TERMALINE® LOAD RESISTOR
SERIES 8860
COVERING MODELS
©Copyright 2012 by Bird Electronic Corporation
Instruction Book Part Number 920-8860S Rev. D
Te rm a l in e
®
and Tenuline® are Registered Trademarks
of Bird Electronic Corporation
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 publication. These precautions must be thoroughly understood and apply to all phases of operation and maintenance.
WARNING
Keep Away From Live Circuits
Operating Personnel must at all times observe general safety precautions. 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.
WARNI NG
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.
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.
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
The vent plug must be used at all times when the unit is operating or cooling. Failure to do
so could result in an explosion or severe burns.
See page 5.
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.
See pages 7, 9, 11, and 12.
WARNING
Disconnect the unit from all power sources before servicing.
The unit may be energized from multiple sources.
The potential for electric shock exists.
See pages 11 and 13.
WARNING
Oil is slippery. If a leak occurs, be careful not to fall.
See pages 11, 12, 13, and 14.
ii
Caution Statements
The following equipment cautions appear in the text and are repeated here for emphasis.
CAUTION
This load is designed for operation in a horizontal position only, with the vent plug up. Do
not use in any other manner.
See pages 5.
CAUTION
Do not contaminate the coolant with pipe sealant.
See pages 6.
CAUTION
If installed, connect optional interlock before applying RF power.
See pages 6.
CAUTION
Use only Bird coolant, P/N 5-1070, to prevent damage to the load.
See pages 13.
iii
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.
iv
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.
v
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.
vi
About This Manual
This manual covers the operating and maintenance instructions for the following models:
8860
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 revision on the title page.
Chapter Layout
Introduction - Describes the features of the Bird Termaline, Semiconductor, RF Load Resistor
lists equipment supplied and optional equipment, and provides power-up instructions.
Theory of Operation - Describes how the Termaline, Semiconductor, RF Load Resistor works
and its functions.
Installation - Describes the how to install the Termaline, Semiconductor, RF Load Resistor.
Operation with Blower - Describes procedures require for operating the load resistor
equipped with a blower unit.
Maintenance — Lists routine maintenance tasks as well as troubleshooting for common prob-
lems. Specifications and parts information are also included..
vii
Table of Contents
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Warning Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii
Caution Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Safety Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii
Changes to this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii
Chapter Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii
Chapter 1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Items Supplied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Items Required but not Supplied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Chapter 2 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Load Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Thermal Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Chapter 3 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
UUnpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installing Thermoswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Interlock Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Connecting RF Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
“QC” Connector Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
13-30 Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Swivel Flanged Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Unflanged Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chapter 4 Operating Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Operation Under Abnormal Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Emergency Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Chapter 5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DC Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Inspecting the Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Replacing the RF Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Replacing the Load Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Storage and Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Storing the Load Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Shipping the Load Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Available “QC” Type Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
. . . . . . . . . . 17
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
viii
Chapter 1 Introduction
MTG. HOLE
DETAIL
13/32”
(10 mm)
3/32”
(2.4 mm)
3/8”
(9.5 mm)
(4) MTG. HOLES
SEE DETAIL
4.5”
(114 mm)
7.5”
(190 mm)
15-7/8”
(403 mm)
13-1/8”
(333 mm)
3”
(75 mm)
DEPENDS ON
INTERLOCK
THERMOSWITCH
(OPTIONAL)
VENT PLUG
15-1/4”
(387 mm)
Bird 8860 Series Loads are portable 50 ohm coaxial RF transmission line terminations, designed for frequency ranges
of dc – 2000 MHz. Bird 8860D Series Loads are identical, except that they are designed for the UHF (470 – 860 MHz)
band. They provide accurate, dependable, and low reflection line terminations. Up to 1500 watts of RF power can be
dissipated.
The load has a coolant chamber surrounded by radiator fins. The front and rear fins form mounting flanges which
can be used as supports for freestanding use or as brackets for fixed mounting. A vent plug at the top of the unit
relieves internal pressure from coolant expansion. The load’s simple and rugged design minimizes maintenance
requirements.
Items Supplied
• Load Resistor: Pre-filled with coolant at the factory
• Shipping Plug
• Vent P lug
• Instruction Manual
Items Required but not Supplied
• Coupling Kit: Connects the load to the RF line
Optional Accessories
• Interlock Thermoswitch: Automatically shuts off the transmitter to prevent over-
heating of the load
Figure 1 Bird 8860 Series Outline Drawing
1
2
Chapter 2 Theory of Operation
O-ring seal
O-ring seal
Load Resistor
Bird 8860 Loads consist of a thin-film-on-ceramic resistor immersed in a dielectric coolant. The resistor, individually
selected for its accuracy, is enclosed in a special housing. When surrounded by the coolant, this produces a uniform,
practically reflectionless line termination over the specified frequencies.
Coolant
The load is cooled by natural fluid and air convection currents. The coolant, chosen for its dielectric and thermal
characteristics, carries heat from the resistor to the walls of the cooling tank, where radiator fins surrounding the
tank transfer the heat to the air.
When the coolant is heated, thermal expansion causes an increase in the internal pressure. The vent plug relieves
this pressure while protecting the opening from dirt or other contaminants.
Thermal Interlock
Loads can be supplied with an optional passive overtemperature thermoswitch. Normally closed, it opens at the
maximum safe load temperature of 236 °C (457 °F), turning off transmitter power. The interlock system will not permit reoperation of the transmitter until the load has reached a lower, safe temperature.
Figure 2 Shipping Plug
Figure 3 Vent Plug
3
4
Chapter 3 Installation
This chapter provides information for on-site requirements, unpacking, inspection, and preparing the load for use.
UUnpacking and Inspection
1. Carefully inspect shipping container for signs of damage.
2. Do one of the following:
• If the shipping container is damaged, do not unpack the unit. Immediately notify
the shipping carrier and Bird Electronic Corporation.
• If the shipping container is not damaged, unpack the unit. Save shipping materi-
als for repackaging.
3. Inspect unit for visual signs of damage.
Note: If there is damage, immediately notify the shipping carrier and Bird Electronic Corporation.
Setup
Note: Before first using the load, get a resistance baseline for future maintenance. Refer to "DC Resistance"
on page 12 for details.
1. Remove the shipping plug from the load.
2. Replace the shipping plug with the vent plug. Refer to Figure 1 and Figure 2 for pictures of the plugs.
WARNING
The vent plug must be used at all times when the unit is operating or cooling. Failure to
do so could result in an explosion or severe burns.
Mounting
Place the load in a dry, dust and vibration free environment. Do not use outdoors or in areas of condensing humidity.
Allow at least 12" (30 cm) of clearance on all sides of the load.
CAUTION
This load is designed for operation in a horizontal position only, with the vent plug up. Do not use in any other manner.
These loads are equipped for either portable use or fixed installation. The mounting brackets on the front and rear
faces have four mounting slots arranged in a 4
(9.53 mm) diameter max.
1
⁄2" x 147⁄32" rectangle (114.3 x 361.2 mm). Use a screw with a 3⁄8"
5
Installing Thermoswitch
Bird 8860 series loads can be equipped with an optional interlock thermoswitch, P/N 8890-008. It is normally closed,
opening at 236 °C (457 °F), with a rating of 10A @ 120Vac and 5A @ 230Vac.
WARNING
The vent plug must be used at all times when the unit is operating or cooling. Failure to do so could result in an
explosion or severe burns.
1. Remove the vent plug.
2. Install the shipping plug.
3. Stand the unit on its front, supporting it so that the connector is not damaged.
Note: In this position there is no danger of the coolant pouring out through
the socket plug hole.
4. Remove the socket plug just above the connector assembly, using a
5. Replace the plug with the thermoswitch.
6. Apply pipe sealing compound to the external threads of the thermoswitch sparingly,
ONLY.
CAUTION
Do not contaminate the coolant with pipe sealant.
1. Check for coolant leaks upon completion.
9
⁄16" hex wrench.
Interlock Connection
If installed, connect optional interlock before applying RF power.
1. Unscrew the large knurled ring-nut (A) at the lower end of the coupling jack assembly.
2. Pull the large knurled ring-nut off the thermoswitch jack (B).
3. Unscrew the small knurled cover fitting from the base plug (D) of the connector to
4. Thread the control switch wires through the clamp (E) with the washers (F) inside
5. Service the control switch wire with short tips and put spaghetti sleeves over the
6. Securely solder the control switch leads to the lugs (G) of the connector base.
7. Screw on the cover ring, then fasten the cable clamp (E) in place and tighten both
2. Put the plug back on the thermoswitch and tighten the nut (A).
CAUTION
release the base.
and with its threaded fitting in place.
wire ends if necessary.
Note: The ring-nut (A) must be in place over the base plug (D) with the knurled
end facing out.
yoke screws (H).
6
Figure 4 Thermoswitch Assembly
Connecting RF Power
After installing the load, the RF transmission line can be attached using standard coaxial line coupling kits.
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.
“QC” Connector Coupling
Use 50 ohm coaxial cable such as RG-218/U or -220/U (-17A or -19A), appropriate for the frequency and power level
of operation.
Use a cable connector which will mate with the one on the load.
13-30 Coupling
Use 50 ohm coaxial cable such as RG-8A/U, RG-9U, RG-213/U, or equivalent with a male 13-30 plug.
Swivel Flanged Coupling
Note: To couple the swivel flange with a flanged RF transmission line, use an
appropriate coupling kit. Refer to Figure 5.
1. Insert the center bullet.
2. Push it in until it is fully seated.
3. Connect the coaxial input in a straight line.
4. Push carefully on the center conductor to close.
Note: The swivel flange on the load makes connection independent of the orientation of the fixed flange on the coaxial input outer conductor.
5. Insert the bolt sets.
6. Tighten evenly all around to transmission line manufacturer’s recommended torque.
Note: Use all of the bolts.
7
Figure 5 Swivel Flanged Coupling
BOLT BULLET LOADRF COAXIAL LINE
RF COAXIAL
LINE
CLAMPING
BANDS
CONNECTOR
SLEEVE
BULLET
LOAD
Unflanged Coupling
To couple the unflanged connector with an unflanged RF line, use an appropriate coupling kit. Refer to Figure 6
while following the instructions below:
1. Insert the center bullet.
2. Bottom it on the midpoint nibs.
3. Position the outer sleeve, with clamping bands, over the input connector.
4. Set the transmission line snugly against the coupling stops.
5. Position the clamping bands evenly about 3/4” from the ends of the sleeve.
6. Tighten the clamping bands.
Figure 6 Unflanged Coupling
8
Chapter 4 Operating Instructions
Normal Operation
Bird 8860 series Loads have no indicators or operating controls. They require no special operating procedures or surveillance when their performance limits are not exceeded. Follow the instructions for the specific transmitter equipment.
Operation Under Abnormal Conditions
The load can be subjected to moderate overloads for short periods. If this is likely, make sure the interlock is properly connected to prevent damage to the load.
Shutdown
These loads are passive devices, so have no way of being turned off. Turn off RF power at the source.
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.
Emergency Shutdown
Turn off RF power at the source.
If the interlock thermoswitch is properly connected, RF power will be automatically turned off when the coolant
temperature reaches an unsafe level.
9
10
Chapter 5 Maintenance
This chapter covers cleaning, inspection, trouble-shooting, and specifications for the Bird 8860 series loads.
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.
WARNING
Disconnect the unit from all power sources before servicing. The unit may be energized from multiple sources.
The potential for electric shock exists.
WARNING
Oil is slippery. If a leak occurs, be careful not to fall.
Troubleshooting
The table below contains troubleshooting information for problems which can occur during normal operation. This
manual cannot list all malfunctions that may occur, or their corrective actions. If a problem is not listed or is not corrected by the listed actions, notify a qualified service center.
Problem Possible Cause Correction
Leaking coolant Loose clamping band Tighten the clamping band
Defective or improperly installed
O-ring
High or low dc
resistance
Overheating radiator RF power too high Lower RF power
Loose RF connector Tighten connector
Faulty RF input connector Model 8860: Replace connector (See “Replacing
Faulty resistor Replace the resistor
Coolant level too low Check the coolant level. Add coolant if necessary
Coolant degraded Replace the coolant
Faulty resistor Replace the resistor
Replace the O-ring
(See “Replacing the Load Resistor” on page 14)
the RF Connector” on page 13)
All other models: Return the unit for service
(See “Replacing the Load Resistor” on page 14)
(See “Coolant Level” on page 13)
(See “Coolant Level” on page 13)
(See “Replacing the Load Resistor” on page 14)
11
Maintenance
Cleaning
The outside surface of the instrument should be wiped free of dust and dirt when necessary. Excessive dust on the
cooling fins will interfere with heat dissipation. Clean the RF connector, both metallic and insulating surfaces, with a
dry, non-residue forming solvent.
WARNING
Oil is slippery. If a leak occurs, be careful not to fall.
Inspection
Inspect the unit every six months. Check for coolant leakage around the clamping band and the thermoswitch. Also
check for corrosion.
DC Resistance
Measuring the dc resistance between the inner and outer conductors of the RF connector shows changes in the load
over time, a good check of the load resistor’s condition. Under normal operating conditions, the resistor should provide at least 5,000 hours of operation before requiring any additional service. DC resistance tracking must start
before the load is put into service, and should be measured annually.
Perform the following steps and record the value for future comparison. Make sure that you have an ohmmeter with
an accuracy of ±1% at 50 ohms and that the load temperature is between 20 and 25 °C (68 to 77 °F) before starting.
Figure 7 Measuring Resistance
WARNING
Never attempt to connect or disconnect RF equipment from the transmission line
while RF power is being applied. Leaking RF energy is a potential health hazard.
1. Turn off the RF power and interlock circuitry.
2. Disconnect the RF line.
3. Connect the multimeter test leads to the center and outer conductor of the load
resistor (see Figure 7).
4. Compare the measured value with the previous measurement and with the baseline
resistance, measured when the load was put into service.
Note: If the new value differs from either of these by more than 1 ohm this
could indicate a failing resistor.
12
Coolant Level
Coolant lifetime will vary greatly depending on the operating temperature. For heavy use (full RF power for long
times, high ambient temperature), check the coolant every 500 hours. If the load has only had light duty (fraction of
full power, low temperature), then inspection may only be necessary every 2,000 hours.
WARNING
Disconnect the unit from all power sources before servicing. The unit may be energized from multiple sources.
The potential for electric shock exists.
WARNING
Oil is slippery. If a leak occurs, be careful not to fall.
CAUTION
Use only Bird coolant, P/N 5-1070, to prevent damage to the load.
Inspecting the Coolant
1. Remove the load resistor.
2. Inspect the coolant.
• The coolant should be clear, with a faint yellow tinge, and have a slightly sweet
smell. If it is black with a burnt or acrid smell, drain it and add about 2.9 gal (11
L) of coolant.
• With the load still on end, the coolant level should be 3
top surface of the resistor assembly mounting ring, at ambient temperature.
3. Add coolant if necessary.
5
⁄8" (92 mm) below the
Repair
WARNING
Disconnect the unit from all power sources before servicing. The unit may be energized from multiple sources.
The potential for electric shock exists.
Replacing the RF Connector
The Model 8860, only, has a special Bird “QC” connector which allows easy changing of the RF connector. This does
not disturb the coolant seal or affect the electrical continuity of the load. To change the connector, proceed as follows:
1. Remove the four screws at the corners of the RF connector.
2. Pull the connector straight out.
3. Push the new connector in.
Note: Make sure that the center pin on the connector is properly seated in the
mating socket on the load.
4. Replace the screws.
Note: If not using the LC connector normally supplied, the frequency and
power must be limited to the capabilities of the connector..
13
Replacing the Load Resistor
1. Remove the vent plug and install the shipping plug.
2. Supporting the unit to prevent damage to the interlock, stand it on its back with the
connector end up.
3. Unscrew and remove the clamping band.
4. Lift the load resistor assembly out of the tank and allow any coolant to drip back into
the tank.
5. The O-Ring should be free of twists and positioned evenly around the flange of the
resistor housing.
6. Replace the entire load resistor assembly.
7. Put the clamping band in place and tighten it.
3. Remove the shipping plug and install the vent plug.
Storage and Shipment
WARNING
Oil is slippery. If a leak occurs, be careful not to fall.
Note: In this position there is no danger of the coolant pouring out through
the resistor hole.
Note: If the O-ring shows signs of deterioration (e.g. is no longer pliable or has
surface cracks) replace it.
Note: It cannot be further disassembled.
Storing the Load Resistor
• Cover Bird 8890 Loads before storing to keep out dust and dirt.
• It is not necessary to install the shipping plug.
• Store in a dry, dust-free environment where the ambient temperature will remain between –40 and +45 °C
(–40 to +113 °F).
Shipping the Load Resistor
1. Remove the vent plug.
2. Install the shipping plug.
3. Wrap the vent plug with padding and tape it to the side of the load for protection.
Note: With the shipping plug installed, it is not necessary to empty out the
coolant.
4. Wrap the connector in padding.
Pack and brace the load in a sturdy wooden crate for shipment.
14
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
15
Specifications
Frequency Range
Power Rating 1500 W continuous duty
Impedance, Nominal 50 ohms
VSWR
Connectors
Interlock Thermoswitch Normally closed. Opens at 236°C (457°F)
Thermoswitch Rating
Ambient Temperature –40 to +45 °C (–40 to +113 °F)
Altitude
Humidity 95% noncondensing max
8862D, 8862D13-30,
8864D
All other models
*
8862D, 8862D13-30,
8864D
All other models
8860
8861
8862, 8862D
8862D13-30
8863
8864, 8864D
115 Va c
230 Vac
†
470 – 860 MHz
dc – 2000 MHz
1.065
dc – 1 GHz: 1.1
1 – 2 GHz: 1.25
Female LC
1-5/8” unflanged
1-5/8” EIA flanged
Female 13-30
3-1/8” unflanged
3-1/8” EIA flanged
10 A
5 A
1520 m (5000 ft.)
16
Cooling method Oil dielectric and convection currents
1
⁄
Dimensions 17.5" L x 7.5" W x 13
8
" H
(445 x 190 x 334 mm)
Weight, Nominal 27.8 lb. (12.6 kg)
Finish Grey Powder Coat
* For model 8860, VSWR is measured using a female type N connector.
† Derate RF power by 250 W for every 305m (1,000 ft.) above 1,520m (5,000 ft.)
Replacement Parts
Description Qty Part Number
RF Load Resistor
8860
8861
8862, 8862D
8862D13-30
8863
8864
8864D
Resistor O-Ring 1 5-230
Clamping Band Assembly 1 2430-055
Plug
Vent
Shipping
Overtemp Thermoswitch 1 8890-008
Coolant, 1.5 gal (5.7 liter) 1 5-1070-3
Radiator Assembly 1 8860-002
Access Plug 3/4"-14 Hex Socket 1 5020-103
1
8890A050
8895-015
8892-015
8862-017
8897-003
8891-050
8891-071
1
2450-094
2450-049
17
Available “QC” Type Connectors
Connector Part Number
BNC-Female 4240-125
BNC-Male 4240-132
C-Female 4240-100
C-Male 4240-110
HN-Female 4240-268
HN-Male 4240-278
LC-Female
LC-Male 4240-025
Open Term.
# 10-32 Nut
LT-Female 4240-018
LT-Male 4240-012
N-Female 4240-062
N-Male 4240-063
SC-Female 4240-090
SMA-Female 4240-336
*
4240-031
4240-080
SMA-Male 4240-334
7/16 Jack, IEC
Type 169-4
7/16 Plug, IEC
Type 169-4
Mini UHF-Female 4240-346
UHF-Female 4240-050
UHF-Male 4240-179
1-5/8” EIA Fixed 4240-096
1-5/8” EIA Swivel 4240-208
7/8” EIA 4240-002
TNC-Female 4240-156
TNC-Male 4240-160
* Normally supplied on the 8860
4240-344
4240-363
18
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 (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. 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 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 WHAT-SOEVER, 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.
19
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