BIRD TERMALINE 8201 User manual

TERMALINE®COAXIAL
LOAD RESISTOR
MODELS 8201 & 8203
Operation Manual
©Copyright 2017 by Bird Technologies Inc.
Instruction Book P/N 920-8201/03 Rev. B
Termaline®is a Registered Trademark
of Bird Electronic Corporation

i
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 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.
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 applied.

Safety Precautions
ii
Safety Symbols
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.
See page 6
See page 7
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.
The caution symbol appears on the equipment indicating
there is important information in the instruction manual
regarding that particular area.
WARNING
When power is in the upper range of the load’s capacity, the radiator will
become hot - care should be used in touching the equipment.
WARNING
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.

Termaline® Coaxial Load Resistor
iii
Caution Statements
The following cautions appear in the text whenever the equipment is in danger
of damage, and are repeated here for emphasis.
See page 5
See page 7
CAUTION
The load is designed for operation in a horizontal plane only, with
mounting brackets down. Do not operate in any other position.
CAUTION
Do not operate this equipment continuously above the rated 500 W for
Model 8201, or 600 W for Model 8203. Load failure will result.

Safety Precautions
iv
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.

Termaline® Coaxial Load Resistor
v
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.

About This Manual
vi
About This Manual
This instruction book covers the Models 8201 and 8203 Termaline Load
Resistors.
Changes To The Manual
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.
Chapter Layout
This instruction book is arranged so that essential information on safety is
contained in the front of the book. Reading the Safety Precaution section before
operating the equipment is strongly advised.
The remainder of this Instruction Book is divided into chapters and sections.
Operation — First time operators should read Chapter 1, Introduction,
page 1 , Chapter 2, Theory of Operation, page 4 , and Chapter 3, Installation,
page 5 , to get an overview of equipment capabilities and how to install it. An
experienced operator can refer to Chapter 4, Operating Instructions, page 6 .
All instructions necessary to operate the equipment, are contained in this
section.
Maintenance — All personnel should be familiar with calibration and repair
information found in Chapter 5, Maintenance, page 8 . If a failure should occur,
the troubleshooting section will aid in isolating and repairing the failure.
Parts — For location of major assemblies or parts refer to the part lists and
associated drawings in Chapter 5, Maintenance, page 8 .

vii
Table of Contents
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Warning Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Caution Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Safety Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Changes To The Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Chapter Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Chapter 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Purpose and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Performance and Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Power and Utility Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Items Supplied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Items Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tools and Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Chapter 2 Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Chapter 3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Chapter 4 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Use and Function of Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Initial Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Table of Contents
viii
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operating Under Emergency, Adverse, or Abnormal Conditions . . . . . . . . . 7
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Emergency Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Chapter 5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DC Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
RF Connector Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Diaphragm and Coolant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
RF Load Resistor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
RF Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Diaphragm and Coolant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
RF Load Resistor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Preparation For Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Replacement Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Models 8201/03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1
Chapter 1 Introduction
This publication refers to the Termaline Load Resistor models 8201 and 8203.
The differences between the models are listed in the specifications. Both
models will generally be referred to as a load throughout this manual.
Purpose and Function
These loads are portable, general purpose 50 ohm coaxial transmission line
terminations. They are self-contained units requiring no outside power source
or additional equipment. The Model 8201 load provides an accurate,
dependable, and practically non-reflective termination for testing and adjusting
transmitters under non-radiating conditions from DC to 2500 MHz and the
Model 8203 from DC to 1000 MHz.
Some examples of the uses of these loads are:
As a substitute antenna.
For tuning RF transmitters - under non-radiating conditions.
For making routine tests and adjustments.
As a substitute for any 50 ohm circuit loading element.
To measure, with a suitable indicating device, the power output of any
coaxially transmitted RF signal within its rating.
Description
These models are rectangular in shape with transverse fins encasing an oil-
dielectric-filled coolant cylinder. A retractable handle is recessed in the radiator
fins. Extra thick fins at the front and rear are bent 90° to form bottom mounting
flanges. These flanges are supports for free standing use or brackets for fixed
mounting. Flange holes are provided for this purpose.
Performance and Capabilities
The Model 8201 Termaline Load Resistor can absorb and dissipate up to 500 W
of RF power continuously over a frequency range of DC to 2500 MHz. It will
show a maximum VSWR of 1.1 to 1.0 from DC to 1000 MHz and 1.25 to 1.0 from
1000 to 2500 MHz.