Product User Manual
Contents
1. 50 AL ets UNEF THREAD GIMBLE CLAMP 2 42 61 4 3 34 84 9 CAVITY WALL NT IR SENSOR GIMBLE 2008 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 7 Multimode Microwave Applicator 930096 Rev 1 INSTALLATION Preliminary Inspection Upon arrival at the installation site the MMA 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 items are supplied with the system 1 Multimode Microwave Applicator p n 912691 2 Mating interlock connector 4 pin CPC style Housing plug p n 371303 04 1 each Socket contact p n 371361 2 4 each 3 Mating mode stirrer connector 2 pin MR style Housing plug p n 371202 02 1 each Socket contact p n 371203 2 2 each 4 Product User Manual this document Mounting Position The MMA must be mounted upright on a level surface capable of supporting its weight Clearance must be provided at the top sides and rear of the oven to allow adequate ventilation Sensor Mount optional Installation and Adjustment The MMA may have been shipped to the customer with the optional sensor mount removed to facilitate packaging and protection from damag2. Product User Manual Multimode Microwave Applicator Document 930096 Rev 1 Gerling Applied Engineering Inc P O Box 580816 e Modesto CA 95358 www 2450mhz com Product User Manual Page 2 Multimode Microwave Applicator 930096 Rev 1 REVISION HISTORY REV DESCRIPTION DATE APPROVAL 1 PROTOTYPE RELEASE 20JUN08 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
3. MICROWAVE GENERATOR A Figure 4 Typical waveguide component configurations for micro wave power delivery to the MMA A With impedance tuner directly connected to MMA B With additional H plane bend for bench top convenience 2008 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 11 Multimode Microwave Applicator 930096 Rev 1 Feed Thru Port Connections A Ad Three fittings are provided at the rear of the MMA for delivery and or extraction of fluids and or gases These ports can remain open without causing excessive microwave leakage or the user may connect any type of hose or tubing that is compatible with the fitting However connections inside the cavity and the associated user provided apparatus must be compatible with use inside a mi crowave field Consult GAE for advice and or design assistance CAUTION Careful attention must be given to the design and installation of user provided apparatus within the MMA cavity Im proper design and or installation of user provided apparatus can result in equipment damage or injury GAE ASSUMES NO LIABILITY WHATSOEVER FOR DAMAGE OR INJURY THAT MAY RESULT FROM THE USE OF USER PROVIDED APPARATUS WARNING Do not insert metal objects such as wires or rods through the feed thru ports into the MMA cavity Inserting metal ob jects through the feed thru ports can cause hazardous levels of mi crowave leak
4. Rev 1 MAINTENANCE The MMA is designed to be maintenance free under normal operat ing conditions No calibration is necessary and no internal devices or components are user serviceable In the event of damage due to improper operation or mishandling the MMA should be returned to GAE for repair Contact GAE for information on repair services 2008 Gerling Applied Engineering Inc Modesto CA
5. 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 rr 2008 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 3 Multimode Microwave Applicator 930096 Rev 1 WARNING The microwave applicator described in this manual is used with a microwave energy source 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 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 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 saf
6. T OUTS 500 F oS CAVITY TEMPERATURE TE en Soy Figure 2 Connections to internal interlock devices Connections to the internal interlock devices are made to the 4 conductor circular plastic connector located on the rear panel of the MMA WARNING To ensure adequate protection from exposure to hazardous levels of microwave radiation the cavity door interlock circuit MUST be connected to the microwave generator such that microwave output power is disabled when the cavity door is open Mode Stirrer Electrical Power The mode stirrer motor requires 24 VAC 20 50 60 Hz 30 mA power for operation Connections are made to the 2 pin MR style connector located above the interlock connector on the MMA rear panel as shown in Figure 3 2008 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 9 Multimode Microwave Applicator 930096 Rev 1 MULTIMODE MICROWAVE APPLICATOR MODE STIRRER AE S1 MOTOR 24 VAC lt lt o oe POE te i Del di IL m Deg P oA 50 V z Figure 3 Mode stirrer schematic diagram Waveguide Connection Microwave power is delivered to the MMA through a waveguide flange located at the rear panel This flange has a 14 20 UNC tapped hole pattern and opening compatible with standard CPR284 UG 1725 U flanges The waveguide flange of the mating waveguide component must have clearance holes a
7. age that can result in injury or death 2008 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 12 Multimode Microwave Applicator 930096 Rev 1 OPERATION Basic Operation The MMA is a passive device having no features designed for con trol of the heating process Control of microwave power delivered to the MMA must be provided externally by the user e g as provided with the microwave generator Similarly other than the cavity over temperature interlocks there are no displays or indicators on the MMA that provide information related to the process Care must be taken when opening the cavity door to prevent exposure to process related hazards The use of equipment to monitor heating process parameters such as load temperature is strongly recommended Cavity Door Interlocks A A Mode Stirrer Interlock switch contacts associated with the cavity door are closed when the door is properly closed The RF seals around the cavity door will prevent hazardous exposure to microwave radiation when the door is closed A very slight rotation of the door handle will cause the switch contacts to open well before the door itself begins to open When the door interlock switch contacts are properly con nected to the microwave generator see previous section micro wave power will be turned off before the door opens thus prevent ing hazardous exposure to microwave radiation WARNING To ensure adeq
8. at they interfere with the mode stirrer rotation Placing load materials directly on the bottom surface of the cavity can have undesirable heating non uniformity due to the absence of a strong microwave field near the metal surface It is generally rec ommended that load materials are placed on a microwave trans parent stand off accessory that provides some space above the cavity bottom surface although the required amount of stand off space depends on many factors such as the shape thickness and properties of the stand off accessory and load material Microwave Power Delivery and Impedance Tuning The efficiency of coupling microwave power to the load material depends largely on the characteristics size shape material prop erties etc of the load and how well the loaded cavity is tuned for resonance i e reflected power is minimized A large load having a high dielectric loss factor might heat very efficiently without any tun ing required Similarly a small low loss load can also be heated efficiently if the cavity is tuned for minimal reflected power A conventional microwave oven is designed with an integrated mi crowave power source and does not have any means for tuning the cavity to resonance Thus its microwave power coupling efficiency may be limited when heating small and or low loss loads In contrast an important characteristic of the MMA that distin guishes it from a conventional microwave oven is that
9. cing or leakage regardless of cav ity tuning Similarly small low loss loads heated at low power lev els may not result in arcing or leakage even when the cavity is criti cally tuned to resonance At the other extreme arcing and or microwave leakage may indeed result when heating small low loss loads at high power while the cavity is tuned for minimal reflected power An example of a proc ess during which this might occur is when attempting to rapidly heat a small amount of pure alumina without any other load materials e g silicon carbide susceptors The user will naturally attempt to operate at a high power level and adjust the cavity tuning to mini mize reflected power Under certain circumstances the reflected power can suddenly drop as the tuning achieves critical coupling to the cavity In this case arcing can suddenly occur if forward micro wave power is already at a high level As safer approach is to tune for low reflection at low forward power and then slowly increase for ward power can cause hazardous levels of microwave leakage which may re sult in severe injury or death Always use a microwave leakage de tector to monitor microwave leakage Turn off the microwave gen erator immediately if excessive microwave leakage is detected WARNING Heating small and or low loss loads at high power 2008 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 15 Multimode Microwave Applicator 930096
10. e Figure 1 illustrates installation of the sensor mount as sembly 1 4 20 NUTS 4X BLE CLAMP HOLE IN TOP COVE Figure 1 Installation of the sensor mount assembly The IR sensor mount is designed to allow adjustment of the sensor aim by rotating the mount in a gimble socket To adjust the sensor loosen but do not remove the four screws securing the gimble 2008 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 8 Multimode Microwave Applicator 930096 Rev 1 A clamp and gently rotate the gimble Tighten the screws securely to fix the gimble in the desired position WARNING The IR sensor mount gimble and clamp must be properly installed and all fastener nuts tightened securely prior to MMA operation Improper installation can cause hazardous levels of microwave radiation resulting in severe injury or death Do not adjust the gimble while microwave power is being delivered to the MMA Interlock Connections A The MMA includes internal interlock devices associated with the cavity door and cavity temperature Two separate interlock circuits are provided as shown in Figure 2 Both circuits consist of multiple series connected dry contact switching devices that are open when the interlock function is not satisfied os MULTIMODE MICROWAVE APPLICATOR CAVITY DOOR SWITCHES 250 VAC 1 AMP a CAVITY DOOR INTERLOCK CAVITY TEMP INTERLOCK THERMAL CU
11. e operation and prevent microwave leakage the equipment must be periodically in spected and maintained as required or recommended 2008 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 4 Multimode Microwave Applicator TABLE OF CONTENTS 930096 Rev 1 EQUIPMENT DESCRIPTION ccccccseseessseeeeeeeeeeeeseesnneeees General Specifications Outline Drawing INSTALLATION coiii naanin eaaa aE Preliminary Inspection Mounting Position Sensor Mount optional Installation and Adjustment Interlock Connections Mode Stirrer Electrical Power Waveguide Connection Feed Thru Port Connections OPERATION scvcctccesecwisrctecnedeciccntutsasanieciccrisiuecaneuaecacucenecscandees Basic Operation Cavity Door Interlocks Mode Stirrer Cavity Load Placement Microwave Power Delivery and Impedance Tuning MAINTENANCE Sisscsssstsscacectiscacacccanasstecdescssacesacsnascccdeacasanenadanes 2008 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 5 Multimode Microwave Applicator 930096 Rev 1 EQUIPMENT DESCRIPTION The multimode microwave applicator MMA is designed for labora tory research in high temperature materials processing at 2 45 GHz While similar to a conventional microwave oven cavity the MMA is used with external microwave power components avail able separately and thus allows greater flexibility with regard to mi crowave power control a
12. nd be the same standard type and size Bolts and nuts must be installed at all flange bolt holes and tightened securely prior to operation Figure 4 illustrates typical configurations of waveguide components for delivering microwave power to the MMA Depending on the na ture of the load to be heated not all components shown are re quired for satisfactory performance If an impedance tuner is used it should be connected as close as practical or directly to the MMA 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 All GAE waveguide components meets these requirements when properly connected to another waveguide component 2008 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 10 Multimode Microwave Applicator MULTIMODE MICROWAVE A 930096 Rev 1 EGUIDE POW ER COUPLE ISOLATOR
13. nd delivery than is possible using a con ventional microwave oven Standard features include ports for gas delivery and sensors a mode stirrer for enhanced cavity field uni formity and interlock devices for the cavity door and temperature Optional features include a gimble mount for an IR camera cavity environmental sealing internal cavity insulation and customization of gas and sensor ports The MMA is constructed almost entirely of stainless steel for rug ged durability and high temperature operation The applicator cavity is thermally isolated from the chassis and insulated to minimize heat transfer to external surfaces Microwave leakage from the cav ity door is nearly eliminated by the use of a dual sealing system consisting of a reactive choke and RF gasket A removable panel at the rear of the MMA allows access to the rear of the cavity to facili tate the addition of ports or other features that may be required for processing Two cavity sizes are available to accommodate a wide range of loads General Specifications Operating Frequency Microwave Power Input Input Flange Operating Temperature Interlocks Mode Stirrer Power Electrical Connections Feed Thru Ports Dimensions Weight 2 45 GHz nominal 3 kW continuous maximum with high loss cavity load 1 5 kW continuous maximum with low loss cavity load CPR284F UG 1725 U with 74 20 tapped holes 250 C max continuous 500 C max intermittent 1600 C max with
14. optional internal cavity insulation Cavity door cavity over temperature 24 VAC 20 50 60 Hz 30 mA Interlocks 4 pin CPC style connector Mode Stirrer 2 pin MR style connector mating connectors supplied for both Swagelok VCO Fitting size 8 SST one port Swagelok Tube Fitting 4 SST two ports see outline drawing 50 Ibs 23 kgm approximate standard configuration 2008 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 6 Multimode Microwave Applicator Gimble mount for IR sensor camera Cavity environmental sealing Custom ports specified by customer Options Outline Drawing OPTIONAL GIMBLE MOUNT 930096 Rev 1 jaa ne he FOR IR SENSOR CAMERA ij 1 CAVITY 1 5 FT 2 2 FT VOLUME 0 04 M 0 06 M DIM A 13 6 345 20 4 518 DIM B 10 0 254 15 0 381 SWAGELOK TUBE FITTING FEED THRU 2X R20 9 R531 DOOR SWING INPUT WAVEGUIDE FLANGE CPR284F SHOWN SWAGELOK VCO FEED THRU 21 0 534 mee 17 8 451 16 5 419 __ gt HANDLE k 188 304 5 6 143 4 7 3 i A B f i N C j l J i TEL US t a ahal RUBBER FEET 4X INTERNAL CAVITY OUTLINE 3 7 93 RS MODE STIRRER CONNECTOR INTERLOCK CONNECTOR m 350 MAX ROTATION 6 75 19 1 i 2 7 e
15. the MMA does not have an integrated microwave power source When con necting an external microwave generator an adjustable impedance matching device is typically installed between the generator and MMA see Figure 4 and used to enhance the power coupling effi ciency by tuning the cavity to resonance However this advantage of the MMA can also be a hazard When microwave power is introduced into the cavity an electric field is established inside the cavity that can lead to arcing and or micro wave leakage if allowed to become very strong The electric field strength depends on the size and dielectric loss factor of the load the level of microwave power and how closely the cavity is tuned to resonance Table 1 shows the relationships between these factors and the propensity for arcing and leakage 2008 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 14 Multimode Microwave Applicator 930096 Rev 1 Table 1 Relative effect of controlled process parameters on the propensity for arcing and microwave leakage Controlled Process Parameters Propensity for Load Size Reflected Forward a Loss Factor Power Power High High or Low High or Low Low Low High High or Low Low Low Low Low Low Low Low High High For example large high loss loads can be heated at the maximum rated input power of the MMA without resulting an electric field strength high enough to cause ar
16. uate protection from exposure to hazardous levels of microwave radiation the cavity door interlock circuit MUST be connected to the microwave generator such that microwave output power is disabled when the cavity door is open WARNING The cavity door must be properly closed before de livering microwave power to the MMA An improperly functioning door can cause excessive microwave leakage which can result in severe injury or death Do not operate the MMA if a Objects are caught in the door frame b The door does not close properly c The door hinges or latches are damaged The mode stirrer inside the MMA cavity is a rotating metallic blade that continuously perturbs the microwave field in a periodic pattern A toggle switch located at the rear of the MMA is used to turn on and off the mode stirrer motor When the mode stirrer is off the mi crowave field pattern inside the cavity remains fixed except due to changes in the cavity loading during heating 2008 Gerling Applied Engineering Inc Modesto CA Product User Manual Page 13 Multimode Microwave Applicator 930096 Rev 1 Cavity Load Placement Materials to be heated may be placed anywhere inside the cavity However placing the load materials directly in front of the micro wave input waveguide can result in undesirably high and or non uniform absorption of microwave energy Also for obvious reasons the load materials should not be placed in such a location th
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