Product User Manual - Gerling Applied Engineering, Inc.
Contents
1. sl fio eee ae WATER FLOW at fa SWITCH 2 2 52 j na o Ju CR2 REFLECTED POWER DETECTOR INPUT DIODE 2005 Gerling Applied Engineering Inc Modesto CA Page 8 Model GA4004 6kW Magnetron Head wing Product User Manual Outline Dra 02 1 anis 6r 3s3MOd 9NI1002 MOOTYSLNI N31VM 53015 H109 310NvH 0 1 TOYLNOD SALAIN NOH LNIANY 1 Nv4 114 9NI009 10 1ndNI AH SISSVHO 1 33MOd 03193743 XZ v l ONILLIY 9NI1009 Ov MM 39NV1J LNdLNO WOLLOG NO Xv 310H ONILNNOW 02 1 Modesto CA 2005 Gerling Applied Engineering Inc Product User Manual Page 9 Model GA4004 6kW Magnetron Head INSTALLATION Preliminary Inspection Upon arrival at the installation site the GA4004 magnetron head should be thoroughly inspected for damage or wear caused during shipping Any visible damage to the packaging material or the magnetron head itself should be noted and reported immediately to the shipping company in accordance with standard claims procedures The following components are included GA4004 Magnetron Head b Mating connector set c Product User Manual this document Waveguide Configuration The GA40042. Product User Manual Model GA4004 6kW Magnetron Head Document 930060 Rev 1 Gerling Applied Engineering Inc P O Box 580816 Modesto CA 95358 www 2450mhz com Product User Manual Page 2 Model GA4004 6kW Magnetron Head REVISION HISTORY REV DESCRIPTION DATE APPROVAL 1 RELEASE 30MARO5 JFG WARRANTY Products manufactured and sold by Gerling Applied Engineering Inc GAE 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 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 product specifications GAE assumes no liability in any event for incidental or consequential damages financial losses penalties or other losses
3. point can allow moisture condensation inside the microwave generator and or waveguide circulator and cause equipment damage Water Fitting Connections Standard 1 4 NPT female fittings are provided at the front of the GA4004 enclosure The source of water can be connected to either fitting It is recommended that a thread sealant such as Teflon pipe 2005 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 11 Model GA4004 6kW Magnetron Head thread tape be used to ensure a leak free connection Care should be taken to prevent debris from falling into the fitting holes Since there may be other waveguide components in the system that require cooling water it may be possible to run all of the water cooling connections in series In this case it is recommended that the magnetron head be connected last in the series Caution should also be exercised to ensure that the resulting water flow rate is adequate for all components Power Supply Connections All electrical power required for operation of the magnetron head is provided by the model GA4107 power supply All cable connections are located at one side of the magnetron head The following describes the basic purpose of each cable required for operation J1 High Voltage Pin 1 8 kKVDC This voltage is delivered to the magnetron cathode Pins 2 and 4 Interlock Loop These two pins must be connected together externally for the interlock loop
4. be periodically inspected and maintained as required or recommended 2005 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 4 Model GA4004 6kW Magnetron Head TABLE OF CONTENTS EQUIPMENT DESCRIPTION seiticcccecscccecissieiecwetenceassccesestuceetecuadsuseavinanweteeconsecbaniuseeeetomees 5 General Specifications 5 Mating Connectors supplied with GA4004 6 INSTALLATION eM E acti 9 Preliminary Inspection 9 Waveguide Configuration 9 Flange Connections 9 Flange Alignment Pins 10 Water Flow Requirements 10 Water Fitting Connections 10 Power Supply Connections 11 Chassis Ground Connection 12 MAINTENANCE AND CALIBRATION 14 Magnetron Removal and Replacement 14 Reflected Power Interface Calibration 15 2005 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 5 Model GA4004 6kW Magnetron Head EQUIPMENT DESCRIPTION The GA4004 Magnetron Head is specially designed for use with the GA4107 Switch Mode Power Supply Together with the line power and control cable set provided with the GA4107 these units make a completely integrated microwave power generation system ideal for laboratory or industrial system applications The compact design of the GA4004 make it suitable for applications where available space is limited Serviceability of the GA4004 was a primary consideration in its d
5. 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 Pb 2005 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 3 Model GA4004 6kW Magnetron Head WARNING All magnetron heads 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 prior 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
6. magnetron head can be connected to and used with any common waveguide component having a compatible flange see below 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 GENERATOR CIRCULATOR POWER MONITOR TUNER SHORT CIRCUIT TERMINATION Figure 1 Typical waveguide configuration for process heating Flange Connections The waveguide flange 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 2005 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 10 Model GA4004 6kW Magnetron Head Model GA4004QD is configured with a flange designed for used with the GA8401 Quick Release clamp when connected to another similarly designed flange Flange Alignment Pins Each waveguide flange connection that uses a quick release clamp requires two alignment pins for proper alignment of the adjacent waveguide sections All GAE waveguide components include one alignment pin for each flange designed for use with quick release clamps Alignment pins can be installed i
7. ETRON CHASSIS COVER FILAMENT LEAD SUPPORT BLOCK FRONT PANEL MAGNETRON STUDS gt COOLING BLOCK PANEL SCREW WAVEGUIDE LAUNCH SECTION CAPTIVE NUT MAGNETRON MOUNTING 4X FAN POWER CONNECTOR J9 Figure 2 Exploded view for magnetron removal and replacement Reflected Power Interface Calibration The GA4004 magnetron head features an optional reflected power signal interface that consists of a detector diode and signal conditioning circuit With this interface the microwave signal from an external waveguide power coupling device is converted to an 2005 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 16 Model GA4004 6kW Magnetron Head e analog 0 10 VDC signal that is proportional to waveguide power The interface is factory calibrated for a coupling factor of 50 dB The interface is designed to be maintenance free and does not require any user maintenance under normal operating conditions However calibration may be necessary after a period of time A calibration period of one year is recommended Damage may occur in the event the input signal is allowed to exceed the maximum rating of the detector diode 100mW In this case the detector diode may be replaced by the user and the interface recalibrated according to the following procedure Replacement detectors are available from GAE by ordering part number 040101 Required Equipment
8. Waveguide coupler WR340 two couplers required a Waveguide dummy load with high return loss rated for 6kW HP model 437B power meter with 8481A sensor or equiv Digital multimeter DMM m Trimmer potentiometer trimpot adjustment tool Coaxial cable with appropriate style connectors typically type N male both ends for connecting the waveguide coupler port to J5 on the GA4004 Procedure 1 Connect the DMM to pins 8 and 9 of connector J3 on the GA4004 front panel 2 Connect the two waveguide couplers in series to the waveguide output flange of the GA4004 Connect the dummy load to the second coupler 3 Turn on the microwave generator and allow at least 2 minutes of warm up time for the output signal to stabilize 4 Attach the HP power meter sensor to the output port of one of the waveguide couplers Using the coaxial cable connect the probe output of the second coupler to J5 on the GA4004 5 Enable microwave power and adjust the microwave generator output power until the reading on the HP meter is 100 of the desired full scale range for input to the interface NOTE Remember to consider the coupling factors of both waveguide couplers when adjusting the microwave power level 2005 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 17 Model GA4004 6kW Magnetron Head 6 While monitoring the analog output voltage signal with the DMM adjust trimpot R4 through sma
9. c Modesto CA Product User Manual Page 13 Model GA4004 6kW Magnetron Head front near the electrical connectors The recommended wire is 12 AWG UL1007 or equivalent with green or green yellow insulation WARNING Failure to provide an adequate ground connection A between the magnetron head and power supply chassis can expose the operator to high voltage and result in severe injury or death 2005 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 14 Model GA4004 6kW Magnetron Head MAINTENANCE AND CALIBRATION The GA4004 magnetron head is designed to be maintenance free with the exception of magnetron replacement The magnetron is considered a consumable component and has a life expectancy of 3000 to 5000 hours depending on operating conditions and usage No calibration is necessary Although the GA4004 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 the magnetron head should be returned to GAE for repair Contact GAE for information on repair services Magnetron Removal and Replacement 1 Turn off the microwave power supply and disconnect line power Disconnect the source of cooling water both supply and drain Disconnect the fan power cord from connector J9 located on the chassis rear panel Remove the eight cover screws and remove the CHASSIS COVER Loosen the fo
10. d Engineering Inc Modesto CA Product User Manual Page 6 Model GA4004 6kW Magnetron Head Mating Connectors supplied with GA4004 High Voltage 4 conductor LGH Series 863022 1 Fan amp Filament Power 7 conductor CPC series Shell AMP 211399 1 Contact AMP 66360 4 Control I O 9 conductor CPC series Shell AMP 211766 1 Contact AMP 66360 4 Water Flow Interlock 2 pin female style Shell AMP 1 640507 0 Contact AMP 640545 2 Reflected Power Input Type N female 2005 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 7 Model GA4004 6kW Magnetron Head Schematic Diagram TO ALTER SM1180 HIGH VOLTAGE INPUT INTERLOCK LOOP INTERLOCK LOOP CHASSIS GROUND L2 PHASE NEUTRAL L1 PHASE FANS CONTROLLED FIL VOLTS GND MW ON INDICATOR ARC DETECT MAGNETRON OVERTEMP AIR PRESSURE WATER FLOW INTERLOCK INTERLOCK LOOP INTERLOCK LOOP 15VDC GND 0 10 REFL PWR CHASSIS GROUND QE E da 1 8 53 54 Coy Ko COVER FLANGE o Tu ANTENNA BLOWER AN AO 1 REFLECTED POWER PCB ASSEMBLY ASSY 911761 SCH 911762 ia YJ1600C MAGNETRON Ll MICROWAVE OUTPUT wu 7 EXTERNAL BLOWER
11. esign Removal and replacement of the internal magnetron can be done using standard tools The GA4004 is designed to use a customized version of the standard YJ1600 water cooled magnetron Inside the GA4004 enclosure are the magnetron filament transformer cooling fans and optional circuitry for detection of reflected microwave power A stainless steel enclosure provides rugged durability while multiple safety interlocks meet compliance requirements Convenient mounting holes facilitate bench top use or integration into process systems The simplicity of the GA4004 also facilitates integration with other switch mode magnetron power supplies Optional features include alternate flange configurations and arc detection Model GA4004QD features the popular Q D quick disconnect style waveguide flange that uses a convenient quick release clamp GAE model GA8401 for waveguide connections General Specifications Output Power max Magnetron Anode Voltage Filament Voltage Supply Output Waveguide Output Flange Frequency Cooling Interlocks 6 kw Modified YJ1600 GAE 911647 7 2 kVDC Controlled 230 VAC WR340 GA4004 UG584 U GA4004QD Quick disconnect round 2450 MHz 30 MHz Water 1 0 nominal 0 5 gpm min flow 35 C max inlet temp dew point min inlet temp 70 psi max inlet pressure Air Provided by internal fans Waveguide flange Access cover Magnetron over temperature 2005 Gerling Applie
12. ll hole in front panel towards bottom until the output signal is 10 0 0 1 VDC While monitoring the HP power meter adjust the microwave power level such that the input signal to the interface is 20 of the desired full scale range While monitoring the interface output voltage signal with the DMM use the trimpot adjustment tool to adjust trimpot R5 through small hole in front panel towards the top until the output signal is 2 0 0 1 VDC Repeat steps previous three steps until the desired output signal accuracy is attained Adjust the microwave generator output power until the input signal to the interface is 10 of the desired full scale range Verify that the output voltage is within the desired accuracy for the desired full scale range Repeat for incremental power levels of 10 up to full scale If necessary to meet the desired accuracy repeat the previous four steps while making small offsetting adjustments to trimpot R5 Turn off microwave power and remove line power from the microwave generator o Of 22 R4 O O 9 O O 45 Figure 3 Front panel of GA4004 magnetron head 2005 Gerling Applied Engineering Inc Modesto CA
13. nto either of two threaded holes centered above and below the waveguide broadwalls For obvious reasons the pins must not be installed such that they are opposite each other on mating flanges 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 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 Water Flow Requirements A source of water must be connected to the GA4004 that provides an adequate rate of flow The nominal water flow rate is 1 0 gpm However the flow rate must be maintained such that the outlet water temperature does not exceed 150 F The minimum allowable flow rate depends on the level of incident microwave power and the inlet water temperature CAUTION The minimum inlet temperature of the cooling water must be above the ambient dew point temperature Allowing the cooling water inlet temperature to drop below the ambient dew
14. r J4 see below which is connected to an external water flow switch The flow switch is Normally Open and closes when the water flow rate exceeds the minimum required for magnetron cooling Pins 5 and 6 Interlock Loop These two pins are connected together internally through several devices having dry contacts that ensure proper connection and or operation Pin 7 15 VDC Power Supply This voltage supplies power to the reflected power interface circuit Pin 8 Chassis ground Pin 9 Reflected power signal 0 10 VDC This signal is proportional to the microwave input power signal connected to J5 see below J4 Water flow interlock switch Pins 1 and 2 Water flow interlock switch These pins are connected together through an external water flow switch The flow switch function should be Normally Open and must be closed only when the water flow rate exceeds the minimum required for magnetron cooling J5 Reflected power input optional This connector receives a low level microwave signal from a waveguide directional coupler or other similar detector that is proportional to reflected power in the waveguide The maximum allowable input signal level is 100 mW Chassis Ground Connection The chassis of GA4004 magnetron head must be connected directly to the chassis of the magnetron power supply Connection to the magnetron head chassis is at the ground stud located at the 2005 Gerling Applied Engineering In
15. to be closed Pin 4 Chassis ground J2 Filament and Fan Power Pin 1 L2 input for filament and fan power 230 VAC This signal is the L2 phase of the power line supplying power to the filament and fan Pin 2 L1 input for fan power 230 VAC This signal is the uncontrolled L1 phase of the power line and supplies power to the fan Pin 3 Controlled filament power controlled 230 VAC This signal is the controlled L1 phase of the power line and supplies voltage to the filament transformer primary Pin 4 Chassis ground Pin 5 Microwave On indicator 230 VAC This signal is on when high voltage is being delivered Pins 6 and 7 No connection J3 Control Signal Input Output Pin 1 Arc detect interlock ground This function is unused and the pin is permanently connected to ground except when the arc detect option is installed 2005 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 12 Model GA4004 6kW Magnetron Head Pin 2 Microwave over temperature ground This pin is connected to ground through the magnetron thermal switch that senses magnetron temperature The thermal switch is Normally Closed and opens upon sensing a magnetron overtemp condition Pin 3 Air pressure interlock ground This function is unused and the pin is permanently connected to ground Pin 4 Water flow interlock ground This pin is connected to ground through connecto
16. ur captive screws that secure the CATHODE BLOWER to the MAGNETRON Lift up the blower duct assembly and disconnect the power cord from the blower Disconnect the two filament transformer secondary leads and high voltage lead from the magnetron filament leads that are supported by the FILAMENT LEAD SUPPORT BLOCK Loosen the two panel screws that secure the COOLING WATER CONNECTION BLOCK to the chassis front panel Remove the five screws securing the FRONT PANEL to the chassis Carefully pull the top edge of front panel slightly away from the chassis until the panel is resting at an angle approximately as shown Carefully lay the magnetron on one side While supporting the magnetron with one hand insert a 7 32 Allen key through the holes in the chassis bottom and loosen the four CAPTIVE NUTS that secure the MAGNETRON to the waveguide launch section After loosening all CAPTIVE NUTS carefully pull the MAGNETRON away from the launch section 2005 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 15 Model GA4004 6kW Magnetron Head 11 Remove the fasteners that secure the FILAMENT LEAD SUPPORT BLOCK to the magnetron and remove the block 12 Loosen the tube compression fittings that connect the WATER FITTING CONNECTION BLOCK to the MAGNETRON and remove the connection block 13 Reassemble in the reverse order of disassembly CATHODE BLOWER AND DUCT COOLING WATER CONNECTION BLOCK f MAGN
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