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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Custom Microwave Oven –Part No. 912112 930062, Rev. 6
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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Custom Microwave Oven –Part No. 912112 930062, Rev. 6
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