INSTRUCTION BOOK
DIGITAL AIR™
LOAD RESISTORS
©Copyright 2010 by Bird Electronic Corporation
Instruction Book Part Number 920-8579AS Rev. F
Thruline
Digital Air™ is a Trademark of Bird Electronic Corporation
®
is a Registered Trademark and
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 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.
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Safety Symbols
WARNING
ing notes call attention to a procedure, which if not correctly
Warn
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 followed.
The caution symbol appears on the equipment indicating
there is important information in the instruction manual
regarding that particular area.
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
for emphasis.
WARNING
Turn off AC power and RF power before removing or replacing the
access panel; the potential for electrical shock exists.
See pages 9 and.24.
WARNING
Ensure the power is turned off when attaching power cable or wire.
See pages 13 and 14,
WARNING
Never attempt to connect or disconnect an RF cable or line while
power is on at the RF power source. Radiated RF energy is a
potential health hazard.
See page 14.
ii
are repeated here
WARNING
Exhausted air may exceed 95°C (203°F).
See page 17.
WARNING
Do not operate above the rated capacity. See “Specifications” on
page 27 if unsure of the rating the model load. The unit will handle
a small percentage of overload for brief periods of time during
transmitter tuning or adjustment. However, long periods of
overload (> 10% of rated power for > 30 min) may damage the unit
or cause the temperature interlock to open.
See page 18.
WARNING
Disconnect this unit from the RF power sources and the ac line
before any disassembly. The potential for electrical shock exists.
See pages 21.
WARNING
Improper wiring could result in electric shock and death.
See page 24.
WARNING
High heat present inside unit! Let cool for at least 10 minutes before
servicing or severe burns could result.
See page 24.
WARNING
Maintenance by other than trained service personnel could result in
electric shock.
See page 24.
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Bird Technologies
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 airflow. Air is forced into the housing via fans on all
four sides and exhausts through a grille on the lower rear of the
unit. Blocking air inputs or exhaust could cause unit failure.
See page 8.
CAUTION
Connect interlock before RF operation.
See page 10.
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.
See page 12.
CAUTION
Do not operate without AC power to the load.
See page 17.
CAUTION
Applying more than the rated average RF power to the load may
damage the load resistor.
See page 18.
CAUTION
Do not disconnect AC line power before turning off RF power to the
load. Application of full RF power to the load while the fans are not
running will cause the load to overheat and destroy the resistor
elements.
See page 18.
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CAUTION
Improper wiring could disable load.
See page 24.
CAUTION
Do not disable fans. Application of full RF power to the load while
the air circulation is off will cause the load to overheat and destroy
the resistor elements.
See page 24.
CAUTION
All replacement wiring must be 18 AWG, with insulation rated to
400º F (205º C). Use of other wiring could result in unit damage.
See page 24.
CAUTION
This circuit diagram for use by trained service personnel only.
Improper use could disable load.
See page 24.
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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.
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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.
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Bird Technologies
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.
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About This Manual
This instruction book covers Bird Digital Air Load Resistor Models:
DA5F15 DA5U15 DA5F30 DA5U30
DA10F15 DA10U15 DA10F30 DA10U30
DA15F15 DA15U15 DA15F30 DA15U30
DA25F15 DA25U15 DA25F30 DA25U30
DA40F15 DA25-4U15 DA40F30 DA25-4U30
DA10V1F15 DA40-5U15 DA10V1F30 DA40-5U30
DA10V3F15 DA10V1U15 DA10V3F30 DA10V1U30
DA25V3F15 DA10V3U15 DA25V3F30 DA10V3U30
DA25V3U15 DA25V4U15 DA25V3U30 DA25V4U30
Changes to this Manual
We have made every effort to ensure this manual is accurate. If any
errors are discovered, or if there are any suggestions for improving
this manual, please send 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.
The most recent revision of this manual can be found on Bird’s website:
http://www.bird-electronic.com.
Literature Contents
Chapter Layout
Introduction
equipment supplied and optional equipment, and provides power-up
instructions.
Installation — Describes the how to set up the loads, reviews features
of the Digital Air Load that help in initial use, and provides power-up
instructions.
Operating Instructions — Describes basic use and various modes of
operation.
Maintenance — Lists routine maintenance tasks as well as trouble-
shooting for common problems.
Theory of Operation — Describes how the Digital Air loads work.
Specifications — Lists specifications and parts information.
— Describes the features of the Digital Air Load, lists
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Table of Contents
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii
Warning Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii
Caution Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Safety Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
About This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Changes to this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Chapter Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Chapter 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Chapter 2 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
RF Section Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Heat Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fan Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Thermal Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Line Power Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Chapter 3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Unit Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Ducting Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Access Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Interlock Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Five Terminal Interlock with Power Relay . . . . . . . . . . . . . . . 10
Five Terminal Interlock without Power Relay . . . . . . . . . . . . . 12
Two Terminal Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
AC Power Hookup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
AC Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
AC Power Cable Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
AC Hard Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Earth Grounding Lug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Connecting RF Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Swivel Flanged Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Unflanged Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-1/16” Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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Chapter 4 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . 17
Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Load Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Interlock Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Manual Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Automatic Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Measurement and Monitoring of RF Power 1 . . . . . . . . . . . . . . . . . 9
Chapter 5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Preparation for Storage or Shipment . . . . . . . . . . . . . . . . . . . . . . 22
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Appendix 1 Difference Data Sheet . . . . . . . . . . . . . . . . . . . . . . . 31
Specifications for 12.5 kW Digital Air Load . . . . . . . . . . . . . . . . . 31
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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xii
Chapter 1 Introduction
Figure 1 Digital Air Outline Drawing
Series Dim. A Dim. B Dim. C Dim. D Dim. E Dim. F Dim. G
DA10V
DA25V
DA5
DA10
DA15
DA25
DA40
23.5”
(597 mm)
27.0”
(686 mm)
17.0”
(432 mm)
19.5”
(495 mm)
25.0”
(635 mm)
27.0”
(686 mm)
27.5”
(701 mm)
23.5”
(597 mm)
27.0”
(686 mm)
17.0”
(432 mm)
19.5”
(495 mm)
25.0”
(635 mm)
27.0”
(686 mm)
27.5”
(701 mm)
49.5”
(1257 mm)
50.8”
(1289 mm)
55.5”
(1410 mm)
60.0”
(1524 mm)
68.0”
(1727
mm)
68.0”
(1727
mm)
78.8”
(1999 mm)
59”
(1499 mm)
61.0”
(1549 mm)
64.0”
(1626 mm)
68.5”
(1740 mm)
76.5”
(1943
mm)
76.5”
(1943
mm)
84.0”
(2134 mm)
*
N/A
1
N/A
1
N/A
1
N/A
24.5”
(622 mm)
24.5”
(622 mm)
24.5”
(622 mm)
1
N/A
1
N/A
1
N/A
1
N/A
6.0”
(152 mm)
6.0”
(152 mm)
6.0”
(152 mm)
N/A
N/A
N/A
N/A
2.0”
(50.8 mm)
2.0”
(50.8 mm)
2.0”
(50.8 mm)
*. Forklift openings are not provided for these models.
1
1
1
1
1
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