Product User Manual - Gerling Applied Engineering, Inc.
Contents
1. REVISIONS ZONE REV DESCRIPTION DATE APPROVED Al A2 X PRELIMINARY RELEASE O9SEPO4 JFG GA4106 POWER SUPPLY 3kW MAGNETRON HEAD SCHEMATIC 912018 HV COAX FEMALE CONN 3 J1 FEMALE FEMALE J4 _ JUMPER I 4 7 COND CPC faites FEMALE CONN 4 J2 MALE PR FEMALE Js JUMPER A2J5 4 14 COND CPC FEMALE CONN 2 J3 MALE I K4C A PROCESS pa AN 12 AWG GRN CONIROLLER 25 INPUT GND STUD GND STUD Ba 177 To AC ha INPUT Mw oN MW STOP z AC E S4 ANALI 1 22 o CoN 8 13 424 voc 7 OUTPUT 11 SENSOR 10 2 y z INPUTS K4 CR4 MW START Q 3 KoA S3 T3 24 VDC eno PN 1 a JE elas FEMALE CONN 5 V V 2 f 8 CAVITY 4 K4A K5A B1 VENTILATION MW ENABLE VOLTAGE 24 VDC _ e E 11 BLOWER 1 4 6 6 12 110VAC MW ENABLE CONTROL COM E S8 parar gt a MW POWER CONTROL 0 10 VDC lt ON 18 MANUAL 6 K2B MW POWER CONTROL COM lt 4 1 R2 ALARM RELAY CONTACT COM m P 200 rere G SANAR O MODE 24 VI L MT1 ALARM RELAY CONTACT NO 9 s y a NE Mass K5 24 VDC 10K s l8 lt READY x 10V e ied DS3 MW POWER S 7 ADJUST K4B x P CR3_L TKS Vv LINE POWER 12 A Y 24 VDC Jt J2 DS1 MW READY SIGNAL VOLTAGE 24 voc lt 1 d 24 VDC 24 VDC 4 2 o Pe MW READY SIGNAL OUTPUT E L FE KSB Geo aa EMO 2 55 2 a a A s9 3 3 EXTERNAL INTERLOCK LOOP 24 VDC 19 T T T FAULT E 18 ra goes 4 N 23 3lls Sila als DS5 va EXTERNA2. Product User Manual 3kW Microwave Batch Oven Document 930057 Rev 1 A GERLING APPLIED amani d ENGINEERING ING P O Box 580816 Modesto CA 95358 www 2450mhz com Product User Manual Page 2 3kW Microwave Batch Oven REVISION HISTORY REV DESCRIPTION DATE APPROVAL 1 PROTOTYPE RELEASE 04JANO5 JFG WARRANTY Products manufactured and sold by Gerling Applied Engineering Inc GAE are war ranted 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 oth erwise 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 ap plicable product specifications GAE assumes no
3. high performance 3kW variable microwave genera tor and delivered to the cavity using standard waveguide compo nents that ensure high reliability and stable operation A waveguide isolator protects the microwave generator from the damaging ef fects of reflected microwave power Power couplers are provided with meters for monitoring actual forward and reflected microwave power The oven chamber incorporates a mode stirrer to enhance heating uniformity Cavity features include a large access door with view port inlet and outlet ventilation ports an outlet blower for forced ventilation internal air circulation fans and a sturdy rack for product support The cavity is supported by a welded structural steel frame with locking swivel casters for easy portability Complete system functionality is controlled locally by manual and automatic programmable controls All system controls are located on a front panel and include meters for monitoring forward and re flected microwave power A programmable process controller en ables multi stage control of a variety of industrial processes General Specifications Microwave Frequency 2 45 GHz 30 MHz Microwave Power 3000 Watts rated output Power Control Continuously variable from 10 to 100 Input Power 190 250 VAC 50 60 Hz 3 Phase 16 Amps phase 208 VAC Cavity Features Product support rack internal air circulation fans view port mode stirrer Cavity Ventilation Inlet and outlet ducts with
4. outlet high temp blower Oven Interlocks Oven door water flow external customer device microwave generator Local Controls Main circuit breaker toggle Emergency Off pushbutton twist to reset System Start Stop pushbuttons Microwave Start Stop pushbuttons Microwave Power Adjust multi turn dial Manual Automatic toggle switch 2005 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 6 3kW Microwave Batch Oven Local Indicators Line Power Connector Cooling Water Flow Water Connections Cavity Dimensions Overall Dimensions Weight Attachments Document Number 911841 911920 912018 n a n a Line Power System On System Ready Microwave On Fault Door Interlock Water Flow Interlock External Interlock Forward Microwave Power analog meter Reflected Microwave Power analog meter NEMA locking style L15 20P flanged inlet 1 0 gpm nominal 0 5 gpm minimum 70 psig maximum Va NPT Female brass fittings 36 wide x 48 high x 36 deep 46 wide x 73 high x 38 deep 500 Ibs approx Description Outline Drawing 3kW Batch Oven Schematic Diagram 3kW Batch Oven Schematic Diagram 3kW Magnetron Head User Manual ESAK T Process Controller User Manual SM1150 Power Generator 2005 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 7 3kW Microwave Batch Oven INSTALLATION Preliminary Inspection Upon arrival a
5. CONTRACT NO APPROVAL UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES TOLERANCES FRACTIONS DECIMALS ANGLES 41 32 XX 03 DRAWN JFG G AE GERLING APPLIED ENGINEERING INC P O BOX 580816 MODESTO CA 95358 XXXE 010 DO NOT SCALE DRAWING N A N A ENGR NEXT ASSY USED ON MATERIAL y THIS DOCUMENT SHALL NOT BE OUTLINE 3kW LAB RESEARCH OVE DRAWING NOTES UNLESS OTHERWISE SPECIFIED d REFERENSE DOCUMENTS FINAL ASSEMBLY DRAWING 911786 SCHEMATIC DIAGRAM 911920 APPLICATION THIRD ANGLE o el PROJECTION N A FINISH N A REPRODUCED NOR SHALL THE INFORMATION CONTAINED HEREIN BE USED BY OR DISCLOSED TO OTHERS EXCEPT AS EXPRESSLY AUTHORIZED IN WRITING BY GAE INC D DWG NO 911841 SCALE NONE 4 5 EE 2 1
6. Disconnect the two wires connected to the thermal switch mounted to the side of the magnetron Connect the two thermal switch wires to the contacts of the thermal switch mounted on the new magnetron Install the new magnetron in the reverse order of removal Connect the cooling water supply and check for water leaks Cleaning the Oven Cavity The presence of residue debris and other containments inside the oven cavity and lead to reduced efficiency and overheating as the contaminants absorb microwave energy This is particularly impor tant on the surfaces of the oven door and choke structure as well as the waveguide feed port located on the cavity bottom The oven cavity may be cleaned with normal detergents and water although care should be exercised to avoid allowing excessive amounts of water to accumulate inside the mode stirrer and fan as semblies Waveguide Feed Port Cover The waveguide feed port consists of a slotted iris covered by a strip of Kapton tape which helps to prevent contaminants from entering 2005 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 13 3kW Microwave Batch Oven G the waveguide The feed port and tape cover can be cleaned by gently wiping over the outside surfaces If the tape should come loose or is punctured then it can be easily replaced with another strip of similar tape No special calibration is required after replac ing the tape NOTE While the Kapton t
7. E FLANGE SUPPORT BRACKET Figure 4 System waveguide components Magnetron Head Removal and Replacement 1 Disconnect line power and cooling water from the system 2 Remove the left when facing oven cavity front side and rear system support frame covers 2005 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 12 3kW Microwave Batch Oven 3 7 Disconnect the three electrical connectors ground wire and wa ter cooling lines from the rear of the magnetron head Remove the two 1 4 20 socket head screws beneath the magne tron head that secures it to the lateral support bracket Remove the single screw waveguide flange clamp that connects the magnetron head to the 3 port circulator Carefully lift the magnetron head away from the 3 port circulator and out from beneath the oven cavity Replace the magnetron head in the reverse order of removal Magnetron Removal and Replacement 1 7 8 Turn the four captive cover screws 4 turn on top of the magne tron head and remove the cover Remove the brown filament lead insulator block and disconnect the filament transformer and high voltage leads from the magne tron Loosen the compression fittings located at the side of the mag netron and disconnect the two hoses from the magnetron water fittings Remove the four 10 32 screws that secure the magnetron to the chassis and carefully lift out the magnetron
8. L INTERLOCK LOOP COM lt K2 V 12 11 10 sys start Y Ktpo gt LA B K6A KA KBA G NO IS a is N EE 25 MALE CONN 1 Na zf CR2 a V 20A J1 ci u gt oto Te RED x i2 ss oro 4 oto BLK Y 190 250 VAC 50 60 HZ 5 RA wur Z 3 PHASE 3 WIRE GROUND L3 M o D gt 16 AMP PHASE 208 VAC GROUND ERN 24 VDC 24 VDC 24 VDC E J2 P2 DOOR WATER EXTNL S MALE CONN 6 NOT USED 7 DS6 7 DS7 71 DS8 lt oe EXTERNAL INTERLOCK DEVICE TKB K7 L Ks 2 2 PROVIDED BY CUSTOMER FEMALE CONN 7 NOT USED eli Q S14 Q O14 Q s s MA MT S ee A lt lt EEE Po GAE SEE CR6 19 CR7 20 CRB 21 424 TOLERANCES APPROVAL DATE ENGINEERING INC lt lt DECIMALS ANGLES P O BOX 580816 MODESTO CA 95358 NOTES UNLESS OTHERWISE SPECIFIED i XE 120 pra JFG DESEOS CHECKED 1 REFERENCE DOCUMENTS Te qomo ia DO NOT SCALE DRAWING se 3kW BATCH OVEN 55 S6 MATERA N A THIS DOCUMENT SHALL NOT BE SCHEMATIC DIAGRAM DOOR1 DOOR2 INFORMATION CONTAINED HEREIN DWG NO N A N A BE USED BY OR DISCLOSED TO sa ri ld Deen ae SH APPLICATION GAE INC SCALE NONE 4 S 2 1 OC6LLE eX L 4 uf 2 1 REVISIONS x ZONE REV DESCRIPTION DATE APPROVED J1 X PRELIMINARY RELEASE 28DEC04 JAS HIGH VOLTAGE 5kV INTERLOCK LOOP CHASSIS GROUND J2 LINE VOLTAGE PHASE CONTROLLED FILAMENT VOLTAGE LINE VOLTAGE NEUTRAL CHASSIS GROUND MW ON INDICATOR LINE VOLTAGE INTER
9. LOCK LOOP J3 ARC DETECTOR MAGNETRON THERMAL SWITCH AIR PRESSURE SWITCH WATER FLOW SWITCH COVER INTERLOCK COVER INTERLOCK MAGNETRON THERMOCOUPLE CHASSIS GROUND MAGNETRON THERMOCOUPLE ANALOG COMMON FORWARD POWER DETECTOR ANALOG COMMON REVERSE POWER DETECTOR 12 VDC CHASSIS GROUND NOT USED CHASSIS GROUND STUD 24 VDC S6 NO 1 2 00 t FLANGE C IN Jo om a lG N COVER SAO DN O Q N N C a o N C ojo N Im om Ww N i NOTES UNLESS OTHERWISE SPECIFIED 1 REFERENCE DRAWINGS 3kW MAG HEAD ASSY DWG 911551 3kW POWER SUPPLY ASSY DWG 91XXXX P4 lt lt lt ES lt lt lt 8 lt PO ES lt lt lt lt K 7 8 ES UNLESS OTHERWISE SPECIFIED CONTRACT NO GERLING APPLIED o n GAE SERRE Re PEDAS ees P O BOX 580816 MODESTO CA 95358 BE 019 1 2 DEG DRAWN JFG 28DEC04 CHECKED DO NOT SCALE DRAWING SkW MAGNETRON HEAD GFT Ge N A THIS DOCUMENT SHALL NOT BE SCHEMATIC DIAGRAM REPRODUCED NOR SHALL THE INFORMATION CONTAINED HEREIN DWG NO N A SkW OVEN Finis BE USED BY OR DISCLOSED TO C 912018 Nea sssr os Sadan ike E APPLICATION GAE INC SCALE NONE 2 1 SLOCLE IX L Aaa ON 9MO HS
10. To ensure safe operation and prevent microwave leakage the equipment must be periodically in spected and maintained as required or recommended 2005 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 4 3kW Microwave Batch Oven TABLE OF CONTENTS EQUIPMENT DESCRIPTION 5 General Specifications 5 Attachments INSTALEATI N uu u l adi 7 Preliminary Inspection 7 Mounting Position 7 Line Power Connection 7 External Interlock Connection 7 Water Fitting Connections 8 Exhaust Duct Connection 8 OPERATION u ua A ZRI 9 Initial Start up 9 Standby Mode 9 Fault Mode 9 Operate Mode 9 Microwave Power Adjustment Manual 10 Process Control Operation Automatic 10 A A S ua assssaysussmsasualspusssasaqaquuspussaskazsquashasspaaupaup a dh 11 Magnetron Removal and Replacement 11 Magnetron Head Removal and Replacement 11 Magnetron Removal and Replacement 12 Cleaning the Oven Cavity 12 Waveguide Feed Port Cover 12 2005 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 5 3kW Microwave Batch Oven EQUIPMENT DESCRIPTION The microwave oven described in this manual is designed for in dustrial processing and laboratory research applications Up to 3kW of microwave power operating a 2 45 GHz is delivered to a 36 ft oven chamber in a compact portable system Microwave power is generated by a
11. ape is necessary to prevent contami nants from entering the waveguide the system will operate nor mally in the absence of this tape In the event the tape becomes damaged and no replacement tape is immediately available the system may be operated until the tape is replaced without loss of performance provided no contaminants are allowed to enter the waveguide 2005 Gerling Applied Engineering Inc Modesto CA DWG NO SH REV 911841 1 3 1 REVISIONS DESCRIPTION DATE ADDED SUPPORT SHELF 22NOVO4 NY po 1 75 46 25 Pn 37 6 DOOR SWING 36 00 CAVITY VENTILATION DOOR HANDLE N EXHAUST DUCT 4 CAVITY EXHAUST BLOWER CAVITY OPENING 3 00 O PRODUCT SUPPORT SHELF 30 00 Da CONTROL PANEL CAVITY VIEW SCREEN EE WATER CONNECTIONS MAINS CIRCUIT BREAKER LINE POWER CONNECTION DATE 200CT04 EMERGENCY OFF SWITCH CAVITY VENTILATION INLET MICROWAVE POWER SUPPLY LOCKING SWIVLE CASTERS
12. be started with the control dial adjusted to any setting NOTE The actual range of power adjustment is from roughly 10 to full power Thus the output power will fall off suddenly be fore the setting reaches zero Process Control Operation Automatic lt to be written gt 2005 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 11 3kW Microwave Batch Oven MAINTENANCE The 3kW batch oven requires routine maintenance for long term re liable operation Maintenance consists mainly of a magnetron re placement and b cleaning the interior of the cavity Magnetron Removal and Replacement The magnetron is considered a consumable component and is ex pected to fail within 3000 to 5000 hours of operation depending on operating conditions and usage No calibration is necessary Removal and replacement of the magnetron involves a first remov ing the magnetron head module from underneath the oven cavity b removing and replacing the magnetron within the magnetron head module and c replacing the magnetron head module See Figure 4 for identification of system components 3 PORT CIRCULATOR MAGNETRON d T o jo iw o jo o S i CE e L WAVEGUID
13. he blower exhaust duct 2005 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 9 3kW Microwave Batch Oven OPERATION Initial Start up Standby Mode Fault Mode Operate Mode After connecting line power to the system as described in the previ ous section the main circuit breaker must be turned on in order to provide line power to the system The presence of line power is then indicated by the LINE POWER indicator on the front panel If the EMERGENCY OFF EMO switch is in the normal on position and the DOOR WATER FLOW and EXTERNAL interlock functions are satisfied then the respective front panel interlock indicators will be on at this time When line power is present and the EMO switch is in the normal position the system may be placed into Standby mode by momen tarily pressing the SYSTEM START pushbutton In this condition the SYSTEM ON indicator on the front panel will be on and line power will be provided to the microwave generator and cavity blower If all of the interlock functions are satisfied the microwave generator then begins a warm up period during which the magnetron filament is heated to its normal operating temperature After the brief 5 10 seconds warm up period the SYSTEM READY indicator turns on Pressing the SYSTEM STOP or the EMO pushbuttons at any time will immediately turn off the system and stop microwave power from being generated If any of the interlock functi
14. liability in any event for incidental or consequential damages financial losses penalties or other losses incurred in conjunc tion with the use of GAE products DOCUMENT CONVENTIONS NOTE Means the reader should take note Notes contain help ful information suggestions or references to other sections chap ters 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 micro wave devices E Pu 2005 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 3 3kW Microwave Batch Oven WARNING The microwave oven described in this manual is capable of producing a microwave field that is potentially hazardous to operating personnel The unit must never be connected or operated in a manner that allows a field in excess of 10 milliwatts per square centi meter 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 electrical cable connections must be secure prior to operation Never operate the mi crowave oven without a properly rated absorbing load inside the oven cavity
15. ons become disabled any time after pressing the SYSTEM START switch or the microwave generator fails for any reason the FAULT indicator will turn on microwave power if on will immediately be turned off and system operation will be suspended If the system is in the warm up period then the warm up will be terminated After clearing the disabled interlock function or generator failure the system will begin the warm up pe riod again When the SYSTEM READY indicator is on the system can then be placed into Operate mode by pressing the MICROWAVE START pushbutton While in the Operate mode the MICROWAVE ON indi cator will be on and the system will generate microwave power at a level determined by either a the setting of the MICROWAVE POWER ADJUST control on the front panel or b the output control 2005 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 10 3kW Microwave Batch Oven signal from the process controller see related subsections within this section Pressing the MICROWAVE STOP pushbutton will immediately turn off microwave power and place the system into the Standby mode and System Ready condition Microwave Power Adjustment Manual G Microwave power can be controlled manually by first setting the MANUAL AUTOMATIC toggle switch in the MANUAL position When in Operate mode microwave power will be delivered at a level approximately proportional to the dial reading Microwave power may
16. t the installation site the oven system should be thor oughly inspected for damage caused during shipping Any visible damage to the packaging material or the system itself should be noted and reported immediately to the shipping company in accor dance with standard claims procedures The following items are supplied with the system 1 3kW Batch Oven 2 Line power connector NEMA style L15 20R 3 Product User Manual this document Mounting Position The batch oven system is supplied as an integrated assembly con sisting of the oven cavity microwave generator and controls lt must be mounted upright on a level surface capable of supporting its weight Sufficient clearance must be provided at the left side and rear of the oven to allow adequate ventilation and connection to the outlet ventilation duct Line Power Connection Line power is supplied to the system by connecting through the locking style flanged inlet located at the rear of the system A mat ing connector is provide with the system and must be wired to the customer s source of electrical power The recommended minimum wire size is 14 AWG Figure 1 is a schematic diagram of the line power connector wiring e L1 y L2 190 250 VAC 50 60 HZ 3 PHASE 3 WIRE GROUND Z L3 16 AMP PHASE 208 VAC lt a PHASE G GND 77 Figure 1 Line power wiring connections External Interlock Connection A connector is located on the rear panel of the sys
17. tem for connect ing a remote interlock device The external interlock device must have dry contacts that are closed when the interlock function is sat isfied Connection is made between contacts 1 and 2 on this con 2005 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 8 3kW Microwave Batch Oven nector The mating connector with spare crimp pins is also pro vided Figure 2 is a schematic diagram of the external interlock connector wiring 1 lt AS EXTERNAL INTERLOCK DEVICE 2 PROVIDED BY CUSTOMER 3 lt 4 a Figure 2 External interlock device connection Water Fitting Connections Standard 1 4 NPT female brass fittings are provided at the rear of the system The source and drain must be connected to the respec tive fittings marked INLET and OUTLET It is recommended that a thread sealant such as Teflon pipe thread tape be used to ensure a leak free connection Care should be taken to prevent debris from entering the fitting holes Exhaust Duct Connection The system is shipped with the exhaust duct removed from the out let of the exhaust blower The duct must be reinstalled using the four sets of fasteners provided Note that the folded edge of the duct flange is positioned towards the oven cavity Figure 3 illus trates the duct installation A suitable 4 flexible hose may then be connected to the exhaust duct Figure 3 Installation of t
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