Bird Technologies 8630B User Manual

INSTRUCTION BOOK

MODULOAD

SERIES 8630 AND 8630B

®

RF LOAD RESISTOR

Bird® Electronic Corporation
30303 Aurora Road
Cleveland (Solon), Ohio 44139

Sales & Technical Support: 440-248-1200

Sales email: [e-mail]

Technical Support email: [e-mail]

Moduload

866-695-4569 toll free

©Copyright 2006 by Bird Electronic Corporation

Instruction Book P/N 920-8630S Rev. G

®

, Econoload®, Econoline®, and Thruline® are

registered trademarks of Bird Electronic Corporation

I am not blank

Safety Precautions

The following are general safety precautions that are not necessarily
related to any specific part or procedure and do not necessarily appear
elsewhere in this publication. These precautions must be thoroughly
understood and applied to all phases of operation and maintenance.

Keep Away From Live Circuits

Operating personnel must at all times observe normal safety regulations.
Do not replace components or make adjustments inside the equipment
with high voltage turned on. To avoid casualties, always remove power.

Shock Hazard

Do not attempt to remove the RF transmission line while RF power is
present.

Do Not Service Or Adjust Alone

Under no circumstances should any personnel reach into an enclosure for
the purpose of service or adjustment of equipment except in the presence
of someone who is capable of rendering aid.

Safety Earth Ground

An uninterruptible earth safety ground must be supplied from the main
power source to test instruments. Grounding one conductor of a two
conductor power cable is not sufficient protection. Serious injury or death
can occur if this grounding is not properly supplied.

Chemical Hazard

Dry cleaning solvents for cleaning parts may be potentially dangerous.
Avoid inhalation of fumes or prolonged contact with skin.

Resuscitation

Personnel working with or near high voltages should be familiar with
modern methods of resuscitation.

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Bird 8630B Series Moduload RF Load Resistor

Safety Symbols

Warning notes call attention to a procedure, which if not correctly

performed, could result in personal injury.

Caution notes call attention to a procedure, which if not correctly

performed, could result in damage to the instrument.

This symbol indicates that a shock hazard exists if the
precautions in the instruction manual are not followed.

The caution symbol appears on the equipment indicating
there is important information in the instruction manual
regarding that particular area.

WARNING

CAUTION

This symbol indicates that the unit radiates heat and
should not be touched while hot.

 NOTE: Calls attention to supplemental information.

Warning Statements

The following safety warnings appear in the text where there is danger to
operating and maintenance personnel and are repeated here for emphasis.

WARNING

Never attempt to connect or disconnect RF equipment from the

transmission line while RF power is being applied.

Leaking RF energy is a potential health hazard.

WARNING

Ethylene glycol is a toxic material. Do not take internally. Avoid eye

contact. Inhaling the vapors may be irritating to the lungs.

Caution Statements

The following equipment cautions appear in the text whenever the
equipment is in danger of damage and are repeated here for emphasis.

CAUTION

This equipment is designed for operation in a horizontal position only,

with mounting brackets down. Do not operate in any other manner.

ii

CAUTION

Before any RF operation of the load is attempted, the transmitter

interlock and ac line attachment to the equipment must be made. First

attach the transmitter interlock connections to the two binding posts on

the front panel and then connect the power cable.

CAUTION

The 115 V or 230 Vac line may be connected, but the ac power must not

be turned on unless coolant is in the system and filled to the correct

level. Damage to the pump will result otherwise.

CAUTION

Operation without sufficient coolant can damage the unit.

CAUTION

Do not use any sealant, leak-stopping material, or automotive antifreeze

in the coolant. Use only distilled water and pure ethylene glycol.

CAUTION

Do not attempt to alter the flow switch setting or disturb the coolant pump.

CAUTION

Do not operate the load without connecting the interlock. Even

momentary application of power to the load while the cooling

circulation is off, or possibly functioning improperly, will cause almost

immediate destruction of the resistor element.

CAUTION

Do not apply more than the rated RF power to the load. Excessive RF

power will damage the load resistor.

CAUTION

Do not block air flow. Air enters the housing through the circular fan

openings and exhausts through the grille opposite.

CAUTION

Do not disconnect the line power first. Even a momentary application of

RF power to the load while the cooling circulation is off will cause

almost immediate destruction of the resistor element.

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Bird 8630B Series Moduload RF Load Resistor

CAUTION

Do not remove any fittings from the water chamber. The elbows could

be damaged, and it may be difficult to restore them to their original

positions while keeping a water-tight seal. Check the switch for free

operation. Flush and clean with mild detergent if necessary, and rinse

thoroughly in clear water

CAUTION
Before storing the unit, follow the storage instructions in the Storage
section of the Maintenance chapter. Failure to follow the instructions

may result in damage to the unit.

CAUTION

Before shipping the unit, follow the shipping instructions in the

Maintenance chapter. Failure to properly prepare the unit for shipping

may result in damage to the unit.

iv

Safety Statements

USAGE
ANY USE OF THIS INSTRUMENT IN A MANNER NOT

SPECIFIED BY THE MANUFACTURER MAY IMPAIR THE

INSTRUMENT’S SAFETY PROTECTION.
USO
EL USO DE ESTE INSTRUMENTO DE MANERA NO ESPECIFICADA

POR EL FABRICANTE, PUEDE ANULAR LA PROTECCIÓN DE
SEGURIDAD DEL INSTRUMENTO.

BENUTZUNG
WIRD DAS GERÄT AUF ANDERE WEISE VERWENDET ALS VOM

HERSTELLER BESCHRIEBEN, KANN DIE GERÄTESICHERHEIT
BEEINTRÄCHTIGT WERDEN.

UTILISATION
TOUTE UTILISATION DE CET INSTRUMENT QUI N’EST PAS

EXPLICITEMENT PRÉVUE PAR LE FABRICANT PEUT
ENDOMMAGER LE DISPOSITIF DE PROTECTION DE
L’INSTRUMENT.

IMPIEGO
QUALORA QUESTO STRUMENTO VENISSE UTILIZZATO IN MODO

DIVERSO DA COME SPECIFICATO DAL PRODUTTORE LA
PROZIONE DI SICUREZZA POTREBBE VENIRNE COMPROMESSA.

SERVICE
SERVICING INSTRUCTIONS ARE FOR USE BY SERVICE -

TRAINED PERSONNEL ONLY. TO AVOID DANGEROUS
ELECTRIC SHOCK, DO NOT PERFORM ANY SERVICING UNLESS
QUALIFIED TO DO SO.

SERVICIO
LAS INSTRUCCIONES DE SERVICIO SON PARA USO EXCLUSIVO

DEL PERSONAL DE SERVICIO CAPACITADO. PARA EVITAR EL
PELIGRO DE DESCARGAS ELÉCTRICAS, NO REALICE NINGÚN
SERVICIO A MENOS QUE ESTÉ CAPACITADO PARA HACERIO.

v

Bird 8630B Series Moduload RF Load Resistor

WARTUNG
ANWEISUNGEN FÜR DIE WARTUNG DES GERÄTES GELTEN NUR

FÜR GESCHULTES FACHPERSONAL.
ZUR VERMEIDUNG GEFÄHRLICHE, ELEKTRISCHE SCHOCKS,

SIND WARTUNGSARBEITEN AUSSCHLIEßLICH VON
QUALIFIZIERTEM SERVICEPERSONAL DURCHZUFÜHREN.

ENTRENTIEN
L’EMPLOI DES INSTRUCTIONS D’ENTRETIEN DOIT ÊTRE

RÉSERVÉ AU PERSONNEL FORMÉ AUX OPÉRATIONS
D’ENTRETIEN. POUR PRÉVENIR UN CHOC ÉLECTRIQUE
DANGEREUX, NE PAS EFFECTUER D’ENTRETIEN SI L’ON N’A PAS
ÉTÉ QUALIFIÉ POUR CE FAIRE.

ASSISTENZA TECNICA
LE ISTRUZIONI RELATIVE ALL’ASSISTENZA SONO PREVISTE

ESCLUSIVAMENTE PER IL PERSONALE OPPORTUNAMENTE
ADDESTRATO. PER EVITARE PERICOLOSE SCOSSE ELETTRICHE
NON EFFETTUARRE ALCUNA RIPARAZIONE A MENO CHE
QUALIFICATI A FARLA.

vi

About This Manual

This instruction book covers the 8630B Series Moduload RF Load
Resistors, which specificaly covers the models listed below:

8631-115 8631-115-5-N 8635-115-5 8638-115 8638-230-6
8631-230 8631-230-6-N 8635-230-6 8638-230 8638-115-5-N
8631-115-5 8635-115 8635-115-5-N 8638-115-5 8638-230-6-N
8631-230-6 8635-230 8635-230-6-N

8631B-115 8635B-115-5 8638B-115
8631B-230 8635B-230-6 8638B-230
8631B-115-5 8635B-115 8638B-230-6
8631B-230-6 8635B-230 8638B-115-5

This instruction book is arranged so that essential information on safety
is in the front of the book. Reading the Safety Precautions before
operating the equipment is strongly advised. The remainder of this
instruction book is divided into Chapters and Sections.

Operation

First time operators should read Chapter 1 - Introduction, Chapter 2 ­Theory of Operation, and Chapter 3 - Installation to get an overview of
equipment capabilities and how to install it. An experienced operator can
refer to Chapter 4 - Operating Instructions. All instructions necessary to
operate the equipment are contained in this chapter.

Maintenance

All personnel should be familiar with preventative maintenance found in
Chapter 5 - Maintenance. If a failure should occur, the trouble-shooting
section will aid in isolating and repairing the failure. Parts lists and
repair instructions are also in this chapter.

Changes To The Manual

We have made every effort to ensure this manual is accurate at the time
of publication. If you should discover any errors or if you have suggestions

vii

Bird 8630B Series Moduload RF Load Resistor

for improving this manual, please send your comment to our factory. This
manual may be periodically updated. When inquiring about updates to
this manual, refer to the part number and revision level on the title page.

viii

Naming Conventions

The following terms will be used throughout this manual to refer to certain
components of the Moduload:

Moduload: The entire unit.

Load: The component which connects to the RF line. It is connected to the HEAT

EXCHANGER with two hoses. It contains the RESISTOR.

Heat Exchanger: The component containing the pump, blower, coolant

reservoir, control panel, and electrical access box. It is connected to the LOAD
with two hoses.

Resistor: A subcomponent of the LOAD. This is the ceramic resistor which

actually absorbs the RF power.

ix

Bird 8630B Series Moduload RF Load Resistor

x

Table of Contents

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

About This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Purpose and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Performance Characteristics and Capabilities . . . . . . . . . . . . . . . . . . . . . . . 1

Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Power and Utility Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Items Supplied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Items Required but not Supplied. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Tools and Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Optional Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Heat Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Flow Interlock Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Site and Shelter Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Filling Coolant Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Blower Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

DC Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Interlock Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

AC Line Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Connecting RF Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Model 8631 and 8631B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Model 8635 and 8635B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Model 8638 and 8638B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

xi

Preliminary Equipment Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Meter Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 15

Use and Function of Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Initial Adjustments and Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Equipment Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Normal Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Emergency Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Performance Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Radiator Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Connector and Outside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Measure Load DC Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Water Flow Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Routine Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Flushing the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

RF Load Resistor Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Pump/Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Water Flow Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Time Delay Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Replace Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Load Resistor Internal Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Resistor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Resistor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Replacement of Fractured Resistor or Damaged Internal Parts. . . . . . . . . . . . 31

Resistor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Input Center Conductor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

xii

Storage and Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Drainage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

xiii

xiv

Chapter 1 Introduction

This publication refers to the Moduload RF Load Resistor Series 8630
and 8630B. The differences between models are listed in the
specifications. All models will generally be referred to as a load
throughout this manual.

The information in this instruction book pertains to all models except
noted differences referred to in the text.

This chapter contains intoductory information including items
supplied, items required, unpacking, inspecting, and the
specifications.

Purpose and

Function

Performance

Characteristics

and Capabilities

The Bird Moduload Loads are self-cooling, low reflection, non­radiating terminations for high power 50 ohm RF transmission lines.

They are for use on CW, AM, FM, SSB, and TV modulation envelopes,
and within certain limits on radar or pulse modes. Information for
use involving pulse type signals should be obtained directly from Bird
Electronic Corporation.

The 8630 and 8630B series Loads are capable of continuous power
dissipation of 10 kW with a voltage standing wave ratio (VSWR) of
less than 1.1 to 1.0 from 1 kHz to 1000 MHz. The respective models
provide direct connection to 3-1/8 inch and 1-5/8 inch 50 ohm coaxial
lines.

The equipment consists of three basic systems: the RF load assembly,
the control system, and the heat exchanger system. The load
assembly contains the resistor element with its internal water cooling
system. The control system includes the electrical circuitry required
to prevent damage to the transmitter in case of malfunction of the
load, and to protect the RF load should the water flow slow down. The
heat exchanger components consist essentially of the pump/motor, the
side blower, the coolant collector tank, and a finned cooling coil unit
opposite the blower.

When used in conjunction with the appropriate Bird Model Thruline
Wattmeter, such as those in the 4600A, 4800A or 4712 series, the
Moduload Coaxial Load may be used for direct RF power
measurements within the equipment ratings.

1

Bird 8630B Series Moduload RF Load Resistor

Dimensions and

Weight

Power and Utility

Requirements

Environmental

Requirements

The 8630 and 8630B Series load is 22-1/8 inches long, exclusive of the
connector, 15-13/16 inches wide, and 15-15/16 inches high (562 x 402
x 405 mm). Its net weight, filled with 100 percent water as coolant, is
113 lb (51.3 kg) and the shipping weight is 125 lb (56.7 kg).

The 8630 and 8630B Series loads are offered in four standard forms
which differ in the ac input power requirements.

y -115 for 115 V, 60 Hz, 9 Amp, single phase.
y -230 for 230 V, 50 Hz, 4.5 Amp, single phase.
y -115-5 for 115 V, 50 Hz, 9 Amp, single phase.
y -230-6 for 230 V, 60 Hz, 4.5 Amp, single phase.

The 8630 and 8630B Series loads are not intended for use outdoors
where they would be exposed to the elements. They should be used
indoors in a clean, dry, dust and vibration-free environment. The
ambient temperature range is determined by the coolant. For 100
percent water the range is +5°C to +45°C (+41°F to +113°F). For a
mixture of 65 percent water and 35 percent ethylene glycol the range
is -20°C to +35°C (-4°F to +95°F).

It is important that the room temperature remain within these limits
for proper operation of the unit, otherwise a derating of its load value
will be necessary. To avoid this derating, it may be necessary to
arrange for venting of the air flow from the load to the outside.
Consult Bird Electronic Corporation for more details.

Items Supplied The 8630 and 8630B Series loads are equipped with standard RF

connectors.

y Model 8630 and 8631B — 3-1/8 inch EIA flanged connector.
y Model 8630 and 8635B — 1-5/8 inch EIA flanged connector.
y Model 8630 and 8638B — 3-1/8 inch unflanged connector.

They are supplied with a container of ethylene glycol, for making the
coolant mixture, when ordered.

Items Required but

not Supplied

The required items are:

y A mating connector on the coaxial transmission line.
y A conveniently located ac power receptacle to plug in the power

cable.

y Distilled water for coolant, or coolant mixture.

2

Tools and Test

Equipment

Only simple tools such as screwdrivers and wrenches are needed for
disassembling a Moduload load resistor. A multimeter or an
ohmmeter with an accuracy of 1 percent or better at 50 ohms is
suggested for checking the DC resistance of the RF load resistor. A
basic VOM will suffice for checking the rest of the circuitry.

Optional Items Dolly, P/N 6771-011 — For ease in moving the load. Consult Bird

Electronic Corporation for more information.

3