Product User Manual - Gerling Applied Engineering, Inc.
Contents
1. Connect the filament transformer HV leads to the HV FEEDTHRU LEADS Also attach the flying HV lead from the rectifier assembly on top of the plate transformer to the near HV feedthru lead Install the phenolic insulator block over these HV lead connections Follow steps 2 2 2 through 2 2 13 as outlined in the Standard Retrofit Procedure above for installation of the new GA8002 MAGNETRON 2000 GERLING APPLIED ENGINEERING INC P O BOX 580816 MODESTO CA 95358 Phone 209 527 8960 Fax 209 527 5385 Email GAE 2450mhz com Web www 2450mhz com DWG NO 910220 vO A8 NI Q3ZhIOHLOV AISS3HdX3 SV 1939 3 SYSHLO OCOLO RNC erp EE E IN3N39V1d3M 9 IVAOW3S Y N NOILWONdd NO Gash DAN SnolnvA 13N9VWO310313 NOSL3NOVN BE 930 2 1 AOHddV 85 66 VO OLSSGOW 91808S5 XOG O d ONI EINEEEEINIENNEI AIHW3SSV SIHL OL ONIIVI3M SNOLLONYLSNI 303 cOO00v6 LNSWNDOG JOINTS TVOINHO3L OL X343 931519395 3SIMN3HIlO SSIINN S310N AI8N3SSV NOILO3S HONNV 3O3ld 310d 133HS 020 JNO YO SI33HS 010 YOLVINSNI LANOVWOYLOATA ONIN INIWALNAD 133HS 020 JNO S133HS 010 YOLVINSNI oar 3Sv3134 ilva NOlLdl49S3Q SNOISIA3H tF 31v9S LON Od OLO FXX2. Product User Manual Model GA4010 3kW Magnetron Head Document 930002 Rev 2 GERLING APPLIED Wy EN ENGINEERING INC P O Box 580816 Modesto CA 95358 www 2450mhz com Product User Manual Page 2 Model GA4010 3kW Magnetron Head REVISION HISTORY REV DESCRIPTION DATE APPROVAL 2 MISC UPDATES 1 4 JFG WARRANTY Products manufactured and sold by Gerling Applied Engineering Inc GAE are war ranted to be free of defects in materials and workmanship under normal use and service for a period of twelve 12 months from the date of original shipment GAE s obligation under this warranty is limited to repairing or replacing at GAE s option all non consumable component parts Consumable parts are specifically excluded from this warranty and may include but are not be limited to magnetrons fuses lamps seals o rings v belts and fluids All warranty repairs are to be done at GAE s facility or as oth erwise authorized by GAE All shipping charges for warranty repair or replacement are the purchaser s responsibility unless otherwise agreed to by GAE This warranty supercedes all other warranties expressed or implied No warranty is given covering the product for any particular purpose other than as covered by the ap plicable product specifications GAE assumes no liability in any event for incidental or consequential damages financial l
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4. AG9131 magnetron manufactured by AGL Inc NOTE This procedure can NOT be used to install the GA8002 magnetron into microwave generators currently using the model GL131C magnetron manufactured by AGL Inc formerly Gerling Labs and ASTeX Gerling Labs Inc or the model L 3858 magnetron manufactured by Litton Industries These generators must first be updated for use with the GA8002 magnetron or AG9131 as described in GAE Technical Service Document 940001 Reference Documents Drawing 910220 Magnetron Electromagnet Removal and Replacement Magnetron Removal and Installation 2 1 Removal 2 1 1 Refer to Drawing 910220 for location of ITEMS referenced in the following discussion 2 1 2 DISCONNECT THE POWER SOURCE FROM THE ELECTRIC POWER CONNECTION AND COOLING WATER CONNECTION 2 1 3 Remove outer cover s as necessary to gain access to the magnetron housing 2 1 4 Disconnect the water hoses from the magnetron MAKE SURE THAT WATER DOES NOT ENTER THE ELECTROMAGNET HOUSING It is recommended that a rag or other absorbent material be placed around the cooling tubes while disconnecting the hoses Carefully disconnect the Fan Cord not referenced from the FAN Remove the four screws which secure TOP COVER and remove the FAN and TOP COVER as an assembly from the power source Remove the two screws holding the vertical SIDE COVER at the bottom of the cover Remove the cover from the power source 2000 GERLING APPLIED ENGINEERI
5. NG INC P O BOX 580816 MODESTO CA 95358 Phone 209 527 8960 Fax 209 527 5385 Email GAE 2450mhz com Web www 2450mhz com GERLING APPLIED F GAE ENGINEERING INC Technical Service Document TSD No 940002 Magnetron and Electromagnet Rev B Removal and Installation Procedure Page 2 of 4 2 1 8 With a suitable Phillips screwdriver carefully loosen and remove the screws securing the inside leads on the HV FEED THRU ASSY to the magnetron filament leads 2 1 9 Carefully bend the magnetron filament leads straight up 2 1 10 Remove the three 8 kepnuts that hold the UPPER POLE PIECE to the UPPER ELECTROMAGNET RETAINER 2 1 11 Remove the UPPER POLE PIECE 2 1 12 Remove the used GA8002 MAGNETRON Save the thrust ring washer which is resting on top of the magnetron 2 1 13 Optional Return the used magnetron to GAE Inc for a no cost failure analysis report Installation 2 2 1 Refer to Drawing 910220 for location of ITEMS referenced in the following discussion 2 2 2 Insert the new GA8002 MAGNETRON into the housing and ensure it is properly seated into the socket of the LOWER POLE PIECE 2 2 3 Ensure that the thrust ring washer is resting on top of the magnetron core assembly and around filament lead mast Note that only one thrust ring washer is required and that one may have been supplied with the replacement GA8002 magnetron Install the UPPER POLE PIECE onto the UPPER ELECTROMAGNET RETAINER with t
6. Procedure Page 3 of 4 2 2 10 Reattach the fan cord to the FAN 2 2 11 Reattach the cooling hoses to the cooling lines of the magnetron DO NOT OVER TIGHTEN THE BANDS 2 2 12 Replace outer access cover s 2 2 13 Perform the Set Up Procedures for installation of a new magnetron as described in the Installation Operation and Maintenance Manual which was originally provided with the generator Electromagnet Removal and Installation 3 1 Removal 3 1 1 Refer to Drawing 910220 for location of ITEMS referenced in the following discussion 3 1 2 DISCONNECT THE POWER SOURCE FROM THE ELECTRIC POWER CONNECTION AND COOLING WATER CONNECTION 3 1 3 Follow steps 2 1 3 through 2 1 12 as outlined in the Standard Retrofit Procedure above for removal of the magnetron Remove the brown phenolic insulator block from around the connection between the filament transformer HV leads and HV FEEDTHRU LEADS Disconnect the filament transformer leads from the feedthru leads Disconnect the electromagnet leads from the two position terminal block located on the side of the housing near the HV feedthru leads Remove the four sets of 3 8 16 BOLTS with nuts and washers and left off the UPPER ELECTROMAGNET RETAINER with the filament housing intact 3 1 8 Remove the ELECTROMAGNET along with the INSULATORS above not below the electromagnet Also remove the plastic CENTERING RING Installation 3 2 1 Refer to Drawing 910220 for location of I
7. TEMS referenced in the following discussion 3 2 5 Set the ELECTROMAGNET onto the lower INSULATOR with the leads on top and towards the rear of the power source away from the output flange 3 2 6 Install the plastic CENTERING RING into the space between the ELECTROMAGNET and LOWER POLE PIECE 2000 GERLING APPLIED ENGINEERING INC P O BOX 580816 MODESTO CA 95358 Phone 209 527 8960 Fax 209 527 5385 Email GAE 2450mhz com Web www 2450mhz com GERLING APPLIED E z GAE ENGINEERING INC Technical Service Document TSD No 940002 Magnetron and Electromagnet Rev B Removal and Installation Procedure Page 4 of 4 3 2 7 Set the other electromagnet Insulator on top of the ELECTROMAGNET and properly centered Be sure the notches are aligned with those of the lower Insulator and the launch section assembly mounting holes 3 2 8 Set the UPPER ELECTROMAGNET RETAINER with filament housing attached over the ELECTROMAGNET with the mounting holes aligned with those of the launch section assembly Install the four 3 8 16 BOLTS through the launch section mounting holes from the bottom Install the flat washers split ring lockwashers and the hex nuts in that order Tighten the hex nuts until the lockwasher is approximately one half compressed this is to allow for thermal expansion of the electromagnet Connect the leads of the electromagnet to the two position terminal block the order of connection is not important
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9. al at the installation site the GA4010 should be thor oughly inspected for damage or wear caused during shipping Any visible damage to the packaging material or GA4010 should be noted and reported immediately to the shipping company in accor dance with standard claims procedures Facilities Requirements Mounting Position e Electrical Power All electrical power required by the GA4010 is provided by the HVPS with which the GA4010 is used e Ventilation Adequate clearance must be provided near the ven tilation ports on the front back and top of the GA4010 such that air is allowed to flow without restriction e Environment Indoors only must be clean and dry The GA4010 may be mounted on a horizontal surface such that the broad wall of the output waveguide is horizontal Orientation may be either normal magnetron up or inverted magnetron down as long as the axis of the magnetron is vertical Maximum allowable tilt of the magnetron axis is 5 degrees Electrical Connections Water Cooling e Control Power 9 pin cable connects between HVPS and J1 on GA4010 e High Voltage 2 pin cable connects between HVPS and J3 on GA4010 The magnetron contained within the magnetron head requires wa ter cooling during operation The nominal water flow is 1 0 and the minimum required flow is 0 5 gpm An internal solenoid valve automatically turns on water flow whenever the system is in opera tion It is recommended that a source
10. he flange towards the bottom Tighten the 8 nuts previously removed until they are just snug Do not over tighten Install and hand tighten the THRUST RING while gently rocking the magnetron by its cooling lines until the magnetron is firmly seated and snug in place The stem of the magnetron must be centered and vertical Finish tightening the three 8 nuts securing the UPPER POLE PIECE Carefully insert the THRUST RING INSULATOR around the magnetron filament leads and into the THRUST RING Carefully bend the magnetron filament leads so that they are positioned towards the HV Feedthru leads Secure the filament leads to the leads from the HV Feedthru attached to the filament housing wall using the previously removed screws and nuts Position these connections such that they are separated from each other and approximately mid way between the bottom and top of the filament housing Reinstall the housing SIDE COVER and fasten it to the FILAMENT HOUSING with two the screws previously removed Install the TOP COVER and FAN assembly and secure it to the filament housing with the four sheet metal screws previously removed 2000 GERLING APPLIED ENGINEERING INC P O BOX 580816 MODESTO CA 95358 Phone 209 527 8960 Fax 209 527 5385 e Email GAE 2450mhz com Web www 2450mhz com GERLING APPLIED E z GAE ENGINEERING INC Technical Service Document TSD No 940002 Magnetron and Electromagnet Rev B Removal and Installation
11. oad which prevents excessive microwave energy leakage and or re flected power Microwave Leakage Regulatory limits for microwave leakage re late to standards for human safety and interference with other elec tronic 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 condi tions The U S Federal Communications Commission FCC has established regulations limiting the emission of energy at frequen cies outside the ISM bands The GA4010 meets these require ments when connected to a suitable waveguide load Reflected Power Microwave power that is reflected back to the magnetron from a waveguide load can cause permanent damage to and or shorten the life of the magnetron Care should be taken to ensure that reflected power does not exceed 200 Watts It is rec ommended that a suitable waveguide isolator be connected at the output flange of the GA4010 to prevent reflected power from reach ing the magnetron Gerling Applied Engineering Inc Modesto CA Product User Manual Page 8 Model GA4010 3kW Magnetron Head BASIC OPERATION System Control Power Control The purpose of this discussion is to provide a basic understanding of the system operation such that a reasonabl
12. of water be permanently con nected and pressurized at all times to ensure the availability of cooling water during operation The water source must be connected to the upper connection fitting and the drain connected to the lower fitting The connection fittings provided with the GA4010 are self sealing to allow disconnection while under pressure Gerling Applied Engineering Inc Modesto CA Product User Manual Page 7 Model GA4010 3kW Magnetron Head The self sealing water connection fittings prevent water from drain ing when the source and drain are disconnected To prevent inter nal damage to the GA4010 steps must be taken to drain the water prior to storage or shipping in the event that freezing temperatures may be encountered T CAUTION Permanent damage to the magnetron can occur if the GA4010 is operated without adequate water flow It is recom mended that a suitable external water flow interlock device be in stalled on the drain side of the water connections and its electrical contacts be included in the interlock chain of the HVPS T 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 gen erator and or waveguide circulator and cause equipment damage Microwave Output The GA4010 must be connected to a suitable waveguide l
13. ories Inc and Gerling Laboratories The GA4010 is functionally identical to the Gerling Labs model GL107 and can be used with any of the following power supplies GL108 GL110 GL120 GL124 GL125 GL126 Electrical Specifications Output Power Magnetron Output Frequency Output Flange Indicators Mechanical Specifications Cooling Air Cooling Water Ambient Conditions Overall Dimensions Net Weight 3kW HV Supply Medium Ripple Bench Mount 3kW HV Supply Standard Waveform Bench Mount 3kW HV Supply Low Ripple Rack Mount 3kW HV Supply Low Ripple Bench Mount 3kW HV Supply Standard Waveform Rack Mount 3kW HV Supply Medium Ripple Rack Mount 0 3kW continuously adjustable Model GA8002 modified Hitachi 2M131 04 2450 MHz 50 MHz WR284 Round with taper for quick disconnect clamp Standby On incandescent lamp amber Microwave On incandescent lamp red Forced air provided by internal fans Flow 1 0 gpm nominal 0 5 min Inlet pressure 30 70 psig Inlet temp ambient dew point min 30 C max Temperature 10 to 50 C non operating 10 to 40 C operating Relative Humidity 0 to 90 non condensing Chassis 12 wide x 12 deep x 15 high Waveguide extension 2 52 Ib 23 6 kgm Gerling Applied Engineering Inc Modesto CA Product User Manual Page 6 Model GA4010 3kW Magnetron Head INSTALLATION Preliminary Inspection Upon arriv
14. osses penalties or other losses incurred in conjunc tion with the use of GAE products DOCUMENT CONVENTIONS NOTE Means the reader should take note Notes contain help ful information suggestions or references to other sections chap ters or documents CAUTION Means the reader should be careful You are doing something that might result in equipment damage or loss of data WARNING Means danger A situation exists that could cause bodily injury or death All personnel must be aware of the hazards involved with high voltage electrical circuitry and high power micro wave devices Pb Gerling Applied Engineering Inc Modesto CA Product User Manual Page 3 Model GA4010 3kW Magnetron Head WARNING This unit is capable of producing a microwave field that is potentially hazardous to oper ating 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 leak age All waveguide flange and electrical cable connections must be secure prior to operation of this unit Never operate the microwave generator without a properly rated absorbing load attached To ensure safe operation and prevent microwave leakage the equipment must be periodically in
15. rough the electromagnet while maintaining a fixed high voltage on the anode of the magnetron The electromagnet establishes a magnetic field inside the magnetron which in turn determines the level of current that is allowed to pass through the magnetron for a given anode voltage With the anode voltage fixed decreasing the electromagnet current will decrease the magnet field and allow more anode current resulting in higher output power Filament Voltage Control The filament voltage must be reduced as microwave output power is increased It is necessary to maintain a constant or nearly con stant filament temperature during operation so the filament volt age is reduced to compensate for excess heating caused by elec tron back bombardment as output power is increased Gerling Applied Engineering Inc Modesto CA Product User Manual Page 9 Model GA4010 3kW Magnetron Head USER MAINTENANCE All service and repair of the GA4010 should be performed by a properly qualified service technician having a reasonable back ground in high voltage power supplies GAE Inc personnel are available to assist with any maintenance problem WARNING Lethal voltages can exist inside the GA4010 during periods of operation Always disconnect line power before perform ing any type of service All service personnel must be aware of the hazards involved with high voltage electrical circuitry and high power microwave devices WARNING Excessi
16. spected and maintained as required or recommended WARNING Lethal voltages may exist inside this unit during operation All maintenance and service must be done by qualified technical personnel only Under no circumstances should improperly trained or underskilled personnel be allowed access inside this unit Gerling Applied Engineering Inc Modesto CA Product User Manual Page 4 Model GA4010 3kW Magnetron Head TABLE OF CONTENTS EQUIPMENT DESCRIPTION Electrical Specifications Mechanical Specifications INSTALLATION Preliminary Inspection Facilities Requirements Mounting Position Electrical Connections Water Cooling Microwave Output BASIC OPERATION System Control Power Control Filament Voltage Control USER MAINTENANCE au OO Magnetron and Electromagnet Replacement 9 ATTACHMENTS Document Type Number Drawing 910221 Tech Serv Doc 940002 Title Schematic Diagram GA4010 Magnetron Electromagnet Removal and Replacement Gerling Applied Engineering Inc Modesto CA Product User Manual Page 5 Model GA4010 3kW Magnetron Head EQUIPMENT DESCRIPTION The model GA4010 3kW Magnetron Head is designed for use with any one of several model high voltage power supplies HVPS manufactured by AGL Inc or its predecessor companies AS TeX Gerling Laborat
17. ve leakage of microwave energy generated by the GA4010 can be lethal Never connect line power to the sys tem without a suitable waveguide load connected to the output flange of the GA4010 the GA4010 is operated without adequate water flow It is recom mended that a suitable external water flow interlock device be in stalled on the drain side of the water connections and its electrical contacts be included in the interlock chain of the HVPS T CAUTION Permanent damage to the magnetron can occur if Magnetron and Electromagnet Replacement Refer to Technical Service Document 940002 for procedures to remove and replace the magnetron and electromagnet The initial set up procedures as outlined in the HVPS operation manual should be performed after replacement of either of these two com ponents Specific attention should be given to the procedures for power output and filament voltage adjustment Gerling Applied Engineering Inc Modesto CA 3105 3V9 NOILYON ddy A8 NI 00016 pyme E EE WVNOVIC DLVWAHOS 38 LON TIVHS SIHL V N on RE QV3H NOXLIN YN MAS 2 MYO 31 95 LON Ud VO OISOON 91808S Od 5 930 Z i XX IHM WHLAAN 3NIT
18. y skilled electronics technician can perform basic diagnostics and service in the event of malfunction However any problem that develops which can not be diagnosed and solved by reference to the following discussion should be referred to GAE Inc for further assistance The HVPS to which the GA4010 is connected contains circuitry that generates a 24 Vac control signal when the System Start button is pressed This system on signal J1 pin B places the system in Standby mode and turns on the water solenoid valve and Standby On indicator in the GA4010 The signal then passes back to the HVPS as an interlock return signal J1 pin F and ensures proper connection of the GA4010 prior to turning on high voltage Simultaneously a 120 Vac signal is delivered to the GA4010 J1 pin A which turns on the cooling fans The electromagnet and fila ment voltage control circuits located in the HVPS are also activated at this time and their respective signals are delivered to the GA4010 J1 pins C D and E Once all of the external and system interlocks are satisfied the Mi crowave button on the HVPS can be pressed to turn on high voltage and place the system into Operate mode This then sends another 24 Vac control to the GA4010 J1 pin H and turns on the Microwave indicator High voltage is also delivered to the GA4010 J3 pin A at this time Microwave power output is controlled by varying the current th
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