Bird Technologies 8930 User Manual

INSTRUCTION BOOK

TERMALINE® LOAD RESISTOR

SERIES 8930

©Copyright 2008 by Bird Electronic Corporation

Instruction Book Part Number 920-8930S Rev. E

Termaline

®

is a Registered Trademark

of Bird Electronic Corporation

This page intentionally left 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.

Keep Away From Live Circuits

Operating personnel must at all times observe normal safety regulations.
Do not replace components or make adjustments inside the equipment
with high voltage turned on. To avoid casualties, always remove power.

Shock Hazard

Do not attempt to remove the RF transmission line while RF power is
present.

Do Not Service or Adjust Alone

Under no circumstances should any person reach into an enclosure for the
purpose of service or adjustment of equipment except in the presence of
someone who is capable of rendering aid.

Safety Earth Ground

An uninterruptible 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.

Chemical Hazard

Dry cleaning solvents for cleaning parts may be potentially dangerous.
Avoid inhalation of fumes or prolonged contact with skin.

Resuscitation

Personnel working with or near high voltages should be familiar with
modern methods of resuscitation.

i

Bird 8930 Series Termaline Coaxial Load Resistor

Safety Symbols

Warning notes call attention to a procedure which, if not correctly

performed, could result in personal injury.

Caution notes call attention to a procedure which, if not correctly

performed, could result in damage to the instrument.

This symbol indicates that a shock hazard exists if the
precautions in the instruction manual are not follwed.

The caution symbol appears on the equipment indicating
there is important information in the instruction manual
regarding that particular area. See page 15 for specific
cautions.

WARNING

CAUTION

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.

WARNING

Turn off ac power and RF power when attaching the power cable.

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.

ii

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.

Caution Statements

The following equipment cautions appear in the text whenever the
equipment is in danger of damage and are repeated here for emphasis.

CAUTION

Do not block airflow. The air intake vent on the bottom of the load must

not be obstructed.

CAUTION

This load is designed for operation in a horizontal position only, with

the vent plug up. Do not use in any other manner.

CAUTION

If installed, connect optional interlock before applying RF power.

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.

CAUTION

Maximum power is 2,500 W when the blower is not running. If the

indicator light should turn off, immediately reduce RF power to less

than 2,500 W.

CAUTION

Use only Bird coolant, P/N 5-1070, to prevent damage to the load.

iii

Bird 8930 Series Termaline Coaxial Load Resistor

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.

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 DESCARGÉAS ELCTRICAS, NO REALICE NINGÚN
SERVICIO A MENOS QUE ESTÉ CAPACITADO PARA HACERIO.

WARTUNG
ANWEISUNGEN FÜR DIE WARTUNG DES GERÄTES GELTEN NUR

FÜR GESCHULTES FACHPERSONAL.

iv

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.

CONNECT INTERLOCK TO TRANSMITTER/GENERATOR/
AMPLIFIER BEFORE OPERATING.

BRANCHER LE VERROUILLAGE À L’ÉMETTEUR/

GÉNÉRATEUR/AMPLIFICATEUR AVANT EMPLOI.
CONECTE EL INTERBLOQUEO AL TRANSMISOR/GENERADOR/

AMPLIFICADOR ANTES DE LA OPERACION.
VOR INBETRIEBNAHME VERRIEGELUNG AM SENDER/

GENERATOR/VERSTÄRKER ANSCHLIESSEN.
PRIMA DI METTERE IN FUNZIONE L’APPARECCHIO, COLLEGARE

IL DISPOSITIVO DI BLOCCO AL TRASMETTITORE/GENERATORE/
AMPLIFICATORE.

v

Bird 8930 Series Termaline Coaxial Load Resistor

This instruction book covers the models listed below:

Connector 115 Vac 230 Vac

Female LC 8931-115 8931-230
1-5/8" EIA Flanged 8932-115 8932-230
3-1/8" EIA Flanged 8936-115 8936-230

About This Manual

3-1/8" Unflanged, Flush

8937-115 8937-230

Center
3-1/8" Unflanged,

8938-115 8938-230

Recessed Center

This instruction book is arranged so that essential information on safety
is contained in the front of the book. Reading the Safety Precautions
Section before operating the equipment is strongly advised.

The remainder of this Instruction Book is divided into Chapters and
Sections. At the beginning of each chapter a general overview will be
given, describing the contents of that chapter.

Operation

First time operators should read Chapter 1 – Introduction, and Chapter 3
– Installation, to get an overview of equipment capabilities and how to
install it. An experienced operator can refer to Chapter 4 – Operating
Instructions. All instructions necessary to operate the equipment, are
contained in this section.

Maintenance

All personnel should be familiar with preventative maintenance found in
Chapter 5 – Maintenance. If a failure should occur, the troubleshooting
section will aid in isolating and repairing the failure. Parts lists and
repair instructions are also in this chapter.

Changes

We have made every effort to ensure this manual is accurate at the time
of publication. If you should discover any errors or if you have suggestions
for improving this manual, please send your comment to our factory. This
manual may be periodically updated, when inquiring about updates to
this manual refer to the part number and revision level on the title page.

vi

Table of Contents

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

About This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . vi

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Items Supplied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Items Required but not Supplied. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Optional Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Load Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Power Rating Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Thermal Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Unpacking and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Thermoswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Interlock Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

AC Power Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Connecting RF Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 11

Blower Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Operation Under Abnormal Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Emergency Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

vii

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

DC Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

RF Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Load Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Indicator Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Storage and Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Available QC Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

viii

Chapter 1 Introduction

Bird 8930 Series Loads are general purpose, 50 ohm, coaxial RF
transmission line terminations, useful as standby reject loads for
single or double sideband transmitters. They provide accurate,
dependable, and low reflection line terminations over a frequency
range of dc – 1000 MHz. Up to 10,000 watts can be dissipated.

The loads have 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. A blower with three axial fans is on the bottom of the load.
The load’s simple and rugged design minimizes maintenance
requirements.

Items Supplied y Load Resistor: Pre-filled with coolant at the factory

y Detachable 3-wire power cable (without male plug for 230 Vac

power cable)

Items Required but

not Supplied

Optional

Accessories

y One Shipping Plug
y One Vent Plug
y Instruction Manual

y Coupling Kit: Connects the load to the RF line
y Male plug for the power cable (230 Vac only)

y Interlock Thermoswitch: Automatically shuts off the transmitter

to prevent overheating of the load

1

Bird 8930 Series Termaline Coaxial Load Resistor

MANUAL

AUTOMATIC

AC ON

9.5”

(241mm)

7”

(178mm)

(4) MTG.

HOLES

29”

(737mm)

33-3/8”

(847 mm)

14-7/8”

(378 mm)

FAN CONTROL

THERMOSWITCH

INTERLOCK

THERMOSWITCH

(OPTIONAL)

VENT PLUG

FAN GRILL

SIDE BAFFLE

SCREWS

“QC” CONNECTOR

SCREWS

CLAMPING BAND

AND O-RING

FUSE

DRAWER

Figure 1

Bird 8930 Series

Outline Drawing

2