BIRD Termaline 8890 Series User manual

INSTRUCTION BOOK
TERMALINE®LOAD RESISTOR
SERIES 8890
Bird® Electronic Corporation
30303 Aurora Road
Cleveland (Solon), Ohio 44139
Sales & Technical Support: 440-248-1200
866-695-4569 toll free
Sales email: [email protected]
Technical Support email: [e-mail]
©Copyright 2009 by Bird Electronic Corporation
Instruction Book Part Number 920-8890S Rev. C
Termaline®and Tenuline®are Registered Trademarks
of Bird Electronic Corporation
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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 publica-
tion. These precautions must be thoroughly understood and apply to all phases of
operation and maintenance.
Safety Symbols
 Note: Calls attention to supplemental information.
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.
WARNING
Remove Power
Observe general safety precautions. Do not open the instrument with the power on.
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.
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ii
Warning Statements
The following safety warnings appear in the text where there is danger to operat-
ing and maintenance personnel, and are repeated here for emphasis.
On page 5 and 6.
On page 7, 11, 13, 15 and 17.
On page 9.
On page 15
On page 16, 17, 18 and 19.
This symbol indicates that a shock hazard exists if the precau-
tions 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. See page 17 for specific cautions.
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. Refer to the Bird web site (See “The Bird
Web Site” on page 22) for more information.
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
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
Turn off AC power and RF power when attaching the power cable.
WARNING
Disconnect the blower assembly from supply voltage before performing any
maintenance.
WARNING
Disconnect the unit from all power sources before servicing. The unit may be
energized from multiple sources. The potential for electric shock exists.
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iii
On page 16.
Caution Statements
The following equipment cautions appear in the text and are repeated here for
emphasis.
On page 5.
On page 6.
On page 6.
On page 9.
On page 11.
On page 13.
On page 17.
WARNING
Do not operate with side panel removed. Doing so could result in
personal injury.
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
Do not contaminate the coolant with pipe sealant.
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
Make sure the interlock is properly connected when overloaded to prevent damage
to the load.
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.
CAUTION
Use only Bird coolant, P/N 5-1070, to prevent damage to the load.
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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.
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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.
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.
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vi
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.
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vii
About This Manual
This manual covers the operating and maintenance instructions for the following
models
 Note: When used in the rest of the manual, 889x refers to all models.
889x–300 refers only to loads without a blower. –315 and –320 refer to
loads with attached blowers.
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 revi-
sion on the title page.
Literature Contents
This instruction book is arranged so that essential information on safety is in the
front of the book. Reading the Safety Precautions before operating the equipment
is strongly advised. The remainder of this instruction book is divided into Chap-
ters and Sections.
Chapter Layout
Introduction - Describes the features of the Bird SignalHawk, lists equipment
supplied and optional equipment, and provides power-up instructions.
Connector
Model Number
Without
Blower
Blower,
115 Vac
Blower,
230 Vac
Female LC 8890-300 8890-315 8890-320
3-1/8" EIA Flanged 8891-300 8891-315 8891-320
1-5/8" EIA Flanged 8892-300 8892-315 8892-320
1-5/8" EIA Unflanged 8895-300 8895-315 8895-320
3-1/8" Unflanged, Flush Center, 51.5Ω8896-300
3-1/8" Unflanged, Flush Center 8897-300 8897-315 8897-320
3-1/8" Unflanged, Recessed Center 8898-300 8898-315 8898-320
Digital, 3-1/8" EIA Flanged 8891D300
Digital, 1-5/8" EIA Flanged 8892D300 8892D320
Digital, Female 13-30 8892D13-30
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viii
Theory of Operation - Describes how to use the SignalHawk’s PC Tool for the Vec-
tor Network 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 resis-
tor equipped with a blower unit.
Maintenance —Lists routine maintenance tasks as well as troubleshooting for
common problems. Specifications and parts information are also included.
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ix
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
Literature Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Chapter Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Items Supplied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Items Required but not Supplied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Chapter 1 Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Load Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Thermal Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Blower Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Chapter 2 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Setting Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installing the Thermoswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installing the Interlock Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Connecting RF Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Using a “QC” Connector Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Using a 13-30 Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Using a Swivel Flanged Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Using a Unflanged Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Using an AC Power Hookup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Chapter 3 Operating Instructions, No Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Operating Under Abnormal Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Shutting Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Emergency Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Chapter 4 Operating Instructions, With Blower. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Blower Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Operating Under Abnormal Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Shutting Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Emergency Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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x
Chapter 5 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Cleaning the Load Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Cleaning the Blower Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Inspecting the DC Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Inspecting the Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Replacing the RF Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Replacing the Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Replacing the Indicator Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Replacing the Load Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Replacing the Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Storage and Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Storing the Load Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Shipping the Load Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Available “QC” Type Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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1
Chapter 1 Introduction
Bird 889x loads are portable, 50 ohm, coaxial RF transmission line termina-
tions, designed for frequency ranges of DC – 2.4 GHz. 889xD loads are
designed for use in the UHF (470 – 860 MHz) band but are otherwise identi-
cal. They provide accurate, dependable, and low reflection line terminations.
Up to 2500 watts of RF power can be dissipated, 5000 watts if the optional
blower assembly is used.
The –300 is the basic load. The –315 and –320 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 freestand-
ing 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 rug-
ged design minimizes maintenance requirements.
Items Supplied
zLoad Resistor: Pre-filled with coolant at the factory
zShipping Plug
zVent Plug
zInstruction Manual
Items Required but not Supplied
zCoupling Kit: Connects the load to the RF line
Optional Accessories
zBird 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)
 The blower and control thermoswitch are standard on the –315
and –320 loads.
zInterlock Thermoswitch: Automatically shuts off the transmitter to
prevent overheating of the load.
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Introduction
2
Figure 1 Bird 8890 Series Outline Drawing - No Blower
Figure 2 Outline Drawing With 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
CO
NNE
C
T
O
R
VENT PLUG
INTERLOCK
THERMOSWITCH
(OPTIONAL)
FAN C
O
NTR
O
L
THERMOSWITCH
POWER CORD
20 ft (6 m) LONG
APPR
O
X.
!
BLOWER
ON
A
UTOMATIC
MANUAL
MANUAL /
AUTOMATIC
SWITCH
INDICATOR
LIGHT
21-7/8”
(556 mm)
4-7/8”
(124 mm)
7-7/8”
(199 mm)
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3
Chapter 2 Theory of Operation
Load Resistor
Bird 889x loads consist of a thin-film-on-ceramic resistor immersed in a dielec-
tric 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
O-ring seal
O-ring seal
DETAIL “A” -
Shipping Plug
DETAIL “B” -
Vent Plug
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Theory of Operation
4
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5
Chapter 3 Installation
This chapter provides information for on-site requirements, unpacking,
inspection, and preparing the load for use.
Unpacking and Inspection
1. Carefully inspect shipping container for signs of damage.
2. Do one of the following:
zIf the shipping container is damaged, do not unpack the unit. Immedi-
ately notify the shipping carrier and Bird Electronic Corporation.
zIf the shipping container is not damaged, unpack the unit. Save ship-
ping materials 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
zBefore first using the load, get a resistance baseline for future mainte-
nance. Refer to "Inspecting the DC Resistance" on page 16 for details.
zRemove the shipping plug from the load and replace it with the vent
plug. Refer to Figure 3 for pictures of the plugs.
Mounting
Place the load in a dry, dust and vibration free environment. Do not use out-
doors or in areas of condensing humidity. Allow at least 12" (30 cm) of clear-
ance on all sides of the load.
Bird 889x 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 41⁄2" x 20
23⁄32" rectangle (114.3 x 526.3 mm). Use a screw with a
3⁄8" (9.53 mm) diameter max.
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.
CAUTION
This load is designed for operation in a horizontal position only, with the
vent plug up. Do not use in any other manner.
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Installation
6
Installing the Thermoswitch
Bird 889x series Loads can be equipped with an optional interlock thermo-
switch, P/N 8890-008. It is normally closed, opening at 236 °C (457 °F), with a
rating of 10A @ 120Vac and 5A @ 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.
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:
zFor Interlock Thermoswitch:
Remove the socket plug just above the connector assembly with a 9⁄16"
hex wrench. See “Installing the Interlock Connection” on page 6.
zFor Control Thermoswitch:
Remove the top socket plug with a 9⁄16" hex wrench.
5. Replace the plug with the thermoswitch.
6. Apply pipe sealing compound to the external threads of the thermoswitch
sparingly, ONLY.
7. Check for coolant leaks upon completion.
Installing the Interlock Connection
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 con-
nector 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.
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.
CAUTION
Do not contaminate the coolant with pipe sealant.
CAUTION
If installed, connect optional interlock before applying RF power.
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Installation
7
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
After installing the load, the RF transmission line can be attached using stan-
dard coaxial line coupling kits.
Using a “QC” Connector Coupling
Use 50 ohm coaxial cable such as RG-218/U or -220/U (-17A or -19A), appro-
priate for the frequency and power level of operation. 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.
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.
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Installation
8
Using a Swivel Flanged Coupling
To couple the swivel flange with a flanged RF transmission line, use an appro-
priate coupling kit. Refer to Figure 5 while following the instructions.
Figure 5 Swivel Flanged Coupling
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 and tighten evenly all around to transmission line
manufacturer’s recommended torque.
 Note: Use all of the bolts.
Using a Unflanged Coupling
To couple the unflanged connector with an unflanged RF line, use an appro-
priate coupling kit. Refer to Figure 7 while following the instructions.
Figure 6 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.
BOLT BULLET LOADRF COAXIAL LINE
RF
CO
AXIAL
LINE
C
LAMPIN
G
BANDS
CO
NNE
C
T
O
R
SLEEVE
BULLET
L
O
AD
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Installation
9
Using an AC Power Hookup
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.
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.
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