Product User Manual - Gerling Applied Engineering, Inc.
Contents
1. Product User Manual Model GA4002 1 83KW Magnetron Head Document 930020 Rev 3 e A GERLING APPLIED 7 a ENGINEERING INC P O Box 580816 Modesto CA 95358 www 2450mhz com Product User Manual Page 2 Model GA4002 1 8kW Magnetron Head REVISION HISTORY REV DESCRIPTION DATE APPROVAL 3 Misc updates 13FEBO4 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 damages financia2. Waveguide Configuration The GA4002 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 DUMMY LOAD gi APPLICATOR 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 Model GA4002 is configured 2001 2004 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 9 Model GA4002 1 8kW Magnetron Head with a flange designed for used with the GA8401 Quick Release clamp when connected to another similarly designed flange This flange can also be connected to any other standard WR284 round flange UG 584 U using suitable fastener hardware Flange Alignment Pins m Each waveguide flange connection that uses a quick release clamp requires two alignment
3. Magnetron Head Outline Drawing ONN OZ 1 anis ANNOYS AVO JOVLIOA HOIH td wz YIMOG NVA 2 ININVII Lr TOULNOJ ATdaNS YIMOJ ZA 3gnns 39an Xv ONY INUNNON YO4 S108 X3H HUM NMOHS ONN OZ L SITOH ONUNNON Xt 0ozi mauvanoo n 8s an dIdVL 0 0 HLM BZUM OMLNOD AONIY EN 3O0NVU LNALNO 3aInoJ3AVM og OQ0O0000000000000009 990000000000000099 g d0000000000000080 Sd0000000000000080 se 6 HOLMS 319901 YOLOFI3S LSNTGY YIMOd ma nani o1 1SNPGV YIMOd MN NOLINEHSNd 03 HOLIMS dO1S MN NOLINGHSNd N3349 HOLMS LAVIS MWN T34 YOLVOIGNI NO AH line SOON SNA JWWad LAN 1 SNOLLOSNNOD YalWM INNOOJ Nid IN3NNOMY JONVLI aivay anv WOLLOB dOl SYINAUSV4 Y3A09 i 3A0I SS300 NUNL 1 Xv Modesto CA 2001 2004 Gerling Applied Engineering Inc Product User Manual Page 8 Model GA4002 1 8kW Magnetron Head INSTALLATION Preliminary Inspection Upon arrival at the installation site the GA4002 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 a GA4002 Magnetron Head b Mating connector set filament amp fan power power supply control and remote control c Product User Manual
4. ite IA MI 1 lt mw CONTROL REF s3 e ALARM RELAY CONTACT com 12X 2L 2 CRN 2 lt 2 ef o P S lt MW CONTROL INPUT R HV ENABLE INPUT 12 voc gt lt gt lt 3 BRN _I3 lt Be EMOTE lt ANODE CURR SENSE MW STOP S2 12 voc outeur AA g 4 AK 4 lt INTERLOCK LOOP OUT KIA MW CONTROL INPUT 0 10 voc E lt lt 5 GRY AJ e S lt INTERLOCK LOOP RTN k18 MW CONTROL VOLTAGE REF E lt KZ 6 Bw AE li S lt HV ENABLE INPUT s ARC DETECTOR INPUT GND t2 lt 7 lt 7 YE I7 7 et Ts eo o 7 lt GROUND FMW START 77 MAGNETRON THERMOSWITCH INPUT GND 8 lt 3 lt 8 BLK 18 lt Be 2 N ANODE CURRENT SENSE 1V 100mA 2 lt 9 lt t 9 sa LAN ANODE VOLTAGE SENSE 1v 1000v X lt P lt 10 N C BLU WHT X N C GRY WHT EXTERNAL INTERLOCK lt Yet n TOL GRN wHT EXTERNAL INTERLOCK 2c I2 lt 12 NOT USED L Set 13 N C chassis cRouno y 14 A BLK F Y w 18 BLK CONNECTOR 1 Ak A 16 BLK a Ka BLK CONTROLLED Li OUTPUT FIL gt gt 17 L1 ouTPUT Fan gt s2 18 YEL GRN s4 L2 OUTPUT FAN amp FL gt gt gt 3 Ya g TS 4 ha GROUND gt c COVER MAG FLANGE not uso gt 5 gt Ae L1 INPUT 208 vac gt gt L2 INPUT 208 vac gt 7 gt 2Z yi A BRN LINE VOLTAGE Y S W L2 180 265 VAC 50 60 HZ 15A MAX SINGLE PHASE f f y YEL GRN Gi 2001 2004 Gerling Applied Engineering Inc Modesto CA Page 7 Product User Manual Model GA4002 1 8kW
5. d the inlet water temperature CAUTION Failure to provide an adequate rate of water flow can result in severe damage to the GA4002 It is strongly recommended that an interlock device such as an in line water flow switch be used to prevent operation of the microwave generator in the event of inadequate or loss of water flow 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 point can allow moisture condensation inside the microwave 2001 2004 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 10 Model GA4002 1 8kW Magnetron Head generator and or waveguide circulator and cause equipment damage Water Fitting Connections Standard 1 4 NPT female fittings are provided at the side of the GA4002 enclosure 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 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 a
6. del GA4002 1 8kW Magnetron Head k pressed This signal must be present for operation of the magnetron head and microwave power generation Pin 5 Interlock loop return 24 VAC The voltage present at pin 4 must be returned through pin 5 before microwave power can be started A dry contact interlock device and or remote Mw Stop switch momentary normally closed may be connected in series between pins 4 and 5 Opening either of these two devices will cause microwave power generation to cease Pin 6 High voltage enable input 24 VAC Connecting the voltage at pin 4 to pin 6 will cause 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 pushbutton switch WARNING Serious injury and or death can result from the use 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 7 Chassis ground Chassis Ground Connection k The chassis of GA4002 magnetron head must be connected directly to the chassis of the magnetron pow
7. dequate for all components Power Supply Connections With the exception of remote control all electrical power required for operation of the magnetron head is provided by the magnetron power supply All connectors are located at one side of the magnetron head The following describes the pinouts for each connector J1 Filament and Fan Power Pin 1 Magnetron head interlock return ground This signal is grounded when all three internal magnetron head interlocks are satisfied Microwave power cannot be generated if any of these interlocks are open Microwave power will cease to be generated if an interlock opens during operation Pin 2 Chassis ground Pin 3 L2 input for filament and fan power 208 VAC This signal is the L2 phase of the power line supplying power to the filament and fan Pin 4 L1 input for fan power 208 VAC This signal is the uncontrolled L1 phase of the power line and supplies power to the fan Pin 5 L1 input for filament power controlled 208 VAC This signal is the controlled L1 phase of the power line and supplies variable power to the filament transformer Pin 6 Ground used for arc detector signal output This signal is intended for future use by the output of an arc 2001 2004 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 11 Model GA4002 1 8kW Magnetron Head detector circuit It must be ground for operation of the magnetron head and ge
8. ent microwave leakage the equipment must be periodically inspected and maintained as required or recommended 2001 2004 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 4 Model GA4002 1 8kW Magnetron Head TABLE OF CONTENTS EQUIPMENT DESCRIPTION ccccecceeeseeeseeeeeeeeeeeeeeseeenneees General Specifications Mating Connectors supplied with GA4002 Recommended Alter Components available separately Schematic Diagram Outline Drawing INSTALLATION icisasicnsctccisataneasetctacacctsietisecdsecicetibetisntiesstaaacic Preliminary Inspection Waveguide Configuration Flange Connections Flange Alignment Pins Water Flow Requirements Water Fitting Connections Power Supply Connections Remote Control Connections Chassis Ground Connection OPERATION 4 kit ki e n n e a ok m auras a Basic Operation Microwave Power Control MAINTENANCE AND CALIBRATION 00202itrrrrrrrrrreeeanananonon Magnetron Removal and Replacement 2001 2004 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 5 Model GA4002 1 8kW Magnetron Head EQUIPMENT DESCRIPTION The GA4002 Magnetron Head is designed to deliver nominally 1 8KW of microwave power when used with the model SM745 Switching Power Supply manufactured by Alter A complete system requires only the GA4002 the SM745 and its mating Line Power Control cable set also available separately from Alter t
9. er supply Connection to the magnetron head chassis is at the ground stud located at the side near the electrical connectors Connection to the power supply chassis is at the ground stud located at the rear of the chassis The recommended wire is 14 AWG UL 1007 or equivalent with green or green yellow insulation WARNING Failure to provide an adequate ground connection between the magnetron head and power supply chassis can expose the operator to high voltage and result in severe injury or death 2001 2004 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 14 Model GA4002 1 8kW Magnetron Head OPERATION Basic Operation All interlocks must be satisfied before operation of the microwave generator can begin This standby condition is indicated by the absence of any lighted indicator lights on the front panel of the magnetron power supply Pressing the Start button on the front panel of the magnetron head will enable magnetron power supply and deliver high voltage to the magnetron However The actual level of microwave power output will be determined by the setting of the microwave power control as explained below Pressing the Stop button on the magnetron head or opening any of the interlocks will stop the generation of microwave power Microwave Power Control The level of microwave power generated is determined by the settings of the power control potentiometers or remo
10. erlock signal is returned to the magnetron head at pin 4 see above Pins 6 and 7 High voltage enable relay contacts These pins are connected to normally open contacts K1A of relay K1 Upon energizing relay K1 by pressing the Mw Start switch S1 contacts K1A close and deliver the high voltage enable signal to the magnetron power supply The contacts are opened by pressing the Mw Stop button Pin 8 Chassis ground 2001 2004 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 12 Model GA4002 1 8kW Magnetron Head Remote Control Connections All connections for remote control of the magnetron power supply and magnetron head are made to connector J3 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 AA 1 MW CONTROL REF MW POWER ADJUST 2 MW CONTROL INPUT a iH ANODE CURR SENSE ANODE CURRENT a EXTERNAL INTERLOCK DEVICE a INTERLOCK LOOP RTN MW STOP lt INTERLOCK LOOP OUT lt lt lt MOMENTARY SWITCHES HV ENABLE INPUT MW START 7 NO GROUND Figure 2 Recommended electrical circuit for remote control Pin 1 Microwave control voltage reference 10 VDC This is a DC voltage generated by the magnetron power supply for use by a remote power co
11. et temp 70 psi max inlet pressure Controls Mw Start pushbutton Mw Stop pushbutton Mw Power Adjust 10 turn Dial 2001 2004 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 6 Model GA4002 1 8kW Magnetron Head Interlocks Mating Connectors supplied with GA4002 High Voltage Fan amp Filament Power Power Supply Control Remote Control HV On Red LED Power Adjust Selector toggle switch Waveguide flange Access cover Magnetron over temperature Lemo series 1Y Shell AMP 206060 1 Contact AMP 66105 4 Shell AMP 211399 1 Contact AMP 66105 4 Shell AMP 211400 1 Contact AMP 66103 4 Recommended Alter Components available separately Switching Power Supply SM745F 003 Cable Set Schematic Diagram T MAGNETRON POWER SUPPLY GA410X 44 1384745 PI HIGH VOLTAGE OUTPUT 4kv amp CONNECTOR 3 MAGNETRON HEAD casoox TERMINAL BOX RI MW POWER 10K CONNECTOR 2 AN A G pe A i ADJUST 7 ALARM RELAY CONTACT NO 4 lt A 1 A PINK
12. hus greatly simplifying the task of system design and integration All mating connectors are provided All controls necessary for operation of the SM745 power supply as well as connections for remote control are provided in the GA4002 The magnetron filament transformer is also packaged inside the unit for added convenience The complete unit is replaceable by simply disconnecting the waveguide flange and electrical connectors Removal and replacement of the internal magnetron can be done in less than ten minutes using standard tools The magnetron is water cooled for enhanced life under high power operation Magnetrons compatible for use in the GA4002 are available from a variety of suppliers A powder coated steel enclosure provides rugged durability while multiple safety interlocks meet compliance requirements Convenient mounting holes and brackets facilitate bench top use or integration into process systems Optional features include alternate flange configurations arc detection and custom private labeling and colors Model GA4002 features the popular WR284 Q D quick disconnect round flange that uses the convenient single screw clamp GAE model GA8401 for waveguide connections General Specifications Output Power max 1 8 kW Magnetron Water cooled Hitachi 2M130 or equivalent Output Waveguide WR284 Output Flange UG584 U Frequency 2450 MHz 30 MHz Cooling 0 5 gpm water 35 C max inlet temp dew point min inl
13. l 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 b pi 2001 2004 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 3 Model GA4002 1 8kW 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 prev
14. neration of microwave power Pin 7 No connection J2 Power Supply Control Pin 1 Microwave control voltage reference 10 VDC This is a DC voltage supplied to the microwave power control potentiometer located in the magnetron head It can also be used as a voltage reference by an external power control potentiometer Pin 2 Microwave control voltage output 0 10 VDC This is an analog DC voltage proportional to the setting of the microwave control potentiometer located either inside the magnetron head R1 or remotely Pin 3 Anode current sense input 1 V 200 mA This signal is generated by the magnetron power supply and is proportional to the magnetron anode current It is proportional to magnetron output power and thus can used as an indication of microwave power generated by the magnetron head Pin 4 Power supply interlock loop return 24 VAC This signal is present when all internal interlocks of the magnetron power supply are satisfied This signal must be present for operation of the magnetron head and microwave power generation Microwave power will cease to be generated if a power supply interlock opens during operation Pin 5 Power supply interlock loop output 24 VAC This signal is delivered to the magnetron power supply where it passes through a normally open alarm relay contact The alarm relay contact closes when all internal interlocks of the magnetron power supply are satisfied and the int
15. ntrol potentiometer Because the current output of the voltage source is limited and for maximum operational stability this voltage should not be used for any other purpose Pin 2 Microwave control voltage input 0 10 VDC The level of microwave power delivered from the magnetron head 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 1 see above may be used as a reference or a separate voltage source referenced to the same ground point can also be used The toggle switch on the front panel of the magnetron head must be set to Remote for this voltage to have effect Pin 3 Anode current sense output 1 V 100 mA This signal is generated by the magnetron power supply and is proportional to the magnetron anode current It is proportional to magnetron output power and thus can used as an indication of microwave power generated by the magnetron head The recommended minimum load impedance for voltage measuring devices is 250 Ohms Pin 4 Interlock loop output 24 VAC This signal is present when all internal interlocks of the magnetron power supply are satisfied and the Mw Stop switch on the front panel of the magnetron head is not being 2001 2004 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 13 Mo
16. 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 bands All GAE waveguide components meets these requirements when properly connected to another waveguide component Water Flow Requirements A A A source of water must be connected to the GA4002 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 an
17. ssary Although the GA4002 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 The magnetron can be replaced by the user as follows 1 Turn off the magnetron power supply and disconnect all electrical connections from the magnetron head 2 Disconnect the source of cooling water both supply and drain 3 Turn the four captive cover screws turn and remove the cover 4 Remove the brown filament lead insulator block and disconnect the filament transformer and high voltage leads from the magnetron 5 Loosen the hose clamps and remove the two hoses from the magnetron water fittings 6 Remove the four nuts below the magnetron securing the magnetron to the chassis and carefully lift out the magnetron 7 Disconnect the two leads connected to the thermal switch mounted to the side of the magnetron 8 Connect the two thermal switch leads onto the thermal switch mounted to the new magnetron 9 Install the new magnetron in the reverse order of removal 10 Connect the cooling water supply and check for water leaks 11 Replace the chassis cover 2001 2004 Gerling Applied Engineering Inc Modesto CA
18. te analog input signal Control potentiometers are located on the front panels of both the magnetron power supply and magnetron head A toggle switch located on the front panel of the magnetron head selects between Mag Head up position Power Supply center position and Remote Analog down position for the location of power control When Power Supply is selected the magnetron head potentiometer and remote analog signal are both disabled The power control potentiometer on the magnetron power supply is the primary control and will override the settings of the other power controls unless set to zero For example if the magnetron head potentiometer is set to 50 power and the magnetron power supply potentiometer is set to zero then microwave output power will be 50 If the magnetron power supply potentiometer is then adjusted to 75 then the microwave output power will be 75 The same interaction occurs between the magnetron power supply potentiometer and the remote analog control signal 2001 2004 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 15 Model GA4002 1 8kW Magnetron Head MAINTENANCE AND CALIBRATION The GA4002 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 1000 to 3000 hours depending on operating conditions and usage No calibration is nece
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