gerling 912112 Operational manual

GERLING
Gerling Applied Engineering, Inc.
P.O. Box 580816 ♦Modesto, CA 95358
www.2450mhz.com
Product User Manual
♦
Custom Microwave Oven
Part No. 912112
Document # 930062, Rev. 6

Product User Manual Page 2
Custom Microwave Oven –Part No. 912112 930062, Rev. 6
2005-2007Gerling Applied Engineering, Inc. Modesto, CA
REVISION HISTORY
REV. DESCRIPTION DATE APPROVAL
1PROTOTYPE RELEASE 21DEC05 JFG
2Corrected Stage 2 programming procedure 12JAN06 JFG
3Updated schematic 27APR06JFG
4Misc. updates 31OCT06 JFG
5Corrected timer setting instructions 11MAY07 JFG
6Changed 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 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.

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Custom Microwave Oven –Part No. 912112 930062, Rev. 6
2005-2007Gerling Applied Engineering, Inc. Modesto, CA
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 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.

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Custom Microwave Oven –Part No. 912112 930062, Rev. 6
2005-2007Gerling Applied Engineering, Inc. Modesto, CA
TABLE OF CONTENTS
EQUIPMENT DESCRIPTION..........................................................................................5
General Specifications 5
Schematic Diagram 7
Outline Drawing 8
INSTALLATION ..............................................................................................................9
Preliminary Inspection 9
Mounting Position 9
Line Power Connection 9
Remote Control and Interlock Connections 9
Timer Programming 10
Pre-Programming 10
Stage 1 Duration 11
Stage 2 Duration 11
Programming Access Cover 12
OPERATION .................................................................................................................14
Basic Oven Operation 14
Control Power 14
Standby Mode 14
Operate Mode 14
Microwave Power Adjustment (Local) 15
Remote Microwave Power Adjustment 15
Magnetron Current Meter 16
OVEN POWER CALIBRATION PROCEDURE ............................................................17
Equipment Required 17
Initial Conditions 17
Procedure 18
Output Power Calculation 18
MAINTENANCE............................................................................................................19
Magnetron Removal and Replacement 19

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Custom Microwave Oven –Part No. 912112 930062, Rev. 6
2005-2007Gerling Applied Engineering, Inc. Modesto, CA
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 the 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

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2005-2007Gerling Applied Engineering, Inc. Modesto, CA
Stage 2 Duration: Selectable between two
programmable settings:
”Long” Duration: 0.1-999.9 seconds
”Short” Duration: 1-999 seconds
Local Controls 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)
Local Indicators System Ready (Green)
Stage 1 On (Red)
Stage 2 On (Red)
Magnetron Power (Digital display)
End of Cycle Buzzer
Remote Control 0-10 VDC input for average power control

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Custom Microwave Oven –Part No. 912112 930062, Rev. 6
2005-2007Gerling Applied Engineering, Inc. Modesto, CA
Schematic Diagram

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Custom Microwave Oven –Part No. 912112 930062, Rev. 6
2005-2007Gerling Applied Engineering, Inc. Modesto, CA
Outline Drawing

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Custom Microwave Oven –Part No. 912112 930062, Rev. 6
2005-2007Gerling Applied Engineering, Inc. Modesto, CA
INSTALLATION
Preliminary Inspection
Upon arrival at the 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)
Mounting Position 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 are made to the 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, ¼ Amp, that provides a
short circuit connection when the interlock function is satisfied. In

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2005-2007Gerling Applied Engineering, Inc. Modesto, CA
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 manufacturershave been provided as a sup-
plement to this Product UserManual as a reference for user pro-
gramming.
Pre-Programming
Since both timers are multifunction programmable, both require
programming of the operation mode.
Stage 1 Timer 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 control module circuitry requires the timer to
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

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Custom Microwave Oven –Part No. 912112 930062, Rev. 6
2005-2007Gerling Applied Engineering, Inc. Modesto, CA
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 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 “P” 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 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

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Custom Microwave Oven –Part No. 912112 930062, Rev. 6
2005-2007Gerling Applied Engineering, Inc. Modesto, CA
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.
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.

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Custom Microwave Oven –Part No. 912112 930062, Rev. 6
2005-2007Gerling Applied Engineering, Inc. Modesto, CA
Figure 2, Installation of programming access cover.

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Custom Microwave Oven –Part No. 912112 930062, Rev. 6
2005-2007Gerling Applied Engineering, Inc. Modesto, CA
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
in 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.
NOTE:Operation of the microwave oven independently of the
custom controls will not be disabled by opening the external inter-
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 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

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Custom Microwave Oven –Part No. 912112 930062, Rev. 6
2005-2007Gerling Applied Engineering, Inc. Modesto, CA
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 longer 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 the 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.

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Custom Microwave Oven –Part No. 912112 930062, Rev. 6
2005-2007Gerling Applied Engineering, Inc. Modesto, CA
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.

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Custom Microwave Oven –Part No. 912112 930062, Rev. 6
2005-2007Gerling Applied Engineering, Inc. Modesto, CA
OVEN POWER CALIBRATION PROCEDURE
The procedure outlined in 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 (3rd 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 with 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
•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
•Potable (tap) water, approximately 1000 grams
•Thermocouple probe thermometer capable of accurately meas-
uring the temperature of the water
•IR optopyrometer capable of accurately measuring the tempera-
ture of the empty container
•Scale capable of accurately measuring the weight of the con-
tainer, both empty and filled with water
Initial Conditions •Line voltage to be within the range per the oven specifications
and within +/-1 % of the voltage to be supplied during normal
operation.
•Ambient temperature to be 20 °C +/-5 °C.
•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 operating the oven for a few hours. External
forced air cooling may be used to shorten this time.

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Custom Microwave Oven –Part No. 912112 930062, Rev. 6
2005-2007Gerling Applied Engineering, Inc. Modesto, CA
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 (mc) 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
(T0) in degrees Celsius.
6. Accurately measure and record the initial water temperature (T1)
in degrees Celsius.
7. Pour the water into the container and accurately measure and
record the filled container weight. Subtract the empty container
weight (mc) to obtain the actual water weight (mw) in grams.
8. Place the filled container 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:
P = [4.187 ∗mw(T2–T1) + 0.55 ∗mc(T2–T0)]/t
The meter reading recorded in step 9 above now corresponds to
the calculated output power.

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Custom Microwave Oven –Part No. 912112 930062, Rev. 6
2005-2007Gerling Applied Engineering, Inc. Modesto, CA
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 custom 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.

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 is a key feature of the B856.
IEC Level 4 noise immunity ensures
flawless operation in harsh electrical
environments, while its IEC IP65
enclosure rating allows use in washdown conditions.
Wiring via an industry standard 11 pin socket and a power supply that can
accept 24 - 240 VAC or 24 VDC vastly simplify setup.
Overview
Panel Mounting page 2
Wiring Connections page 2
Front Panel Operation page 2
Programming
Program Mode page 3-4
Operating Modes
Timing Diagrams page 5
General
Specifications page 8
Ordering Information page 8
Warranty page 8
Index
Technical Manual
702070-0001
Series B856
Multifunction
LCD Timer
• Field programmable choice of 6 operating
modes
• 5 selectable time ranges with resolution down
to 0.01 seconds
• High Contrast LCD display indicates both
process time and preset value
• Simple button per digit interface
• Programmable security levels prevent
unauthorized setpoint or program changes
• Universal Power Supply (24 - 240 VAC,
24 VDC)
• External Start and Reset Inputs
• UL and CUL recognized, CE marked
• IEC IP65 rated front panel
• Model with Instantaneous contacts also
available
Features
Eagle Signal brand