BIRD Moduload 8640 Series Operation Manual Download

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Instruction Book Part Number 920-8640S Rev. G

Moduload

, Econoload

, Econoline

, and Thruline

are

registered trademarks of Bird Electronic Corporation

Moduload

RF Load Resistor

Series 8640 and 8640B

Including Models

8645-xxx & 8646-xxx

Operation Manual

Summary of Contents for Moduload 8640 Series

Page 1: ...on Instruction Book Part Number 920 8640S Rev G Moduload Econoload Econoline and Thruline are registered trademarks of Bird Electronic Corporation Moduload RF Load Resistor Series 8640 and 8640B Including Models 8645 xxx 8646 xxx Operation Manual ...

Page 2: ... 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 uninterruptible earth safety ground must be supplied from the main power source to ...

Page 3: ...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 WARNING HEAVY Do not lift this unit alone WARNING Disconnect the unit from all power sources before servicing The unit may be energized from multiple sources The potential for electric shoc...

Page 4: ...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 tha...

Page 5: ...EGURIDAD 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 SPECIFIC...

Page 6: ...ES 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 POU...

Page 7: ...RATING 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: ...ponent 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 Resistor A subcomponent of the LOAD This is the ceramic resistor which actually absorbs the RF power Literature Contents Introduction Describes the feature...

Page 9: ...ed 1 Items Required but not Supplied 1 Optional Items Available 1 Chapter 2 Theory of Operation 3 Resistor 3 Coolant 3 Flow Interlock 3 Thermal Interlock 3 Chapter 3 Installation 4 Unpacking and Inspection 4 Placement 4 Mounting 4 DC Resistance 5 Meter Rack 5 Interlock Connection 5 AC Mains Connection 5 Coolant 6 Adding Coolant 6 Connecting RF Power 8 Chapter 4 Operating Instructions 9 Normal Oper...

Page 10: ...or Model 864xB 14 Replacing the Flow Switch For Units Manufactured BEFORE 3 1 2010 15 Replacing the Pressure Switch For Units Manufactured AFTER 3 1 2010 15 Removing the Load 16 Model 864x 16 Model 864xB 16 Removing the Pump 18 Servicing the Resistor 19 Removing the Resistor 19 Inspecting the Resistor 20 Removing a Fractured Resistor 20 Replacing the Resistor 20 Replacing the Conductor 21 Preparat...

Page 11: ...W AM FM SSB and TV modulation and certain pulse types Contact Bird Electronic Corporation for information on using Moduloads with pulsed signals Useable to make RF power measurements when used with a Bird 4600 or 4800 Thruline Wattmeter Self contained water based cooling system Time delay interlock ensures steady coolant flow before RF power is applied Indicators Coolant Level Gauge Items Supplied...

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

Page 13: ...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 th...

Page 14: ...hat could be drawn into the air intakes The heat exchanger must be operated in a horizontal position AC power is required Allow a minimum of one foot clearance along the sides and three feet over the top to allow unobstructed air intake and exhaust In small rooms or restricted areas outside venting is recommended Ductwork must not have sharp bends that would restrict air flow or create back pressu...

Page 15: ...s required for the transmitter Note Interlock contact resistance could be as high as 10 ohms for circuits drawing less than 250 mA AC Mains Connection The AC power supply required for this unit is 115 230 V depending on the model 50 60 Hz 1 The unit is equipped with an IEC 320 cold 70 C AC inlet WARNING Disconnect the unit from all power sources before servicing The unit may be energized from mult...

Page 16: ...these steps 1 Ensure 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 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 minute...

Page 17: ...Installation 7 Figure 3 Freezing Point of Ethylene Glycol Distilled Water Mixture ...

Page 18: ...flange on the coaxial input outer conductor 3 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 1 Insert the center bullet and ...

Page 19: ...ower at the source 2 Wait five minutes for the system to cool to room temperature 3 Turn off the Moduload Emergency Shutdown Turn off RF power at the source Note If the interlock is properly connected RF power will be automatically turned off if a fault occurs in the Moduload CAUTION Operation without sufficient coolant can damage the unit CAUTION Do not operate without the interlock Even momentar...

Page 20: ... Replacing the Fuse on page 14 Coolant leaking Loose connections Tighten drain plug and all connections Worn or cracked hose Replace defective hose Interlock opening repeatedly Insufficient coolant flow Check coolant level Add coolant if necessary See Changing Coolant on page 12 Defective flow switch Check flow switch See Replacing the Flow Switch For Units Manufactured BEFORE 3 1 2010 on page 15 ...

Page 21: ...sistor Checking the DC resistance is simply used to measure a change in the resistance over time Tracking the DC resistance should start before the unit is first put into service Perform the following steps and record the value for future comparison Resistance measurements should be taken periodically according to use Preparation Tools Common hand tools Ohmmeter with an accuracy of 1 at 50 ohms or...

Page 22: ... 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 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 WARNING Ethylene glyco...

Page 23: ... a new load the cooling system needs to be flushed to remove any debris or containments that may remain when a damaged load is removed 1 Open the drain plug 2 Drain and discard the coolant 3 Close drain plug 4 Connect a suitable hose from the outlet of the pump to a drain or container to hold the discarded coolant 5 Connect a second hose from the inlet of the heat exchanger to a source of clean po...

Page 24: ...y with the hole in the socket 4 Rotate until the key way engages then push in For Model 864xB Note The relay is located on the inside of the front panel at the upper right side 1 Loosen and remove the nut and washers that secure the relay to the panel 2 Record the color of each wire and the relay terminal to which it connects then remove the wires from the relay 3 Remove the relay from its mountin...

Page 25: ... the red pressure switch wire by gently prying the retaining clips outward while pulling the connector away from its mating connector 6 Unscrew the switch from the output plumbing assembly of the load Note Use a inch wrench on the hex portion of the pressure switch 7 Apply a thin coating of Teflon based thread sealant to the male threads of the pressure switch 8 Thread the switch into the output p...

Page 26: ...nd 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 12 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 9 5 Loosen the hose clamps on both water hose connections to...

Page 27: ...the Load Models AFTER 3 1 2010 Item Description 1 Load mounting clamp screws 2 Flow switch wires 3 Fan supply connector 4 Front panel connector Item Description 1 Load mounting clamp screws 2 Pressure switch wires 3 Fan supply connector 4 Front panel connector 4 3 2 1 2 1 4 3 2 1 2 1 ...

Page 28: ...e coolant See Changing Coolant on page 12 2 Remove the load See Removing the Load on page 16 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 5 Remove the hoses 6 Loosen the hose clamp on the drain tube at the base of the pump 7 Remove the drain tube 8 Unscrew the bolts securing the base of ...

Page 29: ... the water chamber assembly out It may be necessary to rock the chamber gently while pulling Note 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 th...

Page 30: ...d housing If it comes out return it after inspection and cleaning 6 Check the inside of the load housing for damage 7 Remove the inner flow tube 9 and ground cap assembly 10 Note Check them for broken pieces 8 Under clear running water thoroughly wash the inside of the conductor assemblies load housing and water chamber 9 Replace the ground cap assembly and the inner flow tube Replacing the Resist...

Page 31: ...nductor assembly into load housing 6 Ensure the resistor fitting makes a snug fit with the resistor 7 Replace the outer conductor and screw it into place 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 ...

Page 32: ... E G and 65 Dist H2O mixture Distilled water or distilled water ethylene glycol mixture Coolant Capacity 9 qts 8 5 L nominal AC Power 115 230 230 6 115 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 3AB Time Delay 15 A 8 A Fuse Rating 864xB 115 Vac 230 Vac Time Delay 15 A 3AB 8 A 5x20 mm Ambient Temperature2 Water only 35 Ethylene Glycol 2 Above 30 C 86 F w...

Page 33: ... 1 8755 014 4 Water Chamber Inner O Ring 1 5 099 5 Fitting 90 1 BEFORE 3 1 2010 8640 089 AFTER 3 1 2010 8640A089 5A Fitting Straight consisting of Bushing Nipple 1 1 BEFORE 3 1 2010 5 489 1 5 490 1 AFTER 3 1 2010 8645A003 6 Screw 1 4 20 x 2 1 2 inch 6 1121 2508 00 7 Resistor Sleeve 1 8755 026 8 Sleeve O Ring 1 8110 059 9 Inner Flow Tube 1 8755 025 9A Outer Flow Tube 1 8755 024 10 Resistor Ground C...

Page 34: ... 864xB 864xB 115 864xB 230 864xB 230 6 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 1 5 1627 5 1625 5A2787 1 Pressure Switch Replaces Flow Switch in units AFTER March 2010 1 8645C004 Fuse model 864x 864x and 864xB 115 864x 230 864xB 230 2 5 1828 36 15 A 3AB time delay 5 1828 33 8 amp...

Page 35: ...ery such claim for breach of these warranties shall be deemed to be waived by Buyer unless made in writ ing within ten 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 alt...

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