BIRD TERMALINE 8745 Series User manual

INSTRUCTION BOOK
TERMALINE®LOAD RESISTOR
SERIES 8745/8746
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 2010 by Bird Electronic Corporation
Instruction Book Part Number 920-8745/46 Rev. C
Termaline®is a Registered Trademark
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.

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 7 and 9.
On page 10.
On page 14.
Caution Statements
The following equipment cautions appear in the text and are repeated here for
emphasis.
On page 7.
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.
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
Never attempt to disconnect the equipment from the transmission line while RF
power is being applied. Leaking RF energy is a potential health hazard.
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
The resistor used in this load consists of a resistive film on a special substrate.
If the substrate is broken, there will probably be sharp pieces or splinters
inside the load housing. Caution should be exercised to avoid possible injury.
CAUTION
DO NOT disconnect the water flow switch leads from the control assembly. Any
operation of the load without a properly functioning cooling system will cause
almost immediate destruction of the resistor element.

iii
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
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
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
About This Manual
This manual covers the operating and maintenance instructions for the following
models
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
Introduction —Describes the features of the load resistor, lists equipment sup-
plied and optional equipment, and provides power-up instructions.
Theory of Operation —Describes how the load resistor works.
Installation —Describes the power supply and load connection instructions.
Operating Instructions —Describes the base level operation instructions.
Maintenance —Lists routine maintenance tasks as well as troubleshooting for
common problems. Specifications and parts information are also included.
8745 8746

vii
Table of Contents
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Warning Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Caution Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Safety Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Changes to this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Literature Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Chapter 1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Purpose and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Direct Power Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Chapter 2 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Heat Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cooling Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Flow Interlock Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Chapter 3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Load Resistor Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Water Line Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cooling Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Flow Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Control Box (Optional Item) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pre-Operational Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Chapter 4 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operation as a Load Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operating as an RF Wattmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Shutting Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chapter 5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Outside Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
RF Load Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Measuring the DC Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Replacing a Resistive Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removing the Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Inspecting the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Replacing the Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Replacing Fractured Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installing a Replacement Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Removing the Front Connector Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Replacing the Water Flow Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Replacing Time Delay Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Replacing the Pilot Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

viii
Additional Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Front Connector Parts Assigned Per Model Type: . . . . . . . . . . . . . . . . . . . 20
Model 8745 - 3-1/8" EIA Connector 50 ohms . . . . . . . . . . . . . . . . . . . . . . 20
Model 8746 - 3-1/8" Unflanged Connector
Flush Center Conductor 50 ohms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
For Both Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Control and Water Flow Parts - not shown on Figures . . . . . . . . . . . . . . 21
Accessory Connector Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Model 8745 Coupling Kit -
3-1/8. Unflanged Connector Flush - 50 ohms 21. . . . . . . . . . . . . . . . . . . . . .
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22