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Product User Manual - Gerling Applied Engineering, Inc.
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1. Product User Manual Models GA1213 amp GA1214 Dummy Load w Power Reflector WR284 Document 930021 Rev 2 Gerling Applied Engineering Inc P O Box 580816 Modesto CA 95358 www 2450mhz com Product User Manual Page 2 Model GA1213 GA1214 Dummy Load W Power Reflector WR284 930021 Rev 2 REVISION HISTORY REV DESCRIPTION DATE APPROVAL 2 ADDED FIGURE 3 22JUN06 JFG VVARRANTY 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 vvarranty and may include but are not be limited to magnetrons fuses lamps seals o rings v belts and fluids All vvarranty 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 product specifications GAE assumes no liability in any event for incidental or conse
2. Preliminary Inspection Upon arrival at the installation site the dummy load should be thoroughly inspected for damage or vvear caused during shipping Any visible damage to the packaging material or dummy load should be noted and reported immediately to the shipping company in accordance vvith standard claims procedures The follovving components are included a Dummy Load with Power Reflector b Product User Manual Waveguide Configuration The dummy load with power reflector can be connected to and used with any common waveguide component having a compatible flange The mounting position can be in any orientation Figure 1 below illustrates a common configuration in which the dummy load with power reflector is used in conjunction with a 3 port circulator to vary the level of microwave power delivered to the process DUMMY LOAD DUMMY LOAD WITH POWER REFLECTOR 3 3 MICROWAVE 0 0 E POWER HEAD TT he Q CIRC CIRC COUPLER TUNER APPLICATOR 1 2 Figure 1 Typical waveguide configuration using the dummy load with power reflector to vary microvvave power delivered to the applicator Flange Connections The waveguide flange of the dummy load must be properly connected to another waveguide component having a similar flange style Model GA1214 is designed to be used wi
3. dummy load 1 2 5 Insert the hex driver into one of the two screw holes and gently push the insert block out of the dummy load waveguide 1 3 Reassembly 1 3 1 Inspect the inside of the waveguide for signs of damage and or corrosion In particular carefully inspect the four o rings seats on the inside of the back wall Additional repairs may be required in the event of internal damage or excess corrosion CAUTION Excess corrosion can prevent a water tight seal or cause premature failure of the seals and result in damage to other equipment In this case the dummy load may not be repairable 2005 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 14 Model GA1213 GA1214 Dummy Load W Power Reflector WR284 930021 Rev 2 1 3 2 Remove the four greased o rings from the polyethylene bag and place them into each of the four seats on the inside back wall of the dummy load 1 3 3 Carefully slide the insert block assembly into the dummy load waveguide Ensure that the two plugs with smaller o rings on the sides of the block are fully inserted into the counter bore holes CAUTION If the plugs have come out as may happen during shipping ease them back in while being careful to avoid nicking the o rings on the edge of the counter bore 1 3 4 Insert the two 14 20 socket head screws into the counter bored holes at the end of the waveguide and engage the screw threads into the insert block Carefully tighten the s
4. load clockwise to increase the level of microwave power delivered to the process Use the power reflecting stub to vary delivered microwave power Note that output power and thus output frequency from the microwave generator will remain constant Low Power Control Range 1 Connect the dummy load with power reflector as shown in Figure 1 Adjust the power reflector stub to the fully counterclockwise fully extracted position Turn on the microwave generator and set the output power level to the maximum NOTE At this time the level of microwave power delivered to the process will be extremely low Turn the power reflector stub on the dummy load clockwise to increase the level of microwave power delivered to the process Adjust the stub to the maximum level of delivered power required for the process presumably somewhat lower than the maximum output from the microwave generator Varying the power output from the microwave generator will vary the power delivered to the process and the control range of delivered power is now proportional to generated power according to the power settings in steps 2 and 3 Performance Considerations In order to absorb substantially all of the incident microwave energy the characteristic impedance of the dummy load must be a close match to that of the waveguide to which it is connected The factors that influence this impedance match include the microwave frequency the dielectric prop
5. ard WR284 round flange UG 584 U using suitable fastener hardware Waveguide WR284 Flange GA1213 UG 1725 U GA1214 UG 584 U round with taper for quich release clamp Frequency 2450 MHz nominal Incident Power Up to 3kW continuous Return Loss 6 to 23 dB continuously variable VVater Connections 1 8 NPT female 2005 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 6 Model GA1213 GA1214 Dummy Load W Power Reflector WR284 930021 Rev 2 VVater Flovv 1 0 gpm nominal 2 0 gpm maximum Water Pressure 70 psi maximum Water Temp Inlet 40 F 4 C minimum Outlet 150 F 66 C maximum Overall Length 6 50 inches 16 5 cm Net Weight 2 lb 4 4 kgm Outline Drawing ka 6 50 165 w fa 6 50 165 n 1 88 48 1 88 48 POWER REFLECTOR ke vg POWER REFLECTOR JE DIAL JS DIAL SE PI FLANGE ALIGNMENT PIN N INPUT FLANGE CPR284F yo ee l 25 16 4 H INPUT FLANGE WR284 Q D ROUND N WATER CONNECTION 1 8 NPT FEMALE 2X 1 8 NPT FEMALE 2x ol O F o 1 50 38 3 00 76 O Oo O o 38 9 5 kosa a MODEL GA1215 MODEL GA1214 2005 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 7 Model GA1213 GA1214 Dummy Load W Power Reflector WR284 930021 Rev 2 INSTALLATION
6. crews with the hex driver just enough to compress the o rings CAUTION Over tightening the screws will cause the Helicoil inserts inside the block to become loose and may result in permanent damage to the insert block 1 3 5 Install water fittings apply water pressure 70 psi max and check for water leaks 1 3 6 Reinstall dummy load into vvaveguide set up PLUG li INSERT BLOCK S i N LARGE O RING DUMMY LOAD WAVEGUIDE 1 4 20 SOCKET HEAD SCREW ITEMS INCLUDED WITH GA8105 INSERT REPAIR KIT Figure 5 Exploded view of dummy load assembly 2005 Gerling Applied Engineering Inc Modesto CA
7. ds All GAE waveguide components meets these requirements when properly connected to another waveguide component E Water Flow Requirements A source of water must be connected to the dummy load 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 Figure 2 below shows the minimum flow rate vs incident microwave power and inlet water temperature 2005 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 9 Model GA1213 GA1214 Dummy Load W Power Reflector WR284 930021 Rev 2 MINIMUM WATER FLOW RATES 2 50 0 3 0 kW 2 5 kW 2 0 kW 1 5 kW 1 0 kW 0 5 kW Au 1 00 P N o o a Minimum Flow Rate gpm N o a o LT eti SS A E Ce a a 4 E ii ld 0 00 40 50 60 70 80 90 100 110 120 130 140 Inlet Water Temp F Figure 2 Recommended minimum water flow rates for given inlet water temperature and incident microwave power level CAUTION Failure to provide an adequate rate of water flow A can result in severe damage to the dummy load It is strongly recommended that an interlock device such as an
8. erties of the insert block and the water and the physical geometry of the block and the channels through which the water flows The dielectric properties of most materials vary with changes in temperature In the case of water an increase in temperature 2005 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 12 Model GA1213 GA1214 Dummy Load W Power Reflector WR284 930021 Rev 2 causes a decrease in its dielectric loss and in general results in a decrease in microvvave energy absorption Hovvever the geometry of the absorbing load can be optimized or tuned for the dielectric properties at a desired temperature In this case energy absorption is maximized at the design temperature and is reduced at both higher and lovver temperatures As shovvn in Figure 4 belovv the dummy load is designed for optimal performance at inlet water temperatures between 75 F 24 C and 85 F 29 C For best performance the outlet water temperature should remain as close as possible to the inlet temperature A low water flow rate and high incident power causes a large increase in temperature which since the heated water is still inside the load results in a detuning of the load impedance and a decrease in energy absorption TYPICAL PERFORMANCE 2450 MHz WR284 DUMMY LOAD 10 Gei 15 20 25 Return Loss dB 30 40 50 60 70 80 90 100 110 120 I
9. 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 2005 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 4 Model GA1213 GA1214 Dummy Load W Power Reflector WR284 TABLE OF CONTENTS 930021 Rev 2 EQUIPMENT DESCRIPTION 0000 a s ns ssass snas s san nasa Specifications Outline Drawing INSTALLATION sa mi Preliminary Inspection Waveguide Configuration Flange Connections Flange Alignment Pins Water Flow Requirements Water Fitting Connections Storage and Shipping OPERATION if t kara a anang aa na gu ndaga aa ad anaa a a aaa aaa a e kk Basic Operation Typical Application Setup Variable Power at Constant Frequency Low Power Control Range Performance Considerations USER MAINTENANCE AND REPAIR 400neerann nenen nenen nannnnnanananen Insert Block Replacement Procedure 2005 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 5 Model GA1213 GA1214 Dummy Load W Power Reflector WR284 930021 Rev 2 EQUIPMENT DESCRIPTION Specifications The GA1213 and GA1214 dummy loads vvith povver reflector are designed for use in high power microwave networks requiring a dummy load having variable return loss variable reflection These models combine the compact design of GAE s standard
10. in line water flow switch be used to prevent operation of the microwave generator in the event of inadequate or loss of water flow Water Fitting Connections Standard 1 8 NPT female fittings are provided at the end of the dummy load opposite the waveguide flange The source of water can be connected to either fitting 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 falling into the fitting holes Storage and Shipping Upon removing the dummy load from the set up it is recommended that all water be drained prior to storage or shipping This precaution will prevent damage in the event that freezing temperatures are encountered during storage or shipping 2005 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 10 Model GA1213 GA1214 Dummy Load W Power Reflector WR284 930021 Rev 2 OPERATION Basic Operation The GA1213 and GA1214 dummy loads with power reflector utilize water as the medium for absorbing microwave energy that enters through the waveguide flange The internal UHMW polyethylene block through which the water flows is transparent to microwave energy referred to as having low dielectric loss characteristics and allows the energy to be absorbed directly into the water The dielectric loss of water is relatively high and is capable of absorbing over 99 of the incident micr
11. nlet Water Temp F Figure 4 Return loss vs inlet water temperature 2005 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 13 Model GA1213 GA1214 Dummy Load W Power Reflector WR284 930021 Rev 2 USER MAINTENANCE AND REPAIR The GA1213 and GA1214 dummy loads are designed to be maintenance free and do not require any user maintenance under normal operating conditions However the dummy loads can sustain damage if the water flow rate is insufficient to prevent vaporization boiling while operating under conditions of high incident microwave power In the event of damage due to insufficient or lack of water flow the dummy load can be easily repaired by replacing the polyethylene insert block Repair kit model GA8103 available from GAE includes all necessary components for replacement of the insert block Insert Block Replacement Procedure refer to Figure 5 below 1 1 Equipment Requirements Hex Allen driver 3 16 1 2 Disassembly WARNING Turn off microwave power and disconnect line power from the microwave generator before disconnecting any waveguide components 1 2 1 Disconnect the water supply and drain from the water fitting connections at the back of the dummy load 1 2 2 Remove the dummy load from the waveguide set up and drain the water from inside the load 1 2 3 Turn the reflector stub dial fully counterclockwise 1 2 4 Remove the two socket head screws at the back of the
12. owave energy When the stub element is fully extracted from the waveguide fully counterclockwise the insertion loss will be maximized and reflected power minimized Turning the stub dial clockwise will drive the stub into the waveguide causing an impedance mismatch with the dummy load and resulting in some amount of reflected microwave power Increasing the insert depth causes a greater impedance mismatch and higher reflection Figure 3 below shows the relationship between the stub position and reflected power 80 7 70 60 50 40 30 REFLECTED 20 10 0 0 2 4 6 8 10 12 14 DIAL READING Figure 3 Percent reflected power vs dial reading Typical Application Setup The following are procedures for setting up common operation schemes 2005 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 11 Model GA1213 GA1214 Dummy Load W Power Reflector WR284 930021 Rev 2 Variable Povver at Constant Frequency 1 Connect the dummy load vvith povver reflector as shovvn in Figure 1 Adjust the povver reflector stub to the fully counterclockwise fully extracted position Turn on the microwave generator and set the output power level to whatever will be the maximum required for the process NOTE At this time the level of microwave power delivered to the process will be extremely low Turn the power reflector stub on the dummy
13. quential 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 rr 4 2005 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 3 Model GA1213 GA1214 Dummy Load W Power Reflector VVR284 930021 Rev 2 VVARNING All waveguide dummy loads manufactured by GAE are intended for use with other equipment capable of producing a microwave field that is potentially hazardous to operating personnel It 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 this unit 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
14. short dummy loads e g model GA1201 and GA1204 with the same stub tuning element as its precision waveguide multi stub tuners Inserting the stub element into the waveguide causes an impedance mismatch with the dummy load Thus varying the amount of stub insertion varies the amount of incident microwave power that is reflected back from the dummy load When combined with a 3 port circulator these devices are useful in applications where it is desirable to vary the level of microwave power delivered to the process without changing the power output from the microwave generator i e variable power at constant frequency The same configuration also provides a means to vary delivered microwave power at levels much lower than the stable control range of the microwave generator Incident microwave power that is not reflected back out is absorbed by water which internally flows through channels in a solid UHMW polyethylene block Naval brass is used for all water fitting connections to minimize corrosion The waveguide body is fabricated with dip brazed aluminum A precision drive mechanism and locking multi turn dial are provided on the stub enabling highly precise settings The stub housing is designed with a 1 4 wave reactive choke for high power operation The waveguide flange on the GA1214 is designed to be used with the GA8410 Quick Release clamp when connected to another similarly designed flange It can also be connected to any other stand
15. th the GA8410 Quick Release flange clamp when connected to another similarly designed flange It can also be connected to any other standard WR284 round flange UG 584 U using suitable fastener hardware 2005 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 8 Model GA1213 GA1214 Dummy Load W Power Reflector WR284 930021 Rev 2 Flange Alignment Pins Each flange connection that uses a quick release camp 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 into 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 ban
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