TERMALINE® LOAD RESISTOR SERIES 8890 ©Copyright 2012 by Bird Electronic Corporation Instruction Book Part Number 920-8890S Rev.
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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.
This symbol indicates that a shock hazard exists if the precautions 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.
Caution Statements The following equipment cautions appear in the text and are repeated here for emphasis. CAUTION This load is designed for operation in a horizontal position only, with the vent plug up. Do not use in any other manner. On page 5. CAUTION Do not contaminate the coolant with pipe sealant. On page 6. CAUTION If installed, connect optional interlock before applying RF power. On page 6. CAUTION Check the local electrical code for proper AC hookup prior to operation of the unit.
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.
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.
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.
About This Manual This manual covers the operating and maintenance instructions for the following models Note: When used in the rest of the manual, 8890 series refers to all models. 889x–300 refers only to loads without a blower. –315 and –320 refer to loads with attached blowers.
Table of Contents Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i Warning Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii Caution Statements . . . . . . . . . . . . . . . . .
Chapter 6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Cleaning the Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Chapter 1 Introduction The Bird 8890 series loads are portable, 50 ohm, coaxial RF transmission line terminations, designed for frequency ranges of DC – 2.4 GHz. The 8890 series D loads are designed for use in the UHF (470 – 860 MHz) band, otherwise they are identical to the stanard series. These loads provide accurate and dependable low reflection line terminations. Power is dissipated at a level of up to 2500 watts of RF, 5000 watts if the optional blower assembly is used.
Figure 1 Bird 8890 Series Outline Drawing - No Blower 3/8” (10 mm) 3/16” (5 mm) 7.5” (190 mm) 3/8” (9 mm) VENT PLUG MTG. HOLE DETAIL 17.25” (437 mm) ! (4) MTG. HOLES SEE DETAIL 3” (75 mm) 21.5” (546 mm) 4.5” (114 mm) DEPENDS ON CONNECTOR Figure 2 Outline Drawing With Blower FAN CONTROL THERMOSWITCH INTERLOCK THERMOSWITCH (OPTIONAL) 21-7/8” (556 mm) ! MANUAL / AUTOMATIC SWITCH MANUAL BLOWER ON INDICATOR LIGHT POWER CORD 20 ft (6 m) LONG APPROX.
Chapter 2 Theory of Operation Load Resistor Bird 8890 series loads consist of a thin-film-on-ceramic resistor immersed in a dielectric 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.
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Chapter 3 Installation Unpacking and Inspection 1. 2. Carefully inspect shipping container for signs of damage. Do one of the following: • If the shipping container is damaged, do not unpack the unit. Note: Immediately notify the shipping carrier and Bird Technologies Group. • 3. If the shipping container is not damaged, unpack the unit. Save shipping materials for repackaging. Inspect unit for visual signs of damage.
Installing the Thermoswitch Bird 8890 series series Loads can be equipped with an optional interlock thermoswitch, P/N 8890-008. It is normally closed, opening at 236 °C (457 °F), with a rating of 10A at 120VAC and 5A at 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. WARNING The vent plug must be used at all times when the unit is operating or cooling.
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).
Using a Swivel Flanged Coupling 1. 2. 3. 4. 5. Insert the center bullet. Push it in until it is fully seated. Connect the coaxial input in a straight line 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. Insert the bolt sets and tighten evenly all around to transmission line manufacturer’s recommended torque. Note: Use all of the bolts.
Chapter 4 Operating Instructions, No Blower Normal Operation Bird 8890 series– 300 loads have no indicators or operating controls. They require no special operating procedures or surveillance when their performance limits are not exceeded. Follow the instructions for the specific transmitter equipment. Operating Under Abnormal Conditions The load can be moderatly overloaded for short periods. CAUTION Make sure the interlock is properly connected when overloaded to prevent damage to the load.
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Chapter 5 Operating Instructions, With Blower 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. 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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Chapter 6 Maintenance This chapter covers cleaning, inspection, trouble-shooting, and specifications for the Bird 8890 series Loads. 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 Disconnect the blower assembly from supply voltage before performing any maintenance.
Maintenance Cleaning the Load Cleaning the Load Resistor • • The outside surface of the instrument should be wiped free of dust and dirt when necessary. Clean the cooling fins. Note: Excessive dust on the cooling fins will interfere with heat dissipation. • Clean the RF connector, both metallic and insulating surfaces, with a dry, non-residue forming solvent. Cleaning the Blower Assembly • The intake grills, fans, and inside of the baffles should be wiped free of dust and dirt when necessary.
1. Turn off the RF power and interlock circuitry. 2. Disconnect the RF line. 3. Connect the multimeter test leads to the center and outer conductor of the load resistor. 4. Compare the measured value with the previous measurement and with the baseline resistance, measured when the load was put into service. Note: If the new value differs from either of these by more than 1 ohm this could indicate a failing resistor.
Repairing the Load WARNING Disconnect the unit from all power sources before servicing. The unit may be energized from multiple sources. The potential for electric shock exists. Replacing the RF Connector ONLY the Model 8890 has a special Bird “QC” connector which allows easy changing of the RF connector. This does not disturb the coolant seal or affect the electrical continuity of the load. To change the connector, proceed as follows: 1. Remove the four screws at the corners of the RF connector. 2.
Replacing the Load Resistor 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. Unscrew and remove the clamping band. 5. Lift the load resistor assembly out of the tank. 6. Allow any coolant to drip back into the tank. 7. Check the O-Ring. Note: It should be free of twists and positioned evenly around the flange of the resistor housing.
Figure 8 Schematic Diagram TO CONTROL THERMOSWITCH BLACK RED GRN/YEL TOGGLE SWITCH WHT/BLK WHT/BLK FANS L2 L1 INDICATOR LIGHT WHT/YEL ROTATION AC RECEPTACLE N L L2 L1 WHT/BLK Storage and Shipment Storing the Load Resistor • • • Cover Bird 8890 Loads before storing to keep out dust and dirt. It is not necessary to install the shipping plug. Store in a dry, dust-free environment where the ambient temperature will remain between –40 and +45 °C (–40 to +113 °F).
Customer Service Any maintenance or service procedure beyond the scope of those in this chapter should be referred to a qualified service center. If you need to return the unit for any reason, request an RMA through the Bird Technologies website (link shown below). All instruments returned must be shipped prepaid and to the attention of the RMA number. Bird Service Center 30303 Aurora Road Cleveland (Solon), Ohio 44139-2794 Fax: (440) 248-5426 E-mail: bsc@bird-technologies.
Specifications Frequency Range 8891D300, 8892D300, 8892D13-30, 8892D320 All other models Power Rating* Peak Power for Pulse Width† 1 µs 10 µs 100 µs 1000 µs 5000 µs Impedance 8896 All other models VSWR‡ 8891D300, 8892D300, 8892D13-30, 8892D320 All other models** Connectors 8890 8891, 8891D300 8892, 8892D300, 8892D320 8892D13-30 8895 8896 8897 8898 AC Power –315 –320 AC Line Power Rating Fuse Rating 115 Vac 230 Vac Thermoswitch Interlock Fan Control Thermoswitch Rating 115 Vac 230 Vac Ambient Temperature Alt
Replacement Parts Description RF load resistor 8890 8891 8891D300 8892, 8892D300 8892D13-30 8895 8896 8897 8898 Resistor O-Ring Clamping band assembly Plug Vent Shipping Overtemp thermoswitch Thermoswitch body Thermoswitch jack Control thermoswitch* Thermoswitch body Thermoswitch jack Coolant, 2.
Available “QC” Type Connectors Connector Part Number BNC-Female 4240-125 BNC-Male 4240-132 C-Female 4240-100 C-Male 4240-110 HN-Female 4240-268 HN-Male 4240-278 LC-Female* 4240-031 LC-Male 4240-025 Open Term.
Limited Warranty All products manufactured by Seller are warranted to be free from defects in material and workmanship for a period of one year, unless otherwise specified, from date of shipment and to conform to applicable specifications, drawings, blueprints and/or samples.
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