HP 8481A PDF

This says the thermocouple in the A1 bulkhead is open. This is the 1 failure mode for these sensors and is caused by too much input power. The A1 assembly is unfortunately not repairable. The A1 assembly and alternate are both obsolete. And even if you could find one and replace it, the sensor would require recalibration which would be additional cost.

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First try was the silver conductive conducting glue sold in syringes. Not strong enough — a total waste of time. I ended up using a Zeny station instead of my Weller because I could set tip temperature other than a magnetically controlled C or C tip.

Starting at C was not quite enough C worked fine for me. The tiny conical tip used on the ground side got the heat sucked out of it too fast to solder. A small wedge tip about 2mm across worked fine to solder to the ground side and no problem with the gold coming loose from the sapphire substrate. The original gold wire measures about 0. I used silver plate 30 WW wire the normal stuff we used all the time for WW.

I strip off an inch or so of the WW wire insulation, tin the end. A dab of 0. This worked just fine. Trim the end of the new wire to length of original lead with A1 set in place. It would be valuable to have someone with the calibration equipment evaluate performance of a sensor repaired this way to an original with bonded gold wire combination across the sensor frequency range.