GAE GA101 Series Operational manual

P.O. Box 580816 ♦Modesto, CA 95358
www.2450mhz.com
Product User Manual
♦♦
Model GA101x Series
High Power E-H Tuner
Document # 930024, Rev. 2

Product User Manual Page 2
Model GA101x Series High Power E-H Tuner
2002-2003 Gerling Applied Engineering, Inc. Modesto, CA
REVISION HISTORY
REV. DESCRIPTION DATE APPROVAL
2Misc. updates, corrections 29APR03 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, financial losses, penalties or other losses incurred in
conjunction with the use of GAE products.
DOCUMENT CONVENTIONS
NOTE:Means the reader should take note. Notes contain
helpful information, suggestions, or references to other sections,
chapters, or documents.
CAUTION: Means the reader should be careful. You are doing
something that might result in equipment damage or loss of data.
WARNING: Means danger. A situation exists that could cause
bodily injury or death. All personnel must be aware of the hazards
involved with high voltage electrical circuitry and high power
microwave devices.

Product User Manual Page 3
Model GA101x Series High Power E-H Tuner
2002-2003 Gerling Applied Engineering, Inc. Modesto, CA
WARNING
All waveguide tuners manufactured by GAE, Inc. are intended for use with other
equipment 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 prevent microwave
leakage, the equipment must be periodically inspected and maintained as required or
recommended.

Product User Manual Page 4
Model GA101x Series High Power E-H Tuner
2002-2003 Gerling Applied Engineering, Inc. Modesto, CA
TABLE OF CONTENTS
EQUIPMENT DESCRIPTION..........................................................................................5
General Specifications 5
INSTALLATION ..............................................................................................................6
Preliminary Inspection 6
Waveguide Configuration 6
Flange Connections 6
Flange Alignment Pins 7
OPERATION ...................................................................................................................8
Basic Operation 8
Standard Tuning Procedure 8
False Null 9
High Power Operation 9
MAINTENANCE AND CALIBRATION..........................................................................10

Product User Manual Page 5
Model GA101x Series High Power E-H Tuner
2002-2003 Gerling Applied Engineering, Inc. Modesto, CA
EQUIPMENT DESCRIPTION
The GA101x series High Power E-H Tunersare designed for load
impedance matching in high power microwave heating systems.
Sliding plungers inside each waveguide extension are designed
with non-metallic (Teflon) contacting surfaces for reduced wear.
Reactive chokes within the plunger minimize power losses during
high power operation.
Two types of tuner design are offered. The economical Basic
models (GA1011 thru GA1014)are operated using simple push-rod
actuators and feature clamping collars to lock the actuators in the
desired positions. The Precision models (GA1015 thru GA1018)
feature precision-machined plunger drive mechanisms with multi-
turn digital readout dials for accurate and repeatable positioning. In
both models, the stub housings are designed with 1/4-wave
reactive chokes allowing use in high “Q” applications.
Construction of these tuners is dip brazed aluminum waveguide,
aluminum plungers and brass/stainless steel drive mechanisms.
ModelsGA1014 and GA1018 feature the popular WR284 Q-D
(quick-disconnect) round flange that uses the convenient single
screw clamp (model GA8401) for waveguide connections.
General Specifications
Frequency 2450 +/-50 MHz
Basic Models GA1011 GA1012 GA1013 GA1014
Precision Models GA1015 GA1016 GA1017 GA1018
Power 3 kW 6 kW 6 kW 3 kW
Waveguide WR284 WR340 WR430 WR284
Flanges UG1725/U UG554/U UG437B/U UG584/U
Plunger Travel 4.7 inch 3.5 inch 3.0 inch 4.7 inch
12 cm 8.9 cm 7.6 cm 12 cm
Construction Dip brazed aluminum waveguide and plungers,
brass/steel actuator and drive mechanism
Finish Clear chemical film on waveguide;
Black paint (precision models only)

Product User Manual Page 6
Model GA101x Series High Power E-H Tuner
2002-2003 Gerling Applied Engineering, Inc. Modesto, CA
INSTALLATION
Preliminary Inspection
Upon arrival at the installation site the tuner should be thoroughly
inspected for damage or wear caused during shipping. Any visible
damage to the packaging material or the tuner itself should be
noted and reported immediately to the shipping company in
accordance with standard claims procedures. The following
components are included:
a) High Power E-H Tuner
b) Product User Manual
Waveguide Configuration
The high power E-H tuner 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
with either flange positioned towards the process load. Ideally, the
tuner should be located as close to the process load as possible.
Figure 1 illustrates a typical waveguide configuration.
Figure 1 –Typical waveguide configuration for process load
impedance tuning.
Flange Connections
Both flanges of the E-H tuner must be properly connected to
another waveguide component. Bolts and nuts must be installed at
all flange bolt holes on both flanges prior to operation. Model
GA1014 is available with flanges designed for used with the

Product User Manual Page 7
Model GA101x Series High Power E-H Tuner
2002-2003 Gerling Applied Engineering, Inc. Modesto, CA
GA8401 Quick-Release clamp when connected to another similarly
designed flange. These flanges can also be connected to any other
standard WR284 round flange (UG-584/U) using suitable fastener
hardware.
Flange Alignment Pins
Each waveguide flange connection that uses a quick-release clamp
requires two alignment 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/cm2measured at 5
cm from the leakage source under normal operating conditions, and
10 mW/cm2at 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.

Product User Manual Page 8
Model GA101x Series High Power E-H Tuner
2002-2003 Gerling Applied Engineering, Inc. Modesto, CA
OPERATION
Basic Operation The most common intended function of the high power E-H tuners
is to provide an impedance match to the process load. Operating
the tuner for this purpose is a procedure involving the adjustment of
either or both tuning plungers while monitoring power reflected from
the process load.
However, predicting which plunger to operate first or the effect each
plunger will have on producing an impedance match is nearly
impossible without the aid of additional impedance analysis
equipment. Thus, choosing which plunger to adjust at any point
during the tuning procedure is often a matter of either trial and error
or prior experience with a given load.
CAUTION: Care must be taken to avoid operating the
microwave generator at power levels exceeding the rating of the
tuner. Excessive power levels can cause damage to the tuning
plungers.
Standard Tuning Procedure
A recommended tuning procedure for first-time matching of a given
load is as follows:
1. Slowly adjust one plunger in either direction while monitoring the
level of reflected power. If reflected power increases while
adjusting in one direction then reverse directions and continue
adjusting until the reflected power stops decreasing.
2. Repeat step 1 for the other plunger.
3. Return to the plunger adjusted first and re-adjust in whichever
direction causes reflected power to decrease. Continue
adjusting until reflected power stops decreasing.
4. Repeat step 3 while alternating between plungers until reflected
power no longer decreases by adjusting either plunger. Make
note of the plunger positions and the level of reflected power.
5. Return both plungers to the original positions and repeat the
process except to start with a different plunger. Continue until
reflected power has again been minimized and make note of the
plunger positions and reflected power level. Compare to the
results obtained in step 4and then adjust the plungers to the
positions which gave the best results.

Product User Manual Page 9
Model GA101x Series High Power E-H Tuner
2002-2003 Gerling Applied Engineering, Inc. Modesto, CA
False Null The above procedure can sometimes lead to a false indication of
reflected power minimization. That is, it may appear that adjusting
either plunger will result in an increase of reflected power. This
“false null” can be overcome by detuning one plunger and retuning
the other in order to find another null using different plunger
positions.
High Power Operation
The GA101x series tuners are designed for continuous use at
microwave power levels up to 6kW depending on model. However,
under certain high power conditions, such as a high Q factor, it may
be possible to cause excessive heating that may be hazardous to
operating personnel and/or result in damage.
The electric field strength in any waveguide device is a function of
both power level and Q factor. Excessively high electric fields can
result in discharge (arcing) and/or overheating due to resistive
losses. High Q may be tolerable at low power while the same Q can
be damaging at high power. Although the tuners are expected to
perform satisfactorily under moderate Q factors at higher power
levels, the operator should exercise caution to prevent damage due
to arcing or overheating under these conditions.

Product User Manual Page 10
Model GA101x Series High Power E-H Tuner
2002-2003 Gerling Applied Engineering, Inc. Modesto, CA
MAINTENANCE AND CALIBRATION
The GA101x series high power E-Htuners are designed to be
maintenance free and does not require any user maintenance
under normal operating conditions. No calibration is necessary.
Although the GA101x series tuners are very rugged and stable
devices, they can be subject to damage due to excessive power
levels or mishandling. If damage occurs, the circulator should be
returned to GAE for repair. Contact GAE for information on repair
services.