INSTRUCTION BOOK HIGH POWER SEMICONDUCTOR CAL CART Bird® Electronic Corporation 30303 Aurora Road Cleveland (Solon), Ohio 44139 Sales & Technical Support: 440-248-1200 866-695-4569 toll free Sales email: sales@bird-technologies.com Technical Support email: atechapp@bird-technologies.com ©Copyright 2010 by Bird Electronic Corporation Instruction Book Part Number 920-HPCC Rev.
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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.
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.
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.
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.
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.
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.
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.
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.
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 Sensor 01 4028B10M 01 01 Load 01 8640 Series 02 8640B Series 01 1 Voltage and Plug Style RF Connector 01 1-5/8” EIA Flanged 1 115V, 15A Nema 5-15P 2 230V, 30A Nema L6-30P 3 115V, 10A International 4 230V, 10A International Changes to this Manual
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.
Table of Contents Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii Warning Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii Caution Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Resistor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Removing the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Resistor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Removing the Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
Introduction Features Useable with CW, AM, FM, SSB, and TV modulation, and certain pulse types. z Note: Contact Bird Electronic Corporation for information on using Moduloads with pulsed signals.
Chapter 2 Setup This chapter provides information for on-site requirements, unpacking, inspection, and preparing the Bird High Power Cal Cart for use. Unpacking and Inspection 1. Carefully inspect shipping container for signs of damage. 2. Do one of the following: z If the shipping container is damaged, do not unpack the unit. Immediately notify the shipping carrier and Bird Electronic Corporation. z If the shipping container is not damaged, unpack the unit. Save shipping materials for repackaging. 3.
Setup 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 a distilled water/ethylene glycol mixture (with a maximum of 35% 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. Distilled water is the primary coolant for the unit.
Setup Figure 3 Freezing Point of Ethylene Glycol / Distilled Water Mixture 0 Temperature, Degrees Celsius -10 -20 -30 -40 Specifications for ethylene glycol having: specific gravity 1.125 @ 32°F; specific heat .575 @ 68°F -50 -60 10 20 30 40 % Ethylene Glycol 50 60 50 60 40 Temperature, Degrees Fahrenheit 20 0 -20 -40 Specifications for ethylene glycol having: specific gravity 1.125 @ 32°F; specific heat .
Setup Connecting RF Power 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. After installing the Bird High Power Cal Cart, the RF transmission line can be attached using standard coaxial line coupling kits.
Chapter 3 Operating Instructions 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. CAUTION Operation without sufficient coolant will damage the unit. Normal Operation Note: After setting up the Bird High Power Cal Cart: 1. Check that the coolant level is above the minimum mark on the rear coolant gauge. 2. Connect the unit to the AC line. 3. Check that the fans are running properly. 4.
Operating Instructions 8
Chapter 4 4421 Instructions Push Button Functions Figure 5 Push Buttons MODEL 4421 RF POWER METER AUTO FWD RFL SWR MW nW KW µW W mW dBm LO BAT LISTEN REMOTE FWD Push Button FWD, RFL SWR MIN, MAX dBm RFL SWR TALK MIN LOCAL MAX RANGE AUTO DOWN LOCKOUT dBm LIGHT UP ON / OFF Description Press to measure forward (reflected) RF power. FWD (RFL) indicator and current unit of measure turn on. Press to measure standing wave ratio. SWR indicator turns on. Value displayed will be between 1.
4421 Instructions Error Codes The Bird 4421 displays error codes when the RF power is either below the selected range (underrange) or above the selected range (overrange). Figure 6 displays the error codes and Figure 7 lists the function limits. Figure 6 Error Codes Symbol Explanation Value greater than overrange limit of function Value less than underrange limit of function Figure 7 Function Limits Function Limit FWD, RFL Power > 199.
Chapter 5 Maintenance This chapter describes routine maintenance, along with troubleshooting instructions for the power meter and power sensor. Disassembly instructions for the Bird High Power Cal Cart are also provided. For service beyond this level, return the unit to a qualified service center. WARNING To avoid personal injury, disconnect the power cord from the AC line before performing any maintenance, including fuse replacement.
Maintenance DC Resistance Measuring the DC resistance between the inner and outer conductors of the RF connector shows changes in the load over time, a good check of the resistor’s condition. Under normal operating conditions, the resistor should provide at least 5,000 hours of operation before requiring any additional service. DC resistance tracking must start before the load is put into service, and should be measured annually. Perform the following steps and record the value for future comparison.
Maintenance Changing the Coolant Note: To just add coolant, go to step 5. To just drain the coolant, follow steps 1 – 4. 1. Get a clean container, with a capacity of 3 gal. (11 L), to hold the old coolant. 2. Remove the filler cap on the top and at the rear of the unit. Note: This will allow the coolant to drain faster. 3. Unscrew and remove the drain plug at the bottom rear. 4. Drain the coolant into the container. Note: If the coolant has no contaminants it may be reused. 5.
Maintenance PROBLEM Power meter has no power Dash moves across the display POSSIBLE CAUSE Have the batteries been charged? Is the power meter’s AC power cord connected to the terminal strip? Is the Cal Cart’s AC power cord connected to the AC line? Is the ON/OFF rocker switch on the rear panel set to OFF? Unplug the Cal Cart.
Maintenance Push Button Test Note: This test checks that the push buttons and display are functioning properly. If a push button is malfunctioning, return the power meter. 1. Disconnect the power sensor. 2. Turn the power meter On. Note: After the power up display disappears, three dashes “– – –” should scroll across the display. 3. “AUTO” and “FWD” should be displayed, and a reading of “.000 W”. 4. Press RFL. “FWD” should change to “RFL” on the display. Note: The reading should remain the same.
Maintenance Load Troubleshooting PROBLEM POSSIBLE CAUSE Blower not operating Coolant leaking Excessive reflected power CORRECTION Is the load’s AC power cord connected to the terminal strip? Connect the power cord. Is the Cal Cart’s AC power cord connected to the AC line? Connect AC power. Unit turned off. Set the line switch to ON. Fuse burnout. Replace fuse (See "Replacing Fuses" on page 18). Loose connections. Tighten drain plug and all connections. Worn or cracked tubing.
Maintenance Removing the Front Panel Note: To access the power sensor or the AC connections, it will be necessary to remove the cart’s front panel. 1. Remove the screws on the front panel. 2. Pull on the handle set into the base of the front panel to remove it. 3. When making AC connections, refer to the wiring diagram below. Figure 11 Cal Cart Wiring Schematic Replacing the Cord Reel 1. Disconnect the cord reel from the terminal strip. 2. Unscrew the AC connector. 3.
Maintenance 1. Disconnect the RF line from the HPCC. 2. Remove the unit’s front panel (see "Removing the Front Panel" on page 17). 3. Disconnect the sensor cable from the power sensor. 4. Disconnect the RF cable from the sensor output port. 5. Remove the screws on the sensor mounting bracket and remove the sensor from the mounting bracket. 6. Put the new sensor in the bracket and screw it into place.
Maintenance Replacing Batteries WARNING Exposed AC line voltage (115 VAC or 230 VAC). Disconnect the power cord from the AC line before replacing the batteries. Failure to comply may result in severe electrical shock or death. 1. Disconnect the AC power cord from the AC mains supply. 2. Remove the four screws that secure the top cover. 3. Lift the top cover to access the attached ground wire then disconnect the ground wire and remove the cover. 4.
Maintenance Load Servicing Replacing Resistor Assembly WARNING To avoid personal injury, disconnect the power cord from the AC line before performing any maintenance, including fuse replacement. 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. 1. Disconnect the RF line from the Cal Cart 2. Disconnect the Sensor from the Load. 3.
Maintenance Removing the Pump WARNING To avoid personal injury, disconnect the power cord from the AC line before performing any maintenance, including fuse replacement. 1. Drain the coolant (See “Changing the Coolant” on page 13). 2. Remove the load (See “Replacing Resistor Assembly” on page 20). 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, and remove the hoses. 5.
Maintenance Resistor Assembly 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 To avoid personal injury, disconnect the power cord from the AC line before performing any maintenance, including fuse replacement.
Maintenance 4. Remove the following parts and set them aside for reassembly: z Inner flow tube [9] z Resistor sleeve [7] z Cushioning O-ring [8] 5. Remove the ground cap assembly by gently prying it upward using the flat blade of a screw driver and working around the circumference of the part until is is free. Note: The ground cap assembly [10] should now be exposed on the resistor at the end of the load housing. 6. Pull the resistor [1] straight out using a gentle rocking motion.
Maintenance Replacing the Resistor 1. Insert the new resistor [1] into the resistor fitting of the center conductor assembly [15] to test its tightness. Note: The resistor should be snug but should not have to be forced into the fitting. If the resistor is too loose: a. Press the fitting fingers together slightly b. Insert the resistor again. c. Continue closing the ends of the resistor fitting until a snug fit is obtained. 2. Bottom the resistor in the fitting. 3.
Maintenance Replacing the Conductor 1. Remove the cap screws [16] from the RF connector, using a 3⁄16 allen wrench. 2. Remove the outer conductor assembly [12]. Note: If only the outer conductor needs replaced, install it now and screw it into place. 3. Remove the center conductor assembly [11] by pulling it carefully out of the load housing. Note: Make sure the resistor [1] and inner flow tube [9] do not come out with the center conductor. 4.
Maintenance Customer Service Any maintenance or service procedure beyond the scope of those in this chapter should be referred to a qualified service center. If you need to return the unit for any reason, request an RMA through the Bird Technologies website (link shown below). All instruments returned must be shipped prepaid and to the attention of the RMA number. Bird Service Center 30303 Aurora Road Cleveland (Solon), Ohio 44139-2794 Fax: (440) 248-5426 E-mail: bsc@bird-technologies.
Maintenance Specifications To determine the model numbers of the Cal Cart components, see “Numbering” on page ix. Note: Certain sensors or connectors may be incompatible with some models. See “Numbering” on page ix for a list of available components, or contact Customer Service. Max. Power The Cal Cart’s maximum power is the MINIMUM of the max. power of the sensor and the max. power of the load, under normal conditions.
Maintenance Bird 4028B Series RF Power Sensors Frequency Range 4028B10M 10 – 15 MHz RF Power Range 1 kW – 25 kW * Accuracy, Fwd, Best Case ± 2.0% (2σ) Accuracy, Reflected Calculated from FWD accuracy and FWD power FWD Power RFL Accuracy = FWD Accuracy + -------------------------------10 Directivity / 10 Accuracy, VSWR Calculated from FWD and RFL power P R⎞ ⎛ P R⎞ ⎛ VSWR = ⎜ 1 + ------⎟ ⁄ ⎜ 1 – ------⎟ P P F⎠ ⎝ F⎠ ⎝ Calibration Frequencies, Typical (MHz)† 4028B10M 10.0, 13.56, 15.
Maintenance Bird 8640S Series Moduloads Frequency Range 1 kHz – 900 MHz Power Rating 25 kW continuous duty Mode CW, AM, FM, SSB, TV and certain pulse types Impedance, Nominal 50 ohms VSWR, Max 1.10:1 Cooling Method Water dielectric and forced air convection Coolant* Distilled water or distilled water/ethylene glycol mixture Coolant Capacity 9 qts. (8.
Maintenance Resistor Assembly Exploded views are used to illustrate the parts below and indicate their relation to each other. Each part in the exploded view has an item number referencing this list. Item No.
Maintenance Figure 15 Resistor Assembly Exploded View 5 6 Hose Fitting 90° 1/4-20 x 2-1/2 Socket Head Cap Screw (6) 5 Hose Fitting 90° 3 and 4 Water Chamber With O-Ring Inner Seal 10 Ground Cap Assembly 2 Outer O-Ring 17 Inner O-Ring 9 Inner Flow Tube 7 Resistor Sleeve 8 O-Ring 1 Resistor 9A Outer Flow Tube Load Housing 12 Outer Conductor Assembly 16 1/4-20 x 1-1/2 Socket Head Cap Screw (6) 11 Center Conductor Assembly 15 Resistor Fitting Seal O-Ring 1 Resistor Load Housing 31
Maintenance Replacement Parts Description 32 Qty Part Number Casters 4 4421A384 Battery, size C, NiMH 8 5A1230 Cable, IEEE-488 2m 1m 1 Cable, RS-232 10 ft. 5 ft.
Limited Warranty All products manufactured by Seller are warranted to be free from defects in material and workmanship for a period of one year, unless otherwise specified, from date of shipment and to conform to applicable specifications, drawings, blueprints and/or samples.
