Bird Technologies 8640B User Manual

INSTRUCTION BOOK

MODULOAD® RF LOAD RESISTOR

SERIES 8640 and 8640B

INCLUDING MODELS 8645-xxx AND 8646-xxx

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 2008 by Bird Electronic Corporation

Instruction Book Part Number 920-8640S Rev. F

®

, Econoload®, Econoline®, and Thruline® are

registered trademarks of Bird Electronic Corporation

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 remove the RF transmission line while RF power is present.

Capacitors can store a dangerous electric charge. Avoid contact with all
system capacitors. If it is necessary to perform work near a system
capacitor, be sure to discharge the capacitor through a low resistance.

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.

Coolant may contain ethylene glycol. Avoid ingestion, inhaling of vapors
and eye and skin contact.

Resuscitation

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

i

Bird 8640 and 8640B Series Moduload RF Load Resistor

Safety Symbols

WARNING

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

performed could result in personal injury.

CAUTION

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 follwed.

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

 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

Disconnect the unit from all power sources before servicing.

The unit may be energized from multiple sources.

The potential for electric shock exists.

WARNING

Improper wiring could result in electric shock and death.

WARNING

Connect the power cord to the Moduload

BEFORE connecting to ac mains.

WARNING

Ethylene glycol is toxic. Do not take internally.

Avoid contact with eyes, skin, and clothing. Avoid breathing vapor.

Wash thoroughly after handling.

ii

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

HEAVY. Do not lift this unit alone.

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

Do not block air flow. The air intake vents on the side of the heat

exchanger and the exhaust on top must not be obstructed.

CAUTION

Do not operate without the interlock. Even momentary

application of RF power while coolant is not circulating could

cause immediate destruction of the load.

CAUTION

Check the local electrical code for proper ac hookup prior to operation

of the unit. Make sure the neutral or return hookup is only used

for that purpose.

CAUTION

Use only distilled water or ethylene glycol as coolant. Do not use tap

water, automotive antifreeze, sealants, or leak stopping material.

Use of these materials will damage the unit and void all warranties.

CAUTION

Operation without sufficient coolant can damage the unit.

iii

Bird 8640 and 8640B Series Moduload RF Load Resistor

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.

WARTUNG
ANWEISUNGEN FÜR DIE WARTUNG DES GERÄTES GELTEN NUR

FÜR GESCHULTES FACHPERSONAL.
ZUR VERMEIDUNG GEFÄHRLICHE, ELEKTRISCHE SCHOCKS,

SIND WARTUNGSARBEITEN AUSSCHLIEßLICH VON
QUALIFIZIERTEM SERVICEPERSONAL DURCHZUFÜHREN.

iv

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.

CONNECT INTERLOCK TO TRANSMITTER/GENERATOR/
AMPLIFIER BEFORE OPERATING.

BRANCHER LE VERROUILLAGE À L’ÉMETTEUR/

GÉNÉRATEUR/AMPLIFICATEUR AVANT EMPLOI.
CONECTE EL INTERBLOQUEO AL TRANSMISOR/GENERADOR/

AMPLIFICADOR ANTES DE LA OPERACION.
VOR INBETRIEBNAHME VERRIEGELUNG AM SENDER/

GENERATOR/VERSTÄRKER ANSCHLIESSEN.
PRIMA DI METTERE IN FUNZIONE L’APPARECCHIO, COLLEGARE

IL DISPOSITIVO DI BLOCCO AL TRASMETTITORE/GENERATORE/
AMPLIFICATORE.

v

Bird 8640 and 8640B Series Moduload RF Load Resistor

About This Manual

This manual covers the Bird 8645B and 8646B Moduload RF Load
Resistors.

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, 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 troubleshooting
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
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.

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 inside the HEAT

EXCHANGER, connected by two hoses. It contains the RESISTOR.
Heat Exchanger: The parts of the Moduload left when the LOAD is

removed. It contains the pump, fans, coolant reservoir, and controls.

vi

Resistor: A subcomponent of the LOAD. This is the ceramic resistor
which actually absorbs the RF power.

vii

Table of Contents

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

About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . vi

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

Moduload Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Items Supplied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Items Required but not Supplied. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Optional Items Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Resistor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Flow Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Thermal Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Unpacking and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Placement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

DC Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Meter Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Interlock Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

AC Mains Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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

Adding Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Connecting RF Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 11

Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Emergency Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

viii

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

DC Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Changing Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Coolant Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Interlock Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Flow Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Load Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Resistor Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Resistor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Fractured Resistor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Resistor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Conductor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Preparation for Storage or Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

ix

x

Chapter 1 Introduction

Bird 8640 and 8640B Series Moduloads are self-cooling, nonradiating,
low reflection terminations for high power RF lines. They dissipate up
to 25 kW with a VSWR of less than 1.1:1 from 1 kHz to 900 MHz.

The Moduload has an interlock which triggers as a result of either
high coolant temperature or low coolant flow. It will also be active for
about 2 seconds after power up or reset to ensure proper operation of
the cooling system before applying RF power.

Moduload

Features

y Useable with CW, AM, FM, SSB, and TV modulation, and certain

pulse types. Contact Bird Electronic Corporation for information
on using Moduloads with pulsed signals.

y Useable to make RF power measurements when used with a Bird

4600 or 4800 Thruline Wattmeter

y Self-contained water-based cooling system
y Time-delay interlock ensures steady coolant flow before RF power

is applied

Indicators y Coolant Level Gauge

Items Supplied y Moduload

y Instruction Manual
y Power Meter Rack-Mount Kit

Items Required but

not Supplied

y No. 22 AWG wire, with ring terminals, for interlock connection
y RF Coupling Kit
y Ethylene Glycol, Industrial Grade, 1 Gallon - available from Bird

Optional Items

Available

y Dolly (Bird P/N 6771-011) for moving the load

1

Bird 8640 Series Moduload RF Load Resistor

AC ON

INTERLOCK

19.25”

(490 mm)

9.75”

(248 mm)

9.875”

(251 mm)

19.625”

(500 mm)

26”

(660 mm)

Coolant

Reservoir

Pump

Load

Resistor

RF

Input

Flow

Switch

Temperature

Switch

Fan

Fan

Heat Exchanger

Heat Exchanger

Figure 1

8640 Series Moduload

Outline Drawing

Figure 2

System Block

Diagram

2

Chapter 2 Theory of Operation

Resistor Bird 8640 and 8640B Series Moduloads consist of a thin-film-on-

ceramic resistor immersed in coolant. The coolant flows directly over
the resistor instead of using an intermediate heat transfer system,
reducing the load size to a minimum. After passing over the entire
length of the resistor, the coolant is cooled in a forced air heat
exchanger.

Coolant The load’s electrical and thermal performance is reduced by

impurities or chemical additives in the coolant, especially ones which
are deposited as scale on the resistor. This increase in the load’s
thermal resistance may cause the load to overheat and fail. Therefore,
the coolant should be distilled water or a mixture of distilled water
and ethylene glycol.

When the coolant is heated, thermal expansion causes an increase in
the internal pressure. The vent plugs relieves this pressure while
protecting the opening from dirt or other contaminants.

Flow Interlock Dissipation of the heat generated by RF power is critically dependent

on a minimum coolant flow of six gallons per minute at all times,
regardless of coolant temperature. When coolant flow drops below six
gallons per minute, the low flow switch opens causing immediate
transmitter shutdown. The flow switch is a “normally open” type, and
is closed during normal operation.

After flow is restored, a time delay switch keeps the interlock open for
an additional 2 seconds. This ensures proper operation of the cooling
system before RF power is applied to the load, preventing resistor
damage or burnout.

Thermal Interlock The Moduload is equipped with a normally closed thermoswitch

which opens when the coolant temperature exceeds 79 °C (174 °F),
opening the interlock.

3

Bird 8640 Series Moduload RF Load Resistor

4

Chapter 3 Installation

This chapter provides information on site requirements, unpacking,
inspection, and preparing the Bird 8640 Moduload for use.

Unpacking and

Inspection

Placement

1. Carefully inspect the shipping container for signs of damage. If
damage is noticed, do not unpack the unit. Immediately notify the
shipping carrier and Bird Electronic Corporation.

2. If the container is not damaged, unpack the unit. Save the packing
materials in case the unit should need to be shipped again.

3. Inspect all of the components for visible signs of damage.
Immediately notify the shipping carrier and Bird Electronic
Corporation of equipment damage or missing parts.

WARNING

HEAVY. Do not lift this unit alone.

CAUTION

Do not block air flow. The air intake vents on the side of the heat

exchanger and the exhaust on top must not be obstructed.

y Do not use outdoors or in areas of condensing humidity.
y Surrounding air must be free of contaminants or particles that

could be drawn into the air intakes.

y The heat exchanger must be operated in a horizontal position.
y AC power is required.
y Allow a minimum of one foot clearance along the sides and three

feet over the top to allow unobstructed air intake and exhaust.

y In small rooms or restricted areas, outside venting is

recommended. Ductwork must not have sharp bends that would
restrict air flow or create back pressure.

Mounting The Moduload is equipped for either portable use or fixed installation.

The mounting brackets on the front and rear faces have four
mounting slots arranged in a 17" x 25" rectangle (432 x 635 mm). Use
a screw with a
removed by removing the screws holding them to the Moduload.

1

⁄

inch (6.4 mm) diameter max. The brackets may be

4

5

Bird 8640 Series Moduload RF Load Resistor

DC Resistance

Before first using the load, get a resistance baseline for future
maintenance. Refer to “DC Resistance” on page 14 for instructions.

Meter Rack If the Moduload will be used with a power meter, install the meter

rack to provide a convenient place to keep the meter. Use the
supplied #6-32 x

1

⁄

screws to assemble the rack. To install the rack,

4

remove two screws from the Moduload where the rack will be
mounted, then screw it into place with the supplied #8-32 x

WARNING

Disconnect the unit from all power sources before servicing.

The unit may be energized from multiple sources.

The potential for electric shock exists.

WARNING

Improper wiring could result in electric shock and death.

Interlock

Connection

CAUTION

Do not operate without the interlock. Even momentary

application of RF power while coolant is not circulating could

cause immediate destruction of the load.

3

⁄

screws.

8

AC Mains

Connection

y Use number 22 AWG (or heavier) wire for interlock connection.

Attach solderless ring terminals to the wire for ease of installation.

y Connect the interlock wires to the interlock terminal strip as

required for the transmitter.

 NOTE: Interlock contact resistance could be as high as 10 ohms

for circuits drawing less than 250 mA.

CAUTION

Check the local electrical code for proper ac hookup prior to

operation of the unit. Make sure the neutral or return hookup is

only used for that purpose.

WARNING

Connect the power cord to the Moduload

BEFORE connecting to ac mains.

The ac power supply required for this unit is 115/230 V, depending on
the model, @ 50/60 Hz, 1
“cold” (70

°C) ac inlet.

φ. The unit is equipped with an IEC 320

6

Coolant

Installation

WARNING

Ethylene glycol is toxic. Do not take internally.

Avoid contact with eyes, skin, and clothing. Avoid breathing vapor.

Wash thoroughly after handling.

CAUTION

Use only distilled water or ethylene glycol as coolant. Do not use

tap water, automotive antifreeze, sealants, or leak stopping

material. Use of these materials will damage the instrument and

void all warranties.

Distilled water is the primary coolant for the Bird 8640. Ethylene
glycol should be added to prevent bacterial growth and freezing; 10%
to 35% ethylene glycol is recommended. Using at least 10% will
prevent bacterial growth and at least 35% will protect against
freezing to – 20°C.

 NOTE: When using both ethylene glycol and distilled water, add

the water first, then the ethylene glycol, to ensure proper mixing.

Figure 3 on page 8 shows the coolant’s freezing point for a given
percentage of ethylene glycol in the mix. The following example shows
the weights to make a 65% distilled water to 35% ethylene glycol
mixture in 5 and 55 gallon quantities.

5 Gal. (18.9 L) 55 Gal. (208.2 L)
Distilled Water
Ethylene Glycol

28.0 lb (12.7 kg) 310 lb (140.6 kg)

15.2 lb (6.9 kg) 167 lb (75.7 kg)

7

Bird 8640 Series Moduload RF Load Resistor

-60

-50

-40

-30

-20

-10

0

Temperature, Degrees Celsius

10 20 30 40 50 60

% Ethylene Glycol

Specifications for ethylene glycol
having: specific gravity 1.125 @
32°F; specific heat .575 @ 68°F

Adding Coolant

Figure 3
Freezing Point of
Ethylene Glycol /

Distilled Water

Mixture

The Bird 8640 Moduload has a coolant capacity of about 9 quarts
(8.5 L). To fill the coolant reservoir, follow these steps:

CAUTION

Operation without sufficient coolant can damage the unit.

1. Make sure that the drain plug is in place.

2. Remove the filler cap on top of the heat exchanger.

3. Add about 3 quarts (2.9 L) of coolant.

4. Turn the unit on for a few seconds to draw coolant into the system.

5. Repeat steps 3 and 4 twice more, until the the coolant remains
steady at or just below the high mark on the level gauge.

6. Replace the filler cap.

7. Turn the unit on and run it for five minutes to remove any air
trapped in the system.

8

Installation

-80

-60

-40

-20

0

20

40

Temperature, Degrees Fahrenheit

10 20 30 40 50 60

% Ethylene Glycol

Specifications for ethylene glycol
having: specific gravity 1.125 @
32°F; specific heat .575 @ 68°F

BOLT BULLET LOADRF COAXIAL LINE

Connecting RF Power

After installing the Moduload, the RF transmission line can be
attached using standard coaxial line coupling kits.

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.

Swivel Flanged Coupling: To couple the swivel flange with a flanged
RF transmission line, use an appropriate coupling kit. Refer to
Figure 4 while following the instructions below:

Figure 4

Swivel Flanged

Coupling

9

Bird 8640 Series Moduload RF Load Resistor

RF COAXIAL

LINE

CLAMPING

BANDS

CONNECTOR

SLEEVE

BULLET

LOAD

y Insert the center bullet and push it in until it is fully seated.
y Connect the coaxial input in a straight line and push carefully on

the center conductor to close.

 NOTE: The swivel flange on the load makes connection

independent of the orientation of the fixed flange on the coaxial
input outer conductor.

y Insert the bolt sets and tighten evenly all around to transmission

line manufacturer’s recommended torque. Use all of the bolts.

Unflanged Coupling: To couple the unflanged connector with an
unflanged RF line, use an appropriate coupling kit. Refer to Figure 5
while following the instructions below:

Figure 5

Unflanged

Coupling

y Insert the center bullet and bottom it on the midpoint nibs.
y Position the outer sleeve, with clamping bands, over the input

connector.

y Set the transmission line snugly against the coupling stops.
y Position the clamping bands evenly about 3/4” from the ends of

the sleeve.

y Tighten the clamping bands.

10

Chapter 4 Operating Instructions

CAUTION

Operation without sufficient coolant can damage the unit.

CAUTION

Do not operate without the interlock. Even momentary

application of RF power while coolant is not circulating could

cause immediate destruction of the load.

Normal Operation y Check that the coolant level is above the min. mark on the gauge.

y Turn on the Moduload.
y Check that the fans are running properly.
y Wait about 2 seconds for proper coolant flow and for the interlock

to close.

y Apply RF power.

Shutdown y Turn off RF power at the source.

y Wait five minutes for the system to cool to room temperature.
y Turn off the Moduload.

Emergency

Shutdown

Turn off RF power at the source.

If the interlock is properly connected, RF power will be automatically
turned off if a fault occurs in the Moduload.

11

Bird 8640 Series Moduload RF Load Resistor

12

Chapter 5 Maintenance

WARNING

Disconnect the unit from all power sources before servicing.

The unit may be energized from multiple sources.

The potential for electric shock exists.

Troubleshooting

The table below contains troubleshooting information for problems
which can occur during normal operation. This manual cannot list all
malfunctions that may occur, or their corrective actions. If a problem
is not listed or is not corrected by the listed actions, notify a qualified
service center.

PROBLEM POSSIBLE CAUSE CORRECTION

Heat exchanger not
operating

Coolant leaking Loose connections Tighten drain plug and all connections

Interlock opening
repeatedly

Excessive reflected
power

No ac power Connected the unit to ac mains
Unit turned off Set the line switch to ON
Fuse burnout Replace fuse after correcting the burnout

cause (See “Fuse” on page 16)

Worn or cracked hose Replace defective hose
Insufficient coolant flow Check coolant level. Add coolant if necessary

(see “Changing Coolant” on page 15).

Defective flow switch Check flow switch (see “Flow Switch” on

page 17).
RF power too high Lower RF power
Ambient temperature too

high
Air intakes or exhaust are

blocked

DC resistance of the load
has changed

Lower ambient temperature

Check that clearances are at least

1 foot on the sides and 3 feet on top

Clean panels (See “Cleaning” on page 14)

Check dc resistance (See “DC Resistance” on

page 14)

13

Bird 8640 Series Moduload RF Load Resistor

Maintenance

Disconnect the unit from all power sources before servicing.

Cleaning The outside surface of the unit should be wiped free of dust and dirt

when necessary. Clean the RF connector, both metallic and insulating
surfaces, with a dry, non-residue forming solvent.

If dust has collected on the radiator coils, remove the top panel and
vacuum the coils. To remove the panel:

y Remove the screws around the edge of the top panel.
y Lift the top panel to access the fan power connector then

disconnect the fan cable.

WARNING

The unit may be energized from multiple sources.

The potential for electric shock exists.

y Remove the top panel.

Inspection Routinely check the load’s center and outer conductors for visible

damage or excessive wear. The coolant level should be checked once a
week, more often if the Moduload is used continuously or under high
ambient temperatures. The coolant level should be above the min.
mark on the gauge even when the unit is on. To add coolant, see
“Changing Coolant” on page 15.

DC Resistance Measuring the dc resistance between the inner and outer conductors

of the RF connector shows changes in the load over time, a good check
of the resistor’s condition. Under normal operating conditions, the
resistor should provide at least 5,000 hours of operation before
requiring any additional service. DC resistance tracking must start
before the load is put into service, and should be measured annually.

Perform the following steps and record the value for future
comparison. Make sure that you have an ohmmeter with an accuracy
of ±1% at 50 ohms and that the load temperature is between 20 and
25 °C (68 to 77 °F) before starting.

14

Figure 6

Measuring

Resistance

Maintenance

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.

y Turn off the RF power and interlock circuitry.
y Disconnect the RF line.

Coolant

y Connect the multimeter test leads to the center and outer

conductor of the load. Refer to Figure 6.

y Compare the measured value with the previous measurement and

with the baseline resistance, measured when the load was put
into service. If the new value differs from either of these by more
than 2 ohms this could indicate a failing resistor.

WARNING

Ethylene glycol is toxic. Do not take internally. Avoid contact with

eyes, skin, and clothing. Avoid breathing vapor. Wash thoroughly

after handling.

CAUTION

Use only distilled water or the supplied ethylene glycol as coolant.

Do not use tap water, automotive antifreeze, sealants, or leak

stopping material. Use of these materials will damage the

instrument and void all warranties.

CAUTION

Operation without sufficient coolant can damage the unit.

Changing Coolant Follow these instructions to change the coolant. To just add coolant,

go to step 5. To just drain the coolant, follow steps 1 – 4.

15

Bird 8640 Series Moduload RF Load Resistor

1. Get a clean container, with a capacity of 3 gal. (11 L), to hold the
old coolant.

2. Remove the filler cap on top of the heat exchanger. This will allow
the coolant to drain faster.

3. Unscrew and remove the drain plug on the rear of the load. Drain
the coolant into the container.

 NOTE: If the coolant has no contaminants it may be reused.

4. Replace the drain plug and screw it tightly into place.

5. Remove the filler cap on top of the heat exchanger.

6. Add about 3 quarts (2.9 L) of coolant.

7. Turn the unit on for a few seconds to draw coolant into the system.

8. Repeat steps 6 and 7 twice more, until the the coolant remains
steady at or just below the high mark on the level gauge.

9. Replace the filler cap.

10. Turn the unit on and run it for five minutes to remove any air
trapped in the system.

Coolant Flush If the coolant is contaminated, for example by pipe sealant or a

broken resistor, the system should be thoroughly flushed. To do this:

1. Fill the unit with clean, potable water.

2. Run the unit for five minutes with no RF power applied.

3. Drain the coolant and discard it.

4. Repeat steps 1 – 3 until the drained liquid is clear.

5. Refill the system with proper coolant (distilled water or a distilled
water/ethylene glycol mixture) as described above.

Repair

WARNING

Disconnect the unit from all power sources before servicing.

The unit may be energized from multiple sources.

The potential for electric shock exists.

16

Fuse 1. Correct the fuse burnout cause.

2. Use a flat blade screwdriver to lift the tab securing the fuse
drawer, above the ac mains connector.

Maintenance

3. Remove the defective fuse.

4. Replace with the same type and rating fuse

Series 115 Vac: 230 Vac
8640 15 amp 8 amp
8640B 15 amp 8 amp

5. Replace the fuse drawer.

Interlock Relay The interlock relay cannot be repaired in the field. To replace it,

follow the instructions below for your model.

WARNING

Disconnect the unit from all power sources before servicing.

The unit may be energized from multiple sources.

The potential for electric shock exists.

Model 864x

1. The relay is located on the inside of the front panel at the upper
right side.

2. Loosen the screw at the top of the relay clamp.

3. Remove the relay cartridge.

4. Line up the center pin on the new relay with the hole in the
socket, rotate until the keyway engages, then push in.

Model 864xB

1. The relay is located on the inside of the front panel at the upper
right side.

2. Loosen and remove the nut and washers that secure the relay to
the panel.

3. Record the color of each wire and the relay terminal to which it
connects then remove the wires from the relay.

4. Remove the relay from its mounting screw.

5. Install the replacement relay by reversing Step 2 through Step 4.

Flow Switch The coolant flow switch should be inspected every three to six

months, depending on the amount of use. To inspect it:

17

Bird 8640 Series Moduload RF Load Resistor

1. Drain the coolant (see “Changing Coolant” on page 15).

2. Remove the top panel

3. Unscrew the collar holding the wired sensor plug in the flow
switch body.

4. Being careful not to lose the spring and sliding valve on the sensor
plug stem, remove the sensor plug.

5. Clean and replace the sensor plug.

6. Reassemble the unit and replace the coolant.

To replace the flow switch:

1. Disconnect the wires at the flow switch.

2. Disconnect the hoses from the flow switch, then unscrew the flow
switch from the load.

Load Removal

WARNING

Radiator fins are very sharp. Avoid contact with the radiator fins.

Failure to comply may result in severe cuts and bleeding.

WARNING

Dangerous voltages are present.

Disconnect the unit from all power line and RF power sources

before servicing. Do not disconnect the unit from the RF

transmission line while RF power is applied.

Failure to comply may result in severe electrical shock or death.

Model 864x

1. Disconnect the RF line.

2. Drain the coolant (see “Changing Coolant” on page 15).

3. Remove the screws that secure the top panel.

4. Lift the top panel and disconnect the fan-supply plug located on
top of the radiator block.

5. Loosen the hose clamps on both water hose connections to the
load.

18

6. On the inside of the front panel, remove the nuts holding the load
to the front panel.

Maintenance

 NOTE: Remove the nuts only. Do not disturb the screws. The

screws also secure the outer conductor assembly to the load. Hold
this assembly to keep it from falling and being damaged.

7. Unscrew the mounting clamp holding the load to the rest of the
unit. Remove the top half of the clamp.

8. Carefully push the load forward a few inches to access the wires
and water connection fittings.

9. Disconnect the flow switch wires from the front panel.

10. Note the position and direction of the flow switch and the output
elbow on the load. Unscrew these from the load.

11. The load can now be removed from the unit.

Model 864xB

1. Disconnect the RF line.

2. Drain the coolant (see “Changing Coolant” on page 15).

3. Remove the screws that secure the top panel.

4. Lift the top panel and disconnect the fan-supply plug located on
top of the radiator block (Figure 7).

5. Loosen the hose clamps on both water hose connections to the
load.

6. Remove the screws that secure the load mounting clamp. Remove
the top half of the mounting clamp.

7. Disconnect the flow switch wires. One at the flow switch, the
other at the in-line connector near the flow switch.

8. Disconnect the front panel wires at the connector on top of the
radiator.

19

Bird 8640 Series Moduload RF Load Resistor

E

R

M

A

L

I

N

E

R

I

N

OUT

1

1

2

2

3

4

Figure 7

Removing the

Load

Item Description

1 Load mounting clamp screws
2 Flow switch wires
3 Fan-supply connector
4 Front panel connector

20

Maintenance

YEL

GRN / YEL

WHT

BLK

GRN / YEL

WHT

WHT

BLK

BLK

ORG

GRN / YEL

BLK

RED

WHT

BLK

9. Record the wire colors and locations then disconnect the pump
motor wires from the front panel terminal block (TB 1) (Figure 8).

10. Remove the screws that secure the front panel to the unit then tilt
the top of the panel away from the unit and remove the two water
hoses from the load water pipes.

11. Remove the front panel with the load attached.

12. Remove the nuts and lock washers that secure the load to the
panel.

13. Remove the socket head cap screws that secure the water chamber
to the load then remove the water chamber.

14. Inspect the water chamber to be sure it is in good condition and
that the inner o-ring seal is good. If appropriate, order
replacement parts.

Figure 8

Front Panel Wiring

21

Bird 8640 Series Moduload RF Load Resistor

Pump Removal

Disconnect the unit from all power sources before servicing.

1. Drain the coolant (see “Changing Coolant” on page 15).

2. Remove the load (see “Load Removal” on page 18).

3. Disconnect the pump wire leads from the terminal block on the
inside of the front panel.

4. Loosen the hose clamps on the input and output hoses to the
pump, and remove the hoses.

5. Loosen the hose clamp on the drain tube at the base of the pump.
Remove the drain tube.

6. Unscrew the bolts securing the base of the pump to the unit.

WARNING

The unit may be energized from multiple sources.

The potential for electric shock exists.

7. Carefully remove the pump from the unit.

8. Note the position and direction of the fittings, then twist them off
counterclockwise.

9. To replace the pump, reverse the above steps. When replacing the
threaded fittings, carefully coat the external threads, ONLY, with
a pipe sealing compound. Coating only the external threads
reduces the chances of contaminating the coolant.

22

Resistor Servicing

1/4-20 x 2-1/2
Socket Head Cap Screw (6)

Water Chamber With
O-Ring Inner Seal

Outer O-Ring

Inner O-Ring

Resistor Sleeve

Resistor

Outer Flow Tube

Load Housing

O-Ring

Inner Flow Tube

Ground Cap Assembly

Hose Fitting 90°

Hose Fitting Straight

6

3

and

4

2

7

1

5A

5

10

9

8

17

9A

Load Housing

Resistor

Center Conductor
Assembly

1/4-20 x 1-1/2
Socket Head Cap Screw (6)

Outer Conductor
Assembly

Resistor Fitting Seal O-Ring

12

16

11

1

15

The load is designed to be quickly and easily repaired in the field. If a
significant change in the dc resistance is noted or if the resistor
should fail, inexpensive replacement resistors are available.

Maintenance

WARNING

Disconnect the unit from all power sources before servicing.

The unit may be energized from multiple sources.

The potential for electric shock exists.

Figure 9

Load Exploded View

Resistor Removal Numbers in brackets [ ] refer to the labeled parts in Figure 9.

1. Disconnect the load (see “Load Removal” on page 18).

2. Turn the load on end with the hose fitting up.

23

Bird 8640 Series Moduload RF Load Resistor

3. Use a
approximately

3

⁄

hex socket wrench to back the cap screws [6]

16

1

⁄

2

inch.

4. Pull the water chamber assembly out. It may be necessary to rock
the chamber gently while pulling.

5. If the resistor [1] is intact it may be pulled straight out of the load
housing and is ready for replacement. The outer flow tube is
captive and will not come out of the housing at this stage.

The ground cap assembly [10] and the inner flow tube [9] should come
out with the water chamber assembly. To remove the ground cap
assembly [10], hold the resistor sleeve [7] on the flow tube and pull
out the assembly. This includes the cushioning O-Ring [8] which fits
loosely below the stop sleeve; do not lose it.

The resistor sleeve [7] has a small escape hole at the side and an
access counter bore leading to it. If the sleeve is removed, be sure this
counterbore faces the O-Ring and the resistor [1] during reassembly.
This is essential for internal water venting. The base of the inner flow
tube has water outlet holes and a small shoulder. At reassembly,
these must fit into mating recesses in the input fitting.

Inspection y Carefully check the resistor [1] for fractures.

 NOTE: Even in the event of resistor failure the resistor substrate

will usually remain intact.

y Check the inside of the load housing for damage to the internal

parts. If no damage has been found proceed to “Resistor
Replacement”. However, if the resistor is broken, other internal
parts are damaged, or if the parts do not fit together properly,
proceed to “Fractured Resistor”.

Fractured Resistor 1. Turn the load on end with the RF input connector up to allow any

loose pieces of the resistor to fall out of the housing.

3

⁄

2. Use a

3. Remove the outer conductor assembly [12].

4. Pull out the center conductor assembly [11]. Carefully remove any
remaining pieces of the resistor. Normally the outer flow tube will
remain with the load housing. If it comes out, return it after
inspection and cleaning.

5. Check the inside of the load housing for damage.

hex socket wrench to remove the cap screws [16].

16

24

Maintenance

6. Remove the inner flow tube [9] and ground cap assembly [10].
Check them for broken pieces.

7. Under clear running water, thoroughly wash the inside of the
conductor assemblies, load housing, and water chamber.

8. Replace the ground cap assembly and the inner flow tube.

Resistor

Replacement

1. Insert the new resistor [1] into the resistor fitting of the center
conductor assembly [15] to test its tightness.

2. The resistor should be snug but should not have to be forced into
the fitting. If the resistor is too loose, press the fitting fingers
together slightly and try the resistor again. Continue closing the
ends of the resistor fitting until a snug fit is obtained.

3. Bottom the resistor in the fitting.

4. Insert the resistor and the center conductor assembly into the
load housing.

5. Replace the outer conductor assembly [12] and screw it into place.

6. Stand the load on its end with the RF connector down.

7. Replace the ground cap assembly onto the exposed end of the
resistor. Make sure that it seats on the load housing.

8. If the inner flow tube [9] is separated from the water chamber
assembly [3], place it inside the resistor and lower until it reaches
the resistor fitting. Gently twist the flow tube until it seats in the
bottom of the resistor fitting.

9. Check that the O-Ring [8] is on the inner flow tube next to the
resistor and the resistor sleeve [7] is right behind it. Make sure
the counterbore faces the O-Ring and the resistor.

10. Replace the water chamber [3], gently rocking and twisting the
chamber to achieve a flat seat on the outer housing.

 NOTE: If the water chamber does not fit properly make sure that

the inner flow tube is properly placed.

11. Tighten the water chamber screws [6].

12. Check the dc resistance between the inner and outer conductors;
it should be about 50 ohms. Record this measurement as the new
baseline reading.

13. Install the load on the heat exchanger. Connect the hoses and fill
with coolant.

25

Bird 8640 Series Moduload RF Load Resistor

14. Run the pump for five minutes and check for leaks before applying
RF power.

Conductor

Replacement

1. Use a

3

⁄

allen wrench to remove the cap screws [16] from the RF

16

connector.

2. Remove the outer conductor assembly [12].

 NOTE: If only the outer conductor needs replaced, install it now

and screw it into place.

3. Remove the center conductor assembly [11] by pulling it carefully
out of the load housing. Make sure the resistor [1] and inner flow
tube [9] do not come out with the center conductor.

4. Insert the new center conductor assembly into load housing. Make
sure the resistor fitting makes a snug fit with the resistor.

5. Replace the outer conductor and screw it into place.

26

Preparation for Storage or Shipment

Store the Bird 8640 in a cool, dry area. For pure water-cooled units,
the ambient temperature must be within 5°C to 50°C (41°F to 122°F).
For units with 35% ethylene glycol, the ambient temperature must be
within –25°C to 45°C (–13°F to 113°F). Drain the coolant (see
“Changing Coolant” on page 15) if the unit will be stored for more
than 30 days.

To ship, pack the unit in its original shipping container. If this is not
available, securely pack and seal it in a sturdy wooden box or
equivalent, with sufficient padding to avoid shock damage.

Customer Service

Any maintenance or service procedure beyond the scope of those in
this chapter should be referred to a qualified service center.

Maintenance

If you need to return the unit for any reason, contact the Bird Service
Center for a return authorization. All instruments returned must be
shipped prepaid and to the attention of Bird Service Center.

Bird Service Center

30303 Aurora Road
Cleveland (Solon), OH 44139-2794
Phone: [phone]
Fax: [phone]
E-mail: [e-mail]

For the location of the Sales Office nearest you, give us a call or visit
our Web site at:

http://www.bird-electronic.com

27

Bird 8640 Series Moduload RF Load Resistor

Specifications

Frequency Range
Power Rating
Mode
Impedance
VSWR
Connectors

8645
8646

Interlock Rating

Cooling Method
Coolant

*

Coolant Capacity
AC Power

–115
–230
–230–6

1 kHz – 900 MHz
25 kW continuous duty
CW, AM, FM, SSB, TV and certain pulse types
50 ohms nominal

1.10 max

1

3

⁄

inch EIA Flanged

8

1

3

⁄

inch Unflanged

8

NO or NC Connections

5A @ 250 Vac
10A @ 125 Vac

48 Vdc
Water dielectric and forced air convection
Distilled water or distilled water/ethylene glycol

mixture
9 qts. (8.5 L) nominal

115 Vac @ 11 A, 60 Hz
230 Vac @ 5.5 A, 50 Hz
230 Vac @ 5.5 A, 60 Hz

Fuse Rating (864x)

115 Vac
230 Vac

Fuse Rating (864xB)

115 Vac
230 Vac

Ambient Temperature

Water only
35% Ethylene Glycol

Dimensions
Weight, Nominal

* Below 5°C, ONLY use 35% E.G. and 65% Dist. H2O mixture
† Above 30°C (86 °F) with water only, or 25°C (77 °F) with a 35% ethylene

glycol mixture, derate power to 20 kW max.

3AB Time-Delay
15 A

8 A
Time-Delay
15 A (3AB)

8 A (5x20 mm)

†

+5 to +45† °C (41 to 113 °F)
–20 to +35

26"L x 19-5/8"W x 19-1/4"H (670 x 500 x 490 mm)
154 lb. (70 kg)

†

°C (–4 to +95 °F)

28

Replacement Parts

1/4-20 x 2-1/2
Socket Head Cap Screw (6)

Water Chamber With
O-Ring Inner Seal

Outer O-Ring

Inner O-Ring

Resistor Sleeve

Resistor

Outer Flow Tube

Load Housing

O-Ring

Inner Flow Tube

Ground Cap Assembly

Hose Fitting 90°

Hose Fitting Straight

6

3

and

4

2

7

1

5A

5

10

9

8

17

9A

Load Housing

Resistor

Center Conductor
Assembly

1/4-20 x 1-1/2
Socket Head Cap Screw (6)

Outer Conductor
Assembly

Resistor Fitting Seal O-Ring

12

16

11

1

15

The parts lists in this section identify the components of the Bird
Moduload. Exploded views are used to illustrate the component parts
and indicate their relation to each other. Each part in the exploded
view has an item number referencing the part list.

Maintenance

Figure 10

Load Exploded View

29

Bird 8640 Series Moduload RF Load Resistor

Load

ITEM

DESCRIPTION QTY PART NO.

NO.

Load Complete

8645

8646
1 Resistor 1 8755-027
2 Outer O-Ring 1 8410-009
3 Water Chamber 1 8755-014
4 Water Chamber Inner O-Ring 1 5-099
5 Fitting, 90° 1 8640-089
5A Fitting, Straight, consisting of:

Bushing
Nipple

6 Screw

1

⁄

-20 x 2-

4

1

⁄

inch 6 1121-2508-00

2

7 Resistor Sleeve 1 8755-026
8 Sleeve O-Ring 1 8110-059
9 Inner Flow Tube 1 8755-025

1

8745-101-1
8746-101

1
1

5-489-1
5-490-1

9A Outer Flow Tube 1 8755-024
10 Resistor Ground Cap 1 8755-005
11 Center Conductor Assembly

8645
8646

12 Outer Conductor Assembly

8645
8646

1

8755-007
8756-003

1

8755-004

8756-002
15 Center Conductor O-Ring 1 5-1127
16 Screw

1

⁄

-20 x 1-

4

1

⁄

inch 6 1121-1808-00

2

17 Inner O-Ring 1 5-567

30

Maintenance

Heat Exchanger

DESCRIPTION QTY PART NO.

AC Cord

864x-115
864x-230

Fan Assembly (model 864x)

864x-115
864x-230 and 864x-230-6
8646-230-6-N

Fan Assembly (model 864xB)

864xB - 115
864xB - 230 and 864xB -

230-6
Pump (model 864x)

864x-115
864x-230
864x-230-6

Pump (model 864xB)

864xB - 115
864xB - 230
864xB - 230-6

1

5-1836
5-1837

2

8640-668-1
8640-668-2
8640-668-4

2

5A2770-1
5A2770-2

1

8640A505-1
8640A505-2
8640A505-4

1

8640B505-1
8640B505-2

8640B505-4
Flow Switch Assy (model 864x) 1 8645-004
Flow Switch Assy (model 864xB) 1 8645B004
Interlock Relay

864x-115
864x-230
864xB series

Fuse (model 864x)

864x and 864xB -115
864x - 230
864xB - 230

Fuse (model 864xB)

864xB - 115
864xB - 230

1

5-1627

5-1625

5A2787-1

2

5-1828-36 (15 A 3AB time delay)

5-1828-33 (8 amp 3AB time delay)

5A2257-25 (8 amp 5x20 mm)

2

5-1828-36 (15 A 3AB time delay)

5A2257-25 (8 A 5x20 mm)
Coolant Gauge Kit 1 5-1200
Ethylene Glycol 1

5-1134-3

Gal.

31

Bird 8640 Series Moduload RF Load Resistor

32

Limited Warranty

All products manufactured by Seller are warranted to be free from defects in
material and workmanship for a period of one (1) year, unless otherwise
specified, from date of shipment and to conform to applicable specifications,
drawings, blueprints and/or samples. Seller’s sole obligation under these
warranties shall be to issue credit, repair or replace any item or part thereof
which is proved to be other than as warranted; no allowance shall be made for
any labor charges of Buyer for replacement of parts, adjustment or repairs, or
any other work, unless such charges are authorized in advance by Seller.

If Seller’s products are claimed to be defective in material or workmanship or not
to conform to specifications, drawings, blueprints and/or samples, Seller shall,
upon prompt notice thereof, either examine the products where they are located
or issue shipping instructions for return to Seller (transportation-charges
prepaid by Buyer). In the event any of our products are proved to be other than
as warranted, transportation costs (cheapest way) to and from Seller’s plant, will
be borne by Seller and reimbursement or credit will be made for amounts so
expended by Buyer. Every such claim for breach of these warranties shall be
deemed to be waived by Buyer unless made in writing within ten (10) days from
the date of discovery of the defect.

The above warranties shall not extend to any products or parts thereof which
have been subjected to any misuse or neglect, damaged by accident, rendered
defective by reason of improper installation or by the performance of repairs or
alterations outside of our plant, and shall not apply to any goods or parts thereof
furnished by Buyer or acquired from others at Buyer’s request and/or to Buyer’s
specifications. Routine (regularly required) calibration is not covered under this
limited warranty. In addition, Seller’s warranties do not extend to the failure of
tubes, transistors, fuses and batteries, or to other equipment and parts
manufactured by others except to the extent of the original manufacturer’s
warranty to Seller.

The obligations under the foregoing warranties are limited to the precise terms
thereof. These warranties provide exclusive remedies, expressly in lieu of all
other remedies including claims for special or consequential damages. SELLER
NEITHER MAKES NOR ASSUMES ANY OTHER WARRANTY WHAT­SOEVER, WHETHER EXPRESS, STATUTORY, OR IMPLIED, INCLUDING
WARRANTIES OF MERCHANTABILITY AND FITNESS, AND NO PERSON
IS AUTHORIZED TO ASSUME FOR SELLER ANY OBLIGATION OR
LIABILITY NOT STRICTLY IN ACCORDANCE WITH THE FOREGOING.