Bird Technologies 8750 User Manual

INSTRUCTION BOOK
TERMALINE® LOAD RESISTOR
SERIES 8755/8756
Bird® Electronic Corporation 30303 Aurora Road Cleveland (Solon), Ohio 44139
Sales email: sales@bird-technologies.com
Technical Support email: atechapp@bird-technologies.com
866-695-4569 toll free
©Copyright 2010 by Bird Electronic Corporation
Instruction Book Part Number 920-8755/56 Rev. C
Termaline
of Bird Electronic Corporation
®
is a Registered Trademark
I am not blank

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 publica tion. 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. Do not replace components or make adjustments to the inside of the test equipment with
the high voltage supply turned on. To avoid casualties, always remove power.
WARNING
Shock Hazard
Do not attempt 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 uniterruptible 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.
-
WARNING
Resuscitation
Personnel working with or near high voltages should be familiar with modern
methods of resuscitation.
WARNING
Remove Power
Observe general safety precautions. Do not open the instrument with the power on.

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.
Note: Calls attention to supplemental information.
i
This symbol indicates that a shock hazard exists if the precau­tions in the instruction manual are not followed.
The caution symbol appears on the equipment indicating there is important information in the instruction manual regarding that particular area.
This symbol indicates that the unit radiates heat and should not be touched while hot.
This symbol appears on the equipment and indicates the requirement for separate collection of discarded electrical and electronic equipment in accordance with the European Union Directive 2002/96/EC.

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 the equipment from the transmission line while RF
power is being applied. Leaking RF energy is a potential health hazard.
On page 7 and 9.
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 page 10.
WARNING
The resistor used in this load consists of a resistive film on a special substrate.
If the substrate is broken, there will probably be sharp pieces or splinters
inside the load housing. Caution should be exercised to avoid possible injury.
On page 14.

Caution Statements

The following equipment cautions appear in the text and are repeated here for emphasis.
CAUTION
DO NOT disconnect the water flow switch leads from the control assembly. Any
operation of the load without a properly functioning cooling system will cause
almost immediate destruction of the resistor element.
On page 7.
ii

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.
iii
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.
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
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.
v

About This Manual

This manual covers the operating and maintenance instructions for the following models
8755 8756

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. This manual may be periodically updated. When inquiring about updates to this manual refer to the part number and revi sion on the title page.

Literature Contents

Introduction Describes the features of the load resistor, lists equipment sup-
plied and optional equipment, and provides power-up instructions.
Theory of Operation Describes how the load resistor works. Installation Describes the power supply and load connection instructions. Operating Instructions Describes the base level operation instructions. Maintenance Lists routine maintenance tasks as well as troubleshooting for
common problems. Specifications and parts information are also included.
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vi

Table of Contents

Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Warning Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Caution Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Safety Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Changes to this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Literature Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Chapter 1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Purpose and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Direct Power Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Chapter 2 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Heat Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cooling Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Flow Interlock Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Chapter 3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Load Resistor Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Water Line Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cooling Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Flow Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Control Box (Optional Item) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pre-Operational Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Chapter 4 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operation as a Load Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operating as an RF Wattmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Shutting Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chapter 5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Outside Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
RF Load Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Measuring the DC Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Replacing a Resistive Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removing the Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Inspecting the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Replacing the Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Replacing Fractured Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installing a Replacement Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Removing the Front Connector Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Replacing the Water Flow Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Replacing Time Delay Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Replacing the Pilot Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
vii
Additional Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Front Connector Parts Assigned Per Model Type: . . . . . . . . . . . . . . . . . . . 20
Model 8745 - 3-1/8" EIA Connector 50 ohms . . . . . . . . . . . . . . . . . . . . . . 20
Model 8746 - 3-1/8" Unflanged Connector
Flush Center Conductor 50 ohms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
For Both Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Control and Water Flow Parts - not shown on Figures . . . . . . . . . . . . . . 21
Accessory Connector Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Model 8745 Coupling Kit - 3-1/8. Unflanged Connector
Flush - 50 ohms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
viii

Chapter 1 Introduction

The Model 8755/56 Termaline Load Resistor is designed as a compact, low­reflection, and non-radiating termination for RF transmission lines. Cooled by internal water flow, it generates almost no surface heat, mC-aking installation space minimal and convenient. The load can safely dissipate up to 20 kilowatts of continuous power when used in a 50 ohm coaxial transmission line system.

Purpose and Function

Each model uses a 3-1/8 inch connector (refer to the Specifications for individ­ual models) and will maintain a VSWR of less than 1.1 to 1.0 from 1000 Hz up to 900 MHz. This load is intended for us-e on CW, AM, FM, SSB, and TV mod ulation envelopes, and within certain limitation on radar or pulse modes. Information on applications involving pulse-type signals should be obtained directly from Bird Electronic Corporation.
The Model 8755 and 8756 equipment consists of:
z Load resistor z Instruction Manual
Note: Refer to Figure 1 on page 10 for identification of the load.
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Optional Equipment

An accessory protective Control System is available as optional equipment. When properly installed, this system protects the load by shutting off the RF power when water flow is too low or interrupted. Discussions of the flow con trol pertaining to Installation and Maintenance should be ignored when not applicable. The Models 8755 and 8756 Termaline Load Resistor has the fea ture of field replacement of the resistor, described in Chapter 5, Maintenance.

Direct Power Measurement

When used in conjunction with a Bird Model 4600A or 4805A Thruline Watt­meter, these load resistors may be used for direct reading power measure­ments up to 30 kilowatts.
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1
Introduction
2

Chapter 2 Theory of Operation

General

This load resistor utilizes an external water supply for the direct cooling of the resistor element. By using this technique, the need for an intermediate dielec tric fluid to transfer the heat generated in the resistor element has been elim­inated, reducing the physical size of the load to a virtual minimum. This simplified system allows the use of the loads in more varied environments, and attachment in any orientation.

Heat Transfer

The 50 ohm resistor consists of a high temperature substrate tube with a deposited resistive film. The heat generated by absorption of RF power is transferred from the heated film to the water flowing over it, through a restricted chamber surrounding the resistor body. This water, first diverted to the front of the load resistor by a special inside tube, passes over the entire length of the resistor and is discharged through the sealed water chamber at the rear. The dielectric characteristics and distinctive design of these enclo sures provide a very accurate 50 ohm termination over the specified frequency range of this load (1000 Hz to 900 MHz).
The absence of intermediate cooling fluids considerably simplifies the con­struction and sealing of this unit. It can be readily disassembled in the field for resistor element replacement (
see “Maintenance” on page 9).
Because there is practically no heat transfer to the outer housing of the load, the housing remains at a cool ambient temperature even under full power con ditions. Virtually all of the power input to the load is transformed into heat which is carried away by the cooling water. Therefore, the differential in out put and input temperatures of the water, times the amount of flow, consti­tutes an accurate gage of the power consumed by the load. The amount of this power dissipation may be calculated from the following formula:
-
-
-
-
where:
GPM WaterFlowInGallonsPerMinute=
In °F the formula is:
where:
GPM WaterFlowInGallonsPerMinute=
P 0.263 T
P PowerInKilowatts=
T
OutletWaterTemperatureInCelcius=
1
T2InletWaterTemperatureInCelcius=
P 0.146 0.263()T
P PowerInKilowatts=
T
OutletWaterTemperatureInFahrenheit=
1
InletWaterTemperatureInFahrenheit=
T
2
()GPM=
1T2
()GPM=
1T2
3
Theory of Operation

Cooling Water

The electrical performance of these RF loads is affected by impurities or other chemical additives in the cooling water. The presence of salts in the water defi nitely makes the device unusable because salts cause a rapid increase in VSWR. Therefore, sea water or silty water should not be used for cooling the loads.
The thermal performance of these loads is also affected by impurities, particu­larly those impurities that accumulate in the form of scale on the exposed sur­faces of the fluid paths of the load assembly. These deposits may result in an increase in the thermal and/or fluid resistance(s) of the load and may in turn cause the load to overheat and fail.
The following types of water are considered safe for the cooling of the Models 8755 Load Resistor: filtered, city, or soft water. In general, any potable water is suitable for cooling the load.

Flow Interlock Control Circuit

The interlock control circuit provides instantaneous fail-safe protection of the transmitter and load in the event of even a momentary interruption of the cooling water supply. This protection is necessary because dissipation of the heat generated by the RF power absorption is critically dependent upon main taining the required minimum water flow rate regardless of inlet water tem­perature.
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The water flow switch, attached to the water inlet of the load, is factory cali­brated to open the electrical contacts whenever the water flow drops below seven gallons per minute and close when the water flow exceeds this value. When the water flow switch contacts open, the time delay relay switch is deac tivated, which in turn opens the interlock switch, causing immediate shut­down of the transmitter or other signal source. The time delay relay also keeps the interlock switch open for a preset interval of 12 ±2 seconds after the minimum flow of seven gallons per minute has been reestablished. This safe guarding feature assures proper operation of the cooling system before RF power can be applied to the load, preventing damage or burnout of the resistor element.
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4

Chapter 3 Installation

Load Resistor Connection

The compact design of the Models 8745/46 Termaline Load Resistor enables it to be installed in very small spaces. It requires no ventilation and may be placed at any attitude. Do not install it where the load may be subjected to severe vibration or to physical shock.
The load is ready for connection as received from the factory. It is useful to first check the 50 ohm input resistance of the load and record this data before attachment ( attachment.
1. Clean all conductor and insulator surfaces on the transmission line face and, likewise, the RF input connector.
2. Attach the load resistor to the RF line.
3. Use connector kits for respective models as follows:
4. Rotate the load so that the warning label shows and the outlet water tube is placed to the best advantage.
5. Secure the clamps or bolt set firmly and evenly around the RF connection.
see “Maintenance” on page 9). Use the following procedure for RF
Note: Use a dry cleaning solvent that does not leave a residue.
Note: Do not tighten the bolt and nut sets.
a. Models 8755 - 3-1/8” EIA flanged, 50 ohm:
Use a 3-1/8 inch EIA coupling kit (Bird P/N 4600-020) which includes six 3/8-16 x 1-1/2 inch bolt and nut sets, O-Ring, and anchor bullet (center conductor).
b. Models 8756 - 3-1/8” unflanged, 50 ohm flush center conductor:
Use Bird coupling kit P/N 5-726 (RCA MI-27791K-4A) consisting of an outer sleeve with two clamping bands and the center conductor cou­pling bullet.
Note: Do not disturb the socket head cap screws that join the con-
nector section to the main housing.

Water Line Attachment

The RF Load comes supplied with standard 3/4 inch hose fittings for attaching the water supply and drain lines. The water INLET, at the back on center and water OUTLET, adjacent at 90°to the inlet, mate with 3/4 inch water hose con nectors. If the unit is supplied with the optional control system, the water flow switch is installed on the water inlet line. for alternate field installation. To connect to a rigid piping connection, replace the water inlet and outlet hose adapters, Bird P/N 5-065-2, with ½ inch male pipe or pipe fittings. Take special care when connecting the water lines. The inside of the load is designed so that the water flows properly in only one direc tion - from the inlet to the outlet. The water flow must be kept in the proper direction - opposite flow will cause resistor failure when power is applied.

Cooling Water Quality

Water quality is important. See “Cooling Water Quality” on page 5 for an explanation and description. In general, any potable water is satisfactory. This would include purified, filtered, city supply, or soft water.
-
See “Flow Switch (Optional)” on page 6
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5
Installation

Flow Switch (Optional)

The ports of the flow switch are 3/4 inch NPT Female. The direction of flow is marked on the casting of the flow tube and on the operating head. Observe carefully- opposite connection will restrict the water flow and cause load fail ure. The flow switch may be connected to the inlet or the outlet side of the load, preferably as close to the load as possible. Just be certain the flow through the switch is in the correct direction. Connect with a ½ inch NPT Nip ple and a ½ to 3/4 inch bushing, Bird P/N 5-489-1 and 5-490-1, or connect by hose or pipes. In either case, the flow switch should not be over 20 feet from the load. Alternatively, attach hose to switch with a 3/4 inch hose nipple, Bird P/N 5-903.
Do not connect flow switch leads at this time. First turn on the water flow and check the system for leaks and proper operation.

Control Box (Optional Item)

The wiring center and remaining elements of the control system are contained in the control box. This includes a terminal strip and three BX cable clamps for the input connections, a pilot lamp, and a delay timer. Only wiring mate rial is needed for connecting the flow switch to the control box. The control unit operates on 115 Vac, P/N 8750-101-1, or on 230 Vac, P/N 8750-101-2, depending on the unit ordered to suit requirements.
The pilot lamp on top of the box is a safe operation indicator; it lights only when AC power is on and an adequate water supply is flowing. After the pilot lamp lights up, a 12 ±2 second time delay allows sufficient time for the water flow to stabilize before closing the transmitter interlock.
The control box is mounted by means of four 1/4 inch holes on a 5 x 5 inch square in the back. Locate the box for the best view of the pilot light and for easy attachment of the B.S cable and wiring. Connect the leads for each volt age as shown on the wiring schematic inside the control box.
Note: These connections are critical - wire carefully.
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Pre-Operational Checkout

1. Ensure the AC and transmitter interlock power are OFF.
2. Connect an ohmmeter across terminals six and seven (interlock).
3. Turn the AC power on.
4. Turn the water supply on.
5. Note when the water flow switch operates (audible click).
6. Ensure the water flow from the OUTLET connection of the load is not less than that given for the respective models.
6
Note: Before attempting to operate the RF load, whether under test
or actual operating conditions, TEST the complete water system and INTERLOCK CONTROL as follows:
Note: In not less than 10 seconds (12 ±2) the ohmmeter should sig-
nify a closed condition across terminals six and seven, indicating oper­ation of the time delay switch.
Note: As a precautionary measure, it is recommended that the pre-
operational checkout be performed each time the load is put into service.

Chapter 4 Operating Instructions

General

CAUTION
DO NOT disconnect the water flow switch leads from the control assembly.
Any operation of the load without a properly functioning cooling system will
cause almost immediate destruction of the resistor element.
WARNING
Never attempt to disconnect the equipment from the transmission line while
RF power is being applied. Leaking RF energy is a potential health hazard.
The Models 8755/56 Termaline Load Resistors do not have any operating con­trols. Therefore, the presence of operating personnel is not required when in use. Proper operation of the equipment is assured if the instructions contained in
"Installation" on page 5 are followed exactly.
Do not apply more than the rated RF power to the load. The water flow rates and inlet water temperature, +5°C to 60°C (+41°F to +140°F), must be as spec ified in the following table.
In actuality, an adequate and uninterrupted flow of water is more critical than the actual water temperature.
-
Model
Number
8755 20
8756 30

Operation as a Load Resistor

1. Turn on the AC power (if the load is equipped with an interlock system).
2. Turn on the water supply.
3. Check for proper interlock operation.
4. Check that all coaxial power line connections are properly tightened.
5. Apply RF power to the load.
6. Proceed according to instructions pertaining to the specific transmitting equipment.
Power
Kilowatts
Min Flow Temperature
(GPM) (LPM) (°C) (°F)
622.75 41
830.360140
726.55 41
934.060140
7
Operating Instructions

Operating as an RF Wattmeter

The RF load can be combined with a Bird Rigid Line Series Thruline Wattme­ter to form an absorption-type wattmeter by inserting the wattmeter line sec­tion just ahead of the RF load. Installation and operation of the wattmeter is covered in the Thruline Wattmeter Instruction Book.
Note: Select a wattmeter type appropriate to the input connector of
the load resistor. Consult the Bird Catalog or contact the Company.
1. Perform the the same functions as a Load Resistor. See “Operation as a Load Resistor” on page 7.
2. Rotate the element in the line section element socket to monitor incident or reflected power.
Note: Measurement is taken in the direction indicated by the
arrow on the element.

Shutting Down

1. Turn off the RF power to the load.
2. Wait at least one minute to allow the resistor substrate time to cool.
3. Turn the interlock and AC power off.
4. Turn off the water supply - always do this last.
8

Chapter 5 Maintenance

General

WARNING
Never attempt to disconnect the equipment from the transmission line while
RF power is being supplied. Leaking RF energy is a potential health hazard.
The Models 8745/46 Termaline Load Resistors are rugged and simple, requir­ing only nominal and routine attention. The load is designed to operate satis­factorily for long periods of time if care is taken not to exceed its power handling capabilities.

Troubleshooting

For corrections requiring repair or replacement of components, refer to the appropriate section for your specific model.
Problem Possible Cause Correction
Transmitter shuts off or will not stay on.
High load VSWR. Failing resistor (resistance
Low water flow (for units with flow interlock)
change of greater than 5 ohms). Loose input connector. Tighten conntector.
Increase cooling water flow.
Replace resistor.

Cleaning

Outside Surface

Inspection

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 peri odically wipe the accumulated dust and lint off of the load housing. 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-dry ing and leaves no residue to clean the hard to reach internal portions.
Note: Always handle the load with care to prevent subjecting it to
unnecessary shock or impact.
With the rugged and simple construction of the loads, periodic inspection will only be necessary at six-month intervals. Inspection should include the items listed below:
z Cleanliness - Keep the housing and connector free of grime. z Inspect the load for completeness and general condition of the equipment. z A Troubleshooting Chart lists the commonly encountered problems,
their possible causes and remedies. Use this chart as a guide when analyzing symptoms.
-
-
9
Maintenance

Preventative Maintenance

Due to the basic simplicity of construction, the major requirement for preven­tive maintenance is to keep the equipment clean.

RF Load Resistor

Preparation:
z Tools: Common hand tools z Ohmmeter with an accuracy of ± 1% at 50 ohms. z Use low resistance leads, preferably a short piece of 50 ohm coaxial
z Temperature of the load between 20°C to 25°C (68°F to 77°F)
Accurate measurement of the DC resistance between the inner and outer con­ductors of the RF input connector will provide a good check of the condition of the load resistor. Checking the DC resistance is simply used to measure a change in the condition of the resistor over time. The tracking of the DC resis tance must start before the resistor is first put into service. Perform the follow- ing steps and record the value for future comparison. Check and record the resistance of the load periodically according to use.
cable fitted with alligator clips.
-
Never attempt to connect or disconnect RF equipment from the transmission
line while RF power is being applied. Leaking RF energy is a potential

Measuring the DC Resistance

1. Turn off RF power and interlock circuitry before any electrical disconnec­tions are made.
2. Disconnect the RF coaxial line.
3. Connect the multimeter test leads across the center and outer conductor of the load resistor. Refer to figure 2 for placement of the leads.
4. Record the value of the resistance before the load is put into service. Com­pare subsequent values with the latest reading. If the values vary more than 2 ohms this could be an indication of a failing resistive element.
Figure 1 Measuring DC Resistance
WARNING
health hazard.
Note: These tests are by no means a necessity to the operation of
the load but merely guidelines for the users information.
Note: It is recommended that this resistance check be performed
each time the load is to be used.
10

Replacing a Resistive Element

This series of water-cooled loads is designed to be quickly and easily repaired in the field. If in performing the DC resistance check described previously. A significant change in resistance is noted, or if for any reason the resistive ele ment should fail, inexpensive replacement resistors are available. They can be installed in the load, using the following procedures:
Removing the Resistor
Note: Item numbers enclosed in brackets [ ] in the text are so indi-
cated on Figure 2 on page 12 and Figure 3 on page 13.
Note: Turn off RF Power and interlock circuitry prior to proceeding.
1. Ensure the RF power and water supply are turned off.
2. Disconnect the water hoses at the hose fittings [5] on load.
3. Disconnect the unit from the RF transmission line.
Note: Do this if the load is not already removed from the system.
4. Completely drain excess water from the load.
5. Set the load on end, with the water connections up.
6. Unscrew the six 114-20 x 2-112 inch socket head cap screws [6] holding the water chamber [3] to the main load housing.
Note: Use a 3/16 inch hex Allen wrench.
Termaline Load Resistor 8745/8746
-
7. Pull the water chamber assembly (with screws) straight off.
Note: It may be necessary to rock the chamber gently while care-
fully pulling it off.
The inner flow tube [9] will usually come out with the water chamber assem­bly, being held to it by the compression of the inner O-ring [4] (water input) seal. This is normal, and if the resistor body is unbroken, there will be no need to remove the inner flow tube from water chamber assembly.
The ground cap assembly [10] is fitted tightly within the water chamber and should normally remain with it. If the inner flow tube has stayed in the resis tor section, simply grasp the resistor stop sleeve [7] on the flow tube and pull out the assembly.
Note: This includes the cushioning O-Ring [8] which fits loosely
below the stop sleeve - always take care not to lose it by falling off. Also, if the brass stop sleeve [7] is removed at all, notice that it has a small escape hole at the side and an access counterbore leading to it.
8. For reassembly, ensure the counterbore is facing toward the O-Ring and the resistor [1].
Note: This is essential for internal water venting. Notice the water
output holes and also the small shoulder at the base of the inner flow tube. At reassembly, this must fit into amating recess in the input fit­ting at the bottom.
9. Pull the resistor [1], if intact, straight out of the load housing.
Note: The outer flow tube is captive, and will not come out of the
housing at this stage.
-
11
Maintenance

Figure 2 Removing the Resistor

1/4-20 x 2-1/2 Socket Head Cap Screw (6 Req'd)
Water Chamber With O-Ring Inner Seal
O-Ring, Outer
O-Ring Inner
Resistor Sleeve
Resistor
6
3
4
2
17
7
1
Hose Nipple (2) (Not used in Moduload
5
Application)
Ground Cap, Resistor
10
(Normally Remains Inside Water Chamber )
Inner Flow Tube
9
O-Ring
8
3
Outer Flow Tube
Load Housing
12

Figure 3 RF Input Assembly

Termaline Load Resistor 8745/8746

Inspecting the Unit

Note: Perform this once the resistor has been successfully removed.
1. Inspect the resistor carefully to ensure that it is not fractured.
Note: In the majority of cases, even in the event of resistor failure,
the resistor substrate will remain intact.
2. Examine the inside of the load housing assembly for any apparent damage to the internal parts.
3. Do one of the following: z If no damage had been found - Proceed with resistor replacement,
see “Replacing the Resistor” on page 14.
z If the resistor is broken, other internal parts appear to be
damaged, or if they do not fit together properly - See “Replacing
Fractured Resistors” on page 14.
13
Maintenance

Replacing the Resistor

1. Inspect the load housing assembly. See “Inspecting the Unit” on page 13.
2. Insert new resistor [1] into the load housing until it reaches its fitting.
3. Push in the resistor until it bottoms snugly.
4. Place the inner flow tube [9] inside the resistor.
5. Lower the inner flow tube until it reaches the resistor fitting.
6. Gently work and twist the inner flow tube until it seats in the bottom of
7. Ensure that the O-Ring [8] cushion is placed on the inner flow tube next to
Note: If resistor seems to be loose, see “Replacing Fractured Resis-
tors” on page 14 for instructions on how to lighten the resistor fitting.
the input resistor fitting.
Note: This operation may also be done if the inner flow tube is still
in position in the water chamber.
the resistor and the “backup” resistor sleeve [7] is right behind it.
Note: Watch the orientation of the sleeve, see “Replacing a Resis-
tive Element” on page 11.
Note: There is no need to disturb the resistor cap assembly [10] in
the water chamber for this procedure.
8. Replace the water chamber [3], gently rocking and twisting the chamber to achieve the proper flat seat on the outer housing.
Note: If the water chamber [3] does not seem to fit properly, refer
back to step 5. to see that the inner flow tube is properly in place.
9. Tighten the six 1/4-20 x 2-112 inch socket head cap screws [6].
10. Check the DC resistance between the inner and outer conductors.
Note: It should be approximately 50 ohms, see “Inspecting the Unit”
on page 13.
11. Connect the load to a water source and check for leaks.
Note: If none appear, the load is ready for service.

Replacing Fractured Resistors

The resistor used in this load consists of a resistive film on a special
substrate. If the substrate is broken, there will probably be sharp pieces or
splinters inside the load housing. Caution should be exercised to avoid
Note: The load should already be disassembled to the point of step
4 of "Replacing a Resistive Element" on page 11.
1. Turn the load on end.
Note: The RF input connector should be up to allow any loose
pieces of resistor to fall out of the load housing.
WARNING
possible injury.
14
Termaline Load Resistor 8745/8746
2. Loosen and remove the six (6\ 1/4-20 x 1 inch socket head cap screws [16] from the flanged end of the load housing.
Note: Use a 3/16 inch Allen wrench.Note: As shown in Figure 2, the outer conductor assembly may
now be easily removed.
3. Remove the input center conductor assembly [11] or [13] by pulling it out of the load housing (Figure 3 on page 13).
4. Carefully remove any remaining pieces of the resistor.
Note: Normally, at this stage of the disassembly, the outer flow
tube will remain with the load housing. Restore it to this position after inspection and cleaning if it should come out.
5. Inspect the inside of the load housing for any apparent damage. See “Inspecting the Unit” on page 13.
6. Pull out the inner flow tube.
7. Inspect the inner flow tube carefully for broken pieces.
8. Grasp the projecting hub of the resistor cap assembly [10] firmly.
9. Pull the projecting hub straight off with a strong even force.
10. Wash all the inside portions of the three assemblies thoroughly under clear running water (i.e., input section, load housing, and water chamber).
11. Replace the resistor Models 8745/8746 Termaline Load Resistor cap assembly in the water chamber.
12. Push the resistor firmly to the bottom.

Installing a Replacement Resistor

1. Insert replacement resistor [1] into the resistor fitting of the input center conductor assembly to test its tightness.
Note: The resistor should not have to be forced into the fitting,
but it should be quite snug. If the resistor is loose in the fitting, press the slotted finger contacts of the fitting together slightly and try the resistor again.
2. Continue closing the ends of the resistor fitting until a snug fit is obtained.
3. Bottom the resistor in the fitting.
4. Insert the resistor and the input center conductor assembly into the load hous­ing with the resistor still in place in the resistor fitting. (Figure 2 on page 12).
5. Replace the outer conductor assembly and the six 1/4-20 x 1 inch socket head cap screws.
6. Stand the load on end with the RF input connector down.
7. Place the inner flow tube inside the resistor.
8. Lower the inner flow tube until it reaches the resistor fitting.
9. Gently move and twist the inner flow tube until it seats in the bottom of the resistor fitting.
10. Continue the same procedure as given in "Replacing the Resistor" on page 14.
15
Maintenance

Removing the Front Connector Assembly

Note: This portion of the load unit consists of the inner conductor
[11] or [13] and the outer conductor [12] or [14], respectively.
1. Remove the six screws [16] at the front of the housing flange.
2. Remove the front connector assembly and inner conductor.
3. Replace the O-ring seal, if needed.
Note: Do not attempt further disassembly of this part. Return to
the factory for repair, if necessary; consult the company.
Note: Procurement and use of the accessory protective control system
(comprising the water flow switch and control box) is optional. Consider the instructions and replaceable parts described in Front Connector Assembly, Water Flow Switch and Time Delay only when applicable.

Replacing the Water Flow Switch

The Water Flow Switch, P/N 5-898-6, should be checked and cleaned of any accumulated dirt on scale that might impede free movement of the control gate in the switch. This should be done after several months use, or if other wise indicated. This component is non-repairable; if found defective it must be replaced. For replacement proceed as follows:
-
1. Ensure the following is shut off.
z RF power z 115/230 VAC z Transmitter interlock supply
2. Disconnect the water flow switch leads at the control box.
3. Remove the defective switch.
4. Replace with new unit.
5. Connect the flow switch leads to terminals 3 and S.
6. Perform preoperational checkout. See “Pre-Operational Checkout” on page 6.

Replacing Time Delay Relay

box cannot be disassembled or repaired in the field. A faulty unit should simply be replaced according to the following procedure:
1. Ensure RF power, 115/234 VAC, and transmitter inlerlock supply are turned off.
2. Open the door of the control box by turning slotted screw head one quarter turn.
3. Loosen the 8-32 pan head screw at the top of the relay clamp, P/N 8630-193, then press legs in slightly lo release the retaining prongs of the clamp.
4. Pull the delay relay cartridge straight out of the socket.
5. Reverse the procedure above to replace the relay.
6. Rotate the cartridge carefully for alignmenl of the center Post nub in the socket while inserting the relay.
Note: The socket is an ordinary octal type.
Note: The Relay Cartridge, P/N 5-1664 or 5-1665, in the control
16
7. Prongs of the clamp match side slots in the socket holder.
8. Fit the clamp in the slots.
9. Turn the head screw up snugly.
10. Reverse steps 1 and 2.
11. Perform preoperational checkout. See “Pre-Operational Checkout” on page 6.

Replacing the Pilot Light

1. Locate the pilot lamp (P/N 5-970 (-1 or -2)) on the top of the control box.
2. Push down, gently, and twist the pilot lamp lens (P/N 8750-106).
3. Remove the pilot lamp lens.
4. Remove the pilot lamp.
5. Install the new pilot lamp by revsersing this procedure.

Additional Repairs

Repairs beyond what is covered in this instruction book will require return of the equipment to Bird Electronic Corporation for service. vice” on page 18.
Termaline Load Resistor 8745/8746
See “Customer Ser-

Storing

Shipping

Note: If the load is to be unused or stored for any length of time,
completely drain it of any coolant and cap the openings.
1. Contain or cover the unit with plastic.
2. Store in a cool, dust free and dry area.
Note: Ambient storage temperatures are not critical, however,
extreme temperatures should be avoided.
1. Completely drain the unit of all coolant.
2. Cap all openings.
3. Pack the unit securely in a sturdy wooden box or equivalent.
Note: If possible, keep the original shipping carton for reshipment.
4. Pad the container with sufficient padding to avoid shock damage.
5. Seal the container securely.
17
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.com
For the location of the Sales Office nearest you, visit our website at:
http://www.bird-technologies.com
18

Specifications

Termaline Load Resistor 8745/8746
Power Rating 30,000 Watts lmpedance 50 ohms Input Connectors
Model 8745 Model 8746
3-1/8. EIA flanged (50 ohm) 3-1/8. unflanged (50 ohm) flush center conductor
Frequency Range 1000 Hz to 900 MHz VSWR 1.10 max. 1000 Hz to 900 MHz Modes CW, AM, FM, SSB, TV, and certain Pulse types Input Water Temperature Range 5°C to 60°C (41°F to 140°F) AC Power Required 115 V 50/60 Hz or 230 V
50 Hz (with optional items only)
Water Flow - Minimum Rate 7 GPM (26.5 lpm) at 5°C (41°F)
9 GPM (34.0 lpm) at 60°C (140°F
Water Connections 3/4 inch Standard Hose Thread
*
Cooling Water Potable Weight
Model 8755 Model 8756
Dimensions
Length Overall Housing Diameter Maximum Diameter (Input Flange)
15 lb 13 oz. (7.2k9) 15 lb 5 oz. (7.0 kg)
19-1/2" (495 mm) 3-1/2" (89 mm) 5-3/16" (132 mm)
Water
Finish Black Powder Coat Housing Material Aluminum Alloy and Brass Operating Position Any
* Standards for potable water have been established by the U.S. Public Health Service at a maximum of 500 ppm of total dissolved solids (ppm - parts per million or 1 mg per liter). Hardness of water (con­tent of calcium and magnesium salts) should be less than 75 ppm. If the quality of the available water supply is doubtful or the mineral content is questionable, use distilled water.
3-1/8 EIA SWIVEL FLANGE
5-3/16 DIA.
(132mm)
18-11/32 (466mm)
R
R
ERMALINE
Econoload
COAXIAL RESISTOR
16-7/8
(429mm)
WARNING
2-5/8
(67mm)
NOM.
WATER INLET 3/4" HOSE THD.
3-1/2 DIA.
(89mm)
WATEROUTLET 3/4" HOSE THD.
19
Maintenance

Replacement Parts

Customer Replacement Part Consists of Description
RPK8755-027-3 8755-027-3 Resistor 50.75 ohm 30kW
923-RPK000 Instruction Sheet
8740-025 8755-025 Inner Flow Tube
8755-024 Outer Flow Tube 8740-020 O-Ring Kit 8755-005 Resistor Cap Assembly 8755-016 Resistor Contact 8755-026 Resistor Holder 923-8740-025 Instruction Sheet
8740-020 5-099 O-Ring #568-116
5-567 O-Ring AS568A-125 5-1127 O-Ring #568-123 5-1128 O-Ring #568-222 Sili 8110-059 O-Ring #568-211 8410-009 O-Ring #568-224

Front Connector Parts Assigned Per Model Type:

Model 8745 - 3-1/8" EIA Connector 50 ohms
Item Qty Description Part Number
11 1 Center conductor input, assembly 8755-007 12 1 Outer conductor assemblY 8755-004
Model 8746 - 3-1/8" Unflanged Connector Flush Center Conductor 50 ohms
Item Qty Description Part Number
13 1 Center conductor input, assembly 8756-003 14 1 Outer conductor assemblY 8756-002
For Both Models
Item Qty Description Part Number
15 1 Center conductor assembly O-Ring 5-1127 16 1 Socket head cap screws,
17 1 lnner resistor cap seal O-Ring 5-567
1121-1508-00
1/4-20 x 1-1/2", stainless steel
20

Optional Equipment

Control and Water Flow Parts - not shown on Figures
Termaline Load Resistor 8745/8746
Qty Description Part Number
1 Water flow switch 5-898-23
1 Control assembly - 115 V
Control assembly - 230 V
1 Relay retaining clamp 8630-193
1 Time delay relay - 115 V
Time delay relay - 230 V
1 Indicator light 8750-106
*
1 Incandescent lamp - 115 V
Incandescent lamp - 230V*
1 Pipe nipple (flow switch) 5-489-1
Hex bushing (flow switch) 5-490-1
* These items are part of the Control Assembly.
8750-101-1 8750-101-2
5-1664 5-1665
5-970-1 5-970-2

Accessory Connector Kits

Model 8745 Coupling Kit - 3-1/8. Unflanged Connector Flush - 50 ohms
1 Connector Kit 5-726 1 3-1/8. EIA Connector 4600-020 1 Anchor bullet 4600-021 1 O-Ring 4600-022 1 Mounting hardware 4600-023
Qty Description Part Number
21

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. 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 (cheap est 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 war ranties shall be deemed to be waived by Buyer unless made in writing 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 alterations outside of our plant, and shall not apply to any goods or parts thereof furnished by Buyer or acquired from oth ers at Buyer’s request and/or to Buyer’s specifications. Routine (regularly required) cali­bration is not covered under this limited warranty. 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 war ranty 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 WHAT-SOEVER, WHETHER EXPRESS, STATU TORY, 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 FORE GOING.
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