Product User Manual - Gerling Applied Engineering, Inc.
Contents
1. SA CONTROL MODULE FRON NA CONTROL MODULE REAR oe 2006 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 8 Custom Microwave Oven Part No 912315 930070 Rev 1 INSTALLATION Preliminary Inspection Upon arrival at the installation site the custom oven system should be thoroughly inspected for damage or wear caused during ship ping Any visible damage to the packaging material or the magne tron head itself should be noted and reported immediately to the shipping company in accordance with standard claims procedures The following items are supplied with the system 1 Customized Microwave Oven p n 912354 2 Control Module p n 912350 3 Product User Manual this document Mounting Position The custom oven system is supplied as an integral assembly con sisting of the modified microwave oven and control module It must be mounted upright on a level surface capable of supporting its weight Sufficient clearance must be provided at the top sides and rear of the oven to allow adequate ventilation Sensor Mount Installation The microwave oven system is shipped to the customer with the sensor mounts removed to facilitate packaging and protection from damage Figure 1 illustrates installation of the sensor mount as sembly The IR sensor gimble mount is pre installed onto the cam era sensor mount SENSOR MOUNT ASSEMBLY MICROWAVE OV2. Product User Manual 4 Custom Microwave Oven Part No 912315 Document 930070 Rev 1 Gerling Applied Engineering Inc P O Box 580816 Modesto CA 95358 www 2450mhz com Product User Manual Page 2 Custom Microwave Oven Part No 912315 930070 Rev 1 REVISION HISTORY REV DESCRIPTION DATE APPROVAL 1 PROTOTYPE RELEASE O3JANO6 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 liability in any event for incidental or consequenti
3. switch must be in the REMOTE position to enable remote power control The percentage of microwave power generated is approximately equal to ten times x10 the voltage delivered Power can be ad justed at any time before or during operation Magnetron Current Meter The digital LED meter on the control module front panel provides a relative indication of average magnetron current which correlates to the approximate level of microwave power being generated by the magnetron The actual microwave power delivered to the oven cav ity will depend on factors relating the type size and location of the power absorbing load placed inside the oven cavity This meter reading should never be construed to be an accurate measure of microwave power delivered to and absorbed by the load However in conjunction with the calibration procedure out lined in the next section the meter reading can be used to monitor and verify oven performance 2006 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 13 Custom Microwave Oven Part No 912315 930070 Rev 1 OVEN POWER CALIBRATION PROCEDURE D The procedure outlined in this section can be used to correlate the MAGNETRON CURRENT meter reading with actual microwave power delivered by the oven for a specific load It is derived from the international standard IEC 60705 3 Edition 1999 04 used worldwide by microwave oven manufacturers for performance measurement NO
4. A Em Icono O O i SECONDARY PCB INTERLOCK R2 HIGH VOLTAGE MAGNETRON t ald TRANSFORMER LINE POWER MAGNETRON 120VAC wr TCO gt 94 1 20A 60Hz O O 4 JON KI 252 COMMON 12 VDC FUSE aK 15A o 0 1 i PRIMARY P1 P1 P1 INTERLOCK Pi Pr P1 P1 Pi H A B D 1 E FF CONTROL MODULE J1 J1 J1 1 J1 J1 J1 J1 i S4 ENABLE AK CUSTOMER SUPPLIED F1 BANA ODISABLE EXTERNAL MICROWAVE MICROWAVE TURNTABLE p 32 MOMENTARY MOMENTARY u K1B 1 44 i 9 1 1 TET 2 o o 46 3 4 ANALOG INPUT START STOP 5 0 10 voc 1 o o Q 6 s 52 Es 7 READY GREEN i T2 i o o O 1 1 1 i o 2 VDC RANGE 1 XXX SCALE R6 9 1 10 1 az 12W POWER SUPPLY J2 12 VOC A 1 k y1 5 VOC R4 CR1 R3 ADUSE i 75 VOC 75 OS tov 1K 2 COMMON 1 i 1 i 2006 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 7 Custom Microwave Oven Part No 912315 930070 Rev 1 Outline Drawings CONTROL MO UO E T IR SENSOR MOUNT CCD CAMERA MOUNT MIC ROWAV wero power saga O o NG Si T ENABLE SEL CT O O roms DISABLE
5. EN 8 32 X 3 8 PAN HEAD MACHINE SCREWS WITH LOCKWASHERS 16 EACH Figure 1 Installation of the sensor mount assembly O 2006 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 9 Custom Microwave Oven Part No 912315 930070 Rev 1 IR Sensor Adjustment The IR sensor mount is designed to allow adjustment of the sensor aim by rotating the mount in a gimble socket To adjust the sensor loosen but do not remove the four screws securing the gimble clamp and gently rotate the gimble Tighten the screws securely to fix the gimble in the desired position OV COVE GIMBLE Figure 2 IR sensor gimble mount and clamp leakage the CCD camera and IR sensor mounts must be properly installed and all screws tightened securely prior to oven operation A WARNING To ensure adequate protection from microwave Control Module Connection All electrical connections between the oven and control module are made through a 9 conductor cable attached to the rear panel of the oven Connect this cable to the control module at connector J1 lo cated on the control module rear panel The control module may be placed on top of the oven or located anywhere the interconnect ca ble will allow Remote Control and Interlock Connections Remote control and interlock connections are made to the 7 conductor circular plastic connector J2 located on the rear panel of the control module Figure 3 illustrates a t
6. TE This procedure utilizes a standardized water load for cali bration As with any microwave oven the actual power generated may vary with different load types sizes and locations within the oven cavity However the performance variation between two dif ferent loads will remain constant as long as both loads remain un changed The procedure involves heating the water from a starting tempera ture below ambient temperature to approximately ambient tempera ture using energy from the microwave oven This enables a rea sonably accurate compensation for heat loss to the container The procedure may be performed at any microwave power setting as may be required for calibration of normal operation Equipment Required Initial Conditions e Cylindrical container made of borosilicate glass Pyrex with outside diameter of approximately 190 mm height of approxi mately 90 mm and maximum thickness of 3 mm e Potable tap water approximately 1000 grams e Thermocouple probe thermometer capable of accurately meas uring the temperature of the water e IR optopyrometer capable of accurately measuring the tempera ture of the empty container e Scale capable of accurately measuring the weight of the con tainer both empty and filled with water e Line voltage to be within the range per the oven specifications and within 1 of the voltage to be supplied during normal operation e Ambient temperature to be 20 C 5 C e The te
7. al 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 gt Pu O 2006 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 3 Custom Microwave Oven Part No 912315 930070 Rev 1 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 To ensure safe ope
8. by GAE Inc for Mirari Biosciences Inc for use in its proc ess development laboratory The primary purpose of the custom oven system is to provide a means to remotely control the average microwave power delivered to the oven cavity The goal is to pro vide stable delivery of microwave power at variable power levels in a Closed loop process control system Average microwave power delivered to the oven cavity is controlled by varying the duty cycle on fixed time base The standard power control time base of a typical commercially available microwave oven is on the order of 20 seconds which is much too long for many laboratory process control applications The oven defined this specification is modified to shorten the time base to approximately Y second thus allowing a small process control time constant and true average variable power Microwave power can also be ad justed remotely via an analog control voltage provided externally An external interlock device may be connected that will prevent op eration whenever the external interlock function is not satisfied To facilitate the use of sensors for controlling against a parametric set point the oven is modified to include a means to mount an in frared sensor and a photomultiplier tube PMT The original controls provided with the microwave oven remain un changed and can be used separately from the custom controls All safety related functions of the microwave oven also remai
9. mperature of the microwave oven power supply compo nents to be within 5 C of ambient This condition can usually be met by not operating the oven for a few hours External forced air cooling may be used to shorten this time 2006 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 14 Custom Microwave Oven Part No 912315 930070 Rev 1 Procedure 1 Adjust both Stage 1 and Stage 2 microwave power settings on the control panel to the same desired power level 2 Set the cycle timer on the control panel as follows Stage 1 2 seconds this allows filament warm up Stage 2 A value t equal to 52 seconds multiplied by the ratio of full output power to the set output power i e for half power setting the Stage 2 cycle time should be 104 seconds 3 Adjust the water temperature to 10 C 1 C before putting it into the container Ice chips may be used to lower the tempera ture but the ice should be completely melted prior to heating 4 Accurately measure and record the container mass me in grams Note Steps 5 through 10 should be done in rapid succession to minimize heat loss and temperature measurement error 5 Accurately measure and record the initial container temperature To in degrees Celsius 6 Accurately measure and record the initial water temperature Ta in degrees Celsius 7 Pour the water into the container and accurately measure and record the filled container weigh
10. mps of continuous current draw Although a 15 Amp fuse is provided inside the oven the line power supply circuit should also be fused or circuit breaker pro tected 2006 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 11 Custom Microwave Oven Part No 912315 930070 Rev 1 OPERATION Basic Oven Operation D Control Power Standby Mode Operate Mode The microwave oven can be operated independently of the custom controls by means of the original oven control panel The custom controls need not be turned on or operating in order to use the oven in this manner All safety related functions of the original oven re main fully operational NOTE Operation of the microwave oven independently of the custom controls will not be disabled by opening the external inter lock contacts Line power is available to the control module whenever line power is supplied to the oven and the oven door is closed Unplugging the oven from the line power source or opening its door will remove line power from and disable the custom control circuitry altogether Once line power has been supplied to the control circuitry the READY indicator will turn on if the oven door and the external inter lock device are both closed If remote controls are used then the Stop contact device must be closed The system will then be in Standby mode and ready to start generating microwave power Once in Standby mode pre
11. n unmodi fied and fully functional General Specifications Microwave Oven GE model JES1246BH Microwave Power 1000 Watts rated output per original oven manufacturer s specification Power Control Variable duty cycle from zero to 100 in 4 increments 417 millisecond time base Input Power 110 120 VAC 60 Hz 15 Amp max Turntable Original oven turntable Sensor Mounts sensors supplied by customer CCD Camera Fixed mount centered over turntable for Ikegami model ICD 38 with IK 13VM2812ASW lens IR Sensor Off center gimble mount for Raytek model RAYMI D O 2006 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 6 Custom Microwave Oven Part No 912315 Oven Interlocks Remote Interlock Local Controls Remote Controls Schematic Diagram INTERLOCK MONITOR go NC c BLK O NO c 930070 Rev 1 Oven door Magnetron over temp as on original microwave oven Connections for dry contact switch rated for 120 VAC 1 4 Amp Remote Local Power Adjust toggle switch Microwave Start pushbutton switch Microwave Stop pushbutton switch Turntable enable disable toggle switch Input for 0 10 VDC analog signal for aver age power control Microwave Start momentary dry switch relay contact closure Microwave Stop momentary dry switch relay contact opening MICROWAVE OVEN CAVITY TURNTABLE BLOWER h ain ED LAMP MOTOR MOTOR T1 Le om oven orn OVEN E
12. ntact GAE for information on repair services Magnetron Removal and Replacement The magnetron used in the custom microwave oven is the same as that supplied with the original oven by its manufacturer Replace ment of the magnetron should be done only by technical personnel properly trained for repair of residential and commercial microwave ovens 2006 Gerling Applied Engineering Inc Modesto CA
13. ration and prevent microwave leakage the equipment must be periodically in spected and maintained as required or recommended 2006 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 4 Custom Microwave Oven Part No 912315 930070 Rev 1 TABLE OF CONTENTS EQUIPMENT DESCRIPTION iii 5 General Specifications 5 Schematic Diagram 6 Outline Drawings INSTALEATION oasis 8 Preliminary Inspection 8 Mounting Position 8 Sensor Mount Installation 8 IR Sensor Adjustment 9 Control Module Connection 9 Remote Control and Interlock Connections 9 Line Power Connection 10 OPERATION 52 ka aa a a a ai aa a aa a vi a a aa a a a a ea ga aa a em aa aa aa a a ak aaa a a 11 Basic Oven Operation 11 Control Power 44 Standby Mode 11 Operate Mode 11 Microwave Power Adjustment Local 11 Remote Microwave Power Adjustment 12 Magnetron Current Meter 12 OVEN POWER CALIBRATION PROCEDURE 2 ccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 13 Equipment Required 13 Initial Conditions 13 Procedure 14 Output Power Calculation 14 MAINTENANCE 753555555 anggene ga a aa aa daa Ga naa a ia da aa E Han a a a Ga EE gaga a a aa anga ga aga aaa 15 Magnetron Removal and Replacement 15 2006 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 5 Custom Microwave Oven Part No 912315 930070 Rev 1 EQUIPMENT DESCRIPTION The microwave oven described in this document was custom de signed
14. ssing the START button on the control module front panel or closing the Start contact device if remote controls are used will place the system into Operate mode Micro wave energy will then be delivered to the oven cavity at power lev els determined by the settings of the POWER ADJUST dial Any of the following actions at any time during operation will stop the generation of microwave power 1 Pressing the STOP button on the control module front panel 2 Opening the oven door 3 Opening the contacts of the external interlock device 4 Opening the remote control Stop contact device Microwave Power Adjustment Local The average microwave power delivered by the oven can be con trolled locally using the POWER ADJUST dial located on the con trol module front panel The REMOTE LOCAL selector switch 2006 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 12 Custom Microwave Oven Part No 912315 930070 Rev 1 must be in the LOCAL position to enable power control using the front panel dial The dial can be adjusted at any time before or dur ing operation The dial readings when multiplied by ten x10 pro vide an approximate indication of average microwave output power Remote Microwave Power Adjustment The average microwave power can also be controlled remotely us ing a 0 10 VDC analog control signal see the previous section for connection information The REMOTE LOCAL selector
15. t Subtract the empty container weight me to obtain the actual water weight my in grams 8 Place the filled container inside the oven cavity centered on the turntable and close the oven door 9 Press the Start button on the control panel to turn on microwave power During Stage 2 record the reading of the Magnetron Current meter Allow the system to operate through both cycle stages The oven will turn off automatically 10 Upon completion of Stage 2 open the oven door and accurately measure and record the final water temperature T2 in degrees Celsius Gentle stirring will provide a more accurate measure ment of average temperature Output Power Calculation Calculate the microwave output power using the following formula P 4 187 my T2 T1 0 55 me T2 To Vt The meter reading recorded in step 9 above now corresponds to the calculated output power 2006 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 15 Custom Microwave Oven Part No 912315 930070 Rev 1 MAINTENANCE The custom microwave oven is designed to be maintenance free with the exception of magnetron replacement The magnetron is considered a consumable component and is expected to fail within 1000 to 3000 of operation depending on operating conditions and usage No calibration is necessary In the event of damage due to improper operation or mishandling the system should be returned to GAE for repair Co
16. ypical configuration us ing standard relay or switch devices The Stop device should be normally closed NC and the Start device should be normally open NO Both devices should dry contact momentary operation non latching devices rated for 120 VAC Ya Amp For remote control of microwave peak power connect a 0 10 VDC analog signal between contacts 4 and 5 with the positive side connected to contact 4 In the absence of remote controls or an external interlock device a jumper wire must be connected between positions 1 and 2 to en able system operation 2006 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 10 Custom Microwave Oven Part No 912315 930070 Rev 1 7 CUSTOMER SUPPLIED S AERA v en VE MICROWAVE T OINO NA START is p MOMENTARY MOMENTARY 1 O O Q 2 O O i 4 ANALOG INPUT 0 10 VDC 6 N C 7 N C Figure 3 Typical remote control connections while the oven is in operation The user must employ proper design and exercise caution when installing the remote controls to ensure adequate protection from exposure to live circuits A WARNING 120 VAC may exit on the remote control circuit Line Power Connection Line power is supplied to the system by connecting the oven power cord located at the rear of the oven to a standard 120 VAC grounded outlet receptacle The circuit supplying voltage to the re ceptacle must be rated for at least 15 A
Download Pdf Manuals
Related Search