KTL FM DUMMY LOAD DL-10K-FM User manual

Page 1 of 12 KINTRONIC LABS INC. ISO 9001:2015(E) QUALITY MANAGEMENT SYSTEM QP-835-067 Rev. A 2018-08-31
MAILING ADDRESS:PO Box 845, Bristol, TN 37621-0845
SHIPPING ADDRESS: 144 Pleasant Grove Rd., Bluff City, TN 37681
PHONE: [phone] e-mail: [e-mail] website: www.kintronic.com
KTL FM DUMMY LOAD DL-10K-FM
INSTALLATION INSTRUCTIONS
INSTALLATION INSTRUCTIONS –KTL DUMMY LOAD DL-10K-FM
Copyright © 2019 KINTRONIC LABORATORIES INC.

Page 2 of 12 KINTRONIC LABS INC. ISO 9001:2015(E) QUALITY MANAGEMENT SYSTEM QP-835-083 Rev. A 2019-02-11
MAILING ADDRESS:PO Box 845, Bristol, TN 37621-0845
SHIPPING ADDRESS: 144 Pleasant Grove Rd., Bluff City, TN 37681
PHONE: [phone] e-mail: [e-mail] website: www.kintronic.com
TABLE OF CONTENTS
INTRODUCTION………………………………………………………………………………………………….…….….3
INSTALLATION………………………………………………………………………………………………...….……….4
OPERATION…………………………………………………………………………………………………………...…...5
TROUBLESHOOTING……………………………………………………………………………………………….……6
MAINTENANCE…………………………………………………………………………………………………….………7
THEORY OF OPERATION………………………………………………………………………………………….……8
APPENDICES
RECOMMENDED SPARE PARTS…………………………………………………………………………. 9
SPECIFICATIONS………………………………………………………………………………………………… 10
FACTORY SERVICE……………………………………………………………………………………………… 11
WARRANTY……………………………………………………………………………………………………….. 11
LIST OF ILLUSTRATIONS
FIGURE 1. POWER CIRCUIT SCHEMATIC………………………………………………………………… 8

Page 3 of 12 KINTRONIC LABS INC. ISO 9001:2015(E) QUALITY MANAGEMENT SYSTEM QP-835-083 Rev. A 2019-02-11
MAILING ADDRESS:PO Box 845, Bristol, TN 37621-0845
SHIPPING ADDRESS: 144 Pleasant Grove Rd., Bluff City, TN 37681
PHONE: [phone] e-mail: [e-mail] website: www.kintronic.com
INTRODUCTION
The DL-10K-FM is a low reflection and non-radiating forced-air cooled test load for coaxial RF transmission line.
It is used primarily to assist in tuning and troubleshooting of transmitting equipment. An interlock is provided
to protect the load from overheating.
The load can be used for the following specific purposes:
- tuning of transmitters under non-radiating conditions,
- making routine tests and adjustments, and
- substituting for any circuit loading element.
Kintronic Labs Inc. has prepared this manual to ensure the most effective use of the RF test load DL-25K-FM.
However, before attempting to use this product, it is important that this manual be carefully reviewed.
Particular attention should be given to cautionary remarks and statements which involve the proper operation
of the product and the safety of the operator.
Please carefully read over the following:
***WARNING***
VERTICAL CABINET HOUSING WILL BECOME
HOT DURING OPERATION –DO NOT TOUCH
This unit may be operated at full power rating only when ambient air temperature is not above 110oF
(43.33oC).
***CAUTION***
THE INTERLOCK SHOULD BE PROPERLY
CONNECTED TO RF POWER SOURCE TO PREVENT
DAMAGE IN THE EVENT OF MALFUNCTION
Loss of air flow for even a short period of time can result in resistor failure. The interlock will enable the
transmitter to be shut down instantly and automatically in case of insufficient air flow or excessive
temperature.
***WARNING***
DISCONNECT AC POWER
BEFORE SERVICING THE UNIT

Page 4 of 12 KINTRONIC LABS INC. ISO 9001:2015(E) QUALITY MANAGEMENT SYSTEM QP-835-083 Rev. A 2019-02-11
MAILING ADDRESS:PO Box 845, Bristol, TN 37621-0845
SHIPPING ADDRESS: 144 Pleasant Grove Rd., Bluff City, TN 37681
PHONE: [phone] e-mail: [e-mail] website: www.kintronic.com
INSTALLATION
1. Unpack unit from shipping container and inspect for possible shipping damage. Claims for damage in
shipment must be filed promptly with the transportation company.
2. Place unit in operating location. Be sure that there is sufficient clearance on each side for free flow of
air through intake and outlet grates—exhaust air must not be directed back to intake. Do not install
unit near other heat sources.
3. Use unit grounding stud to provide a secure electrical ground separate from AC power cord.
4. Check that AC power switch is OFF and connect power cord to a 120 VAC +/- 10% 50/60 Hz source.
5. Use connector provided to prepare an interlock cable for the associated RF transmitter.
6. Connect transmission line to the RF termination input.
--- NOTE ---
Connection of the transmission line to the RF input connector should be performed carefully to prevent
damage to the mounting studs. Avoid any bending or shearing stress to the RF input connector studs.
--- The RF Test Load DL-10K-FM is now ready for operation ---

Page 5 of 12 KINTRONIC LABS INC. ISO 9001:2015(E) QUALITY MANAGEMENT SYSTEM QP-835-083 Rev. A 2019-02-11
MAILING ADDRESS:PO Box 845, Bristol, TN 37621-0845
SHIPPING ADDRESS: 144 Pleasant Grove Rd., Bluff City, TN 37681
PHONE: [phone] e-mail: [e-mail] website: www.kintronic.com
OPERATION
1. Check that installation requirements were properly carried out, particularly with regards to the
following:
a. Be sure that there is no obstruction to air flow at both intake and exhaust grating.
b. Be sure that there exists an electrical ground to unit frame which is separate from ac power
line ground.
*** CAUTION ***
THE INTERLOCK SHOULD BE PROPERLY
CONNECTED TO RF POWER SOURCE TO PREVENT
DAMAGE IN THE EVENT OF MALFUNCTION
2. Connect ac power source of transmitter to interlock receptacle so that RF output will be disabled in
event of malfunction. Normal condition (safe) is AB closed, and in a fault condition AB is open.
3. Connect transmitter RF cable to load RF input. If necessary, provide support to prevent any shearing or
bending stress to connector.
*** CAUTION ***
DO NOT APPLY RF TO LOAD
UNLESS FAN IS RUNNING
4. Apply AC power to fan by moving the switch to ON. The pilot light should illuminate and the fan should
start.
5. Check that air is flowing freely into and out of the gratings.
6. While performing the following steps, be sure that transmitter power output, including modulation,
does not exceed 10 kW continuous.
*** WARNING ***
VERTICAL CABINET HOUSING WILL BECOME
HOT DURING OPERATION –DO NOT TOUCH
7. Apply power to the transmitter and proceed with normal operation.
8. To discontinue operation:
a. Shut down transmitter.
b. Allow fan to run until exhaust air is close to ambient temperature.
c. Move load power switch to OFF.

Page 6 of 12 KINTRONIC LABS INC. ISO 9001:2015(E) QUALITY MANAGEMENT SYSTEM QP-835-083 Rev. A 2019-02-11
MAILING ADDRESS:PO Box 845, Bristol, TN 37621-0845
SHIPPING ADDRESS: 144 Pleasant Grove Rd., Bluff City, TN 37681
PHONE: [phone] e-mail: [e-mail] website: www.kintronic.com
TROUBLESHOOTING
SYMPTOM OR TROUBLE
POSSIBLE CAUSE
No indication of AC power
Defective Switch.
Open Fuse.
Low or no line voltage.
Fan will not start.
Defective fan circuit wiring.
Defective fan motor.
Unit overheats.
Panel not secured.
Excessive RF input.
Low line voltage.
Ambient air too hot.
Interlock will not close.
Excessive heat.
Defective sensor switch.

Page 7 of 12 KINTRONIC LABS INC. ISO 9001:2015(E) QUALITY MANAGEMENT SYSTEM QP-835-083 Rev. A 2019-02-11
MAILING ADDRESS:PO Box 845, Bristol, TN 37621-0845
SHIPPING ADDRESS: 144 Pleasant Grove Rd., Bluff City, TN 37681
PHONE: [phone] e-mail: [e-mail] website: www.kintronic.com
MAINTENANCE
*** WARNING ***
DISCONNECT AC POWER BEFORE SERVICING UNIT
Access to components can be gained by removal of blank panels.
PERIODIC INSPECTION AND SERVICING
1. The RF input connector should be kept clean at all times. It is recommended that a protective cover be
placed over the RF connector when the coaxial cable is not installed.
2. The following should be performed at intervals of one to six months depending upon usage:
a. Remove accumulations of dust, dirt and other obstructions to air flow.
b. Fan blades should be inspected and brushed clean.
c. Inspect and tighten hardware as required.
3. Cabinet may be cleaned with mild detergent and warm water.
4. Fan motor bearings are permanently lubricated and should need no servicing.
5. The over-temperature switch is factory set to 175oF (79.4oC).
LOAD TESTS AND REPAIRS
1. The load should be stabilized at room temperature before making any measurements.
2. A vector-impedance meter should be used to measure VSWR across resistive load at RF input
connector.
3. Use 50 coaxial adaptersbetween vector-impedance meter and RF input to load.
4. Impedance measurements should be made at frequencies that fall within the frequency range of
particular load used.
5. If high VSWR is noted, the DC resistance of the load may be checked at the RF connector. A bridge-type
(Wheatstone) ohmmeter should be used for DC resistance measurements.
6. Individual resistors should measure within 10% of indicated value.

Page 8 of 12 KINTRONIC LABS INC. ISO 9001:2015(E) QUALITY MANAGEMENT SYSTEM QP-835-083 Rev. A 2019-02-11
MAILING ADDRESS:PO Box 845, Bristol, TN 37621-0845
SHIPPING ADDRESS: 144 Pleasant Grove Rd., Bluff City, TN 37681
PHONE: [phone] e-mail: [e-mail] website: www.kintronic.com
THEORY OF OPERATION
The DL-10K-FM Dummy Load consists of sixteen 200resistors. The associated transmitter output is
applied to the resistor load at the 3-1/8 EIA (or optional 1-5/8 EIA) coaxial connector. This same output power
is dissipated as resistive heat. The heat is then removed by forced air. An interlock circuit provides protection
for load resistors against excessive high temperature.
The resistor load assembly consists of sixteen resistors and resistor shield. The resistor load assembly is
designed to maintain a 1.1:1 or less VSWR through 110 MHz. When RF energy is applied to the coaxial
connector, most of the RF energy is converted to heat energy.
The resultant heat energy is dissipated into the surrounding air. The fan, located beneath the load
resistors, causes a higher volume of air to pass over the resistors than would be possible by convection cooling
alone. The increased volume of air removes heat at a higher rate thereby permitting the load to operate with
higher input power levels.
Figure 1 is the schematic diagram for the DL-10K-FM AC circuit. The circuit is protected by a 5 amp
slow blow fuse (F1) and controlled by switch S1. The power indicator lamp DS1 and fan motor B1 comprise
separate parallel sub-circuits.
Figure 1 also shows operation of the Interlock relay circuit. The interlock thermostat is set for 175oF.
Figure 1. Power Circuit Schematic

Page 9 of 12 KINTRONIC LABS INC. ISO 9001:2015(E) QUALITY MANAGEMENT SYSTEM QP-835-083 Rev. A 2019-02-11
MAILING ADDRESS:PO Box 845, Bristol, TN 37621-0845
SHIPPING ADDRESS: 144 Pleasant Grove Rd., Bluff City, TN 37681
PHONE: [phone] e-mail: [e-mail] website: www.kintronic.com
APPENDICES
Recommended Spare Parts
Reference No.
Description
Part No.
R1 –R16
200resistor
KTL-FM200
S1
ON / OFF Switch
W28-XQ1A-5
S2
Over-temperature Switch
STO-175
B1
Fan Motor
4WT44
DS1
Pilot Indicator
1052A5
J1
Interlock Plug
MS3102A16S-4P

Page 10 of 12 KINTRONIC LABS INC. ISO 9001:2015(E) QUALITY MANAGEMENT SYSTEM QP-835-083 Rev. A 2019-02-11
MAILING ADDRESS:PO Box 845, Bristol, TN 37621-0845
SHIPPING ADDRESS: 144 Pleasant Grove Rd., Bluff City, TN 37681
PHONE: [phone] e-mail: [e-mail] website: www.kintronic.com
SPECIFICATIONS
RF CHARACTERISTICS
Rated power, continuous
Frequency range
VSWR (maximum)
Impedance, nominal
Input connector
(Optional)
10 kW
DC to 110 MHz
1.1:1
50 
3-1/8 EIA, male
1-5/8 EIA
1-5/8 unflanged
POWER REQUIREMENTS
Voltage
Current
120 Vac, 50/60Hz, 1
5 Amps
COOLING UNIT
Type
Fan Motor
Displacement
Ambient Temperature
(maximum permitted)
Forced air
1/10 hp, 1550 RPM
480/580 CFM
104oF (40oC)
DIMENSIONS
Width
Depth
Height
Weight
16-3/4 inches
15-3/4 inches
35-1/8 inches
75 pounds

Page 11 of 12 KINTRONIC LABS INC. ISO 9001:2015(E) QUALITY MANAGEMENT SYSTEM QP-835-083 Rev. A 2019-02-11
MAILING ADDRESS:PO Box 845, Bristol, TN 37621-0845
SHIPPING ADDRESS: 144 Pleasant Grove Rd., Bluff City, TN 37681
PHONE: [phone] e-mail: [e-mail] website: www.kintronic.com
FACTORY SERVICE
Kintronic Laboratories, Inc.
Shipping Address: 144 Pleasant Grove Rd., Bluff City, TN 37618
Mailing Address: PO Box 845, Bristol, TN 37621
Phone: [phone]
E-mail: [e-mail]
12 MONTH LIMITED WARRANTY
Kintronic Laboratories, Inc. warrants each unit of its manufacture to be free from defects in material
and workmanship for a period of 12 months. Our obligation under this Warranty is limited to servicing and/or
replacing defective parts of any unit returned to our factory for that purpose, and to making good at our
factory any part or parts thereof, except those parts which normally wear out and have a short life, such as,
but not limited to, bulbs, fuses, belts, filter cartridges, semi-conductor devices, seals and wear items, within 12
months after shipment from our plant as determined by original invoice to the original purchaser.
Repaired materials and associated labor are covered for a 6 month period only on the work performed.
Similarly, repair parts sold separately are covered for a six month period and are limited to repair or
replacement of the part(s) at our plant.
The defective equipment must be brought to our attention in writing and must be returned to us only if we
have so authorized in writing, with round-trip transportation charges having been prepaid by buyer, for
examination and correction by us, if the defect is covered under this Warranty, as determined by our
inspection. If the defect has been caused by misuse, customer installation error, abnormal conditions of
operation, neglect, repair or attempted repair by anyone not authorized by Kintronic Laboratories, Inc., or if
the repairs are for ordinary, minor adjustments, calibration adjustments, and/or ordinary maintenance items,
the same are deemed not to be covered by this Warranty and will be repaired, corrected and/or replaced and
will be billed under the normal rate schedules of Kintronic Laboratories, Inc. In such case, an estimate will be
submitted by Kintronic Laboratories, Inc. to customer before such work is undertaken and a written
authorization to proceed will be required of buyer prior to initiation of repair functions.
If any fault develops, the following steps should be taken:
1. Notify us, giving full details of the difficulty, and include the model number and serial number, your name,
email, and telephone number. On receipt of this information, we will give you service instructions and/or
shipping instructions.
2. On receipt of shipping instructions, forward the unit, round-trip freight prepaid and insured to the factory
and repairs will be made at the factory subject to the foregoing.
Kintronic Laboratories, Inc. reserves the right to make changes in design at any time without incurring any
obligation to install same on units previously sold.

Page 12 of 12 KINTRONIC LABS INC. ISO 9001:2015(E) QUALITY MANAGEMENT SYSTEM QP-835-083 Rev. A 2019-02-11
MAILING ADDRESS:PO Box 845, Bristol, TN 37621-0845
SHIPPING ADDRESS: 144 Pleasant Grove Rd., Bluff City, TN 37681
PHONE: [phone] e-mail: [e-mail] website: www.kintronic.com
This Warranty is expressly in lieu of all other obligations or liabilities on the part of Kintronic Laboratories,
Inc. and Kintronic Laboratories, Inc. neither assumes nor authorizes any other person to assume for them, any
other liability in connection with the sale of Kintronic Laboratories, Inc. products.
This Warranty applies regardless of conditions to the contrary that are included as part of the buyer’s purchase
order.
THERE ARE NO EXPRESS OR IMPLIED WARRANTIES OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR
PURPOSE AND THE SAME ARE HEREBY DISCLAIMED IN WHOLE OR IN PART, BY THE SELLER, AS BUYER HAS
THOROUGHLY EXAMINED AND INSPECTED THE SUBJECT EQUIPMENT AND HAS ACCEPTED THE SAME IN “AS IS”
CONDITION. IN THE EVENT LOCAL LAWS PROHIBIT THIS DISCLAIMER, THE DURATION OF THESE WARRANTIES
SHALL BE LIMITED TO THE LENGTH OF TIME OF THIS WARRANTY.
The obligation of Kintronic Laboratories, Inc. under this Warranty is limited strictly to the terms set forth
herein above and buyer, consumer or user of the products shall claim no setoff or counterclaim from any
monies which may be due and owing Kintronic Laboratories, Inc. as a result of the sale of such product to such
buyer, consumer or user, and Kintronic Laboratories, Inc. shall not be liable for any damages of any kind,
whether incidental or consequential or otherwise, except for repair or replacement as set forth above.