Product User Manual - Gerling Applied Engineering, Inc.
Contents
1. 7 930038 Rev 2 Product User Manual GA4306 700W Microwave Generator 5 8 GHz Magnetron Head Outline Drawing ONN 02 9 GNIS ANNOYS 0021 ONN 02 9 STOH 0 1 90 68 83 62 9 39NV13 104110 ANNI 39VIIOA 33WOd GV3H 8 GV3H SVW 310 33 000000000000000000 000000000000000000 4 HOLIMS 319901 gt 50123135 1Snr0v ma 01 MN NOLLNSHSNd 03 HOLMS 4015 MN NOLLNEHSNd 3339 LYVIS YOLVOIONI YOLVOIGNI AH ANI E 401 5 3 315 4 Y3A0D SS300V 9 1 Modesto CA 2004 2006 Gerling Applied Engineering Inc Product User Manual Page 8 GA4306 700W Microwave Generator 5 8 GHz 930038 Rev 2 Power Supply Outline Drawing 10 04 255 le 57 15 91 23 7 09 ali 5 12 130 LED STATUS INDICATORS N 1 197 25 0 LINE POWER 9 3942. ANODE CURRENT pi ANODE CURR SENSE lt INTERLOCK LOOP OUT EXTERNAL INTERLOCK DEVICE INTERLOCK LOOP RTN MW STOP MOMENTARY SYSTEM READY INDICATOR lt SYSTEM READY HV ENABLE INPUT lt MW START MOMENTARY 24 VDC OUTPUT lt GROUND Figure 2 Recommended electrical circuit for remote control Pin 1 6 5 VDC Reference This is a DC voltage generated by the magnetron power supply for use by a remote power control potentiometer for the control input voltage see Pin 2 below The maximum allowable current draw from this source is 10 mA Because of this current limitation and for maximum operational stability this voltage should not be used for any other purpose Pin 2 Microwave control voltage input 0 6 5 VDC The level of microwave power delivered from the magnetron head is controlled by varying the voltage present at this pin from 0 to 6 5 VDC The use of a precision multi turn 10K Ohm potentiometer rated for 1 2 Watt is recommended for high control resolution and stability The voltage provided at Pin 1 see above may be used as a reference or a separate voltage source referenced to the same ground point can also be used The toggle switch on the front panel of the magnetron head must be set to Remote for this voltage to have effect CAUTION The maximum allowable input voltage for microwave power control is
3. Pin 1 Line Power Input Neutral Phase connection for one phase of nominal 230 VAC When using Delta connected line power either phase can be connected to this pin When using Wye connected line power the neutral phase must be connected to this pin Pin 2 Line Power Input Hot Phase connection for one phase of nominal 230 VAC When using Delta connected line power either phase can be connected to this pin When using Wye connected line power the hot phase must be connected to this pin Pin 3 Chassis Ground CAUTION The user must provide an external line power circuit A protection device such as a fused disconnect or circuit breaker rated no more than 15A The line power connection wire must be rated no less than the rating of the circuit protection device Failure to provide proper circuit protection may result in permanent damage to the system Remote Control Connections All connections for remote control of the magnetron power supply and magnetron head are made to connector J4 Figure 2 below is a diagram of a recommended electrical circuit configuration While other configurations are possible the following interface requirements must be met for safe and reliable operation 2004 2006 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 13 GA4306 700W Microwave Generator 5 8 GHz 930038 Rev 2 6 5 VDC REF MW POWER ADJUST MW CONTROL INPUT lt
4. Product User Manual Model 4306 700W Microwave Generator 5 8 GHz Document 930038 Rev 2 GERLING APPLIED I U ENGINEERING INC P O Box 580816 Modesto CA 95358 www 2450mhz com Product User Manual Page 2 GA4306 700W Microwave Generator 5 8 GHz 930038 Rev 2 REVISION HISTORY REV DESCRIPTION DATE APPROVAL 1 PROTOTYPE RELEASE 13JAN04 JEG 2 UPDATED SCHEMATIC 26JAN06 JEG WARRANTY Products manufactured and sold by Gerling Applied Engineering Inc are warranted to be free of defects in materials and workmanship under normal use and service for a period of twelve 12 months from the date of original shipment GAE s obligation under this warranty is limited to repairing or replacing at GAE s option all non consumable component parts Consumable parts are specifically excluded from this warranty and may include but are not be limited to magnetrons fuses lamps seals o rings v belts and fluids All warranty repairs are to be done at GAE s facility or as otherwise authorized by GAE All shipping charges for warranty repair or replacement are the purchaser s responsibility unless otherwise agreed to by GAE This warranty supercedes all other warranties expressed or implied No warranty is given covering the product for any particular purpose other than as covered by the applicable pr
5. 6 5 VDC Permanent damage to system can result if the input voltage exceeds this value Pin 3 Anode current sense output 1 V 100 mA This signal is generated by the magnetron power supply and is proportional to the magnetron anode current It is proportional to magnetron output power and thus can used 2004 2006 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 14 GA4306 700W Microwave Generator 5 8 GHz 930038 Rev 2 as an indication of microwave power generated by the magnetron head The recommended minimum load impedance for voltage measuring devices is 250 Ohms Pin 4 Interlock loop output 24 VAC This signal is present when all internal interlocks of the magnetron power supply are satisfied and the Mw Stop switch on the front panel of the magnetron head is not being pressed This signal must be present for operation of the magnetron head and microwave power generation Pin 5 Interlock loop return 24 VAC The voltage present at pin 4 must be returned through pin 5 before microwave power can be started A dry contact interlock device and or remote Mw Stop switch momentary normally closed may be connected in series between pins 4 and 5 Opening either of these two devices will turn off microwave power NOTE Connection between pins 4 5 is required for operation of the GA4306 even if remote control will not be used A jumper wire is factory installed
6. FCC has established regulations limiting the emission of energy at frequencies outside the ISM bands All GAE waveguide components meets these requirements when properly connected to another waveguide component Interconnect Cables All electrical power required for operation of the magnetron head is provided by the power supply through a cable harness delivered with the system Table 1 below lists the cable interconnections between the magnetron head and power supply WARNING Failure to provide an adequate ground connection between the magnetron head and power supply chassis can expose the operator to high voltage and result in severe injury or death 2004 2006 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 12 GA4306 700W Microwave Generator 5 8 GHz 930038 Rev 2 Table 1 Cable harness interconnections Mating Connectors Function Conductors Power Supply Magnetron Head 3 TB1 5 contact J2 ower Control I O 8 ground TB2 10 contact J3 Ground 1 Ground Stud Ground Stud Line Power Connections Connections for line power are made to the 5 contact terminal block located on the end panel of the power supply This terminal block is part of the interconnect cable harness described above The functions and electrical specifications of these connections are detailed as follows refer also to the Schematic Diagram in the previous section
7. 210 0 TERMINALS BLOCK COOLING AIR EXHAUST BOTH SIDES 28 7 e CONTROL SIGNAL TERMINAL BLOCK 7 01 178 COOLING CABLE STRAIN RELIEF 1 M5 METRIC GROUND STUD W NUT Jt 280 gt 2004 2006 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 9 GA4306 700W Microwave Generator 5 8 GHz Schematic Diagram HIGH VOLTAGE POWER SUPPLY MAGNETRON HEAD GA4007A GROUND STUD GROUND STUD J3 HV ENABLE INPUT 8 24VDC 12 VDC OUTPUT ANALOG REFERENCE INPUT 0 6 5VDC ANODE CURRENT SENSE 1V 100 EXTERNAL INTERLOCK EXTERNAL INTERLOCK MAGNETRON HEAD INTERLOCK ALARM CONTACT 130VAC 1A 220 HIGH VOLTAGE CONTACT CIRCUIT BREAKER BY CUSTOMER N 2 gt a lt lt lt lt lt lt lt lt lt 180 265 VAC 50 60 HZ 12 AMP 230 VAC 930038 Rev 2 6 5 VDC REF MW CONTROL INPUT ANODE CURR SENSE INTERLOCK LOOP 21 CONTROL SYSTEM READY IND HV ENABLE INPUT 24 VDC GROUND 2004 2006 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 10 GA4306 700W Microwave Generator 5 8 GHz 930038 Rev 2 INSTALLATION Preliminary Inspection Upon arrival at the installation site
8. in the mating connector provided with the system Pin 6 System Ready Indicator Ground This pin is connected to ground whenever the system is in the Standby or Operate mode indicating all interlocks are satisfied and the system is operating normally Pin 7 High voltage enable input Ground Connecting pin 6 to ground will enable the magnetron power supply to deliver high voltage to the magnetron head Microwave power will then be generated according to the setting of the microwave power control potentiometer s The recommended device for making this connection is a momentary normally open pushbutton switch When the system is in Standby mode this pin is referenced to 24 VDC by internal circuitry of anon momentary switching device for enabling high voltage and microwave power The use of a latching device can allow high voltage to be enabled inadvertently and unknowingly such as can happen upon resetting an interlock device It is strongly recommended that a momentary switching device be used for the high voltage enable function Pin 8 24 VDC Power Supply Output This pin is connected internally to 24 VDC which may be WARNING Serious injury and or death can result from the use 2004 2006 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 15 GA4306 700W Microwave Generator 5 8 GHz 930038 Rev 2 used for purposes of supplying power to remote control dev
9. is off On High voltage is on and microwave power is being generated at the level determined by the Analog Reference Input signal Off External interlock device s open On External interlock device s closed After connecting line power the presence of line power is indicated on the power supply when the green Power On LED is on When all of the interlock conditions are satisfied the Interlock LED on the power supply and the System Ready indicator on the magnetron 2004 2006 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 17 GA4306 700W Microwave Generator 5 8 GHz 930038 Rev 2 head will then be on The system is now in the Standby mode of operation Microwave power may now be enabled by pressing the Microwave Start pushbutton switch on the magnetron head or by applying the remote control HV Enable input signal which places the system into Operate mode The generator will now deliver microwave power at a level according to the setting of the Microwave Power Adjust potentiometer or the remote microwave control input signal see next subsection Pressing the Microwave Stop pushbutton switch on the magnetron head will immediately disable high voltage and turn of microwave power The system will then be in Standby mode and ready to be enabled for microwave power again Similarly opening any of the external interlock devices or r
10. other available options and custom configurations General Specifications Output Power max 700 Watts Frequency 5 8 GHz 30 MHz Magnetron Panasonic M5801 GAE p n 911405 Output Waveguide WR159 RG344 U Output Flange CPR159 UG1731 U Cooling Forced air by internal fans Input Line Power 180 265 VAC 50 60 Hz single phase 12 A max at 230 VAC Remote Controls Mw Enable 8 30 VDC input Mw Adjust 0 6 5 VDC input 2004 2006 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 6 GA4306 700W Microwave Generator 5 8 GHz 930038 Rev 2 Interlocks Mating Connectors Anode Current Reference 1 VDC 100 mA System Ready Indicator Interlock Loop Access cover Magnetron over temperature Cooling Fans supplied with interconnect cable set High Voltage Filament Fan Power Control Input Output Remote Control Components Supplied Item Description Magnetron Head Power Supply Interconnect Cable Set Product User Manual AMP 863022 1 includes shell contacts strain relief Shell AMP 206060 1 Contact AMP 66360 4 Cable Clamp AMP 206062 1 Shell AMP 205203 1 Contact AMP 66569 3 Cable Clamp AMP 748676 1 Shell AMP 205204 1 Contact AMP 66570 3 Cable Clamp AMP 748676 1 GAE Part Number GA4007 includes mating remote control connector 911393 911492 930038 2004 2006 Gerling Applied Engineering Inc Modesto CA
11. the GA4306 system components should be thoroughly inspected for damage or wear caused during shipping Any visible damage to the packaging material or the equipment itself should be noted and reported immediately to the shipping company in accordance with standard claims procedures Magnetron Head Installation The magnetron head is designed for use in a clean dry environment such as a laboratory or cleanroom Adequate clearance must be provided at both ends of the enclosure to allow ventilation air to flow freely The magnetron head can be installed in any orientation that is convenient for connection to the waveguide components Mounting holes are provided at both ends of the enclosure for securing the magnetron head These hole are tapped for 74 20UNC bolts and allow up to 72 of insertion depth Power Supply Installation The power supply is designed for installation inside another electrical equipment enclosure having adequate safety shielding for protection from the exposed electrical connections The enclosure should provide adequate clearance at the sides and rear of the power supply to allow ventilation air to flow freely The power supply can installed on any vertical or horizontal surface in any orientation Brackets with keyed mounting holes are provided for convenience Waveguide Configuration The GA4306 generator system can be connected to and used with any common waveguide component having a compatible flange see bel
12. 306 microwave generator system is designed to be maintenance free with the exception of magnetron replacement The magnetron GAE part number 911405 is considered a consumable component and has a life expectancy that depends on operating conditions and usage No calibration is necessary Although the magnetron head is a very rugged and stable device it can be subject to damage due to improper operating conditions or mishandling If damage occurs other than to the magnetron itself the magnetron head should be returned to GAE for repair Contact GAE for information on repair services Magnetron Removal and Installation Removal and replacement of the magnetron can be performed by the user as follows see Figure 3 1 Turn off the magnetron power supply and disconnect all electrical connections from the magnetron head 2 Unscrew the four captive cover screws and remove the access cover 3 Disconnect the wire leads to the magnetron filament terminals and thermal cut out 4 Loosen the two captive screws on each of two cooling air ducts one on each side of the duct and carefully lift the ducts past the magnetron and out of the enclosure 5 Loosen the four captive screws two on each side of the magnetron securing the magnetron to the chassis and carefully lift out the magnetron 6 Install the new magnetron in the reverse order of removal 2004 2006 Gerling Applied Engineering Inc Modesto CA Product User Manual
13. Page 19 GA4306 700W Microwave Generator 5 8 GHz MAGNETRON 2 930038 Rev 2 AIR COOLING DUCTS FILAMENT TERMINALS THERMAL CUT OUT ACCESS COVER Figure 3 Exploded view of GA4007 Magnetron Head part of GA4306 microwave generator system showing magnetron installation 2004 2006 Gerling Applied Engineering Inc Modesto CA
14. emote Stop switch will turn off high voltage and microwave power However this will cause a system fault as indicated by turning off the Interlock LED indicator on the power supply and the System Ready indicator on the magnetron head Upon closing the external interlock devices or remote Stop switch the system will return to Standby mode as indicated by the Interlock and System Ready indicators Microwave Power Control The level of microwave output power can be controlled either locally or remotely Local control is by the 10 turn dial on the magnetron head front panel and remote control is by the microwave control input signal see previous subsection on Remote Control Only one control is active at any time and is selected by the toggle switch located below the front panel control dial Alarm Fault Reset A permanent alarm fault condition exists whenever any one of the four red LED indicators is on This condition will also be indicated by open alarm relay contacts terminal block pins 13 and 14 and turning off the System Ready status indicators To reset the system set the Microwave Power Adjust dial to zero or if used the remote Microwave Control Input signal to 0 Volts 2004 2006 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 18 GA4306 700W Microwave Generator 5 8 GHz 930038 Rev 2 MAINTENANCE AND CALIBRATION The GA4
15. ices such as relays and indicators The maximum allowable current draw is 200 mA This voltage is referenced to ground Pin 9 Chassis ground 2004 2006 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 16 GA4306 700W Microwave Generator 5 8 GHz 930038 Rev 2 OPERATION Basic Operation The operating status of the GA4306 system is indicated by the LED indicators located on the top panel of the power supply and the front panel of the magnetron head The functions of each indicator on the power supply are as follows POWER ON green OVERVOLT red LEAKAGE red RACK OVERTEMP red TUBE OVERTEMP red ENABLE blue INTERLOCK green Off Line power is disconnected On Line power within the rated voltage range is connected Off No alarm condition On Anode voltage exceeded 5kV for more than 0 4 ms System must be reset before operation can continue see below Off No alarm condition On Leakage current caused the anode voltage to drop below 2kV for more than 0 4 ms System must be reset before operation can continue see below Off No alarm condition On Internal temperature of power supply has exceeded safe limits System must be reset before operation can continue see below Off No alarm condition On One or more of the magnetron head interlock devices faulted System must be reset before operation can continue see below Off High voltage
16. oduct specifications GAE assumes no liability in any event for incidental or consequential damages financial losses penalties or other losses incurred in conjunction with the use of GAE products DOCUMENT CONVENTIONS NOTE Means the reader should take note Notes contain helpful information suggestions or references to other sections chapters or documents CAUTION Means the reader should be careful You are doing something that might result in equipment damage or loss of data WARNING Means danger A situation exists that could cause bodily injury or death All personnel must be aware of the hazards involved with high voltage electrical circuitry and high power microwave devices gt 2 2004 2006 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 3 GA4306 700W Microwave Generator 5 8 GHz 930038 Rev 2 WARNING All microwave generators manufactured by GAE Inc are capable of producing a microwave field that is potentially hazardous to operating personnel They must never be connected or operated in a manner that allows a field in excess of 10 milliwatts per square centimeter to be generated in an area accessible to operating personnel Contact GAE Inc for technical support prior to installation and or operation of these units if there is any question or concern about microwave leakage All waveguide flange and electrical cable connections throughout the system must be secure pri
17. or to operation Never operate the microwave generator without a properly rated absorbing load attached To ensure safe operation and prevent microwave leakage the equipment must be periodically inspected and maintained as required or recommended 2004 2006 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 4 GA4306 700W Microwave Generator 5 8 GHz 930038 Rev 2 TABLE OF CONTENTS EQUIPMENT DESCRIPTION u a a a r a rea E e Naia 5 General Specifications 5 Mating Connectors 6 Components Supplied 6 Magnetron Head Outline Drawing 7 Power Supply Outline Drawing 8 Schematic Diagram 9 IN 10 Preliminary Inspection 10 Magnetron Head Installation 10 Power Supply Installation 10 Waveguide Configuration 10 Flange Connections 11 Interconnect Cables 11 Line Power Connections 12 Remote Control Connections 12 OPERA TI N a le 16 Basic Operation 16 Microwave Power Control 17 Alarm Fault Reset 17 MAINTENANCE AND CALIBRATION 18 Magnetron Removal and Installation 18 2004 2006 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 5 GA4306 700W Microwave Generator 5 8 GHz 930038 Rev 2 EQUIPMENT DESCRIPTION The model GA4306 Microwave Generator is a completely integrated system designed for high performance ye
18. ow Mounting can be in any convenient position and orientation Ideally the magnetron head should be connected directly to an isolator or 3 port circulator and dummy load to ensure adequate protection of the magnetron from reverse power Figure 1 illustrates a typical waveguide configuration 2004 2006 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 11 GA4306 700W Microwave Generator 5 8 GHz 930038 Rev 2 MICROWAVE GENERATOR DUMMY LOAD APPLICATOR CIRCULATOR DIRECTIONAL COU SHORT CIRCUIT TERMINATION Figure 1 Typical waveguide configuration for process heating Flange Connections The waveguide flanges of the magnetron head must be properly connected to another waveguide component or series of components that provide an adequate load for the microwave power being generated Bolts and nuts must be installed at all flange bolt holes prior to operation Microwave Leakage Regulatory limits for microwave leakage relate to standards for human safety and interference with other electronic devices Standards for human safety as adopted by OSHA the International Electrotechnical Commission IEC and other regulatory agencies limit leakage to 5 mW cm measured at 5 cm from the leakage source under normal operating conditions and 10 mW cm at 5 cm from the source under abnormal operating conditions The U S Federal Communications Commission
19. t economical delivery of 5 8 GHz microwave power Consisting of separate magnetron head and switch mode power supply modules this user friendly system is easily configured for laboratory use or integrated into production equipment with minimal design effort All control functionality is located conveniently near the work area as well as available remotely for automated processing The magnetron head is designed to comply with safety regulations when used in the laboratory or as part of an industrial process system The power supply must be installed inside a compliant enclosure to meet safety regulations Both units are housed of brushed metallic enclosures for a striking appearance and rugged durability Convenient mounting holes facilitate equipment integration and installation Safety and serviceability were primary considerations in design of the GA4306 system Removal and replacement of the internal magnetron can be accomplished in less than ten minutes using standard tools In addition captive hardware is used for all fasteners relating to magnetron removal thus preventing loss or misuse of loose hardware The complete system includes mating connectors and a standardized 10 ft cable harness for connecting between the magnetron head and power supply alternate lengths may be specified by customer Optionally the interconnect cables and or connector set may be ordered separately Contact GAE for more detailed information on these and
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