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INSTRUCTION BOOK
OPERATING INSTRUCTIONS
TERMALINE®COAXIAL
LOAD RESISTOR
SERIES 8000
Electronic Corporation
Cleveland (Solon) Ohio USA
© Copyright 1997 by Bird Electronic Corporation
Instruction Book Part Number 920-8000S Rev. A
®
Termaline
and Thruline®are Registered Trademarks
of Bird Electronic Corporation
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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.
Keep Away From Live Circuits
Operating personnel must at all times observe normal safety regulations. Do
not replace components or make adjustments inside equipment with the high
voltage supply turned on. To avoid casualties, always remove power.
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.
Safety Earth Ground
An uninteruuptible 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.
Shock Hazard
Do not attempt to disconnect an RF transmission line while RF is present.
Radiated RF power is a potential health hazard.
Resuscitation
Personnel working with or near high voltages should be familiar with modern
methods of resuscitation.
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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 appears on the equipment indicating there is important information in the instruction manual regarding that particular area.
+ 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
Never attempt to disconnect RF equipment from the transmission line
while RF power is being applied. Leaking RF energy is a potential
health hazard.
WARNING
This product contains a resistor substrate made of beryllium oxide.
This is a potentially toxic ceramic and may be harmful to your health.
Beryllia oxide must be disposed of in accordance with the legal statutes
dealing with hazardous material.
Do not attempt to repair this unit, but return to BIRD ELECTRONIC
CORPORATION.
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CAUTION STATEMENT
The following equipment caution appears in the text whenever the equipment
is in danger of damage and is repeated here for emphasis.
CAUTION
Do not operate these loads continuously above their maximum power
rating. Load failure will result.
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 ELCTRICAS, NO REALICE NING¤N
SERVICIO A MENOS QUE EST 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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About This Manual
This instruction book covers the models 8080, 8085, 8163, 8164, 8166, 8173,
8431 Termaline Coaxial Load Resistor.
This instruction book is arranged so that essential information on safety is
contained in the front of the book. Reading the Safety Precautions Section before operating the equipment is strongly advised.
The remainder of this Instruction Book is divided into Chapters and Sections.
At the beginning of each chapter a general overview will be given, describing
the contents of that chapter.
Operation
First time operators should read Chapter 1 - Introduction, Chapter 2 - Theory
of Operation, and Chapter 3 - Installation, to get an overview of equipment
capabilities and how to install it. An experienced operator can refer to Chapter 4 - Operating Instructions. All instructions necessary to operate the
equipment, are contained in this section.
Maintenance
All personnel should be familiar with preventative maintenance found in
Chapter 5 - Maintenance. If a failure should occur, the troubleshooting section will aid in isolating and repairing the failure.
Parts
For location of major assemblies or parts refer to the part lists in Chapter 5.
Changes To This Manual
We have made every effort to ensure this manual is accurate at the time of
publication. If you should discover any errors., or if you have suggestions for
improving this manual, please send your comments to our factory. This manual may be periodically updated, when inquiring about updates to this manual refer to the part number and revision level on the title page.
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Table Of Contents
Safety Precautions ......................i
Warning Statements ....................ii
Caution Statements ....................iii
Safety Statements.....................iii
About This Manual ....................v
Introduction .........................1
Purpose and Function...................1
Performance Characteristics and Capabilities .........1
Dimensions and Weight ..................1
Power and Utility Requirements ...............2
Environmental Requirements ................2
Items Furnished......................2
Items Required ......................2
Tools and Test Equipment .................2
Specifications..........................3
Theory of Operation .....................5
General .........................5
Installation .........................7
General .........................7
Mounting Location .....................7
Operating Instructions ....................9
Use and Function of Controls ................9
Initial Adjustments ....................9
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Bird Model 8000 Series Termaline Coaxial Load Resistor
Start-Up .........................9
Normal Operation .....................9
Operation Under Emergency, Adverse or Abnormal Conditions . . 9
Shutdown ........................9
Emergency Shutdown ...................10
Maintenance ........................11
Cleaning ...........................11
Outside Surface .....................11
Inspection...........................11
Preventive Maintenance.....................12
RF Assembly Test .......................12
DC Resistance ......................12
Disassembly..........................12
RF Connector ......................12
Reassembly ..........................13
RF Connector ......................13
Repairs ............................13
Customer Service .....................13
Storage .........................14
Shipment ........................14
RF Connector .........................14
Replacement Parts List ..................14
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Chapter 1
Introduction
This instruction book is intended for use by operators of the
Models 8080, 8085, 8163, 8164, 8166, 8173, and 8431
Termaline Coaxial Load Resistor.
This chapter contains introductory information including
product specifications, items supplied, and accessory items
available.
Purpose and
Function
Performance
Characteristics
Capabilities
and
The Series 8000 Termaline Load Resistors are portable,
general purpose 50 ohm coaxial transmission line terminations. They are self-contained units, liquid free and air
cooled, requiring no outside power source or additional
equipment. They provide accurate, dependable, and practically nonreflective terminations for testing and adjusting
transmitters under nonradiating conditions. These loads are
useful for the following purposes:
s As a substitute antenna.
s For tuning RF transmitters under
nonradiating conditions.
s For making routine tests and adjustments.
s
As a substitute for any circuit loading element.
s
To measure, with a suitable indicating device,
the power output of any coaxially transmitted
RF signal within their rating.
Series 8000 dry loads can absorb their individual maximum
rated RF power levels continuously and dissipate them
harmlessly as heat over their entire frequency range. Because they are dry, they are attitude insensitive and can
therefore, with some restrictions, be used in any position.
Consult the Specification Sheet, Page 3, for a listing of their
individual power ratings, frequency ranges, and VSWR values.
Dimensions
and Weight
Consult the Specifications on Page 3 for the size and weight
of each load.
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Bird Model 8000 Series Termaline Coaxial Load Resistor
Power and
Requirements
Environmental
Requirements
Utility
These loads are passive devices that are self contained and
do not require any external source of power or utility to
function other than the RF input power.
These loads should be operated in a dust and vibration-free
environment. The ambient temperature range should remain between -40°C and +45°C (-40°F and +113°F) for
proper operation. Allow at least six inches of clearance
around the units to permit an unimpeded access of convection air currents for adequate heat dissipation.
Items
Furnished
Series 8000 Loads are normally equipped with a
Quick-Change “QC” connector for convenient and easy interchange with other AN type “QC” connectors. Model 8431 has
a Small Quick-Change “SQC” connector which is not interchangeable with “QC” types. Consult the Specification
Sheet, Page 3, for the connector type normally supplied with
each load.
Items Required The only other item required is a mating connector on the
coaxial transmission line to which the load will be connected.
Tools and Test
Equipment
Only a screwdriver will be necessary for changing the “QC”
connectors. None of these loads are subject to any further
disassembly. An ohmmeter or resistance bridge with an accuracy of one percent or better at 50 ohms is useful for
checking the resistance value of the RF section assembly.
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Introduction
Specifications
Impedance 50 ohms nominal
Ambient Temperature -40°C to +45°C
(-40°F to +113°F)
Cooling Method Convection air currents
Operating Position Any ††
MODEL
8080 1.1 dc-1000
1.25 1000-3500
8085 1.1 dc-1000 N-M† 50 dc-3500 5-9/64"L x 1-3/4"sq 15
8163 (Similar to Model 8164, see Installation, Chapter 2)
8164 1.1 dc-1000
1.2 1000-2500
8166 1.1 dc-1000
1.2 1000-2500
8173 1.1 dc-1000
1.25 1000-2000
8431 1.1 dc-1000 N-F* 500/600 dc-2500 13-7/64"L x 7-1/8"H
CONNS.
N-M† 25 dc-3500 5-9/64"L x 1-1/4"sq
N-F† 100 dc-2400 6-63/64"L x
N-M† 150 dc-2500 7-31/64"L x 4"sq
N-F† 300 dc-2000 9"L x 9-9/16"H x
MAX. VSWR
MAX.
WATTS
FREQ.
MHz
SIZE
(130.6 x 31.8 mm)
2-3/4"sq
(177.4 x 69.9 mm)
(190 x 101.6 mm)
5-1/8"W
(228.6 x 242.9 x
130.2 mm)
x 9-1/4"W
(333 x 181 x 235
mm)
WT. OZ.
(225g)
(425g)
(1.36 kg)
(1.36 kg)
(2.84 kg)
(5.9 kg)
9
48
96
100
206
†“QC” Connector
* “SQC” Connector
†† See Text
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Bird Model 8000 Series Termaline Coaxial Load Resistor
4-1/4
(108mm)
Male N "QC" Connector
Model 8085 Outline Drawing
Figure 1
57/64
(23mm)
COAXIAL RESISTOR
CORP.
1-3/4
(44mm)
Square
ELECTRONIC
4
4240-063
BIRD
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Chapter 2
Theory of Operation
General The resistive element, in these dry Termaline Loads, is indi-
vidually selected for its accuracy, and enclosed in a heat
sink housing. The housing is specially contoured inside to
provide the load with its unusually low reflection characteristics throughout its entire frequency range. The housings
for the 25, 50, 100, and 150 Watt models are deeply slotted
and painted black with a lusterless finish to improve their
heat dissipation. Models 8173 and 8431 are fabricated with
sheet metal fins to more efficiently meet their higher heat
dissipation requirements.
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Bird Model 8000 Series Termaline Coaxial Load Resistor
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Chapter 3
Installation
General These loads may be used for portable operation or fixed in-
stallation. The Models 8080, 8085 and 8164 are, in general,
light enough to be attached directly to the mating RF connector of another device such as a Bird Thruline Wattmeter
or simply set on the workbench like the Models 8166, 8173,
and 8431. Attach the load resistor as close as possible to the
transmitter’s output and use only suitable connectors. Try
to connect direct to minimize cable length and avoid the use
of adapters as much as possible. The Model 8166, because of
its weight, has a provision for special mounting. The housing has four tapped mounting holes on one side. They are
1/2 inch (13 mm) deep for 8-32 screws and arranged in a
6-3/8 x 1-3/4 inch (162 x 44.4 mm) rectangle. The Model
8431, mounted horizontally, will dissipate up to 500 Watts,
and mounted vertically, up to 600 Watts. Model 8173 should
be operated only in a horizontal position.
The Model 8163 Termaline Load Resistor is identical to the
Model 8164 load electrically and physically except for
mounting holes. The Model 8163 load resistor has four
mounting holes with Heli-Coil stainless steel inserts to accommodate 8-32 mounting screws. These mounting holes
are located two on the lower front face of the unit and two
on the lower rear face.
Mounting
Location
Allow at least six inches of clearance around these units to
permit an unimpeded access of natural convection of air for
adequate heat dissipation. Place the loads to permit the
shortest possible cable length between the unit and the
transmitting equipment.
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Bird Model 8000 Series Termaline Coaxial Load Resistor
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Chapter 4
Operating Instructions
Use and
Function of
Controls
Initial
Adjustments
These loads, being passive devices, have no indicators or operating controls.
No initial adjustments are required other than to connect
the load to the RF source by means of a coaxial cable
equipped with a suitable matching connector plug.
Start-Up Connect these loads to the transmitting equipment under
test with 50 ohm coaxial cable where necessary (RG-8A/U,
RG-9/U, RG-213/U or equal) equipped with a suitable plug
which mates with the RF input connector of the load. After
the load has been connected to the transmitter, proceed according to the transmitter manufacturer’s instructions.
When reconnecting the antenna, it may be necessary to
slightly readjust the transmitter due to possible differences
in VSWR between the load and the antenna system.
Normal
Operation
CAUTION
Do not operate these loads continuously above their
maximum power rating. Load failure will result.
Having no indicators or operating controls, these loads require no special operating procedures or surveillance when
the stated performance limits are not exceeded.
Operation
Under
Emergency,
Adverse or
Abnormal
Conditions
These units will sustain an input moderately greater than
their maximum rated power for short periods of time. Such
loading must be spaced at reasonable intervals to allow sufficient time for cooling to a safe temperature. Apply the excessive power for a few minutes at most and allow at least a
half hour for adequate cooling before reapplying power. Because of the excessive heat generated by overloading, touch
the load with caution to avoid painful burns.
Shutdown These loads, being passive devices, have no operating con-
trols to be turned off. Their source of RF power must be
turned off instead.
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Bird Model 8000 Series Termaline Coaxial Load Resistor
Emergency
Shutdown
WARNING
Never attempt to disconnect RF equipment from the
transmission line while RF power is being applied.
Leaking RF energy is a potential health hazard.
Turn off the RF power at its source.
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Troubleshooting
Table 1
Chapter 5
Maintenance
For corrections requiring repair or replacement of components, refer to the appropriate section for your specific
model.
PROBLEM POSSIBLE CAUSE REMEDY
Excessive overheating
High or low dc resistance values
Cleaning
Transmitter power
too high
Faulty RF resistor Return to factory
Faulty RF input
“QC” connector
Loose “QC” connector
Faulty RF resistor Return to factory
Reduce transmitter
power.
for repair.
Replace.
Tighten with
screwdriver.
for repair.
Outside
Surface
The outside surface of these loads should be wiped free of
dust and dirt when necessary. The principle maintenance
required by the operator will be to periodically wipe the accumulated dust and lint off of the radiator fins. Excessive
collection of dust and lint on the cooling fins will interfere
with efficient dissipation of heat. If the Teflon insulator or
metallic contact surfaces of the connector should become
dirty or grimy, wipe them off with a soft cloth. Use a contact
cleaner that is self-drying and leaves no residue to clean the
hard to reach internal portions.
Inspection
With the rugged and simple construction of the loads, periodic inspection will be necessary at only about six-month intervals. Inspection should include the items listed below:
a. Cleanliness - Keep the housing and
connector free of grime.
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Bird Model 8000 Series Termaline Coaxial Load Resistor
b. Inspect the load for completeness and
general condition of the equipment.
c. A Troubleshooting Chart lists the com-
monly encountered problems, their
possible causes and remedies. Use this
chart as a guide when analyzing
symptoms.
Preventive Maintenance
Due to the basic simplicity of construction, the major requirement for preventive maintenance is to keep the equipment clean, particularly the radiator fins. It is important to
maintain the heat transfer efficiency of the cooling fins.
RF Assembly Test
DC Resistance Check the condition of these load resistors by accurate mea-
surement of the dc resistance between the inner and outer
conductors of the RF input connector. Use a resistance
bridge or ohmmeter with an accuracy of one percent or
better at 50 ohms for this purpose. The measured resistance
should be a nominal 50 ohms. For greater accuracy the resistance of the load should be carefully checked prior to use
at ambient room temperature. This resistance value should
be recorded and used as a reference. Subsequent resistance
measurements should not deviate more than two percent
from this value.
Disassembly
Except for the “QC” connector, “SQC” on Model 8431, there
is no disassembly possible with these loads. To change the
connector use the following procedure.
RF Connector The connector is a “QC” design which permits easy inter-
change with the use of only a screwdriver. This process does
not interfere with the essential coaxial continuity of the load
resistor RF input. For replacement, proceed as follows:
a. Remove the four 8-32 x 5/16 inch pan
head machine screws from the corners
of the RF connector.
b. Pull the connector straight out of its
socket.
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Maintenance
Reassembly
RF Connector To install a new connector, reverse the procedures in para-
graph RF Connector, Disassembly. Be sure that the projecting center pin on the connector is carefully engaged and
properly seated with the mating socket of the load resistor
input.
Repairs
WARNING
This product contains a resistor substrate made of
beryllium oxide. This is a potentially toxic ceramic and
may be harmful to your health. Beryllia oxide must be
disposed of in accordance with the legal statutes
dealing with hazardous material.
Do not attempt to repair this unit, but return to BIRD
ELECTRONIC CORPORATION.
Due to the unitized nature of the construction, these loads
are not field repairable other than replacement of the “QC”
connector.
Customer
Service
Repairs beyond what is covered in this instruction book will
require return of the equipment to Bird Electronic Corporation for service. Please consult the factory.
Any maintenance or service procedure beyond scope of those
provided in this section should be referred to a qualified service center. Bird Electronic Corporation maintains complete
repair and calibration facilities at the following addresses:
Service Group
U.S.A. Sales and Manufacturing
Bird Electronic Corporation
30303 Aurora Road
Cleveland (Solon), Ohio 44139-2794
Phone: (440) 248-1200
Fax: (440) 248-5426
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Bird Model 8000 Series Termaline Coaxial Load Resistor
Sales Offices
For the location of the sales office nearest you, give us a call
or visit our Web site at
http://www.bird-electronic.com
Storage No special preparations for storage are necessary other than
to cover the equipment to keep out dust and dirt. Store
these units in a dry and dust-free environment where the
ambient temperature will remain within the -40°C to +45°C
(-40°F to +113°F) working range of the loads.
Shipment
RF Connector
Wrap the RF connector with padding and tape securely in
place. Pack and brace the load in a suitable shipping container; a corrugated paper box should suffice.
Replacement Parts List
Models 8080, 8085, 8164, 8166, and 8173 use “QC” connectors only.
Available QC Type Connectors
N-Female 4240-062 LT-Female 4240-018
N-Male 4240-063 LT-Male 4240-012
HN-Female 4240-268 C-Female 4240-100
HN-Male 4240-278 C-Male 4240-110
LC-Female 4240-031 UHF-Female 4240-050
LC-Male 4240-025 UHF-Male 4240-179
7/8" EIA Air Line 4240-002
Model 8431 uses “SQC” small connectors only.
N-Female 4100-014
M-Male 4100-015
UHF-Female 4100-017
UHF-Male 4100-021
C-Female 4100-045
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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 specifications, 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; no allowance shall be made
for any labor charges of Buyer for replacement of parts, adjustment or repairs, or any other work, unless such charges are authorized in advance by
Seller.
If Seller’s products are claimed to be defective in material or workmanship or
not to conform to specifications, drawings, blueprints and/or samples, Seller
shall, upon prompt notice thereof, either examine the products where they
are located or issue shipping instructions for return to Seller (transportation-charges prepaid by Buyer). In the event any of our products are proved
to be other than as warranted, transportation costs (cheapest way) to and
from Seller’s plant, will be borne by Seller and reimbursement or credit will
be made for amounts so expended by Buyer. Every such claim for breach of
these warranties shall be deemed to be waived by Buyer unless made in writing within ten (10) 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 alterations outside of our plant, and shall not apply to any goods or parts thereof
furnished by Buyer or acquired from others at Buyer’s request and/or to
Buyer’s specifications. In addition, Seller’s warranties do not extend to the
failure of tubes, transistors, fuses and batteries, or to other equipment and
parts manufactured by others except to the extent of the original manufacturer’s warranty to Seller.
The obligations under the foregoing warranties are limited to the precise
terms thereof. These warranties provide exclusive remedies, expressly in lieu
of all other remedies including claims for special or consequential damages.
SELLER NEITHER MAKES NOR ASSUMES ANY OTHER WARRANTY
WHATSOEVER, WHETHER EXPRESS, STATUTORY, OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY AND FITNESS, AND
NO PERSON IS AUTHORIZED TO ASSUME FOR SELLER ANY OBLIGATION OR LIABILITY NOT STRICTLY IN ACCORDANCE WITH THE
FOREGOING.
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DECLARATION OF CONFORMITY
Manufacturer: Bird Electronic Corporation
Product: Termaline RF Coaxial Load Resistors
The undersigned hereby declares, on behalf of Bird Electronic Corporation of
Cleveland, Ohio, that the above-referenced product, to which this declaration relates, is
in conformity with the provisions of the following standards;
1. European Safety Standard EN 61010-1:1993 - Safety, Group II.
This standard is in accordance with Council Directive 73/23/EEC and 93/68/EEC.
The technical documentation file required by this directive is maintained at the corporate
headquarters of Bird Electronic Corporation, 30303 Aurora Road, Cleveland, Ohio.
30303 Aurora Road
Cleveland, Ohio 44139-2794
Models: 8065 8431 8085
8166 8431-020 8085A020
8173 8431-030
8173-030 8164
Ken DeVore
QA/Metrology Manager
Bird Electronic Corporation
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