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 general safety precautions. 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.
Shock Hazard
Do not attempt to disconnect an RF transmission or any other high voltage
line while power is present. Radiated RF power is a potential health hazard.
Resuscitation
Personnel working with or near high voltage should be familiar with modern
methods of resuscitation.
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.
i
Page 4
Warning Statements
The following safety warnings will appear in the text and are repeated here
for emphasis.
WARNING
When power is in the upper range of the load’s capacity, the radiator
will become hot - care should be used in touching the equipment.
WARNING
Do not attempt to disconnect these loads from the coaxial cable while
RF energy is still being applied. Leaking RF power is a potential
health hazard.
Caution Statements
The following equipment cautions appear in the text and are repeated here
for emphasis.
CAUTION
The load is designed for operation in a horizontal plane only, with
mounting brackets down. Do not operate in any other position.
CAUTION
Do not operate this equipment continuously above the rated 600 W.
Load failure will result.
Safety Statements
ii
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.
Page 5
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.
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.
iii
Page 6
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.
iv
Page 7
About this Manual
This instruction book covers the Models 8401, 8402, and 8404 Termaline
Load Resistors.
This instruction book is arranged so that essential information on safety is
contained in the front of the book. Reading the Safety Precaution section before operating the equipment is strongly advised.
The remainder of this Instruction Book is divided into chapters and sections.
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 chapter.
Maintenance
All personnel should be familiar with calibration and repair information
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 and associated
drawings in Chapter 5.
Changes To This Manual
We have made every effort to ensure this manual is accurate. 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.
v
Page 8
Bird Series 8400S Termaline Coaxial Load Resistor
vi
Page 9
Table Of Contents
Safety Precautions. .......................i
Warning Statements. ....................ii
Cautions Statements. ....................ii
Safety Statements .....................ii
About This Manual .....................v
Introduction. ..........................1
Purpose and Function. ...................1
Description. ........................1
Performance Characteristics and Capabilities. ..........1
Dimensions and Weight. ...................2
Power and Utility Requirements. ...............2
Environmental Requirements. .................2
Items Supplied. ......................2
Items Required. ......................2
Tools and Test Equipment...................2
Specifications. .......................3
Theory of Operation. ......................5
General. .........................5
Cooling. .........................5
Installation. ..........................7
Location. .........................7
Mounting. .........................7
Operating Instructions. .....................9
Use and Function of Controls. ................9
vii
Page 10
Initial Adjustments. .....................9
Start-up. .........................9
Normal Operation. .....................9
Operating Under Emergency, Adverse, or Abnormal Conditions....9
Shutdown. ........................10
Emergency Shutdown. ...................10
Maintenance. .........................11
Cleaning. ........................11
Inspection. ........................12
Preventive Maintenance. ..................12
DC Resistance. ......................12
Disassembly...........................13
RF Connector Replacement..................13
Diaphragm and Coolant Oil. .................13
RF Load Resistor Assembly. ................13
Assembly. ...........................14
RF Connector. ......................14
Diaphragm and Coolant Oil. .................14
RF Load Resistor Assembly. ................14
Repairs.............................14
Preparation For Shipment. .................15
Storage. .........................15
Customer Service. .......................15
Sales /Repair Facilities....................15
Sales Offices........................15
Replacement Parts List. .....................16
viii
Page 11
Chapter 1
Introduction
This publication refers to the Termaline Load Resistors
Models 8401, 8402, and 8404. The difference between
models is listed in the specifications. These models will
generally be referred to as a load throughout this manual.
Purpose and
Function
These loads are portable, general purpose 50 ohm coaxial
RF transmission line terminations. They are selfcontained units requiring no outside power source or additional equipment. They provide an accurate, dependable,
and practically nonreflective termination for testing and
adjusting RF transmitters operating in the stated frequency band.
Some examples of the uses of these loads are:
As a substitute antenna.
s
s For tuning RF transmitters - under nonradiat-
ing conditions.
s
For making routine tests and adjustments.
s As a substitute for any 50 ohm circuit loading
element.
Description These models are rectangular in shape with transverse
fins encasing an oil-dielectric-filled coolant cylinder. Extra
thick fins at the front and rear are bent 90° to form bottom mounting flanges. These flanges are supports for free
standing use or brackets for fixed mounting. Flange holes
are provided for this purpose. A retractable handle is recessed in the radiator fins.
Performance
Characteristics
and Capabilities
The loads can absorb and dissipate up to 600 W of RF
power continuously. They show a VSWR of 1.1 to 1.0
from dc to 1000 MHz, 1.2 to 1.0 from 1000-2800 MHz,
and 1.3 to 1.0 from 2800-3000 MHz.
Dimensions and
Power and Utility
Weight
Requirements
All three models have the same dimensions: 16-1/16
inches L x 5-15/16 inches W x 8-1/2 inches H (408 x 151
x 216 mm). They each have a net weight of 19.6 lb (8.9
kg) and a shipping weight of approximately 25 lb (11.34
kg).
These load resistors are passive devices that are self contained and do not require a source of power or utility
1
Page 12
Bird Series 8400S Termaline Coaxial Load Resistor
service to perform their function, other than the RF input
power.
Environmental
Requirements
The load should be operated in an environment as free of
dust and vibration as possible. For proper operation the
ambient temperature should remain within the range of
-40°C to +45°C (-40°F to +113°F). Allow at least 12
inches (304.8 mm) of clear space around the load to provide an unimpeded flow of convection air currents for
adequate heat dissipation.
Items Supplied The load is equipped with:
Model 8401 — Female N “QC” (quick change)
s
connector.
Model 8402 — Female C “QC” (quick change)
s
connector with a dust cap and secured by a
ball chain anchor.
Model 8404 — Female N with a Male N/Male
s
N adaptor, dust cap, and secured by a ball
chain anchor.
Instruction Manual
s
Item Required Coaxial cable with the appropriate connector plug.
Tools and Test
Equipment
s Screwdriver — for disassembly of this equip-
ment.
s
An ohmmeter with an accuracy of 1 percent or
better at 50 ohms — is recommended for
checking the resistance value of the resistor.
2
Page 13
Specifications
Impedance:50 ohms nominal
VSWR:
dc-1000MHz
1000-2800MHz
2800-3000MHz
Connectors:
Model 8401
Model 8402
1.1:1.0 Maximum
1.2:1.0 Maximum
1.3:1.0 Maximum
Female N “QC” type normally supplied
Female C “QC” type with dust cap normally supplied
Introduction
Model 8404
Power Range600 W continuous
Frequency Rangedc-3000 MHz
Dimensions16-1/16"L x 5-15/16" W x 8-1/2"H
Ambient Temperature-40°C to +45°C (-40°F to +113°F)
Coolant MethodOil dielectric and air convention currents
Weight19.6 lb (9 kg)
Operating PositionHorizontal only
FinishGrey Powder Coat
Same as 8401 plus UG-57G/U N(M) to
N(M) adapter and dust cap
(408 x 151 x 216 mm)
3
Page 14
Bird Series 8400S Termaline Coaxial Load Resistor
4
Page 15
Chapter 2
Theory of Operation
General The Models 8401, 8402, and 8404 Termaline Load Resis-
tors consist essentially of a carbon film-on-ceramic resistor immersed in a dielectric coolant. The resistor,
individually selected for its accuracy, is enclosed in a special exponentially tapered housing. This provides a linear
reduction in surge impedance directly proportional to the
distance along the resistor. When surrounded by the dielectric coolant, the characteristic impedance is therefore
50 ohms at the front (connector end), 25 ohms at the
mid-point to compensate for the resistance already passed
over, and zero ohms at the rear where the resistor joins
the housing, forming the return conductor of the coaxial
circuit. This produces a uniform and practically reflectionless line termination over the stated frequencies for the
load resistor.
Cooling The dielectric coolant is chosen for its desirable dielectric
and thermal characteristics. Cooling of the load is accomplished by natural fluid and air convection currents. The
0.7 gallon of dielectric coolant carries the electrically generated heat from the resistor to the walls of the cylindrical cooling tank. This tank is encased in a set of
radiating fins constructed from heavy gauge aluminum alloy and firmly pressed onto the cylinder. The heat from
the dielectric fluid is transferred to the surrounding air
by the fins.
Expansion of the coolant, caused by the rise in its temperature, is allowed by means of a synthetic rubber diaphragm (not visible) inside the rear cover dome of the
unit.
5
Page 16
Bird Series 8400S Termaline Coaxial Load Resistor
6
Page 17
Chapter 3
Installation
Location
CAUTION
The load is designed for operation in a horizontal plane
only, with mounting brackets down. Do not operate in
any other position.
Install the Termaline Load Resistor in a location that:
1. Has sufficient room to provide at least twelve
inches (304.8 mm) of free space around and
above the unit.
2. Is the shortest possible distance, or cable length
from the transmitting equipment.
3. Ensures the operation of the load in a horizontal
position only, with the handle on top.
Mounting The load may be used for portable operation or for fixed
installation, that is, it may stand free or may be secured
to a bench or any convenient flat surface. The front and
rear fins are made of heavier gauge material bent outward 90 degrees to form mounting flanges. At each corner of these flanges is a rubber bumper foot attached
with an acorn nut. To fasten the load by means of its
base mounting flanges:
1. Remove the four rubber bumpers
2. Fasten the load with four screws. Put one screw
in each of the four 9/32 inch holes.
Note: Use screws up to 1/4 inch diameter.
The holes are arranged in a 5-1/8 x 12-17/32 inch rectangle (130.2 x 318.3 mm).
7
Page 18
Bird Series 8400S Termaline Coaxial Load Resistor
8
Page 19
Chapter 4
Operating Instructions
Use and
Function of
Controls
Adjustments
Because these are passive devices, there are no operating
controls on the Load Resistors.
Initial
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-up1. Connect a Male type plug, which mates with the
RF input connector, to the load.
2. Connect the load to the transmitting equipment
under test with 50 ohm coaxial cable.
3. After the transmitter has been connected to the
load, 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
WARNING
When power is in the upper range of the load’s
capacity, the radiator will become hot - care should be
used in touching the equipment.
Operating Under
Emergency,
Adverse, or
Abnormal
Conditions
Having no indicators or controls, these loads require no
special operating procedures or surveillance when properly used.
CAUTION
Do not operate this equipment continuously above the
rated 600 W. Load failure will result.
9
Page 20
Bird Series 8400S Termaline Coaxial Load Resistor
Shutdown Because the loads are passive devices, there is no way to
turn them off. Power must be shut off at the source of
the RF energy.
Emergency
Shutdown
WARNING
Do not attempt to disconnect these loads from the
coaxial cable while RF energy is still being applied.
Leaking RF power is a potential health hazard.
Turn off the RF power at the source.
10
Page 21
Chapter 5
This chapter contains operator maintenance instructions,
troubleshooting, and parts information.
Troubleshooting
ProblemPossible CauseRemedy
Leakage of coolant oil
around band or radiator
housing.
Overheating of the radiator.
High or low dc resistance values.
Maintenance
Clamping band not
tight.
Faulty O-Ring (front).Replace per the RF
Faulty diaphragm (rear). Replace per the Dia-
Transmitter power is
too high.
Coolant level is too low. Add more coolant per
Faulty RF section.Replace the RF section
Faulty RF input connector.
Loose RF input connector.
Faulty RF section assembly.
Tighten clamping band
with a screwdriver.
Load Resistor paragraph.
phragm and Coolant Oil
paragraph.
Reduce the transmitter
power.
the Diaphragm and
Coolant Oil paragraph.
per the RF Load Assembly paragraph.
Replace per the RF
connector replacement
paragraph.
Tighten the connector
with a screwdriver.
Replace the RF section
per the RF Load Assembly paragraph.
Cleaning
The principle maintenance required by the operator will
be the cleaning of the radiator fins. Periodically wipe
away the accumulated dust and lint. If the insulator or
metallic contact surfaces of the connector should become
dirty or grimy, wipe them off with a soft cloth and use a
contact cleaner that is self drying and leaves no residue
to clean the inaccessible internal parts.
11
Page 22
Bird Series 8400S Termaline Coaxial Load Resistor
Inspection With the rugged and simple construction of the Load Re-
sistors, periodic inspection will be necessary at only about
six-month intervals. Inspection should include the items
listed below:
1. Oil Leakage - Check for coolant oil seepage
around the radiator tank, particularly at the
front and back around the underside of the
clamping band.
2. Inspect the Load for completeness and general
condition of the equipment.
The Troubleshooting Chart lists the symptoms of commonly encountered troubles, their causes, and suggested
corrective measures. Use this chart as a guide when analyzing symptoms.
Preventive
Maintenance
Because of the basic simplicity of construction, no special
maintenance procedures are required. Keep the equipment clean, and occasionally check the coolant level in
the radiator tank.
DC Resistance Check the condition of the load resistor by accurate meas-
urement of the dc resistance between the inner and outer
conductors of the RF connector. Use an ohmmeter with
an accuracy of 1 percent or better at 50 ohms for this
purpose. The measured resistance should be a nominal 50
ohms, ±2 ohms. Perform this test only when the load has
cooled down to room temperature. Refer to figure 1.
Figure 1
DC
Resistance
Measurement
50.0
12
Page 23
Maintenance
Disassembly
There are no special techniques required for the repair or
replacement of components in the loads. A screwdriver is
the only tool needed.
RF Connector
Replacement
Diaphragm and
Coolant Oil
The connector is a patented “Quick Change” design.
This process does not interfere with the essential coaxial
continuity of the load resistor RF input or the coolant oil
seal.
For replacement, proceed as follows:
1. Remove the four 8-32 x 5/16 inch round head
machine screws from the corners of the RF connector.
2. Pull the connector straight out of its socket.
Remove the diaphragm to replace or examine the coolant
oil. Replacement of the diaphragm and coolant are listed
in the steps below:
1. Stand the load vertically, with the back end up.
Brace it carefully to avoid tipping it over.
2. Loosen the clamp screw until the clamping band
is released.
3. Remove the diaphragm cover and lift the diaphragm from the back end of the radiator tank.
Inspect the diaphragm. It should be soft and pliable. If it has hardened or shows signs of surface
cracks, replace it.
RF Load
Resistor
Assembly
4. The coolant oil level should be about one inch below the top of the radiator cylinder. If the oil appears to be contaminated; i.e., it doesn’t have a
clear light yellow color, replace it.
To replace the load resistor assembly, it is not necessary
to drain the unit of coolant oil. Proceed with the steps below:
1. Stand the load vertically, with the front end up.
2. Loosen the clamp screw until the clamping band
is released.
3. Hold the load assembly by the RF connector and
pull the assembly slowly out of the radiator al-
13
Page 24
Bird Series 8400S Termaline Coaxial Load Resistor
lowing coolant excess to drip back into the radiator.
4. Inspect the O-Ring seal which is located just inside the mounting flange of the resistor assembly.
Do not reuse the O-Ring if it is not soft and pliable or if it shows signs of surface cracks.
Assembly
RF Connector Before pushing the RF connector in, be sure that the pro-
jecting center contact pin on the connector is carefully engaged and properly seated in the mating socket of the
load resistor input.
Install the four 8-32 x 5/16 inch round head machine
screws into the corners of the RF connector.
Diaphragm and
Coolant Oil
RF Load
Resistor
Assembly
To assemble, follow the instructions below.
1. Fill the unit with coolant until the level is about
one inch (25.4 mm) below the top of the radiator
cylinder.
2. Install the diaphragm and place the diaphragm
cover on the back end of the radiator tank.
3. Install and tighten the clamping band screw.
4. Check for leaks. Pay particularly close attention
to the area around the clamping band.
To replace the assembly:
1. Hold the load assembly by the RF connector and
slowly lower the assembly into the radiator
2. Place the clamp band on and tighten the clamp
screw until the clamping band is tight.
3. Place the unit on its flanges, in a horizontal position.
4. Check for leaks. Pay particularly close attention
to the area around the clamping band.
14
Page 25
Maintenance
REPAIRS
Any maintenance or service procedure beyond the scope
of those provided in this chapter should be referred to a
qualified service center.
Preparation For
Shipment
Wrap and tape the RF connector to keep out foreign material, then pack and brace the load in a suitable container. A sturdy corrugated paper box is recommended.
Storage No special preparations are needed for storage other than
to cover the equipment to keep out dust and dirt. Store
the unit in a clean dry environment where the ambient
temperature will remain within the approximate working
range of the instrument -40°C to +45°C (-40°F to +113°F).
Customer Service
Sales /Repair
Facilities
Sales Offices For the Sales Office nearest you, call Bird Electronic Cor-
U.S.A Sales and Manufacturing
Service Group
Bird Electronic Corporation
30303 Aurora Rd
Cleveland (Solon), Ohio 44139-2794
Phone: (440) 248-1200
Fax: (440) 248-5426
poration at the telephone number above, or visit our Web
site at:
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.
17
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