Bird Technologies 8650B User Manual

INSTRUCTION BOOK

MODULOAD® RF LOAD RESISTOR

SERIES 8650B

©Copyright 2010 by Bird Electronic Corporation

Instruction Book Part Number 920-8650S Rev. D

Moduload, 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 apply to all phases of
operation and maintenance.

WARNING

Keep Away From Live Circuits

Operating Personnel must at all times observe general safety precautions. Do not
replace components or make adjustments to the inside of the test equipment with

the high voltage supply turned on. To avoid casualties, always remove power.

WARNING

Shock Hazard

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

WARNING

Do Not Service Or Adjust Alone

Under no circumstances should any person 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.

WARNING

Safety Earth Ground

An uniterruptible 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.

WARNING

Resuscitation

Personnel working with or near high voltages should be familiar with modern

methods of resuscitation.

WARNING

Remove Power

Observe general safety precautions. Do not open the instrument with the power on.

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.

i

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. Refer to page 13 for specific instructions.

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

Do not attempt to handle or move this unit alone. More than one person is

needed to move this unit to avoid possible injury.

See page 7.

WARNING

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

and clothing. Avoid breathing vapor. Wash thoroughly after handling.

See page 9

WARNING

Never attempt to connect or disconnect an RF transmission line while power is

on at the RF power source. Radiated RF energy is a potential health hazard.

See pages 16, 19, and 21.

WARNING

Disconnect from RF power sources and the AC line before any disassembly or

service. Electrical shock hazard.

See page 18.

WARNING

Improper wiring could result in electric shock and death.

See page 18.

ii

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

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.

See page 8.

CAUTION

The 115 VAC 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.

See page 8.

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.

See page 9.

CAUTION

Operation without sufficient coolant can damage the unit.

See page 10.

CAUTION

Do not block air flow. Air enters through the side openings of the Moduload and

exhausts through the top.

See page 13.

CAUTION

Do not operate the load without proper coolant levels. Operation without

sufficient coolant can damage the unit.

See page 13.

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.

See page 13.

iii

CAUTION

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

damage the load resistor.

See page 13.

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.

See page 14.

CAUTION

Incorrect hose connections will reverse coolant flow and could destroy the load.

See page 18.

CAUTION

Do not attempt further disassembly of this part.

See page 25.

CAUTION

Failure to follow the special storage instructions may result in damage to the

unit. Consult the factory for the special instructions.

See page 28.

CAUTION

Failure to properly prepare the unit for shipment using the special storage

instructions may result in damage to the unit. Consult the factory for the special

instructions.

See page 28.

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.

v

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.

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

CONNECT INTERLOCK TO TRANSMITTER BEFORE OPERATING.

BRANCHER LE VERROUILLAGE À L'ÉMETTEUR AVANT EMPLOI.

CONECTE EL INTERBLOQUEO AL TRANSMISOR ANTES DE LA OPERACION.

VOR INBETRIEBNAHME VERRIEGELUNG AM SENDER ANSCHLIESSEN.

PRIMA DI METTERE IN FUNZIONE L'APPARECCHIO, COLLEGARE IL
DISPOSITIVO DI BLOCCO AL TRASMETTITORE.

vii

About This Manual

This manual covers the operating and maintenance instructions for the following
models:

8655B115-6 8655B230-5 8655B230-6
8656B115-6 8656B230-5 8656B230-6

Changes to this Manual

We have made every effort to ensure this manual is accurate. If you discover any
errors, or if you have suggestions for improving this manual, please send your
comments to our Solon, Ohio factory. This manual may be periodically updated.
When inquiring about updates to this manual refer to the part number and revi­sion on the title page.

Terminology

There are some unique terms used throughout this literature. They are defined
here to clarify any misunderstanding.

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 actu-

ally absorbs the RF power.

Literature Contents

Introduction — Describes the features of the Moduload, lists equipment supplied

and optional equipment, and provides power-up instructions.

Theory of Operation — Describes how the Moduload works.
Installation — Describes the power supply and load connection instructions.
Operating Instructions — Describes the base level operation instructions.
Maintenance — Lists routine maintenance tasks as well as troubleshooting for

common problems. Specifications and parts information are also included.

viii

Table of Contents

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

Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

Warning Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

Caution Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Safety Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii

Changes to this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii

Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii

Chapter 1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Power and Utility Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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

Items Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Optional Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Dolly (P/N 6772B011) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Ethylene Glycol (P/N 5-1134-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Chapter 2 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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

Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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

Chapter 3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Interlock Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

AC Line Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Filling the Coolant Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Blower Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Connecting RF Power To Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Model 8655B (3-1/8 inch EIA, 50 ohm, swivel flanged) . . . . . . . . . . . . . . . 11

Model 8656B (3-1/8 inch unflanged, 50 ohm impedance) . . . . . . . . . . . . . . 11

Preliminary Equipment Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Meter Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Chapter 4 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Use and Function of Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Initial Adjustments and Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Equipment Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Normal Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Emergency Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Performance Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Chapter 5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

RF Load Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Measuring DC Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Routine Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Inspecting the Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Inspecting the External Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

ix

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Cleaning the Instrument Housing and Panels . . . . . . . . . . . . . . . . . . . . . . 17

Cleaning the Connector and Outside Surface . . . . . . . . . . . . . . . . . . . . . . 17

Flushing the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Repair and Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

RF Load Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Removing the RF Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Pump/Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Installing the Pump/Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Replacing the Water Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Replacing the Time Delay Relay for 8655B and 8656B . . . . . . . . . . . . . . . 22

Replacing the Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Load Resistor Internal Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Removing the Resistor Main Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Removing the Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Inspecting the Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Replacing the Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Replacing Fractured Resistors or Damaged Internal Parts . . . . . . . . . . . . . . 25

Removing Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Installing the Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Assembling the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Assembling the Front Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Drainage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Replacement Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Models 8655B and 8656B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Models 8775-100 and 8776-100

Load resistor for Moduload 8655B/56B Units . . . . . . . . . . . . . . . . . . . . . . 32

Front Connector Parts assigned Per Model Type . . . . . . . . . . . . . . . . . . . . 32

Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

x

Chapter 1 Introduction

The Bird 8655B/56B Moduload Coaxial Load is a self-cooling, low reflection,
non-radiating termination for high power RF transmission lines. The Load is for
use on CW, AM, FM, SSB, and TV modulation envelopes. The load may also be
used within certain limits on radar or pulse modes. Information for use involv­ing pulse type signals should be obtained directly from Bird Electronic Corpora­tion. The Loads are capable of continuous power dissipation of 50 kW with a
maximum voltage standing wave ratio (VSWR) of 1.10 from 1000 Hz to 900
MHz. These models provide direct connection to 3-1/8 inch 50 ohm coaxial lines.

The equipment consists of three basic systems:

z RF Load Assembly

Contains the resistor element with its internal water cooling system.

z 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.

z Heat Exchanger System

The heat exchanger components consist essentially of the pump/motor, collec­tor tank, four cover fans and four finned water cooling heat exchangers
arranged in a mated pair sets.

When used in conjunction with the appropriate Bird Model Thruline Wattme­ter, such as those used in the 4600 and 4800 series, the 8655B/56B Moduload
Load Resistor may be used for direct RF power measurements within the
equipment ratings.

Power and Utility Requirements

The 8655B/56B loads are offered in three standard forms which differ in the
AC input power requirements.

z -115-6 for 115 V, 60 Hz
z -230-5 for 230 V, 50 Hz
z -230-6 for 230 V, 60 Hz

Items Supplied

The 8655B and 8656B loads are equipped with standard connectors. The
Model 8655B has a 3-1/8 inch EIA flanged connector. The Model 8656B has a
3-1/8 inch unflanged connector.

Items Required

z A mating connector on the coaxial transmission line.
z A conveniently located AC power receptacle to plug in the power cable.
z Distilled water for coolant.

1

Bird 8650 Series Moduload RF Load Resistor

Optional Items

Dolly (P/N 6772B011)

For ease in moving the load.

 Note: Consult the Bird Electronic Catalog for more information.

Ethylene Glycol (P/N 5-1134-3)

A one gallon container of industrial grade ethylene glycol.

Figure 1 Top View, All Models

Mounting Holes (8)

1-1/2

(38mm)

Filler and Vent Plug

14"

(356mm)

17" ±1/64

(432 ±.4mm)

2