Product User Manual - Gerling Applied Engineering, Inc.
Contents
1. bo E H Figure 1 Control module chassis showing Stage 2 Short duration timer Programming Access Cover A cover is provided that restricts operator access to the front panel cycle timer and microwave power adjust dials to prevent changes to settings during repeated operation cycles After setting the power adjust dials as described in the following section the access cover may be attach to the front panel using two 8 32 screws provided with the cover 2005 2007 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 13 Custom Microwave Oven Part No 912112 PROGRAMMING ACC ESS COVER 930062 Rev 6 Figure 2 Installation of programming access cover 2005 2007 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 14 Custom Microwave Oven Part No 912112 930062 Rev 6 OPERATION Basic Oven Operation The microwave oven can be operated independently of the custom controls by means of the original oven control panel The custom controls need not be turned on or operating in order to use the oven in2. CNM 5 series Multifunction Time Delay Relay For Plug In or Panel Mounting Five timing functions selectable via rotary switch 0 1 sec to 9 990 hr timing range Fixed input type 120VAC 15 10A output relay with DPDT contacts 1 16 DIN style enclosure with 11 pin plug in base Thumbwheel switches for programming delay time A File 22575 File LR15734 Users should thoroughly review the technical data before selecting a product part number It is recommended that user also seek out the pertinent approvals files of the agencies laboratories and review them to ensure the product meets the requirements for a given application Timing Functions See the following page for a complete description of timing functions Timing Specifications Timing Ranges 0 1 to 99 9 1 to 999 sec 0 1 to 99 9 1 to 999 min 0 1 to 99 9 1 to 999 10 to 9 990 hr Timing Adjustment Digital adjustment via thumbwheel switches Initial Dielectric Strength Between Output Poles 1 500V rms 60 Hz Between Input and Output 1 500V ms 60Hz Input Data 25 C Voltage 120VAC 15 60 Hz Power Requirement 3VA 120VAC Transient Protection 13 J oule MOV Input Voltage amp Limits Tolerance 0 05 0 04 sec Repeatability Including first cycle of operation lt 0 05 0 04 sec Reset Time power interruption 45 ms typ 60 ms max Nominal Minimum Maximum Voltage Voltage Voltage
3. Magnetron Power Digital display End of Cycle Buzzer 0 10 VDC input for average power control 2005 2007 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 7 Custom Microwave Oven Part No 912112 930062 Rev 6 Schematic Diagram MICROWAVE OVEN CAVITY TURNTABLE BLOWER WHT CONTROL RED RED MOTOR e RED 1 WHT BLU O O WHT DUTY RED YEL WHT SECONDARY RELAY i INTERLOCK 55 R8 VOLTAGE MAGNETRON 100 TRANSFORMER 25W LINE POWER e 120 15 60Hz ie N o FILTER MONTOR GRN BLU WHT e L mh h FUSE RD Ro 15 BLK BLK BLK BLK 12W we qe ew a ok a2 a BRN BLK PRIMARY MAGNETRON RED G
4. Product User Manual Custom Microwave Oven Part No 912112 Document 930062 Rev 6 Gerling Applied Engineering Inc Box 580816 Modesto 95358 www 2450mhz com Product User Manual Page 2 Custom Microwave Oven Part No 912112 930062 Rev 6 REVISION HISTORY REV DESCRIPTION DATE APPROVAL 1 PROTOTYPE RELEASE 21DEC05 JFG 2 Corrected Stage 2 programming procedure 12JANO06 JFG 3 Updated schematic 27APR06 JFG 4 Misc updates 310CT06 JFG 5 Corrected timer setting instructions 11 07 JFG 6 Changed Stage 2 Short timer 10JUL07 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
5. 240 VAC 24 VDC B856 511 WARRANTY Standard B856 products manufactured by the Company are warranted to be free from defects in workmanship and material for a period of two years from the date of shipment and products which are defective in workmanship or material will be repaired or replaced at the option of the Company at no charge to the Buyer Final determination as to whether a product is actually defective rests with the Company The obligation of the Company hereunder shall be limited solely to repair and replacement of products that fall within the foregoing limitations and shall be conditioned upon receipt by the Company of written notice of any alleged defects or deficiency promptly after discovery within the warranty period and in the case of components or units purchased by the Company the obligation of the Company shall not exceed the settlement that the Company is able to obtain from the supplier thereof No products shall be returned to the Company without its prior consent Printed in U S A 702070 0001 February 1998 Revision A 8 Operation Supply Voltage 24 240 VAC 50 60Hz or 24 VDC Power Consumption 50 VA 240 VAC Time Ranges Hours Minutes Seconds Hours Minutes Minutes Seconds Resolution Settable for XXXX or XX XX for Hours Minutes and Seconds ranges Operating Modes On Delay Off Delay Interval 1 Interval 2 Repeat Delay Interval Repeat Accuracy 0 03 Electrical Service Life 100 000 cy
6. Applied Engineering Inc Modesto CA Product User Manual Page 16 Custom Microwave Oven Part No 912112 930062 Rev 6 Magnetron Current Meter The digital LED meter on the control module front panel provides a relative indication of average magnetron current which correlates to the approximate level of microwave power being generated by the magnetron The actual power level will depend on factors relating the type size and location of the power absorbing load placed in side the oven cavity This meter reading should never be construed to be an accurate measure of microwave power delivered to and absorbed by the load However in conjunction with the calibration procedure out lined in the next section the meter reading can be used to monitor and verify oven performance 2005 2007 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 17 Custom Microwave Oven Part No 912112 930062 Rev 6 OVEN POWER CALIBRATION PROCEDURE The procedure outlined this section can be used to correlate the MAGNETRON CURRENT meter reading with actual microwave power delivered by the oven for a specific load It is derived from the international standard IEC 60705 3 Edition 1999 04 used worldwide by microwave oven manufacturers for performance measurement NOTE This procedure utilizes a standardized water load for cali bration As with any microwave oven the actual power generated may vary w
7. out of the cabinet and remove the top cover Lo cated the timer mounted horizontally to the bracket on the chassis bottom see Figure 1 The Stage 2 Short duration timer TM2 must first be pre programmed to the On Delay function by setting the rotary switch 2005 2007 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 12 Custom Microwave Oven Part No 912112 930062 Rev 6 on its front panel accordingly This timer begins counting down at the end of Stage 1 and actuates a relay to terminate Stage 2 upon completion of its programmed delay time Adjust the three left most thumbwheel switches to the desired set ting in seconds for the Stage 2 Short duration time out For prac tical reasons this timer should not be set for a time out delay greater than the Stage 2 Long duration ROTARY FUNCTION SWITCH AND DURATION TIMER 1 2 1 ey pg 5 TEP D 97 N
8. the START button Microwave energy will then be delivered to the oven cavity at power levels determined by the settings of the POWER ADJUST dials for each stage of operation Upon pressing the START button the cycle timer display will begin counting down in seconds and the STAGE 1 indicator will be on After the first stage has counted down the STAGE 1 indicator will 2005 2007 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 15 Custom Microwave Oven Part No 912112 930062 Rev 6 turn off the STAGE 2 indicator will turn on and the Interval Time will begin to count down on the timer display If the Stage 2 LONG SHORT select switch is set to LONG then mi crowave power will turn off after the cycle timer display has counted down to zero If the select switch is set to SHORT and the pro grammed Short stage 2 duration is shorter than the programmed Long stage 2 duration then microwave power will turn off at the end of the short duration delay period However if the programmed Short duration is Jonger than the programmed Long duration then microwave power will turn off after the cycle timer display has counted down to zero After completion of the second stage microwave power will turn off and the timer will be automatically reset to display the Stage 1 du ration setting Pressing the STOP button at any time during operation or opening the oven door or the contacts of th
9. the timer digital display Once set the value will be retained for each consecutive cycle until readjusted by the operator Stage 2 Duration Stage 2 operation of the system may be preset to one of two opera tor selectable durations The Long stage 2 duration is determined by the front panel timer TM1 while the Stage 2 Short duration is determined by the timer TM2 located inside the control module chassis Stage 2 Long Duration Programming Press the P button and hold for 3 seconds This puts the timer into Program Mode where it will stay until a the button is again pressed and held for 3 seconds or b there has been no key activ ity for 60 seconds Once in Program Mode press the P button once more to enter the Interval Time parameter int appears on the upper line of the LCD display Use the 1 thru 4 keys to set the value in the range of 0 1 to 999 9 seconds as shown in the lower line of the LCD display Press and hold the P button for 3 seconds to save the value and return the timer to operate mode Note that the Stage 2 Long duration preset value will not be shown on the timer display prior to system operation Stage 2 Short Duration Programming WARNING Disconnect line power before performing the fol lowing step to protect against exposure to hazardous voltages To gain access to the Stage 2 Short duration timer TM2 slide the control module
10. this manner All safety related functions of the original oven re main fully operational However no preprogramming of the original oven controls has been done by the oven manufacturer or GAE Consult the oven op erating instructions supplied by the oven manufacturer provided with this manual for detailed operating and programming instruc tions custom controls will not be disabled by opening the external inter NOTE Operation of the microwave oven independently of the lock contacts Control Power Line power is available to the custom control module whenever line power is supplied to the oven and the oven door is closed Turning on the POWER switch on the control module front panel supplied line power to and enable the control circuitry which is evidenced by the timer display Unplugging the oven from the line power source opening its door or turning off the POWER switch will remove line power from and disable the custom control circuitry altogether Standby Mode Once line power has been supplied to the control circuitry the READY indicator will turn on if the external interlock device is closed The system is then in Standby mode and ready to start generating microwave power Opening the contacts of the external interlock device or pressing the STOP button will return the system to Standby mode and turn off microwave power Operate Mode Once in Standby mode the two stage operating cycle can be started by pressing
11. 120VAC 102VAC 138VAC Minimum Pulse Width Control 50 ms Timing is synchronized with input voltage frequency Accuracy is dependent on input voltage frequency Tolerance shows maximum variation from utility companies Contact Data 25 C Arrangement 2 Form DPDT Material Silver cadmium oxide alloy Rating 10A 30VDC or 277VAC resistive 1 2 250VAC 1 3 HP 120VAC Expected Mechanical Life 10 million operations Expected Electrical Life 100 000 operations min at rated load Environmental Data Temperature Range Storage 40 C to 85 C Operating 10 C to 55 C Humidity 85 relative humidity non condensing Mechanical Data Termination 11 pin octal style plug Enclosure Black plastic 1 16 DIN 48mm x 48mm case Sockets Fits either 27E123 or 27E892 snap on screw terminal sockets Weight 4 3 oz 122g approximate Ordering Information Authorized distributors are more likely to stock boldface items listed below Time Delay Relay Accessory Input Voltage Part Number Part Number Name Description 120VAC CNM5 SSA 24C667 Mounting Ratchet fit clip slides onto CNM5 from behind to secure CNM5 in panel mount applications Outline Dimensions Mounting Clip Dimensions aar 188 2 83 55 24 667 478 gt j
12. 6 position terminal block TB1 located on the rear panel of the con trol module WARNING Disconnect line power before performing the fol lowing step to protect against exposure to hazardous voltages Positions TB1 1 and TB1 2 are to be connected to a dry contact type interlock device rated for 120 VAC 1 4 Amp that provides a short circuit connection when the interlock function is satisfied In 2005 2007 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 10 Custom Microwave Oven Part No 912112 930062 Rev 6 the absence of an external interlock device connect a jumper wire between positions 1 and 2 to enable system operation For remote control of microwave peak power connect a 0 10 VDC analog signal between positions TB1 3 and TB1 4 with the positive side connected to TB1 3 Timer Programming The control module includes two multifunction programmable tim ers The timer located on the control module front panel TM1 can be programmed for Stage 1 and Stage 2 Long duration while an other timer located inside the control module TM2 can be pro grammed for Stage 2 Short duration The operating instructions supplied by the timer manufacturers have been provided as a sup plement to this Product User Manual as a reference for user pro gramming Pre Programming Since both timers are multifunction programmable both require programming of the operation mode Stage 1 Time
13. Illuminates to display when an input or output is active IN for the start input OUT for the timed output and RST for the external reset signal Time Indicators The word Timing flashes when a timing function is taking place The applicable arrow also lights to indicate if the display is set to time up or time down Time Value Indicates the elapsed remaining time to preset Edit Key Many of the parameters in Program Mode require selection of a specific choice as opposed to a numeric value The Edit key is used to scroll through the available choices In Operation mode the Edit key can be pressed simultaneously with the Program key to reset the timer To wire the unit an 11 pin socket is required The unit can then either be DIN rail mounted or panel mounted using the supplied mounting bracket For panel mounting place the unit in the cutout then slide the bracket forward over the rear of the unit so that the tabs catch in the grooves on the housing and the bracket is as far forward as possible Tighten the panel mount screws until there is a snug fit against the panel Do not overtighten Time Range Indicator Illuminates to show the time base for hours for minutes 5 for seconds Multiple indicators will be illuminated when the time base is Hours Minutes or Minutes Seconds Set Value Settable value used to trigger the timed output Numeric Keys Each of the number keys is used to increment or dec
14. RN 1 CONTROL MODULE L 1 T C INTERLOCK 1 1 P2 L H P2 1 L 1 7h 1 J2 J1 J2 J2 TB2 1 KIA 182 3 182 2 Q f 1 412 F2 POWER ON 1 48 1 4 2 1 2 s1B i i ND OR Tg i EXTERNAL 4 2 5 POWER OFF oO INTERLOCK BUZZER ae 2 SUPPLIED BY z 2 L CUSTOMER TM2 He 2 K1B 5 1 2 6 TB1 A R7 2 6 5 2 9 8 1 10K Q 14 13 1 4W TB2 7 2 7 6 oote 3 2 ANALOG INPUT RESET SRT Ji zoko 271 To of 7 0 4 0 10 VDC 7 ar KB L m2 K2 Lp oS 2 051 gt sst 2 2 1 STAGE 1 READY 2 2 RELAY 1 olac 11 RED 2 GREEN 8 1 1 052 9 9 DEL 8 VOT 2 3 4 1 9 LOCAL 54 CYCLE TIMER STAGE 2 1 DELAY INTVL RED REMOTES T OA t 7 LONG 55 1 4 SHORT 5 82 8 2 STAGE 1 i 2 K3c KSA Rowe 12 11 10 d 1K J1 2 99 01 1 id STG 2 SHORT gt 2 2 2 782 10 8 DELAY 2 12 Lig dics Al 02 1 Qo smc 2 DUTY CYCLE 1 R4 R2 POWER J2 3 CONTROLLER 1 ADJUST R6 0 J2 1B2 13 mi 75 2 CRI 1K 100K d 12 voc 1 10 2 2 5 voc 2 7 i 5 voc 3 MI TB2 15 2 COMMON 4 MAGNETRON i 2 9 CURRENT 8 i 3 COMMON 5 O T 22uF 1 A2 12 vo
15. at Cycle Power 1 Start 1 T lt T Output Reset Timing begins on the leading edge of the start signal cycleis initiated where the output will be OFF for the preset time then ON for the preset time This cycle will continue until a reset signal is applied or power is interrupted The unit can also be programmed for the timing sequence to begin with an ON cycle The Power Reset parameter in Program Mode can be set so that a timing sequence will not be reset upon power interruption but instead continue on when power is restored On the leading of the start input the output is activated and timing begins The output will remain active until the preset time has elapsed or power is interrupted The reset input is not used Delay Interval Power Output T2 Reset The delay cycle begins upon application of the start signal The output will activate at the completion of the preset time T1 Upon activation of the output the Interval cycle will begin The output will be deactivated at the end of the Interval time T2 T1 is the primary preset value and is set in Operation Mode 2 is setin Program Mode ina range from 0 1 to 999 9 seconds The timing sequence and output can also be reset through the reset input or interruption of power NOTES DANAHER CONTROLS
16. c 6 i A 2 11 FOE RE R SUPPLY R5 10 12W 1 XXX SCALE 1 2005 2007 Gerling Applied Engineering Inc Modesto CA Page 8 Product User Manual Custom Microwave Oven Part No 912112 930062 Rev 6 Outline Drawing 22 60 55 18 80 2 00 4 94 00 OUTLET 2 00 12 80 jae ACCESS COVER 1 7 INLET DUCT bo 2000 0 A 24 17 50 MICROWAVE OVEN CONTROL PANEL SUPPLIED BY GAE HUMIDITY CONTROLLER CONTROL PANEL SUPPLIED BY CUSTOMER CONTROLLER CABINET HAMMOND RCBS SEREIS SUPPLIED BY GAE MICROWAVE OVEN CONTROLLER 2 MW START Mw STOP MAGNETRON CURRENT 5 meet 2 0000 2225 Qe cerne Ss prowroF CONTROL MODULE FRONT PANEL a T Ua 5 5 1254 Cs q CONTROL MODULE REAR PANEL Modesto CA 2005 2007 Gerling Applied Engineering Inc Product User Manual Page 9 Custom Microwave Oven Part No 912112 930062 Rev 6 INSTALLATION Preliminary Inspection Mounting Position Upon arrival at th
17. cles at full load Mechanical Service Life 10 million cycles at min load Weight 100 grams 3 5 ounces Environmental Front Panel Rating IEC IP65 Operating Temperature B856 500 0 to 60 C 32 to 140 F B856 511 0 to 50 C 32 to 122 F Storage Temperature 40 to 90 40 to 194 F Humidity 5 to 95 RH non condensing Approvals UL CUL recognized CE certified Description Model 11 Pin Socket 60SR3P06 11 Pin Socket Outward Facing Terminals PBT 03172 Products which the Company consents to have returned shall be shipped F 0 B the Company s factory The Company cannot assume responsibility or accept invoices for unauthorized repairs to its components even though defective The life of the products of the Company depends to a large extent upon the type of usage thereof and THE COMPANY MAKES NO WARRANTY AS TO FITNESS OF ITS PRODUCTS FOR SPECIFIC APPLICATIONS BY THE BUYER NOR AS TO PERIOD OF SERVICE UNLESS THE COMPANY SPECIFICALLY AGREES OTHERWISE IN WRITING AFTER THE PROPOSED USAGE HAS BEEN MADE KNOWN TO IT THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE a Danaher Controls 1675 Delany Road Gurnee IL 60031 1282 Phone 847 662 2666 Fax 847 662 6633 Email dancon dancon com tyco Electronics Catalog 1308242 Issued 3 03 P amp B
18. e 0 1 to 99 9 Hours Hours Timing Range 1 to 999 Hours 10H 10 Hours Timing Range 10 to 9990 Hours Repeat Output relay is turned on at end of programmed time interval which is started by application of input power Relay stays on for equal time interval then turns off and cycle is repeated on a free running basis with equal on and off times until terminated by removal of input power LED is flashing when output relay is off and on continuously when the relay is on Applying CONTROL input during timing will have no effect on timing or the state of the relay One Shot Output relay is tumed on by applying CONTROL input with input voltage present or application of input voltage with the CONTROL input on Immediately upon either timing is initiated with the output relay turning off at the completion of the selected time interval Applying CONTROL input after time out will reset the timer turn onthe output relay and initiate another time interval LED 5 on continuously when output relay is off and flashes when the relay is on Applying CONTROL input during timing will have no effect on timing or the state of the relay Off Delay Output relay is tumed on by applying CONTROL input with input voltage present or application of input voltage with the CONTROL input on The time interval will be started by removing the CONTROL input with the output relay turning off at completion of the time interval Reapplying the CONTROL during timing will re
19. e 22 719 Mounting Clip oH ic 188 2 283 1970 478 58 0 50 0 dddd 52 0 591 560 315 16 3 15 0 14 2 80 0 gt 1654 Fits 1 77 x 1 77 45 x 45 panel cutout 42 0 1890 Wiring Diagrams Bottom Views 48 0 pins numbered clockwise from keyway EXTERNAL CONTROL SWITCH CONTROL o tal at R Important dry circuit switch is recommended dry circuit switch is one rated to reliably switch currents of less than 50mA Use of a switch rated for other than dry circuit may result in failure of the time delay relay to function properly Optional Solid State Input Interface Dimensions are in inches over millimeters unless otherwise specified Dimensions are shown for reference purposes only www tycoelectronics com Technical support Refer to inside back cover Specifications and availability subject to change 1215 tyco Electronics Catalog 1308242 Issued 3 03 P amp B Timer Function Descriptions LED to show time status See functional explanation for details REPEAT ONE SHOT OFF DELAY INTERVAL ON DELAY 4144 L_tmeser Time 000TO 999 BASE Time Base 1S 1 10Seconds Timing Range 0 1 to 99 9 Seconds S Seconds Timing Range 1 to 999 Seconds 1M 1 10Minutes Timing Range 0 1 to 99 9 Minutes Minutes Timing Range 1 to 999 Minutes 1 10 Hours Timing Rang
20. e external interlock device will stop the generation of microwave power and return the system to Standby mode Also changing the LONG SHORT select switch po sition while microwave power is on will terminate the cycle and re turn the system to Standby mode Microwave Power Adjustment Local The average microwave power delivered by the oven can be con trolled locally using the two POWER ADJUST dials located on the front panel The REMOTE ANALOG LOCAL selector switch must be in the LOCAL position to enable power control using the front panel dials Two dials are provided for independent power control during each stage of the operating cycle The dials can be adjusted either be fore or during cycle operation The dial readings when multiplied by ten x10 provide an approximate indication of the percentage of microwave output power Remote Microwave Power Adjustment The average microwave power can also be controlled remotely us ing a 0 10 VDC analog control signal see the previous section for connection information The REMOTE ANALOG LOCAL selector switch must be in the REMOTE ANALOG position to enable re mote power control The same analog control signal is used to control microwave power during both stages of the operating cycle The percentage of mi crowave power generated is approximately equal to ten times x10 the voltage delivered Power can be adjusted at any time before or during operation 2005 2007 Gerling
21. e installation site the custom oven system should be thoroughly inspected for damage or wear caused during ship ping Any visible damage to the packaging material or the magne tron head itself should be noted and reported immediately to the shipping company in accordance with standard claims procedures The following items are supplied with the system 1 Custom Oven System microwave oven control module and cabinet 2 Fabric covered turntable and support roller ring 3 Original oven user manual 4 Product User Manual this document The custom oven system is supplied as an integral assembly con sisting of the modified microwave oven control module control cabinet It must be mounted upright on a level surface capable of supporting its weight Sufficient clearance must be provided at the top and rear of the oven to allow adequate ventilation and connec tion to the inlet and outlet ventilation ducts Line Power Connection Line power is supplied to the system by connecting the oven power cord located at the rear of the oven to a standard 120 VAC grounded outlet receptacle The circuit supplying voltage to the re ceptacle must be rated for at least 15 Amps of continuous current draw Although a 15 Amp fuse is provided inside the oven the line power supply circuit should also be fused or circuit breaker pro tected Remote Control and Interlock Connections Remote power control and interlock connections made to the
22. gineering Inc Modesto CA Product User Manual Page 5 Custom Microwave Oven Part No 912112 930062 Rev 6 EQUIPMENT DESCRIPTION The microwave oven described in this manual was custom de signed by GAE Inc for Sherwin Williams Company for use in their product development laboratories It was designed for use in con junction with a humidity control system supplied by the Nyle Corpo ration of Bangor Maine The primary purpose of the custom oven system is to provide a means to quickly dry test samples of paint under controlled ambient conditions The goal is to maintain consistency and repeatability be tween drying runs under same test conditions and between multi ple systems in use at either the same or different lab locations To achieve the above goal a special control system has been de veloped for use with a custom modified Sanyo model EM E1100 commercial microwave oven This control system provides variable average power control of the microwave oven that can be adjusted either locally or remotely via an analog control voltage provided ex ternally Also provided is a two stage programmable timer that al lows the operator to set the duration and microwave power level of each stage An external interlock device may be connected that will prevent operation in the event the external interlock function is not satisfied The controls provided with the microwave oven remain unchanged and can be used separately from t
23. has representatives and distributors located in major cities within the United States and throughout the world For information about the distributor or sales office nearest you contact our customer Worldwide Brands service department Veeder Root Customer Service Internet Presence call Toll Free 800 873 8731 E Mail dancon dancon com Dynapar 6 or 847 662 2666 Worldwide Web hitp www dancon com Fagle Signal NOTES DANAHER CONTROLS has representatives and distributors located in major cities within the United States and throughout the world For information about the distributor or sales office nearest you contact our customer Worldwide Brands service department Veeder Root Customer Service Internet Presence call Toll Free 800 873 8731 E Mail dancon dancon com Dynapar or 847 662 2666 Worldwide Web http www dancon com Eagle Signal 7 GENERAL SPECIFICATIONS Inputs Start NPN or Dry Contact Reset NPN or Dry Contact Outputs Timed B856 500 DPDT 5 amp Timed B856 51 1 SPDT 5 amp Instantaneous B856 511 SPDT 5 amp Activation Time 15 msec max Physical Dimensions 48mm x 48mm 81mm deep Mounting Panel Mounting 45 x 45 cutout or DIN rail Wiring Connection Via 11 pin plugin socket ORDERING INFORMATION Description Model Multifunction Timer 24 240 VAC 24 VDC B856 500 Timer w Instant Cont 24
24. he custom controls All safety re lated functions of the microwave oven also remain unmodified and fully functional General Specifications Microwave Power 11000 Watts rated output per original oven manufacturer s specification Power Control Variable duty cycle from zero to 100 in 4 increments 417 millisecond time base Input Power 110 120 VAC 60 Hz 15 Amp max Turntable Standard oven turntable covered with high temp silica cloth Cavity Ventilation Oven cavity modified for connection to 4 inlet and outlet air ducts All other cavity perforations sealed Oven Interlocks Oven door Magnetron over temp Remote Interlock Connections for dry contact switch rated for 120 VAC 1 4 Amp Cycle Timer 2 Stage digital programmable timer Stage 1 Duration 1 9999 seconds 2005 2007 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 6 Custom Microwave Oven Part No 912112 930062 Rev 6 Local Controls Local Indicators Remote Control Stage 2 Duration Selectable between two programmable settings Duration 0 1 999 9 seconds Short Duration 1 999 seconds Power On Off toggle switch Stage 1 Mw Power Adjust 10 turn dial Stage 2 Mw Power Adjust 10 turn dial Stage 2 Long Short Select toggle switch Remote Local Power Adjust toggle switch Mw Start pushbutton switch Mw Stop pushbutton switch System Ready Green Stage 1 On Red Stage 2 On Red
25. if there is any question or concern about microwave leakage All electrical cable connections must be secure prior to operation Never operate the mi crowave oven without a properly rated absorbing load inside the oven cavity To ensure safe operation and prevent microwave leakage the equipment must be periodically in spected and maintained as required or recommended 2005 2007 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 4 Custom Microwave Oven Part No 912112 TABLE OF CONTENTS 930062 Rev 6 EQUIPMENT General Specifications Schematic Diagram Outline Drawing INSTALLATION Preliminary Inspection Mounting Position Line Power Connection Remote Control and Interlock Connections Timer Programming Pre Programming Stage 1 Duration Stage 2 Duration Programming Access Cover OPERATION Basic Oven Operation Control Power Standby Mode Operate Mode Microwave Power Adjustment Local Remote Microwave Power Adjustment Magnetron Current Meter OVEN POWER CALIBRATION PROCEDURE Equipment Required Initial Conditions Procedure Output Power Calculation Magnetron Removal Replacement 2005 2007 Gerling Applied En
26. ifferent levels of security are available 0 Full Access 1 SP Locked Out 2 Access to Program Mode only by holding the P key for 8 seconds 3 SP Locked Out and access to Program Mode only by holding the key for 8 seconds OPERATING MODES TIMING DIAGRAMS On Delay Power Sat a Output Rest _ _ L__ Instant Li Output Timing begins on the leading edge of the start input The output will activate at the completion of the preset time T and will remain active until the reset signal is applied or power is interrupted The instantaneous output will activate upon the start signal and will remain active until the reset signal is applied or power is interrupted Interval 1 Power _ ee ee Tee Off Delay Power _ sit The outputis activated at the leading edge of the start signal Timing begins on the trailing edge The output will remain active until the preset time has elapsed or power is interrupted Reapplying the start signal before T has elapsed will reset the time value The reset input is not used Interval 2 On the leading of the start input the output is activated and timing begins The output will remain active until the preset time T has elapsed or power is interrupted Removal of the start signal will also cause the output to be deactivated and the time value to be reset The reset input is not used Repe
27. inside the oven cavity centered on the turntable and close the oven door 9 Press the Start button on the control panel to turn on microwave power During Stage 2 record the reading of the Magnetron Current meter Allow the system to operate through both cycle stages The oven will turn off automatically 10 Upon completion of Stage 2 open the oven door and accurately measure and record the final water temperature T2 in degrees Celsius Gentle stirring will provide a more accurate measure ment of average temperature Output Power Calculation Calculate the microwave output power using the following formula 4 187 mw T2 T1 0 55 T2 The meter reading recorded in step 9 above now corresponds to the calculated output power 2005 2007 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 19 Custom Microwave Oven Part No 912112 930062 Rev 6 MAINTENANCE The custom microwave oven is designed to be maintenance free with the exception of magnetron replacement The magnetron is considered a consumable component and is expected to fail within 1000 to 3000 of operation depending on operating conditions and usage No calibration is necessary In the event of damage due to improper operation or mishandling the system should be returned to GAE for repair Contact GAE for information on repair services Magnetron Removal and Replacement The magnetron used in the cu
28. is a key feature of the 856 IEC Level 4 noise immunity ensures flawless operation in harsh electrical 2 Eagle Signal brand environments while its IEC IP65 enclosure rating allows use in washdown conditions 5 ri e 9 0 5 Wiring via an industry standard 11 pin socket and a power supply that can accept 24 240 VAC or 24 VDC vastly simplify setup Multifunetion ae LCD Timer Field programmable choice of 6 operating EAGLE SIGNAL 4 3 4 Technical Manual 702070 0001 modes Panel Mounting page 2 Wiring C ti 5 selectable time ranges with resolution down page 2 Front Panel Operation page 2 to 0 01 seconds rogramming High Contrast LCD display indicates both Program Mode page 3 4 process time and preset value Operating Modes Simple button per digit interface Timing Diagrams page 5 General Programmable security levels prevent Specifications page 8 unauthorized setpoint or program changes Ordering Information page 8 e Universal Power Supply 24 240 VAC Warranty page 8 24 VDC External Start and Reset Inputs ULandCULrecognized CE marked JECIP65 rated front panel Model with Instantaneous contacts also available OVERVIEW INSTALLATION amp WIRING 8mm Socket For the 511 version Pins 1 3 4 are the instantaneous contacts FRONT PANEL OPERATION I O Status Indicators
29. ith different load types sizes and locations within the oven cavity However the performance variation between two dif ferent loads will remain constant as long as both loads remain un changed The procedure involves heating the water from a starting tempera ture below ambient temperature to approximately ambient tempera ture using energy from the microwave oven This enables a rea sonably accurate compensation for heat loss to the container The procedure may be performed at any microwave power setting as may be required for calibration of normal operation Equipment Required Initial Conditions Cylindrical container made of borosilicate glass Pyrex with outside diameter of approximately 190 mm height of approxi mately 90 mm and maximum thickness of 3 mm e Potable tap water approximately 1000 grams e Thermocouple probe thermometer capable of accurately meas uring the temperature of the water e optopyrometer capable of accurately measuring the tempera ture of the empty container e Scale capable of accurately measuring the weight of the con tainer both empty and filled with water e Line voltage to be within the range per the oven specifications and within 1 of the voltage to be supplied during normal operation e Ambient temperature to be 20 C 5 C e The temperature of the microwave oven power supply compo nents to be within 5 C of ambient This condition can usually be met by not o
30. nction has timed out Use the 1 through 4 keys to set the value in range from 0 1 to 999 9 seconds 5 Note This parameter will only appear if Delay Interval is chosen as the Operating Function rc Time Range Sets the unit of measure for the time values that will be shown on the display in Operation Mode Choices Seconds Minutes Hours Minutes Seconds Hours Minutes E p Decimal Position Sets the decimal position for the time display Choices are no decimal point 0 d 1 10ths position 0 0 or Hundredths position 0 00 The time range selected in the previous Os parameter will remain illuminated for reference Note This parameter will not appear if Minutes Seconds or is selected as the time range PROGRAMMING P O toa Timing Direction Determines whether the time value will increment from zero and change the state of the output at the set value uP or decrement from the set value and change the state of the output at zero dn Power Reset Enable After a loss of power the unit can be programmed to either reset upon reapplication of power On or continue from the point of power interruption Off Front Panel Reset Enable When active On the timing operation can be reset in Operation Mode by simultaneously pressing the E and P keys Ifinactive Off the timing operation can only be reset through the remote input Security Level 4 d
31. perating the oven for a few hours External forced air cooling may be used to shorten this time 2005 2007 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 18 Custom Microwave Oven Part No 912112 930062 Rev 6 Procedure 1 Adjust both Stage 1 and Stage 2 microwave power settings on the control panel to the same desired power level 2 Set the cycle timer on the control panel as follows Stage 1 2 seconds this allows filament warm up Stage 2 A value t equal to 52 seconds multiplied by the ratio of full output power to the set output power i e for half power setting the Stage 2 cycle time should be 104 seconds 3 Adjust the water temperature to 10 C 1 C before putting it into the container Ice chips may be used to lower the tempera ture but the ice should be completely melted prior to heating 4 Accurately measure and record the container mass in grams Note Steps 5 through 10 should be done in rapid succession to minimize heat loss and temperature measurement error 5 Accurately measure and record the initial container temperature To in degrees Celsius 6 Accurately measure and record the initial water temperature T4 in degrees Celsius 7 Pour the water into the container and accurately measure and record the filled container weight Subtract the empty container weight to obtain the actual water weight my in grams 8 Place the filled container
32. r Pre Programming The front panel timer TM1 has been preprogrammed by GAE for the following program modes Operating Function Delay Interval provides 2 stage timer func tionality WARNING The contro module circuitry requires the timer to A be programmed for the Delay Interval operating function ONLY Operating the oven system with the timer programmed for a differ ent operating function can result in faulty and possibly unsafe sys tem operation Time Range Seconds Decimal Position 1 10ths 0 0 Timing Direction Down timing will decrement from the preset value and change the output state at zero Power Reset Enable On timer is reset upon application of line power Front Panel Reset Enable On timer can be reset by simultane ously pressing E and P keys Security Level 0 Full access 2005 2007 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 11 Custom Microwave Oven Part No 912112 930062 Rev 6 Stage 2 Short Timer Pre Programming The internal timer TM2 has been preprogrammed by GAE for the following program modes Operating Function rotary switch On Delay relay operates at end of timing cycle Time Base right most thumbwheel switch S seconds Stage 1 Duration Use the numeric keys 1 through 4 to adjust the Stage 1 duration from 1 to 9999 seconds Prior to system operation the value will be displayed in both lines large and small numbers of
33. rement the value of the corresponding digit of the preset or a parameter value increments ifunit is set in time up mode and decrements if set in time down mode Program Key Pressing the key continuously for 3 seconds moves the unit in and out of Program mode Once in Program mode pressing and releasing the key will scroll the display from one parameter to the next PROGRAMMING PROGRAM MODE Enter the Program Mode by holding down the P key for 3 seconds e Press the P key to move the top display from one parameter to the next e Press the E key to scroll the bottom display through the available choices for that parameter e While in Program Mode the unit will stop timing and the output will retain its last state The new settings will only become effective after returning to Operation Mode by holding down the P key for 3 seconds P D For 3 Seconds E Operating Function Determines how outputs will operate in relation to the set value Choices are une On Delay Off Delay OFdL Interval 1 int1 Interval 2 int2 Delay Interval dint Repeat Cycle CYCL See Appendix A for timing charts L First Operation Determines whether the Repeat Cycle will start with an On or an Off Operation Note This parameter will only appear if Repeat Cycle is chosen as the Operating Function Interval Time Sets the amount of time the output will be active after the On Delay fu
34. set the time to zero and inhibit timing until removed LED is off when CONTROL input is on flashing during timing and on continuously when the output relay is off Interval Output relay is tumed on for a programmed time interval by applying input voltage LED flashes when output relay is on and is on continuously when the output relay is off Applying CONTROL input will have no effect on timing or the state of the relay On Delay Output relay is off for a programmed time interval which is started by applying input voltage LED flashes when output relay is off and is on continuously when the output relay is on Applying CONTROL input will have no effect on timing or the state of the relay Dimensions are in inches over millimeters unless otherwise specified Dimensions are shown for 1216 reference purposes only Specifications and availability subject to change www tycoelectronics com Technical support Refer to inside back cover
35. stom microwave oven is the same as that supplied with the original oven by its manufacturer Replace ment of the magnetron should be done only by technical personnel properly trained for repair of residential and commercial microwave ovens 2005 2007 Gerling Applied Engineering Inc Modesto CA Introduction An excellent value in its class the B856 features a compact 1 16 DIN package the precision of digital setting versatile functionality and a straightforward button per digit interface It can be easily programmed to perform any standard timing operation On Delay Off Delay Interval 1 Interval 2 or Repeat Cycle A unique On Delay Interval Mode can in many cases perform the function of two separate timers Output is via DPDT relay contacts Five selectable time ranges and a programmable decimal point provide preset times ranging from 01 seconds to 9999 hours An available model s output features separate timed and instantaneous SPDT contacts Simplicity of operation is maintained while still providing a high level of functionality All programming is done through the front panel with an intuitive button per digit keypad that makes entry of preset times quick and easy A crisp dual line LCD display lets the operator readily view elapsed or remaining cycle time as well as the preset value Prominent annunciators indicate information such as the time range and the status of the input and outputs Reliability
36. 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 losses 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 gt 4 2005 2007 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 3 Custom Microwave Oven Part No 912112 930062 Rev 6 WARNING The microwave oven described in this manual is capable of producing a microwave field that is potentially hazardous to operating personnel The unit must never be connected or operated in a manner that allows a field in excess of 10 milliwatts per square centi meter 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
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