Bird Technologies SCC8 User Manual
INSTRUCTION BOOK
HIGH POWER
SEMICONDUCTOR
CAL CART
Bird® Electronic Corporation
30303 Aurora Road
Cleveland (Solon), Ohio 44139
Sales & Technical Support: 440-248-1200
Sales email: sales@bird-technologies.com
Technical Support email: atechapp@bird-technologies.com
866-695-4569 toll free
©Copyright 2010 by Bird Electronic Corporation
Instruction Book Part Number 920-HPCC Rev. G
Thruline® and Termaline® are a Registered Trademarks
of Bird Electronic Corporation
THIS PAGE INTENTIONALLY LEFT 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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Bird High Power Semiconductor Cal Cart
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 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 are repeated here for emphasis.
WARNING
Do not attempt to lift the cart by the handle.
On page 3.
WARNING
Ethylene glycol is toxic. Do not take internally. Avoid contact with eyes, skin,
and clothing. Avoid breathing vapor. Wash thoroughly after handling.
On page 4.
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.
On pages 6, 12, 16, 17 and 20.
WARNING
To avoid personal injury, disconnect the power cord from the AC line before
performing any maintenance, including fuse replacement.
On pages 11, 16, 17, 18, 20, 21 and 22.
On page 11.
ii
WARNING
The Bird 4421 contains no user-serviceable parts. Do not remove its cover.
Caution Statements
The following equipment cautions appear in the text and are repeated here for
emphasis.
CAUTION
Check the 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.
On page 3.
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.
On page 3.
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.
On pages 4 and 12.
CAUTION
Operation without sufficient coolant will damage the unit.
On pages 4, 7 and 12.
CAUTION
Due to the complexity of the Bird Power Sensor, field repairs beyond general
maintenance should not be attempted. Removal or disturbance of the power
sensor cover can result in cancellation of lifetime warranty.
On pages 13 and 17.
CAUTION
The Bird 4421 must be powered off when connecting or disconnecting the power
sensor from the power meter.
On page 17.
CAUTION
Failure to install a properly rated fuse may result in damage to equipment or
nuisance failure.
On page 18.
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Bird High Power Semiconductor Cal Cart
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.
iv
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.
v
Bird High Power Semiconductor Cal Cart
UNITS ARE EQUIPPED WITH RECHAREABLE BATTERIES.
THESE ARE TO BE REPLACED BY AUTHORIZED SERVICE PERSONNEL
ONLY!!!
LAS UNIDADES VIENEN EQUIPADAS CON BATERIAS RECARGABLES.
¡¡¡Y SOLAMENTE EL PERSONAL DE SERVICIO AUTORIZADO PUEDE
REEMPLAZARLAS!!!
GERÄTE SIND MIT WIEDER AUFLADBAREN BATTERIEN BESTÜCKT.
BATTERIEN SIND NUR VON QUALIFIZIERTEM SERICE PERSONAL
AUSZUWECHSELN!!!
CES DISPOSITIFS SONT ÉQUIPÉS DE BATTERIES RECHARGEABLES.
SEUL LE PERSONNEL D’ENTRETIEN AUTORISÉ EST HABILITÉ À LES
REMPLACER !
LE UNITÀ SONO DOTATE DI BATTERIE RICARICABILI,
CHE DEVONO DA COME SPECIFICATO DAL PRODUTTORE LA
PROTEZIONE DI SICUREZZA POTREBBE VENIRNE COMPROMESSA.
vi
USE CORRECT VOLTAGE SETTING AND FUSE - SEE MANUAL.
UTILISER UNE TENSION ET UN FUSIBLE CORRECTS - CONSULTER LE MODE
D'EMPLOI.
USE LA INSTALACION Y FUSIBLE DE VOLTAJE CORRECTO - VEA EL MANUAL.
AUSSCHLIESSLICH VORSCHRIFTSMÄSSIGE WECHSELSPANNUNGSEINSTELLUNG UND SICHERUNG BENUTZEN - SIEHE DAZU HANDBUCH.
UTILLIZZARE TENSIONE E FUSIBLE ADATTI - FARE RIFERIMENTO AL
MANUALE.
vii
Bird High Power Semiconductor Cal Cart
BE SURE THE 115/230V AC VOLTAGE SELECTOR IS SET TO THE PROPER LINE
VOLTAGE, AND THE CORRECT AC LINE FUSE IS INSTALLED BEFORE AC
POWER IS APPLIED.
S'ASSURER QUE LE SÉLECTEUR DE TENSION 115/230V C.A. EST BIEN RÉGLÉ
POUR LA TENSION DU RÉSEAU ET QUE LE FUSIBLE DE LIGNE C.A. CORRECT
EST EN PLACE AVANT DE METTRE SOUS TENSION C.A.
CERCIORESE QUE EL SELECTOR DE VOLTAJE DE 115/230V CA ESTE
COLOCADO A LA LINEA DE VOLTAJE APROPIADA Y QUE EL FUSIBLE ESTE
INSTALADO A LA LINEA CA ANTES DE APLICAR LA CORRIENTE ALTERNA.
VOR EINSCHALTEN DER WECHSELSTROMZUFUHR SICHERSTELLEN, DASS
DER 115/230V WECHSELSPANNUNGS-SELEKTOR AUF DIE
VORSCHRIFTSMÄSSIGE LEITUNGSSPANNUNG EINGESTELLT UND DIE
RICHTIGE WECHSELSTROM-HAUPTSICHERUNG EINGESETZT IST.
PRIMA DI EROGARE CORRENTE, ASSICURARSI CHE IL SELETTORE DI
VOLTAGGIO 115/230 V.C.A. SIA REGOLATO CORRETTAMENTE E CHE IL
FUSIBLE ADATTO ALLA LINEA DI ALIMENTAZIONE C.A. SIA INSTALLATO.
viii
About This Manual
Numbering
This manual covers the operating and maintenance instructions for the following
models:
Cal Cart with 4421 meter, 4028B10M sensor,
8640 load, 1-5/8” flanged connector,
115Vac power supply and standard US plug
SCC81 01 01 01 1
Voltage and
Sensor Load RF Connector
01 4028B10M 01 8640 Series 01 1-5/8” EIA
Flanged
02 8640B Series 2 230V, 30A
Plug Style
1 115V, 15A
Nema 5-15P
Nema L6-30P
3 115V, 10A
International
4 230V, 10A
International
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 clarify any misunderstanding.
Cal Cart - The entire unit.
Sensor - The power sensor
Meter- The power meter and display
Load - The entire load (water-cooled RF termination).
Resistor Assembly - The load component which connects directly to the RF line.
It is inside the HEAT EXCHANGER, connected by two hoses.
Heat Exchanger - The parts of the Moduload left when the LOAD is removed. It
contains the pump, fans, coolant reservoir, and controls.
Resistor - A subcomponent of the RESISTOR ASSEMBLY. This is the ceramic
resistor which actually absorbs the RF power.
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Bird High Power Semiconductor Cal Cart
Chapter Layout
Introduction — Describes the features of the Cal Cart, lists equipment supplied
and optional equipment, and provides power-up instructions.
Setup — Describes the power supply and connection instructions.
Operating Instructions — Describes the base level operation instructions.
4421 Instructions — All instructions necessary to operate the 4421 Power Meter
in conjunction with the Bird Semiconductor Cal Cart.
Maintenance — Lists routine maintenance tasks as well as troubleshooting for
common problems. Specifications and parts information are also included.
x
Table of Contents
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii
Warning Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Caution Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Safety Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Changes to this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Chapter Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .x
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Items Supplied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
RF Power Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Power Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Chapter 1 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Adding Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Connecting RF Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Chapter 2 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Chapter 3 4421 Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Audible Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chapter 4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DC Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Changing the Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Flushing the Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Power Meter and Sensor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Push Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Load Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Removing the Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Replacing the Cord Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Replacing the Power Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Replacing Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Replacing Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Load Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
xi
Replacing Resistor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Removing the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Resistor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Removing the Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Inspecting the Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Replacing a Fractured Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Replacing the Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Replacing the Conductor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Storage and Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Storing the Load Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Shipping the Load Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Max. Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Bird High Power Cal Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Bird 4421 RF Power Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Bird 4028B Series RF Power Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Bird 8640S Series Moduloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Cal Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Resistor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
xii
Chapter 1 Introduction
This instruction book is intended for use by operators of the Bird High Power
Cal Cart (HPCC). This chapter contains introductory information including
component descriptions and items supplied.
The HPCC is designed for immediate, effortless use. It has three primary components. The Bird 4421 RF Power Meter displays RF power measurements.
Bird 4028 Series Power Sensors are highly accurate sensors that measure RF
power without requiring calibration or external couplers or attenuators. Bird
Moduloads are low reflection 50 Ω terminations that can dissipate 25 kW.
These components are installed on a cart for easy transportation. The cart is
suitable for use in a cleanroom environment, and is equipped with four swivel
casters for maximum maneuverability. The only setup required is adding coolant and connecting AC and RF power.
Items Supplied
Stainless Steel Cart with the following items installed:
z Bird 4421 RF Power Meter
z Bird 4028 Series Sensor
z Bird 8640 or 8640B Series Moduload
z Cabling
z Instruction Manual
RF Power Meter
Power Sensor
Load
The Bird 4421 RF Power Meter measures forward and reflected RF power
when used with a Bird power sensor. Measurement units can be either Watts
or dBm. Because of the quality of the attached load, reflected power will be
negligible and can usually be ignored.
Note: The 4421 is equipped with rechargeable batteries. These are
shipped uncharged. Connect the unit to AC power the first time you use
it to charge the batteries.
Bird 4028 Series Power Sensors are designed for use in semiconductor processing and calibration applications. 4028 Sensors are accurate to ±2%(2σ) at
specified calibration frequencies and power levels. Sensors are controlled by
the Power Meter.
Bird 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.
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