Product User Manual - Gerling Applied Engineering, Inc.
Contents
1. Product User Manual 2 kW Microwave Generator WR340 Ceralink Document 930052 Rev 2 Gerling Applied Engineering Inc P O Box 580816 e Modesto CA 95358 www 2450mhz com Product User Manual Page 2 2kW Microwave Generator WR340 Ceralink REVISION HISTORY REV DESCRIPTION DATE APPROVAL 1 PROTOTYPE RELEASE 05MAR04 JFG 2 UPDATES TO REMOTE CONTROL 01MAY04 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 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 consequential d2. Failure to provide adequate protection from high voltage electrical connections can expose the operator to high voltage and result in severe injury or death AA 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 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 launch assembly and control module is provided by the power supply through a cable harness delivered with the system Table 1 below lists the cable interconnections between the power supply control module
3. HV ENABLE INPUT 24 VDC D 2S N C 4 4 4 READY ew pe AE 3 3 BLU 3 24 VDC OUTPUT lt lt N c Be lt GRN Mai RED MW CONTROL INPUT 0 10 VDC 2 3 S 4 lt 4 ech 6 6 BLK 6 5 5 WHT 5 MW CONTROL VOLTAGE REF lt lt lt Wy 7 F WHT 7 12 6 6 BRN 6 ARC DETECTOR INPUT GND Qm O a Isi BLK 8 ae 7 7 Joen 7 MAGNETRON THERMOSWITCH INPUT GND lt lt SE E lt y a io BLK 9 SM Ge fein heey LJ 8 ANODE CURRENT SENSE 1V 100mA y H L VY R1 K ko s5 Ne bai J M1 T r UeBHsIH 4 1M ANODE Al l MAG TEMP b i CONNECTOR 1 A N AN I CURRENT Lo pma vil ny D BLK 1 tia J BRN D CONTROLLED L1 OUTPUT FIL gt lt 52 2 2 BLK 2 17 BLK SN 2 L1 OUTPUT FAN Q 81 a S 3 3 BLK 3 WHT N FIFA L2 OUTPUT FAN amp FIL gt Y lt 2 T1 10 GRN AROUND 4 14 YEL GRN 4 P t A 5 5 J K i 7 be A NOT USED gt J gt L1 INPUT 208 VAC 2 S 5 7 CIRCUIT BREAKER SC L2 INPUT 208 VAC gt y SUPPLIED _BY_CUSTOMER eF EE A Eech LINE VOLTAGE BLU S D F 180 265 VAC 50 60 HZ PE 2an MAX SINGLE SE 20 AMPS 208 VAC YEL GRN arn A Beer Seen BATE GAE SSES pee ay E S P O BOX 580816 MODESTO CA 95358 SCC 2 DEG DRAWN JFG 16FEB04 DO NOT SCALE DRAWING ae 2kW MICROWAVE GENERATOR MMERIAG THIS DOCUMENT SHALL NOT BE SCH EMATIC DIAG RAM N A REPRODUCED NOR SHALL THE DWG NO NZA NA hs BE USED BY OR DISCLOSED TO C 941531 Next assy ve oN AUTHORIZED IN WRITING BY APPLICATION GAE INC 4 3 2 1
4. S GROUND t A MW CONTROL INPUT W CONTROL REF 2 MW POWER ADJUST 6 SYSTEM READY FAULT L 7 INTERLOCK LOOP O Gm EX 8 INTERLOCK LOOP ERNAL INTERLOCK Figure 2 Recommended electrical circuit for remote control Pin 1 HV Enable Input 24 VDC Connecting pin 8 to 24 VDC 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 dry contact switch or relay After releasing the switch this pin will remain at 24 VDC while the system is generating microwave power operate mode or when a Fault condition exists see pin 6 below WARNING Serious injury and or death can result from the use A 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 2 HV Relay Return Ground This pin is provided as a means to connect a momentary normally closed dry contact Microwave Stop switch or relay This pin must be connected to ground for g
5. fans Input Line Power 180 265 VAC 50 60 Hz single phase 23 Amps max 18 Amps at 230 VAC Local Controls Microwave Start switch pushbutton Microwave Stop switch pushbutton System Ready indicator neon lamp Microwave On indicator neon lamp 2004 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 6 2kW Microwave Generator WR340 Ceralink Remote Controls Interlocks Components Supplied Item Description Fault indicator neon lamp Anode Current meter LED digital Microwave Start Microwave Stop Microwave Power Adjust External Interlock Magnetron over temperature External GAE Part Number Magnetron Launch Assembly 911533 High Voltage Power Supply 000303 Alter SM745 Control Module Product User Manual 911532 930052 this document 2004 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 7 2kW Microwave Generator WR340 Ceralink INSTALLATION Preliminary Inspection Upon arrival at the installation site the 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 Power Supply and Control Module Installation The power supply and control modules are designed for use in a clean dry environment such as a laborat
6. functions are also available via remote control The following sections explain the individual operational features at each location Power Supply Controls and Indicators Local controls provided on the power supply front panel include a main power on off switch and a multi turn dial for adjustment of microwave output power level No local controls are provided for turning on and off microwave power see the following sections ON OFF rotary switch This switch turns on and off line power to the entire system When in the ON position the ON indicator see below will illuminate if line power is connected to the system POWER LEVEL multi turn dial This knob adjusts the level of microwave output power Upon enabling high voltage see below microwave power will be delivered according to the setting of this dial The LED bar graph located below the status indicators see below provides an indication of the magnetron anode current which is proportional to microwave output power The operating status of the system is indicated by the LED indicators located on the front panel of the power supply and control module The functions of each indicator on the power supply are as follows ON green Off Line power is disconnected and or main switch on front panel is off On Line power within the rated voltage range is connected and main switch is on RACK ALARM red Off No alarm condition On A fault condition exists caused by a
7. internal power supply over temperature b error between input control signal and 2004 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 13 2kW Microwave Generator WR340 Ceralink TUBE OVERTEMP red ARC DETECTION red OVERVOLT red LEAKAGE red ENABLE blue Bar Graph amber Control Module Controls and Indicators output reference or c magnetron anode over current permanent fault requiring manual reset Off Normal operation On Fault from either the magnetron thermal switch or external interlock This is a temporary fault that will be cleared upon resetting the interlock device s Off Normal operation On Arc condition has been detected temporary fault condition NOTE This function is not used in the microwave generator system described in this manual Off No alarm condition On Anode voltage exceeded 5kV for more than 500 ms This is a permanent alarm requiring manual 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 1 ms System must be reset before operation can continue see below Off High voltage is off On High voltage is on and microwave power is being generated at the level determined by the Analog Reference Input signal This 12 lamp bar graph indicates magnetron anode current in milliamperes mA which is proportional to microwave ou
8. nominally 2 kW microwave power Included in the assembly is a filament transformer cooling blower WR340 output waveguide and cables for connecting to the high voltage power supply High Voltage Power Supply Alter Systems model SM745 designed to operate the Hitachi 2M130 magnetron and its associated filament transformer c Control Module custom designed and manufactured by GAE for interfacing with and operating the above components The control module provides the local start stop control functionality for microwave power as well as an indication of operating status and magnetron anode current The power supply and control modules are designed for installation in a standard 19 rack cabinet while the launch assembly can be located at the process applicator furnace at a distance of up to 10 feet from the rack cabinet Cables are provided for connection between the modules as well as line power to the power supply Also included with the system are connections for remote control of microwave start stop functions and output power level Connections are also provided for external customer provided interlock devices such as the furnace access door switch cooling water flow and other safety devices oO General Specifications Output Power max 2 kilowatts average continuous Frequency 2450 MHz 30 MHz Magnetron Hitachi 2M130 Output Waveguide WR340 RG113 U Output Flange CPR340 UG554 U Cooling Forced air by internal
9. aker rated no more than 25A 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 Chassis Ground Connection The launch assembly waveguide must be electrically grounded directly to the chassis of the power supply The ground connection to the launch assembly may be anywhere on the waveguide although preferably near the magnetron Connection to the power supply chassis is at the ground stud located on the rear panel The recommended wire is 12 AWG UL 1007 or equivalent with green or green yellow insulation between the magnetron head and power supply chassis can expose the operator to high voltage and result in severe injury or death A WARNING Failure to provide an adequate ground connection Remote Control Connections All connections for remote control of the microwave generator are made to terminal block TB1 located on the launch assembly 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 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 10 2kW Microwave Generator WR340 Ceralink 1 e eee e HV ENABLE INPUT o o MW START NO MOMENTARY HV RELAY RETURN Q F MW STOP NC MOMENTARY
10. amages 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 wu 2004 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 3 2kW Microwave Generator WR340 Ceralink 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 prior to operation Never operate the microwave generator without a properly rated absorbing load attached To ensure sa
11. and launch assembly Table 1 Interconnect Cable Set Part l Mating Connectors Bieber Function Power Control Launch Supply Module Assy 911524 03 Filament Line Power J1 J1 911525 03 Control I O J2 J2 n a High Voltage J3 V1 FA 911363 10 Chassis Ground Ground Ground 2004 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 9 2kW Microwave Generator WR340 Ceralink Line Power Connection All connections for line power are made to the 3 conductor cable which connects to J1 on the power supply rear panel Schematic drawing 911531 see attachments illustrates the electrical connections The functions and electrical specifications of each connection are detailed as follows Pin 4 Chassis Ground GND Pin 6 Line Power Input Hot Phase L1 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 7 Line Power Input Neutral Phase L2 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 CAUTION The user must provide an external line power circuit A protection device such as a fused disconnect or circuit bre
12. eneration of microwave power and microwave power will cease to be generated if the connection is opened during operation Pin 3 Chassis Ground NOTE Connection between pins 2 and 3 is required for operation of the microwave generator even if remote control will not 2004 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 11 2kW Microwave Generator WR340 Ceralink be used A jumper wire is factory installed at this location on the terminal block Pin A Microwave Control Voltage Input 0 10 VDC The level of microwave power delivered from the magnetron is controlled by varying the voltage present at this pin from 0 to 10 VDC The use of a precision multi turn 10K Ohm potentiometer rated for 2 Watt is recommended for high control resolution and stability The voltage provided at Pin 5 see above may be used as a reference or a separate voltage source referenced to the same ground point can also be used NOTE Automatic adjustment of microwave power output can be accomplished by delivering an analog voltage signal to pin 4 from a process controller such as a PLC programmable logic controller or DAC data acquisition and control system This voltage should be in the 0 10 VDC range and referenced to ground at pin 3 Pin 5 Microwave Control Voltage Reference 10 VDC This is a DC voltage generated by the magnetron power supply for use by a remote power control potentiometer for the co
13. fe operation and prevent microwave leakage the equipment must be periodically inspected and maintained as required or recommended 2004 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 4 2kW Microwave Generator WR340 Ceralink TABLE OF CONTENTS EQUIPMENT DESCRIPTION ccccceceesseseeeeeeeeeeeeeeeeeeenneees General Specifications Components Supplied RE ee WE NEEN Preliminary Inspection Power Supply and Control Module Installation Launch Assembly Installation Flange Connections Interconnect Cables Line Power Connection Chassis Ground Connection Remote Control Connections OPERATION H Power Supply Controls and Indicators Control Module Controls and Indicators Basic Operation Microwave Power Control Alarm Fault Reset MAINTENANCE AND CALIBRATION cccccceeeeesseeseeeees Magnetron Removal and Installation ATTACHMENTS Doc Number Description 911531 Schematic Diagram 2kW Mw Generator 2004 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 5 2kW Microwave Generator WR340 Ceralink EQUIPMENT DESCRIPTION The 2kW Microwave Generator described in this manual was configured as a customized product specifically for Ceralink Inc It consists of three separate modules described as follows a Magnetron Launch Assembly manufactured by Alter Systems Italy using a Hitachi 2M130 type magnetron designed to deliver
14. he magnetron launch assembly 2 Remove the filament lead insulator block and disconnect the wire leads to the magnetron filament terminals and thermal cut out 3 Loosen the four locknuts securing the magnetron to the waveguide two on each side of the magnetron and carefully lift out the magnetron 4 Install the new magnetron in the reverse order of removal 2004 Gerling Applied Engineering Inc Modesto CA REVISIONS ZONE REV DESCRIPTION DATE APPROVED 2 MISC_UPDATES O1MAYO4 JFG D MAGNETRON POWER SUPPLY GA4105 LAUNCH SECTION ASSY 911533 GROUND STUD 17 CONNECTOR 3 P1 HIGH VOLTAGE OUTPUT 4kV CG lt Q CONTROL MODULE ASSEMBLY 911532 AR CONNECTOR 2 j2 MW START ww STOP N J S ECH RED no 51 c dye S2 Men 7 ALARM RELAY CONTACT NO N nee 2 i 2 CRI 7 J3 a T BLU 3 8 IN4005 g DSS K1 ORN 2 2 2 ion 1 1 D 1 ALARM RELAY CONTACT COM lt lt GD 2 lt O 3 3 BLK 3 Di R2 8 2 2 _ BLK 2
15. ntrol input voltage see Pin 4 above 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 6 System Ready Fault 24 VDC will be present at this pin when the system is either ready to start microwave power standby mode or currently generating microwave power operate mode A Fault condition exists if the voltage drops to approximately 12 VDC while the voltage present at pin 1 is 24 VDC Pins 7 and 8 Interlock Loop Ground These two pins are part of the interlock chain and must be connected together to satisfy the interlock requirements of the power supply Pin 8 is connected to ground through the magnetron thermal cutout switch NOTE Connection between pins 7 and 8 is required for operation of the microwave generator even if remote control will not be used A jumper wire is factory installed at this location on the terminal block 2004 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 12 2kW Microwave Generator WR340 Ceralink OPERATION The power supply itself provides limited local control functionality thus necessitating additional controls separately For this reason the control module provides additional local controls and indicators that allow convenient and safe operation of the microwave generator system Certain
16. ontrol signal voltage Alarm Fault Reset A permanent fault condition exists whenever the power supply OVERVOLT LEAKAGE or in some cases the RACK ALARM indicators are on or if an interlock device opens while in Operate mode This will be indicated when both the MW ON and FAULT indicators are on see also the description for pin 6 in the Remote Control Connections section To reset the system set the POWER LEVEL dial to zero or if used the remote analog control input signal to 0 Volts and press the MW STOP switch 2004 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 16 2kW Microwave Generator WR340 Ceralink MAINTENANCE AND CALIBRATION The microwave generator system is designed to be maintenance free with the exception of magnetron replacement The magnetron is considered a consumable component and has a life expectancy that depends on operating conditions and usage No calibration is necessary Although the system components are very rugged and stable devices they can be subject to damage due to improper operating conditions or mishandling If damage occurs other than to the magnetron itself the system 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 1 Turn off the power supply and disconnect all electrical connections from t
17. ory or cleanroom Installation can be either on a bench top or in a standard 19 rack enclosure If installed in a rack then both modules should be supported underneath and not cantilevered off the front panel mounting rails Adequate clearance must be provided at the rear and sides of the power supply to allow ventilation air to flow freely Launch Assembly Installation The waveguide launch assembly can be connected to and used in any convenient orientation horizontal or vertical with any common waveguide component having a compatible flange see below Ideally the launch assembly 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 ISOLATOR DIRECTIONAL COUPLER 5 STUB TUNER Figure 1 Typical waveguide configuration for process heating 2004 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 8 2kW Microwave Generator WR340 Ceralink The launch assembly must be installed inside a protective enclosure to isolate personnel from the exposed high voltage electrical connections Alternately covers can be installed over the electrical connection areas such that they cannot be removed without the use of tools As an added safety measure cover interlock switches should be utilized to shut off electrical power in the event of cover removal WARNING
18. t Reset section ANODE CURRENT digital panel meter This meter indicates magnetron anode current in milliamperes mA which is proportional to microwave output power After connecting line power the system can be turned on by turning the rotary switch located on the far right side of the power supply front panel The presence of line power is indicated on the power supply by illumination of the green ON indicator The magnetron cooling blower will also be operating When all of the interlock conditions are satisfied the TUBE OVERTEMP indicator on the power supply will be off and the READY indicator on the control module will be on The system is now in the standby mode of operation NOTE Power is supplied to the magnetron filament whenever the system is in standby mode Since magnetron life is consumed whenever the filament power is on it is good practice to turn off the 2004 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 15 2kW Microwave Generator WR340 Ceralink system during extended periods of non use in order to conserve magnetron life Microwave power may now be enabled by pressing the START pushbutton switch on the control module or by applying the remote control HV Enable input signal This places the system into operate mode as indicated by the power supply ENABLE indicator and control module MW ON indicator The generator will now deliver microwave power at a le
19. tput power The control module provides the start stop control functions for microwave power which are not provided locally by the power supply These controls are momentary pushbutton switches which energize and de energize latching circuitry inside the control module Indicators provided by the control module are described as follows READY green Off The system is off or line power is not connected or one or more interlocks 2004 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 14 2kW Microwave Generator WR340 Ceralink Basic Operation Je is not satisfied Microwave power can not be started when this indicator is off On The system is ready to begin generating microwave power standby mode or high voltage has been enabled to generate microwave power operate mode MW ON red Off High voltage has not been enabled to generate microwave power On High voltage has been enabled to generate microwave power at the output level as determined by the setting of the microwave output power adjust control s When the FAULT indicator is also on a fault has occurred which has caused the system to shut down The system must be reset before operation can resume FAULT red Off Normal operation On When the MW ON indicator is also on a fault has occurred which has caused the system to shut down The system must be reset before operation can resume see the Alarm Faul
20. vel according to the setting of the POWER LEVEL dial or the remote microwave control input signal see next subsection Pressing the STOP pushbutton switch on the control module or remote Stop switch will immediately disable high voltage and turn off microwave power The system will then return to standby mode and ready to be enabled for microwave power again Opening any of the external interlock devices will disable high voltage and turn off microwave power This will cause a system fault as indicated by the power supply TUBE OVERTEMP indicator and control module indicators Upon closing the external interlock devices the system will return to standby mode as indicated by the associated indicators Microwave Power Control The level of microwave output power can be controlled either locally or remotely Local control is by the multi turn dial on the power supply front panel and remote control is by the microwave control input signal The power supply POWER LEVEL dial is the primary control and will override the settings of the remote power control input signal except when the POWER LEVEL dial is set to zero For example if the remote analog control input signal is set to 50 power 5 volts and the magnetron power supply potentiometer is set to zero then microwave output power will be 50 If the power supply POWER LEVEL dial is then adjusted to 75 then the microwave output power will be 75 regardless of the remote c
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