BIRD TERMALINE 8400 SERIES User manual

INSTRUCTION BOOK
OPERATING INSTRUCTIONS
TERMALINE®
LOAD RESISTOR
SERIES 8400
©Copyright 1998 by Bird Electronic Corporation
Instruction Book Part Number 920-8400S Rev. A
Termaline®is a Registered Trademark
of Bird Electronic Corporation
Electronic Corporation
Cleveland (Solon) Ohio USA
Advanced Test Equipment Rentals
www.atecorp.com 800-404-ATEC (2832)
®
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1

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.
Keep Away From Live Circuits
Operating personnel must at all times observe general safety precautions. Do
not replace components or make adjustments inside equipment with the high
voltage supply turned on. To avoid casualties, always remove power.
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 some-
one who is capable of rendering aid.
Shock Hazard
Do not attempt to disconnect an RF transmission or any other high voltage
line while power is present. Radiated RF power is a potential health hazard.
Resuscitation
Personnel working with or near high voltage should be familiar with modern
methods of resuscitation.
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.
This symbol appears on the equipment indicating there is
important information in the instruction manual regard-
ing that particular area.
+Note: Calls attention to supplemental informa-
tion.
i

Warning Statements
The following safety warnings will appear in the text and are repeated here
for emphasis.
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
Do not attempt to disconnect these loads from the coaxial cable while
RF energy is still being applied. Leaking RF power is a potential
health hazard.
Caution Statements
The following equipment cautions appear in the text and are repeated here
for emphasis.
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 600 W.
Load failure will result.
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 ANU-
LAR LA PROTECCIÓN DE SEGURIDAD DEL INSTRU-
MENTO.
ii

BENUTZUNG
WIRD DAS GERÄT AUF ANDERE WEISE VERWEN-
DET ALS VOM HERSTELLER BESCHRIEBEN, KANN
DIE GERÄTESICHERHEIT BEEINTRÄCHTIGT WER-
DEN.
UTILISATION
TOUTE UTILISATION DE CET INSTRUMENT QUI
N’EST PAS EXPLICITEMENT PRÉVUE PAR LE FABRI-
CANT PEUT ENDOMMAGER LE DISPOSITIF DE PRO-
TECTION DE L’INSTRUMENT.
IMPIEGO
QUALORA QUESTO STRUMENTO VENISSE UTILIZ-
ZATO IN MODO DIVERSO DA COME SPECIFICATO
DAL PRODUTTORE LA PROZIONE DI SICUREZZA
POTREBBE VENIRNE COMPROMESSA.
SERVICE
SERVICING INSTRUCTIONS ARE FOR USE BY SERV-
ICE - TRAINED PERSONNEL ONLY. TO AVOID DAN-
GEROUS 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 CA-
PACITADO. PARA EVITAR EL PELIGRO DE DESCAR-
GAS 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 SERV-
ICEPERSONAL DURCHZUFÜHREN.
iii

ENTRENTIEN
L’EMPLOI DES INSTRUCTIONS D’ENTRETIEN DOIT
ÊTRE RÉSERVÉ AU PERSONNEL FORMÉ AUX OPÉ-
RATIONS 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 EFFETTU-
ARRE ALCUNA RIPARAZIONE A MENO CHE QUALI-
FICATI A FARLA.
iv

About this Manual
This instruction book covers the Models 8401, 8402, and 8404 Termaline
Load Resistors.
This instruction book is arranged so that essential information on safety is
contained in the front of the book. Reading the Safety Precaution section be-
fore 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, Chapter 2 - Theory
of Operation, and Chapter 3 - Installation, to get an overview of equipment
capabilities and how to install it. An experienced operator can refer to Chap-
ter 4 - Operating Instructions. All instructions necessary to operate the
equipment, are contained in this chapter.
Maintenance
All personnel should be familiar with calibration and repair information
found in Chapter 5 - Maintenance. If a failure should occur, the troubleshoot-
ing 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.
Changes To This Manual
We have made every effort to ensure this manual is accurate. If you should
discover any errors, or if you have suggestions for improving this manual,
please send your comments 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.
v

vi
Bird Series 8400S Termaline Coaxial Load Resistor

Table Of Contents
Safety Precautions. .......................i
Warning Statements. ....................ii
Cautions Statements. ....................ii
Safety Statements .....................ii
About This Manual .....................v
Introduction. ..........................1
Purpose and Function. ...................1
Description. ........................1
Performance Characteristics and Capabilities. ..........1
Dimensions and Weight. ...................2
Power and Utility Requirements. ...............2
Environmental Requirements. .................2
Items Supplied. ......................2
Items Required. ......................2
Tools and Test Equipment...................2
Specifications. .......................3
Theory of Operation. ......................5
General. .........................5
Cooling. .........................5
Installation. ..........................7
Location. .........................7
Mounting. .........................7
Operating Instructions. .....................9
Use and Function of Controls. ................9
vii

Initial Adjustments. .....................9
Start-up. .........................9
Normal Operation. .....................9
Operating Under Emergency, Adverse, or Abnormal Conditions....9
Shutdown. ........................10
Emergency Shutdown. ...................10
Maintenance. .........................11
Cleaning. ........................11
Inspection. ........................12
Preventive Maintenance. ..................12
DC Resistance. ......................12
Disassembly...........................13
RF Connector Replacement..................13
Diaphragm and Coolant Oil. .................13
RF Load Resistor Assembly. ................13
Assembly. ...........................14
RF Connector. ......................14
Diaphragm and Coolant Oil. .................14
RF Load Resistor Assembly. ................14
Repairs.............................14
Preparation For Shipment. .................15
Storage. .........................15
Customer Service. .......................15
Sales /Repair Facilities....................15
Sales Offices........................15
Replacement Parts List. .....................16
viii

1
Chapter 1
Introduction
This publication refers to the Termaline Load Resistors
Models 8401, 8402, and 8404. The difference between
models is listed in the specifications. These models will
generally be referred to as a load throughout this man-
ual.
Purpose and
Function
These loads are portable, general purpose 50 ohm coaxial
RF transmission line terminations. They are self-
contained units requiring no outside power source or ad-
ditional equipment. They provide an accurate, dependable,
and practically nonreflective termination for testing and
adjusting RF transmitters operating in the stated fre-
quency band.
Some examples of the uses of these loads are:
sAs a substitute antenna.
sFor tuning RF transmitters - under nonradiat-
ing conditions.
sFor making routine tests and adjustments.
sAs a substitute for any 50 ohm circuit loading
element.
Description These models are rectangular in shape with transverse
fins encasing an oil-dielectric-filled coolant cylinder. Extra
thick fins at the front and rear are bent 90° to form bot-
tom mounting flanges. These flanges are supports for free
standing use or brackets for fixed mounting. Flange holes
are provided for this purpose. A retractable handle is re-
cessed in the radiator fins.
Performance
Characteristics
and Capabilities
The loads can absorb and dissipate up to 600 W of RF
power continuously. They show a VSWR of 1.1 to 1.0
from dc to 1000 MHz, 1.2 to 1.0 from 1000-2800 MHz,
and 1.3 to 1.0 from 2800-3000 MHz.
Dimensions and
Weight
All three models have the same dimensions: 16-1/16
inches L x 5-15/16 inches W x 8-1/2 inches H (408 x 151
x 216 mm). They each have a net weight of 19.6 lb (8.9
kg) and a shipping weight of approximately 25 lb (11.34
kg).
Power and Utility
Requirements
These load resistors are passive devices that are self con-
tained and do not require a source of power or utility

service to perform their function, other than the RF input
power.
Environmental
Requirements
The load should be operated in an environment as free of
dust and vibration as possible. For proper operation the
ambient temperature should remain within the range of
-40°C to +45°C (-40°F to +113°F). Allow at least 12
inches (304.8 mm) of clear space around the load to pro-
vide an unimpeded flow of convection air currents for
adequate heat dissipation.
Items Supplied The load is equipped with:
sModel 8401 — Female N “QC” (quick change)
connector.
sModel 8402 — Female C “QC” (quick change)
connector with a dust cap and secured by a
ball chain anchor.
sModel 8404 — Female N with a Male N/Male
N adaptor, dust cap, and secured by a ball
chain anchor.
sInstruction Manual
Item Required Coaxial cable with the appropriate connector plug.
Tools and Test
Equipment
sScrewdriver — for disassembly of this equip-
ment.
sAn ohmmeter with an accuracy of 1 percent or
better at 50 ohms — is recommended for
checking the resistance value of the resistor.
Bird Series 8400S Termaline Coaxial Load Resistor
2

Specifications
Impedance: 50 ohms nominal
VSWR:
dc-1000MHz
1000-2800MHz
2800-3000MHz
1.1:1.0 Maximum
1.2:1.0 Maximum
1.3:1.0 Maximum
Connectors:
Model 8401
Model 8402
Model 8404
Female N “QC” type normally supplied
Female C “QC” type with dust cap nor-
mally supplied
Same as 8401 plus UG-57G/U N(M) to
N(M) adapter and dust cap
Power Range 600 W continuous
Frequency Range dc-3000 MHz
Dimensions 16-1/16"L x 5-15/16" W x 8-1/2"H
(408 x 151 x 216 mm)
Ambient Temperature -40°C to +45°C (-40°F to +113°F)
Coolant Method Oil dielectric and air convention currents
Weight 19.6 lb (9 kg)
Operating Position Horizontal only
Finish Grey Powder Coat
3
Introduction

4
Bird Series 8400S Termaline Coaxial Load Resistor

Chapter 2
Theory of Operation
General The Models 8401, 8402, and 8404 Termaline Load Resis-
tors consist essentially of a carbon film-on-ceramic resis-
tor immersed in a dielectric coolant. The resistor,
individually selected for its accuracy, is enclosed in a spe-
cial exponentially tapered housing. This provides a linear
reduction in surge impedance directly proportional to the
distance along the resistor. When surrounded by the di-
electric coolant, the characteristic impedance is therefore
50 ohms at the front (connector end), 25 ohms at the
mid-point to compensate for the resistance already passed
over, and zero ohms at the rear where the resistor joins
the housing, forming the return conductor of the coaxial
circuit. This produces a uniform and practically reflection-
less line termination over the stated frequencies for the
load resistor.
Cooling The dielectric coolant is chosen for its desirable dielectric
and thermal characteristics. Cooling of the load is accom-
plished by natural fluid and air convection currents. The
0.7 gallon of dielectric coolant carries the electrically gen-
erated heat from the resistor to the walls of the cylindri-
cal cooling tank. This tank is encased in a set of
radiating fins constructed from heavy gauge aluminum al-
loy and firmly pressed onto the cylinder. The heat from
the dielectric fluid is transferred to the surrounding air
by the fins.
Expansion of the coolant, caused by the rise in its tem-
perature, is allowed by means of a synthetic rubber dia-
phragm (not visible) inside the rear cover dome of the
unit.
5

6
Bird Series 8400S Termaline Coaxial Load Resistor

Chapter 3
Installation
Location
CAUTION
The load is designed for operation in a horizontal plane
only, with mounting brackets down. Do not operate in
any other position.
Install the Termaline Load Resistor in a location that:
1. Has sufficient room to provide at least twelve
inches (304.8 mm) of free space around and
above the unit.
2. Is the shortest possible distance, or cable length
from the transmitting equipment.
3. Ensures the operation of the load in a horizontal
position only, with the handle on top.
Mounting The load may be used for portable operation or for fixed
installation, that is, it may stand free or may be secured
to a bench or any convenient flat surface. The front and
rear fins are made of heavier gauge material bent out-
ward 90 degrees to form mounting flanges. At each cor-
ner of these flanges is a rubber bumper foot attached
with an acorn nut. To fasten the load by means of its
base mounting flanges:
1. Remove the four rubber bumpers
2. Fasten the load with four screws. Put one screw
in each of the four 9/32 inch holes.
Note: Use screws up to 1/4 inch diameter.
The holes are arranged in a 5-1/8 x 12-17/32 inch rectan-
gle (130.2 x 318.3 mm).
7

8
Bird Series 8400S Termaline Coaxial Load Resistor

Chapter 4
Operating Instructions
Use and
Function of
Controls
Because these are passive devices, there are no operating
controls on the Load Resistors.
Initial
Adjustments
No initial adjustments are required other than to connect
the load to the RF source by means of a coaxial cable
equipped with a suitable matching connector plug.
Start-up 1. Connect a Male type plug, which mates with the
RF input connector, to the load.
2. Connect the load to the transmitting equipment
under test with 50 ohm coaxial cable.
3. After the transmitter has been connected to the
load, proceed according to the transmitter manu-
facturer’s instructions.
When reconnecting the antenna, it may be necessary to
slightly readjust the transmitter due to possible differ-
ences in VSWR between the load and the antenna sys-
tem.
Normal
Operation
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.
Having no indicators or controls, these loads require no
special operating procedures or surveillance when prop-
erly used.
Operating Under
Emergency,
Adverse, or
Abnormal
Conditions
CAUTION
Do not operate this equipment continuously above the
rated 600 W. Load failure will result.
9

Shutdown Because the loads are passive devices, there is no way to
turn them off. Power must be shut off at the source of
the RF energy.
Emergency
Shutdown
WARNING
Do not attempt to disconnect these loads from the
coaxial cable while RF energy is still being applied.
Leaking RF power is a potential health hazard.
Turn off the RF power at the source.
10
Bird Series 8400S Termaline Coaxial Load Resistor