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.
Note: Calls attention to supplemental information.
i
Page 4
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
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.
On page 5 and 6.
WARNI NG
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 7, 9, 11, 13 and 14.
WARNING
Turn off AC power and RF power when attaching the power cable.
On page 8.
WARNING
Disconnect the blower assembly from supply voltage before performing any maintenance.
On page 13
WARNING
Disconnect the unit from all power sources before servicing. The unit may be energized
from multiple sources. The potential for electric shock exists.
On page 14, 15, 16 and 17.
WARNING
Do not operate with side panel removed. Doing so could result in personal injury.
On page 14.
ii
Page 5
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.
On page 5.
CAUTION
Do not contaminate the coolant with pipe sealant.
On page 6.
CAUTION
If installed, connect optional interlock before applying RF power.
On page 6.
CAUTION
Check the local electrical code for proper AC hookup prior to operation of the unit. Make
sure the neutral or return hookup is only used for that purpose.
On page 8.
CAUTION
Make sure the interlock is properly connected when overloaded to prevent damage to the load.
On page 9.
CAUTION
Maximum power is 1,250 W when the blower is not running. If the indicator light should
turn off, immediately reduce RF power to less than 1,250 W.
On page 11.
CAUTION
Use only Bird coolant, P/N 5-1070, to prevent damage to the load.
On page 15.
iii
Page 6
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
Page 7
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
Page 8
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
Page 9
About This Manual
This manual covers the operating and maintenance instructions for the following models
Note: When used in the rest of the manual, 8890 series refers to all models.
889x–300 refers only to loads without a blower. –315 and –320 refer to loads
with attached blowers.
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.
Literature Contents
Chapter Layout
Introduction - Describes the features of the Bird SignalHawk, lists equipment supplied and
optional equipment, and provides power-up instructions.
Theory of Operation - Describes how to use the SignalHawk’s PC Tool for the Vector Net-
work Analysis function and how to transfer readings from the SignalHawk to the computer and
back again.
Operation without Blower - Describes procedures require for operating the 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.
The Bird 8890 series loads are portable, 50 ohm, coaxial RF transmission line terminations, designed for frequency
ranges of DC – 2.4 GHz. The 8890 series D loads are designed for use in the UHF (470 – 860 MHz) band, otherwise
they are identical to the stanard series. These loads provide accurate and dependable low reflection line terminations. Power is dissipated at a level of up to 2500 watts of RF, 5000 watts if the optional blower assembly is used.
The 8890 series –300 is the basic load. The –315 and –320 models consist of a load with an installed blower assembly for 115 or 230 VAC lines, respectively.
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
Note: Pre-filled with coolant at the factory
•Shipping Plug
•Vent Plug
•Instruction Manual
Items Required but not Supplied
•Coupling Kit: Connects the load to the RF line
Optional Accessories
•Bird BA-310 Blower Assembly: Doubles the RF power capacity of the load. Includes control thermoswitch
and detachable 3-wire power cable (without male plug for 230 Vac cable)
Note: The blower and control thermoswitch are standard on the –315 and –320 loads.
•Interlock Thermoswitch: Automatically shuts off the transmitter to prevent overheating of the load.
1
Page 14
Figure 1 Bird 8890 Series Outline Drawing - No Blower
MTG. HOLE
DETAIL
3/8”
(9 mm)
3/16”
(5 mm)
3/8”
(10 mm)
!
4.5”
(114 mm)
7.5”
(190 mm)
(4) MTG. HOLES
SEE DETAIL
21.5”
(546 mm)
17.25”
(437 mm)
3”
(75 mm)
DEPENDS ON
CONNECTOR
VENT PLUG
INTERLOCK
THERMOSWITCH
(OPTIONAL)
FAN CONTROL
THERMOSWITCH
POWER CORD
20 ft (6 m) LONG
APPROX.
!
BLOWER
ON
AUTOMATIC
MANUAL
MANUAL /
AUTOMATIC
SWITCH
INDICATOR
LIGHT
21-7/8”
(556 mm)
4-7/8”
(124 mm)
7-7/8”
(199 mm)
Figure 2 Outline Drawing With Blower
2
Page 15
Chapter 2Theory of Operation
O-ring seal
O-ring seal
DETAIL “A” Shipping Plug
DETAIL “B” Vent Plug
Load Resistor
Bird 8890 series 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 (Figure 3,
Detail “B”) relieves this pressure while protecting the opening from dirt or other contaminants.
Thermal Interlock
When installed, a passive, normally closed over-temperature thermoswitch opens above the maximum safe load
temperature of 236 °C (457 °F), turning off transmitter power. The interlock will not permit use of the transmitter
until the load has reached a safe temperature.
Blower Assembly
When installed, the blower assembly provides forced airflow with two blowers. Baffles direct the airflow from the
blowers over the radiator fins, doubling the heat transfer efficiency.
Example - A 2.5 kW load will safely dissipate 5 kW. A passive,
normally open control thermoswitch closes when the coolant reaches 155 °C (311 °F), turning the fans on.
The baffles interfere with the free flow of normal air currents, causing a 50% reduction in heat transfer efficiency if
the forced airflow is stopped. Thus, a 2.5 kW load will have its maximum power dissipation reduced to 1.25 kW.
Figure 3 Blower Plugs
3
Page 16
4
Page 17
Chapter 3Installation
Unpacking 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.
Note: Immediately notify the shipping carrier and Bird Technologies Group.
•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.
Setting Up the Load
Note: Before first using the load, get a resistance baseline for future maintenance. Refer to "Measuring
the DC Resistance" on page 14.
1.Remove the shipping plug from the load.
2.Install the vent plug.
Note: Refer to Figure 3 on page 3 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 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.
Bird 8890 series 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
3
a
⁄8" (9.53 mm) diameter max.
1
⁄2" x 2023⁄32" rectangle (114.3 x 526.3 mm). Use a screw with
•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.
5
Page 18
Installing the Thermoswitch
Bird 8890 series 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 at 120VAC and 5A at 230VAC.
Note: A control thermoswitch, P/N 2450-085, is used to control the optional blower assembly. It is normally
open, closing at 155 °C
(311 °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 back with the connector end up.
Note: In this position there is no danger of the coolant pouring out through
the socket plug hole.
4.Do one of the following:
•For Interlock Thermoswitch:
Remove the socket plug just above the connector assembly with a
wrench. See “Installing the Interlock Connection” on page 6.
9
⁄16" hex
•For Control Thermoswitch:
Remove the top socket plug with a
5.Replace the plug with the thermoswitch.
6.Apply pipe sealing compound sparingly to ONLY the external threads of the thermoswitch.
9
⁄16" hex wrench.
7.Check for coolant leaks upon completion.
Installing the 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 nut off the thermoswitch jack (B).
3.Unscrew the small knurled cover fitting from the base plug (D) of the connector to
release the base.
4.Thread the control switch wires through the clamp (E) with the washers (F) inside and
with its threaded fitting in place.
5.Service the control switch wire with short tips and put spaghetti sleeves over the wire
ends if necessary.
CAUTION
Do not contaminate the coolant with pipe sealant.
CAUTION
6
Page 19
6.Securely solder the control switch leads to the lugs (G) of the connector base.
Note: The ring-nut (A) must be in place over the base plug (D) with the knurled
end facing out.
7.Screw on the cover ring, then fasten the cable clamp (E) in place and tighten both
yoke screws (H).
8.Put the plug back on the thermoswitch and tighten the nut (A).
Figure 4 Thermoswitch Assembly
Connecting RF Power
Note: After installing the load, the RF transmission line can be attached using standard coaxial line cou-
pling 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.
Using a “QC” Connector Coupling
Use a 50 ohm coaxial cable such as RG-218/U or -220/U (-17A or -19A), appropriate for the frequency and power
level of operation.
Note: Use a cable connector which will mate with the one on the load.
Using a 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.
7
Page 20
Using a Swivel Flanged Coupling
BOLTBULLETLOADRF COAXIAL LINE
RF COAXIAL
LINE
CLAMPING
BANDS
CONNECTOR
SLEEVE
BULLET
LOAD
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.
5.Insert the bolt sets and tighten evenly all around to transmission line manufacturer’s
recommended torque.
Figure 5 Swivel Flanged Coupling
Using a Unflanged Coupling
1.Insert the center bullet
2.Push until it sets 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
Note: The swivel flange on the load makes connection independent of the
orientation of the fixed flange on the coaxial input outer conductor.
Note: Use all of the bolts.
Using an AC Power Hookup
WARNING
Turn off AC power and RF power when attaching the power cable.
CAUTION
Check the local electrical code for proper AC hookup prior to operation of the unit. Make sure the neutral or return
hookup is only used for that purpose.
AC power is only required if the blower assembly is installed. The AC power supply required is 115/230 V, depending
on the blower, @ 50/60 Hz, 1φ. The blower is equipped with an IEC 320 “cold” (65 °C) AC inlet.
8
Page 21
Chapter 4Operating Instructions, No Blower
Normal Operation
Bird 8890 series– 300 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.
Operating Under Abnormal Conditions
The load can be moderatly overloaded for short periods.
CAUTION
Make sure the interlock is properly connected when overloaded to prevent damage to the load.
Shutting Down
Note: 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.
Note: If the interlock thermoswitch is properly connected, RF power will be automatically turned off when
the coolant temperature reaches an unsafe level.
9
Page 22
10
Page 23
Chapter 5Operating Instructions, With Blower
CAUTION
Maximum power is 1,250 W when the blower is not running. If the indicator light should turn off, immediately
reduce RF power to less than 1,250 W.
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.
Blower Controls
Bird 8890 series –310 and –320 Loads are equipped with a control switch and indicator light on the front of the
blower assembly. The switch is labelled MANUAL/AUTOMATIC.
•When the switch is set to MANUAL, the fans run continuously.
•When set to AUTOMATIC, the fans turn on when the coolant reaches a preset temperature.
Note: The indicator light, labeled BLOWER ON, turns on whenever the unit is connected to AC power.
Normal Operation
1.Ensure the indicator light is on.
2.Set the switch to MANUAL for a few moments.
3.Ensure the fans are working properly.
4.Set the switch back to AUTOMATIC.
5.Apply RF power.
Operating Under Abnormal Conditions
The load can be subjected to higher power levels for short intervals. If this is likely, make sure the interlock is properly connected to prevent damage to the load.
Note: A properly connected interlock will prevent overload.
If the indicator light turns off or the fans stop unexpectedly, do one of the following:
•Immediately turn off RF power.
•Reduce the RF power to less than 1,250 W.
Note: Refer to "Troubleshooting" on page 13 to correct the problem.
Shutting Down the Load
1.Turn off RF power at the source.
2.Wait approximately 15 minutes, or for the fans to stop running.
Note: This will allow the load to cool without causing heat stress.
3.Turn off the blower.
Emergency Shutdown
Turn off RF power at the source.
Note: If the interlock thermoswitch is properly connected, RF power will be automatically turned off when
the coolant temperature reaches an unsafe level.
11
Page 24
12
Page 25
Chapter 6Maintenance
This chapter covers cleaning, inspection, trouble-shooting, and specifications for the Bird 8890 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 blower assembly from supply voltage before performing any maintenance.
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.
ProblemPossible CauseCorrection
No air flow from blowers;
“BLOWER ON” light off.
No air flow from blowers;
“BLOWER ON” light on.
Air flow from blowers;
“BLOWER ON” light off.
Leaking coolant.Loose clamping band.Tighten the clamping band.
High or low DC
resistance.
Overheating radiator.RF power too high.Lower RF power. See “Specifications” on page 20 for
Unplugged power cable.Connect the power cable.
No AC power.Make sure AC power is properly connected and turned
Fuse burnout.Replace fuse after correcting the burnout cause. See
Fan obstructed by bent grill.Straighten the grill.
Fan motors overheated.Clean the grill and fan blades. See “Cleaning the Load
Fan motors burnt out.Replace the fan motors (See “Replacing the Fan” on
Lamp burnout.Replace lamp. See “Replacing the Indicator Light” on
Defective or improperly
installed O-ring.
Loose RF input connector.Tighten connector.
Faulty RF input connector.Model 8890: Replace connector. See “Replacing the RF
Faulty resistor.Replace the resistor. See “Replacing the Load Resistor”
Coolant level too low.Check the coolant level. Add coolant if necessary. See
Coolant degraded.Replace the coolant. See “Inspecting the Coolant Level”
Faulty control thermoswitch
(blower only).
Faulty resistor.Replace the resistor. See “Replacing the Load Resistor”
on.
“Replacing the Fuse” on page 16.
Resistor” on page 14.
page 17).
page 16.
Replace the O-ring. See “Replacing the Load Resistor”
on page 17.
Connector” on page 16.
All other models: Return the unit for service.
on page 17.
maximum RF power.
“Inspecting the Coolant Level” on page 15.
on page 15.
Replace control thermoswitch. See “Installing the
Thermoswitch” on page 6.
on page 17.
13
Page 26
Maintenance
Cleaning the Load
Cleaning the Load Resistor
•The outside surface of the instrument should be wiped free of dust and dirt when necessary.
•Clean the cooling fins.
Note: 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.
Cleaning the Blower Assembly
•The intake grills, fans, and inside of the baffles should be wiped free of dust and dirt when necessary.
Note: Excessive dust will interfere with heat dissipation.
When the blower assembly is installed, it will be necessary to partially disassemble the blower to clean the load’s
radiator fins.
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
Do not operate with side panel removed. Doing so could result in personal injury.
1.Unscrew both 10-32 truss head screws that secure one of the side baffles and remove it.
2.Clean the load
3.Secure the side baffle with the 10-32 truss head screws.
4.Repeat Steps 1-3 for the other side baffle.
Inspecting the Load
•Inspect the unit every six months.
a.Check for coolant leakage around the clamping band.
b.Check for coolant leakage around the thermoswitch.
c.Check for corrosion.
Measuring the 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.
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.
14
Page 27
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.
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.
Figure 7 Measuring Resistance
Inspecting the Coolant Level
Coolant lifetime will vary greatly depending on the operating temperature.
•Heavy Use (full RF power for long times, high ambient temperature, 50 Hz AC supply):
Inspect the coolant every 500 hours.
•Light Use (fraction of full power, low ambient temperature, 60 Hz AC supply):
Inspect coolant every 2,000 hours.
Note: Correct any coolant leakage before inspection. See “Troubleshooting” on page 13.
WARNING
Disconnect the unit from all power sources before servicing. The unit may be energized from multiple sources.
The potential for electric shock exists.
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.
Note: Correct any coolant leakage before inspection. (See “Troubleshooting” on page 11).
1.Remove the load resistor (Refer to “Load Resistor” on page 18).
Use only Bird coolant, P/N 5-1070, to prevent damage to the load.
2.Inspect the coolant.
n
CAUTION
•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 4
below the top surface of the resistor assembly mounting ring, at ambient temperature.
3.Add coolant if necessary.
3
⁄4 to 5 inches (125 mm)
15
Page 28
Repairing the Load
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
ONLY the Model 8890 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. 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.
Replacing the Fuse
Note: Correct the fuse burnout cause. Common causes include stuck or blocked fans or a short circuit in the
motor or blower wiring. See “Troubleshooting” on page 13.
WARNING
Disconnect the unit from all power sources before servicing. The unit may be energized from multiple sources.
The potential for electric shock exists.
Note: The fuse is located in the AC module on the back of the blower.
1.Press the locking tab on the fuse drawer.
2.Remove the drawer.
3.Replace the fuse.
4.Push the drawer into the AC module until it locks into place.
Replacing the Indicator Light
1.Remove the four 8-32 pan head screws from the front and back of the base frame.
2.Pull the fan guard straight off the bottom.
3.Remove the quick disconnects on the light.
4.Unscrew the retaining sleeve.
5.Remove the light unit.
6.Remove the lens while pressing both locking tabs.
7.Release the lamp by pressing the housing’s center slot with a small screwdriver.
8.Push the new lamp into the housing until it snaps into place.
9.Replace the lens.
10. Put the light unit back in place.
11. Secure the fan guard with the 8-32 pan head screws.
Note: See “Specifications” on page 20 for fuse type and current rating.
Note: If the fans still do not run or if the fuse burns out again, return the
blower assembly to the factory.
16
Page 29
Replacing the Load Resistor
1.Remove the vent plug.
2.Install the shipping plug.
3.Stand the unit on its back with the connector end up.
4.Unscrew and remove the clamping band.
5.Lift the load resistor assembly out of the tank.
6.Allow any coolant to drip back into the tank.
7.Check the O-Ring.
8.Replace the entire load resistor assembly.
9.Put the clamping band in place and tighten it.
10. Remove the shipping plug.
11. Install the vent plug.
Replacing the Fan
Note: In this position there is no danger of the coolant pouring out through
the socket plug hole.
Note: It should be free of twists and positioned evenly around the flange of the
resistor housing.
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.
WARNI NG
Disconnect the unit from all power sources before servicing. The unit may be
energized from multiple sources. The potential for electric shock exists.
1.Remove the four 8-32 pan head screws from the front and back of the base frame.
2.Pull the fan guard straight off the bottom.
3.Carefully unsolder the color coded connecting wires.
Note: Note the connections for resoldering.
4.Remove the four fan mounting screws.
5.Remove the defective fan.
Note: Be careful not to lose the lipped retaining washers.
6.Insert the replacement fan with the fan blade assembly facing down, towards the fan
guard grill.
7.Insert the mounting screws and retaining washers into the mounting holes.
8.Turn the washers so that the lipped portion fits over the rim of the fan frame.
9.Tighten the screws.
Note: If the fan replaced is the one closest to the power socket, reattach the
green ground wire to the closest mounting screw.
10. Solder the connecting wires to the solder lugs on the motor unit according to the
color coding.
11. Replace the fan guard and screws.
Note: Before reattaching the blower assembly to the load, check the fans for
free and unimpeded movement of the blades.
12. Connect the unit to AC power.
13. Set the switch to MANUAL.
14. Ensure that the fans work properly.
15. Set the switch back to AUTOMATIC.
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Page 30
Figure 8 Schematic Diagram
N L
L1
L2
L1
L2
ROTATION
FANS
GRN/YEL
AC
RECEPTACLE
WHT/YEL
TO CONTROL
THERMOSWITCH
BLACK
RED
TOGGLE
SWITCH
WHT/BLK
WHT/BLK
INDICATOR
LIGHT
WHT/BLK
Storage and Shipment
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
18
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.
5.Pack and brace the load in a sturdy wooden crate for shipment.
Page 31
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.
115 V ±10% @ 50/60 Hz ±3%
230 V ±10% @ 50/60 Hz ±3%
AC Line Power Rating460 W max
IEC (5 x 20 mm) Type T
Fuse Rating
115 Va c
230 Vac
1 A
500 mA
Thermoswitch
Interlock
Fan Control
Normally closed. Opens at 236 °C (457 °F)
Normally open. Closes at 155 °C (311 °F)
Thermoswitch Rating
115 Va c
230 Vac
10 A
5 A
Ambient Temperature–40 to +45 °C (–40 to +113 °F)
Altitude
††
1520 m (5000 ft.)
Humidity95% noncondensing max
Cooling methodOil dielectric and convection currents
Dimensions
Without blower
With blower
21.75" L x 7.5” W x 17.25" H (551 x 190 x 437 mm)
21.75" L x 7.5” W x 21
7
⁄
" H (551 x 190 x 556 mm)
8
Weight, Nominal59 lb. (27 kg)
FinishGrey Powder Coat
* Power rating with blower installed and operating: 5000 W
Power rating with blower installed and NOT operating: 1250 W
† Set the duty factor so that the average power rating of the load is not exceeded.
‡ VSWR measured using a female N connector.
** For models 8890-300, -315, and -320 VSWR Measured using a female N connector
†† Derate RF power by 2.5% for every 305m (1,000 ft.) above 1,520m (5,000 ft.).
* Optional on the –300, standard on the –315 and –320
† Optional on the –300
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Page 34
Available “QC” Type Connectors
ConnectorPart Number
BNC-Female4240-125
BNC-Male4240-132
C-Female4240-100
C-Male4240-110
HN-Female4240-268
HN-Male4240-278
LC-Female
LC-Male4240-025
Open Term.# 10-32 Nut4240-080
LT-Female4240-018
LT-Male4240-012
N-Female4240-062
N-Male4240-063
*
4240-031
SC-Female4240-090
SMA-Female4240-336
SMA-Male4240-334
7/16 Jack, IEC Type 169-44240-344
7/16 Plug, IEC Type 169-44240-363
Mini UHF-Female4240-346
UHF-Female4240-050
UHF-Male4240-179
1-5/8” EIA Fixed4240-096
1-5/8” EIA Swivel4240-208
7/8” EIA4240-002
TNC-Female4240-156
TNC-Male4240-160
* Normally supplied on the 8890
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Page 35
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.
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