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BIRD Moduload 8640 Series Operation Manual

Rf load resistor
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®
Moduload
RF Load Resistor
Series 8640 and 8640B
Including Models
8645-xxx & 8646-xxx
Operation Manual
©Copyright 2016 by Bird Electronic Corporation
Instruction Book Part Number 920-8640S Rev. G
®
®
®
®
Moduload
, Econoload
, Econoline
, and Thruline
are
registered trademarks of Bird Electronic Corporation

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Summary of Contents for BIRD Moduload 8640 Series

  • Page 1 ® Moduload RF Load Resistor Series 8640 and 8640B Including Models 8645-xxx & 8646-xxx Operation Manual ©Copyright 2016 by Bird Electronic Corporation Instruction Book Part Number 920-8640S Rev. G ® ® ® ® Moduload , Econoload , Econoline , and Thruline...

  • Page 2: Safety Precautions

    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.

  • Page 3: Safety Symbols

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

  • Page 4: Caution Statements

    Moduload® RF Load Resistor 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 8 and 11. WARNING Disconnect from RF power sources and the AC line before any disassembly or service. Electrical shock hazard.

  • Page 5: Safety Statements

    Safety Precautions Safety Statements USAGE ANY USE OF THIS INSTRUMENT IN A MANNER NOT SPECIFIED BY THE MANUFACTURER MAY IMPAIR THE INSTRUMENT’S SAFETY PROTECTION. 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.
  • Page 6 Moduload® RF Load Resistor 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 SERVICIO LAS INSTRUCCIONES DE SERVICIO SON PARA USO EXCLUSIVO DEL PERSONAL DE SERVICIO CAPACITADO.
  • Page 7 Safety Precautions 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.

  • Page 8: About This Manual

    Moduload® RF Load Resistor About This Manual This manual covers the operating and maintenance instructions for the following models: 8640 8640B 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.

  • Page 9: Table Of Contents

    Table of Contents Safety Precautions ..............i Safety Symbols .
  • Page 10 Moduload® RF Load Resistor Maintenance ................. 10 Cleaning .

  • Page 11: Chapter 1 Introduction

    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.
  • Page 12 Moduload® RF Load Resistor Figure 1 8640 Series Moduload Outline Drawing Figure 2 System Block Diagram...

  • Page 13: Chapter 2 Theory Of Operation

    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.

  • Page 14: Chapter 3 Installation

    Chapter 3 Installation This chapter provides information on site requirements, unpacking, inspection, and preparing the Bird 8640 Moduload for use. Unpacking and Inspection 1. Carefully inspect shipping container for signs of damage.  If the shipping container is damaged, do not unpack the unit. Immediately notify the shipping carrier and Bird Technologies.

  • Page 15: Dc Resistance

    Installation DC Resistance Before first using the load, get a resistance baseline for future maintenance. Refer to "RF Assembly Resistance for instructions. Test" on page 11 Meter Rack If the Moduload will be used with a power meter, install the meter rack to provide a convenient place to keep the ...

  • Page 16: Coolant

    15.2 lb (6.9 kg) 167 lb (75.7 kg) Ethylene Glycol Adding Coolant 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.
  • Page 17 Installation Figure 3 Freezing Point of Ethylene Glycol / Distilled Water Mixture...

  • Page 18: Connecting Rf Power

    Moduload® RF Load Resistor 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.

  • Page 19: Chapter 4 Operating Instructions

    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 1.

  • Page 20: Chapter 5 Maintenance

    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.

  • Page 21: Cleaning

    Maintenance 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: 1.

  • Page 22: Coolant

    Moduload® RF Load Resistor Figure 6 Measuring DC Resistance Coolant 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.

  • Page 23: Flushing The Coolant

    Maintenance Flushing the Coolant Whenever maintenance work has been performed, including resistor repair, or there is a reason to suspect that contamination has been introduced or dislodged into the coolant, the system should be thoroughly flushed. Note: If the unit is to remain fully or partially drained for two weeks or more, see "Preparation for Storage or Shipment"...

  • Page 24: Repair

    Moduload® RF Load Resistor 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. Replacing the 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. 3.

  • Page 25: Replacing The Flow Switch (For Units Manufactured Before 3/1/2010)

    Maintenance Replacing the Flow Switch (For Units Manufactured BEFORE 3/1/2010) Note: The coolant flow switch should be inspected every three to six months, depending on the amount of use. To inspect it: 1. Drain the coolant. See "Changing Coolant" on page 12 2.

  • Page 26: Removing The Load

    Moduload® RF Load Resistor Removing the Load 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.
  • Page 27 Maintenance Figure 7 Removing the Load (Models BEFORE 3/1/2010) Item Description Load mounting clamp screws Flow switch wires Fan-supply connector Front panel connector Figure 8 Removing the Load (Models AFTER 3/1/2010) Item Description Load mounting clamp screws Pressure switch wires Fan-supply connector Front panel connector...

  • Page 28: Removing The Pump

    Moduload® RF Load Resistor 9. Record the wire colors and locations then disconnect the pump motor wires from the front panel terminal block (TB 1) ( Figure 10 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.

  • Page 29: Servicing The Resistor

    Maintenance Servicing the Resistor 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. WARNING Disconnect the unit from all power sources before servicing. The unit may be energized from multiple sources.

  • Page 30: Inspecting The Resistor

    Moduload® RF Load Resistor 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.

  • Page 31: Replacing The Conductor

    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 (–...

  • Page 32: Specifications

    Moduload® RF Load Resistor Specifications 1 kHz – 900 MHz Frequency Range 25 kW continuous duty Power Rating CW, AM, FM, SSB, TV and certain pulse types Mode 50 ohms nominal Impedance 1.10 max VSWR Connectors  inch EIA Flanged 8645 ...

  • Page 33: Replacement Parts

    Replacement Parts 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.

  • Page 34: Heat Exchanger

    Moduload® RF Load Resistor Heat Exchanger Description Part No. AC Cord 864x-115 5-1836 864x-230 5-1837 Fan Assembly (model 864x) 864x-115 8640-668-1 864x-230 and 864x-230-6 8640-668-2 8646-230-6-N 8640-668-4 Fan Assembly (model 864xB) 864xB - 115 5A2770-1 864xB - 230 and 864xB - 230-6 5A2770-2 Pump (model 864x) 864x-115...

  • Page 35: Limited Warranty

    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 specifica- tions, 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;...

This manual is also suitable for:

Moduload 8640b seriesModuload 8646 seriesModuload 8645 series

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