K27 k19 K50 ka1busA K83
k4b K24 k12 K48 k19a K52 ka2busA K82
k5 K21 k12a K47 k19b K51 ka3busA K81
k5a K19 k12b K46 k20 K73 kb0busB K80
k5b K20 k13 K45 k20a K72 kb0busB K87
k6 K16 k13a K44 k20b K71 kb0busB K86
k6a K17 k13b K43 k21 K70 kb0busB K85
k6b K18 k14 K42 k21a K68 Spare K49
k7 K13 k14a K41 k21b K69 — —
Figure 3. Mezzanine Board Relay Locations

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Table 3. Mezzanine Board Relay Locations
Channel Name Relay Name Channel Name Relay Name Channel Name Relay Name Channel Name Relay Name
k26 K57 k36b K85 k47a K11 k58 K93
k26a K56 k37 K21 k47b K10 k58a K92
k26b K55 k37a K20 k48 K66 k58b K91
k27 K72 k37b K19 k48a K65 k59 K90
k27a K71 k38 K30 k48b K64 k59a K89
k27b K70 k38a K29 k49 K63 k59b K88
k28 K3 k38b K28 k49a K62 k60 K78
k28a K2 k39 K33 k49b K61 k60a K77
k28b K1 k39a K32 k50 K69 k60b K76
k29 K6 k39b K31 k50a K68 k61 K114
k29a K5 k40 K42 k50b K67 k61a K113
k29b K4 k40a K41 k51 K84 k61b K112
k30 K45 k40b K40 k51a K83 k62 K111
k30a K44 k41 K39 k51b K82 k62a K110
k30b K43 k41a K38 k52 K102 k62b K109
k31 K60 k41b K37 k52a K101 k63 K75
k31a K59 k42 K9 k52b K100 k63a K74
k31b K58 k42a K8 k53 K81 k63b K73
k32 K18 k42b K7 k53a K80 k64 K126
k32a K17 k43 K15 k53b K79 k64a K125
k32b K16 k43a K14 k54 K105 k64b K124
k33 K24 k43b K13 k54a K104 k65 K117
k33a K23 k44 K36 k54b K103 k65a K116
k33b K22 k44a K35 k55 K123 k65b K115
k34 K27 k44b K34 k55a K122 k66 K120
k34a K26 k45 K54 k55b K121 k66a K119
k34b K25 k45a K53 k56 K99 k66b K118
k35 K48 k45b K52 k56a K98 k67 K108
k35a K47 k46 K51 k56b K97 k67a K107
k35b K46 k46a K50 k57 K96 k67b K106
k36 K87 k46b K49 k57a K95 — —
k36a K86 k47 K12 k57b K94 — —

Replace the Relay

The module uses lead-free assemblies.

Note NI recommends using lead-free solder for relay replacement on lead-free assemblies.
Caution Do not rework lead assemblies using a lead-free work station. Lead solder from the unit could contaminate the station.
Caution If a lead-free assembly is reworked with lead solder, label the assembly to indicate this. This can prevent the same unit from being reworked later on a lead-free solder station, which could contaminate the station.

Make sure you have the following:

  • Temperature-regulated soldering iron set to 371 °C (700 °F) for lead-free solder rework
  • 96.5/3.0/0.5 Tin/Silver/Copper solder (flux core) for lead-free solder rework
  • Solder wick
  • Fine pick
  • Isopropyl alcohol
  • Cotton swabs

Replace the relay as you would any other through-hole part. Trim the replaced relay leads to no more than 1 mm(0.04 inch) from the PCB.

Reassemble the Module

  1. Ground yourself using a grounding strap or a ground connected to your PXI chassis.
    Note Properly grounding yourself prevents damage to your module from electrostatic discharge.
  2. Attach the mezzanine board to the base board.
  3. Secure the boards together with the four screws.
Tip You can use the NI-SWITCH Switch Soft Front Panel to reset the relay count after you have replaced a failed relay. Refer to the Switch Soft Front Panel Help for more information.