CHAPTER- 4

MICROWAVE CONTROLLER
AND ITS APPLICATIONS
 4. MICROWAVE CONTROLLER
AND ITS APPLICATION

4.1 INTRODUCTION
It was during a radar-related research project around 1964 that Dr. Percy Spencer,
a self-taught engineer with the Raytheon Corporation, noticed something very unusual.
He was testing a new vacuum tube called a magnetron. He suddenly found that the
candy bar in his pocket had melted. This intrigued Dr. Spencer, so he tried another
experiment. This time he placed some popcorn kernels near the tube and, perhaps
standing a little farther away, he watched with an inventive sparkle in his eye as the
popcorn sputtered, cracked and popped all over his lab.

The very next morning Dr. Spencer decided to put the magnetron tube near an
egg. A curious colleague joined Dr. Spencer, and they both watched as the egg began
to tremor and quake. The rapid temperature rise within the egg was causing tremendous
internal pressure. Evidently the curious colleague moved in for a closer look just as egg
exploded and splattered hot yoke all over his amazed face. The face of Dr. Spencer lit
up with a logical scientific conclusion: the melted candy bar, the popcorn, and now the
exploding egg, were all attributable to exposure to low-density microwave energy. Dr.
Spencer fashioned a metal box with an opening into which he fed microwave power.
The energy entering the box was unable to escape, thereby creating a higher density
electromagnetic field. When food was placed in, the temperature of the food rose very
rapidly. Dr. Spencer had invented what was to revolutionize cooking, and formed the
basis of a multimillion-dollar industry, the microwave oven. Microwave controller works
on the same principle as that of microwave oven.

The frequencies spectrum and different bands in the microwave region are shown
in fig. 4.1 and 4.2 respectively.

33
 top Chi
lOGHat

1000 Mitt

100 MU*

10 Mitt

1 Mitt

100 KHz

10 Kltt

IKK*
toom

Fig. 4.1 Frequency spectrum showing the microwave region

34
 i

Wavelength [mj
Longer
Microwaves
10*4: Wavelength Frequency
1km-* (metres) (QHz)
10a
1 m-*‘f.Q
■04

lcm-*1QT P-band 30*100 cm

1
1a4- L-band 15-30 cm
>-1 2
84> and 7.5*15 cm
ia- 4
mrn-* 10 C-band 3.75*7.5 cm
10 i X-band 2.4-3.75 cm
8

I|
•12
= u*'=<i !(•■ ■ ■.-tjvjrrzrni IIs
10 K-band 1.1*1.57 cm 285
_ T.i*w
Shorter °
Ka-band 0.75*1.1 cm
40
mlllmetre band

1C

sub-milimetre band

Fig 4.2 Different bands in microwave region

35
4.2 THE KEY COMPONENTS OF A MICROWAVE CONTROLLER
The microwave controller has the following key components [101] and are
shown in fig. 4.3.
1. Magnetron

2. High Voltage Transformer

3. Waveguide

4. High Voltage Capacitor

5. Power Rectifier

6. Timer And Controller

7. Interlock Switches

8. Sensors

9. Cooling Fans

10. Power Relay

4.2.1 Magnetron
The magnetron as shown in fig.4.4 is the earliest source of significant amount of
microwave power device. The device is capable of converting dc to microwave power
with efficiencies between 50% - 80%, pulse power levels of the order of megawatts
and CW powers of several Kilowatts. In spite of high power levels, the high efficiency
of the device greatly reduces the problem of heat dissipation. For more than a decade
after World War-II, the magnetron was almost exclusively the high power microwave
source for use in radar for military and civilian applications. Because of the limited
electronic tuning and modulation capabilities of the magnetron and development of
broadband klystron amplifiers, the later tubes have accepted the magnetron as the
transmitting tubes in sophisticated high power radars particularly military applications.
In relatively simple radars, however, the magnetron is still the most used oscillator for
the output stage, providing a low cost highly efficient operation. Magnetrons are also
being used in industrial heating, diathermy equipment, microwave ovens etc. Microwave
dielectric heating is used in wood processing for gluing plywood sheets and for drying
wood etc. Because of its high efficiency of the order of 80%, the amplitron, which is a

36
 Fig. 4.3 Block diagram of microwave controller

37
Fig. 4.4 Sectional view of a magnetron
modified version of the magnetron, is being used in satellite power stations as a viable
source of energy in future.

4.2.2 High Voltage Transformer

Microwave transformer as shown in fig.4.5 is basically a high voltage transformer.
The primary winding of high voltage transformer gets a phase controlled a.c. voltage
after the controller activates the relay. It has two secondary windings. The first secondary
winding is low voltage winding and it is used to feed the filament of the magnetron
(typically 3.3 V at 10A). The second secondary winding is high voltage winding about
2000 V a.c. with current of about 0.25 A. This winding is connected to magnetron’s
anode through RC network and diode.

Actually in the positive half cycle of the secondary voltage, the very high voltage
capacitor charges to its peak value Vm through forward biased diode, whereas in negative
half cycle capacitor discharges very slightly through a large resistance. This process
develops a full sine voltage across diode, which has an average (dc) value of Vm. The
negative terminal ofthis large dc potential is connected at anode ofthe magnetron. This
is how the basic microwave transformer operates in the microwave source.

4.2.3 Rectangular Waveguide

A rectangular waveguide is a hollow metallic tube with a rectangular cross section.
The conducting walls of the guide confine the electromagnetic fields and there by guide
the electromagnetic wave. A number of distinct field configurations or modes can exist
in waveguides. When the waves travel longitudinally down the guide, the plane waves
are reflected from wall to wall. This process results in a component of either electric or
magnetic field in the direction of propagation of the resultant wave; therefore the wave
is no longer a transverse electromagnetic (TEM) wave. Fig. 4.6 shows that any uniform
plane wave in a lossless guide may be resolved into TE and TM waves.

It is clear that when the wavelength A is in the direction of propagation of the

incident wave, there will be one component An in the direction normal to reflecting
plane and another Ap parallel to the plane. These components are

An = A / cos 0 --------- (1)

39
 (Controller not shown)

I-Interlock
TP-Thermal prot.

Fig. 4.5 High voltage transformer

40
Fig. 4.6 Plane wave reflected in a waveguide

41

14282
A
 Xp = X / sin 0 — (2)
Where 0 = angle of incidence
X = wavelength of impressed signal in unbounded medium

A plane wave in waveguide resolves into two components: one standing wave in
the direction normal to the reflecting walls of the guide and other traveling wave in the
direction parallel to the reflecting walls. In lossless waveguides the modes may be
classified as either transverse electric (TE) mode or transverse magnetic (TM) mode. In
rectangular guides the modes are designated TEmn or TMnm. The integer m denotes the
number of half waves of electric or magnetic intensity in the x direction, while n is the
number of halfwaves in the y direction if the propagation of the wave is assumed in the
positive z direction.

4.2.4 High Power Capacitance

The capacitor is used to smooth out the ripples in the direct current before it
reaches the magnetron. [54]

4.2.5 Power Rectifier

The power rectifier converts the alternating current from the transformer into the
direct current needed by the magnetron.

4.2.6 Timer and Controller

The digital timer controls the amount of time the microwave is allowed to remain
on or off. This is the interface that allows the user to control how much time is spent
during radiation. After the specified time has elapsed the digital timer sends an electrical
signal to the power relay.

4.2.7 Interlock Switches

Various door interlock switches prevent inadvertent generation of microwaves
unless the door is closed completely. At least one of these will be directly in series with
the transformer primary so that a short in the relay or triac cannot accidentally turn on
the microwaves with the door open. The interlocks must be activated in the correct
sequence when the door is closed or opened. Interestingly, another interlock is set up
to directly short the power line if it is activated in an incorrect sequence. The interlocks

42
are designed so that if the door is correctly aligned, they will sequence correctly.
Otherwise, a short will be put across the power line causing the fuse to blow forcing the
source to be serviced. In addition, a monitoring system stops controller operation in
case one or both of the interlock systems fail.

4.2.8 Sensors
More sophisticated microwave source may include various sensors. The sensor is
a special device, which converts a physical size (i.e.: temperature and moisture) in an
electrical signal, which duly considered and elaborated, permits the controlling and the
monitoring of the examined phenomena. Hence the sensors govern and control the
physical parameters in the microwave source.

4.2.9 Cooling Fans

In a microwave source we can always find a fan, which is used to cool the magnetron
to prevent its exaggerating heating. In a microwave source 30% - 50 % power is
dissipated as heat by the magnetron. This fan is activated by its own electric motor.

4.2.10 Power Relay

The power relay allows the controller to turn on or offthe magnetron microwave
source.

4.3 SYSTEM DESIGN FOR MICROWAVE CONTROLLER

4.3.1 Magnetron Oscillator
For pulsed magnetrons, magnetic fields on the order of 2000-3000 gauss are
typical and are provided by permanent magnets into which the magnetron tube is
mounted. Somewhat lower magnetic fields are used for domestic microwave oven
magnetron where the magnet weight is a consideration. From the power output Po
requirement, one decides the first anode to cathode voltage Va. For the pulsed, voltage
on the order of25-3 5 KV are typical. These high voltages help to lower the requirements
reducing therefore the strain on cathode, which must supply the current in the form of
electron emission. Pulses are commercially available with a voltage rating in this range
and this is an added incentive to design the tube for the voltages on this order. Pulsed
voltages higher than 35-40 KV make the pulser design more complicated, and these
voltages are generally used only if the power output requirements dictate their use to

43
keep the current down. Since the magnetron efficiencies or the high power tubes are on
the order of 50%, the current rating of pulser can now be determined because the input
power Pin is given by (power output/efficiency) and peak anode current is Pin / Va.

Specifications of Magnetron
The magnetron used here is having following specifications (Courtesy SHARP)
1. N0.2M231 AH(L)

2. Frequency of oscillations = 2.44 - 2.46 GHz.

3. Center frequency = 2.45 GHz.

4. Typical output wattage = 800watts.

5. Percentage typical efficiency = 62%

6. Operating anode to cathode voltage = 2500V d.c.

7. Peak anode current = 0.3 A

8. Filament voltage required for indirectly heated cathode = 6.3 V a.c./50Hz

4.3.2 Rating of High Voltage TVansformer

The rating of the high voltage transformer and other associated components are
selected as follows
The secondary voltage should have a peak value Vm=2500V.
Therefore, Vrms at secondary =Vm / V2 =2500 / V2 = 1767.5V.
Secondary Current = Peak anode current = Im = 300 mA.
Therefore, Inns at secondary = Im / V2 = 300 / V2 = 212 mA.
Secondary VA rating = 374.6 VA

Assuming 80 % efficiency of transformer

The primary VA rating = 374.7 / 0.8 = 468.25 VA.
The primary r.m.s. current = 468.225 / 230 = 2.1A
The primary voltage and current affect the selection of triac for phase control.

The diode connected at secondary winding should have a PIV rating greater than
250V. Hecce the diode selected is number IN 3768 having Vrms = 300V, Vi = 1.5,
If = 2A.

44
 The high voltage electrolytic capacitor C is having dielectric strength greater than
250V. The filament required for the indirect heating of the cathode is connected to 6.3 V,
5 A winding on secondary side.

4.3.3 Design of Rectangular Waveguide

The microwave energy at 2.45 GHz developed by the magnetron is transmitted to
the load by means of a waveguide. To find the dimensions ofthe waveguide the following
approach is taken.

The frequency 2.45 GHz lies in the recommended frequency range of 2.66-3.3
GHz. In this range cut-off frequency for air filled waveguide is 1.737 GHz.

Therefore, fc / f = 1737 / 2.45 = 0.635

10 = Wavelength in air = C / 2450 MHz =12.244 cm
Xg = Wavelength in waveguide = XoH (l-(fc/f) 2) = 15.36 cm
fc = C/2a
a = C / 2fc = 9.64 cm
Width of guide = a = 9.64 c
b = a / 2 = 4.82 cm = height of guide.

4.3.4 Measurement Of Microwave Power Supplied Of Magnetron.

The microwave power supplied by magnetron to the food load can be indirectly
found out using laws of thermodynamics. The well known Joules Law states that ratio
of work done to heat developed is constant known as joules constant (J).

Thus, W / H = J = 4.2 Joules/cal ----------(1)

Where, W = work done in Joules.
H = the heat developed in Cal.
J = the Joules constants.
The work done,
W = (Voltage X Charge)
= (Voltage X current X time)
= (Power X time) j oules
= (Pout Xt) joules. ---------- (2)

45
 Where, Pout = Output Power radiated by the magnetron in watts.
t = Radiation time in seconds.
The heat developed,
H m (T2 - Tl) + M (T2 - Tl) (3)
Where, M Mass of container in grams
m Mass ofwater in grams
(T2 - T1) = total rise in temperature in °C due to absorption of microwave
energy by the water, (measured by thermometer).
Therefore, from equations (1), (2) and (3)
Pout = [m(T2-Tl) + M(T2-Tl)]X J/t ---------(4)

Hence microwave power transmitted by the magnetron through the wave guide is
calculated from the equation 4 for different radiation times and shown in table 4.1.

Table 4.1 Microwave power transmitted by the magnetron

Sr. No. Radiation Time Initial Final Pout

(Sec.) Temp. (°C) Temp. (°C) (Watts)

1 3 21.00 21.40 361.53

2 6 21.40 22.00 271.15
3 9 22.00 23.20 361.53
4 12 23.20 25.00 406.70
5 15 25.00 27.50 451.91
6 18 27.50 30.80 497.10
7 21 30.80 35.00 542.30
8 24 35.00 38.50 395.42
9 27 38.50 42.00 401.70

10 30 42.50 47.50 491.91

Average power transmitted by the magnetron = 4181.20/10 = 418.12 watts.

Percentage efficiency of magnetron = Output Power/Input Power
= (418.12 / 800) X 100
= 52.26%

46
4.4 CONTROL SYSTEM FOR MICROWAVE CONTROLLER
A control system for a microwave controller includes a programmable digital logic
control circuit which enables a user to program information into it. The digital logic
control circuit of the present invention allows a user to program information into the
control, relating to the amount of time the magnetron tube is to be energized. A timer is
also provided by the control of the present invention. The user programs information
into the control by means of a touch plate, which is sectioned off into a plurality of
areas, each area representing certain information to be entered into the control.
Information in the control such as the time remaining in any of the microwave modes,
the time remaining in the timer mode, or the information which has been entered by the
user, is displayed to provide a visual feedback to the user

The fundamental controls for a microwave controller are

• The radiation time on seed.
• The average level of power of the emitted microwaves.

The selected radiation time is set up according to the seed to be tested. The average
power level of the emitted microwaves takes place varying the switching-on time
and the switching-offtime ofthe magnetron inside every unitary period (cycle) as shown
in fig. 4.7

The higher is the ratio between the switching-on time and that one ofthe switching-
off (duty cycle) inside the unitary period, the higher will be the average power of the
emitted microwaves, which heat the seed. The most recent and sophisticated microwave
source control the different functions by a microcomputer duly programmed to develop
the requested operations, which are

• Controlling of radiation time and its visualization by a display

• Controlling and regulation of the emitting power ofmicrowaves and visualization

of the level
• Monitoring oftemperature and moisture given by the sensors inside the controller.

The pre-selected values are started up through a keyboard visualized by displays

and the electronic controller (IC - LSI) varies the working parameters of the source

47
 Off
H : Gnd.
Maximum output
On
- L: -5V

Off Off
H:Gnd.
70% ofmaximum 24 sec.
' o sec.—*
output On
L:-5V

Off Off
H:Gnd.
■17 sec. ■15 sec.-
50% Of maximum
On
output L:-5V

Off Dff
H:Gnd.
30% of maximum •-10.3 sec.— ■21.7 sec.-
output On
L:-5V

Off Off____________________
A A
H:Gnd,
10% of maximum ----------------------- 28.6 sec.---------------- ►
output on
L:-5V

Fig. 4.7 : Waveforms : Switching On / Off of magnetron

48
according to the inserted values. The control of the switching-on and the switching-off
of the source takes place through a traic or a special relay for high voltages.

4.4.1 Control Panel

The control panel has at least two commands.
• The first one is used to decide the duration of radiation.
• The second one is used to stabilize the average energy of the electromagnetic
waves irradiated by the magnetron.

The control panel is in the form of a key matrix as shown in fig 4.8 (courtesy
SHARP) Here Gl, G2, G3, G4, G5, G6 are connected to pin numbers 16 to 21 of the
controller LSI.

Therefore from pin numbers 16 to 21, the signals are output signals from LSI Pin
numbers 23 to 26 are input to the LSI to detect any input. Thus the controller senses
any key pressed by a combination of signals on these lines.

4.4.2 Keys Used

The information about the control action and staring ON and OFF of the microwave
is entered through the different keys of the control panel.

• Digit Keys
These are used to enter the radiation time, clock time, weight of seed.

• Power Level Key

This key is used to select microwave power setting. If not selected, HIGH is
automatically selected.

• Timer/Clock Key
This key is used to set clock and timer.

• Stop / Clear Key

This key is used to clear during programming. Ifpressed once the source working
is stopped. If pressed twice then the radiation program is cancelled.

• Start Key
This key is to start the source after setting programmes. Ifpressed once then the

49
 Connected to Pin No. 16 to 21

[Ql3 fG2l [GS] fG6l

—H" 6 2 Frozen Jacket Beverage

vegetable potato
Connected to Pin No. 23 to 26

Easy 3 5 4 Dinner Power

Defrost plate level

Rice Timer 0 1 Express Stop

pasta Clock Defrost Clear

Fresh Instant
~0 -
9 8 7 vegetable Cook
Start

Fig. 4.8 Key matrix for control panel

50
 source radiates for 1 min. at 100% efficiency or increase the time in multiples of
1 min. each time this key is pressed during radiation.

4.5 TESTING OF MICROWAVE COMPONENTS

4.5.1 Power Transformer
Causes
• A shorted winding or short between a winding and the core/chassis in the HV
transformer may result in a blown fuse, loud hum, overheating, audible arching,
a burnt aroma, or simply no heat..

Testing
• Disconnect the primary of the HV transformer and initiate a radiation cycle. If
the fuse still blows, there is a problem such as a defective interlock or shorted
wire.

• Assuming the fuse does not blow, unplug the source and reconnect the primary
of the HV transformer.

• If the other components - HV diode, HV capacitor, and magnetron test out,

remove the high voltage and filament connections to the transformers. Power up
the source and initiate a radiation cycle. Ifthe fuse does not blow, the transformer
is likely good. If there are still problems in high voltage components, possibly
something is failing only when full voltage is applied.

• If the fuse still blows, then the problem is likely with the triac ifused a shorted
wire or short transformer.

• If the fuse does not blow with secondary isolated, reconnect only the magnetron
filament to the transformer and power it up again. Ifthe fuse does not blow, then
it is possible that the magnetron filament is shorted.

• If any microwave source uses a triac remove and bypass it. Now, if the fuse still
blows when the source is plugged in, the problem is likely with the transformer

• Check for damaged wires that may be shorting to the chassis. Repair or replace
as it is necessary.

51
 • Where the HV transformer does not blow a fuse but overheats or produces
insufficient output, the test ofthe HV transformer using an a.c. current meter
may be useful.

4.5.2 High Voltage Diode

Causes
• A short HV diode will likely result in a loud hum from the HV transformer when
a radiation cycle is initialized. The main fuse will not blow.

Testing
• An open high voltage diode will result in a.c. instead of d.c. across the magnetron
with a peak negative value about l/2of what it should be. The result will likely
be little or not detectable heat but no other symptoms.

• Its forward voltage drop will therefore be too large i.e. 6V or more for DMM to
produce a definite answer as to whether it actually works as a rectifier.

• The HV diode can be tested with a d.c. supply even an adapter of at least 12 or
15 V supply, series resister to limit current. This will determine proper behavior,
at least low voltages.

• The voltage drop in the forward direction should be at least 6V with a few mA
of current but may be somewhat higher 8 V or more with a few hundred mA.

4.5.3 High Voltage Capacitor

Causes
• A shorted high voltage capacitor is capable ofblowing down the fuse instantaneously.

• An open high voltage capacitor will result in no heat.

Testing
• Assume that there is no internal rectifier or other circuitry except of a bleeder
resistor.

• The resistance measured across the terminals of a high voltage capacitor should
be very high- several Mohms, for bleeder resistor.

• If it is less than 1 Mohms, the capacitor is definitely shorted. If it is zero ohms

52
 across the terminals, then the capacitor is positively bad. A high resistance doesn’t
prove that the capacitor is actually functional, just not shorted with no voltage
across it. If there is a capacitor meter then check it for proper value. Even this
does not prove that it will not short when full voltage is applied. Substitution is
the only sure test beyond this.

4.5.4 Magnetron
Causes
• A magnetron with an open filament will result in no heat. The bad connections
may be internal. In each case the magnetron will need to be replaced.

• A magnetron with a short between the filament / cathode and anode will result in
a loud hum from the high voltage and or the magnetron when the radiation cycle
is initialized but the main fuse will probably not blow.

Testing
A magnetron may result in a variety of symptoms including erratic or low output
power or interrupted operations. There is not a single precised way to determine whether
a magnetron is good without actually powering it under operating condition. But still the
following test will catch most ofthe problems

• Magnetron filament resistance should be infinite from the filament connections

to the case and a fraction of an ohm between the filament terminals with the
wiring disconnected from the magnetron.

• While measuring resistance from filament chassis, gently tap the magnetron to
determine if there is an intermittent short. However such problems may only
show up once the filament heats up parts expands.

• It may be possible to determine if the magnetron filament is actually working by

connecting just the filament connections to a low voltage high current supply on
a variac.

• Evidence of arching visible blackening around ventilation holes in base or burnt

odour usually indicates a bad magnetron.

• Melting or other damage to the antenna cover may be the result of arcing due to

53
 the problems in the source cavity or wave guides or a defective magnet.

4.5.5 Interlock Switches

• With the source unplugged, put an ohmmeter across the a.c. input just before
the interlock switch.

• Open and close the door slowly several times. There should be no significant
change in resistance and it should be more than a few ohms. If it approaches to
zero while opening or closing the door the interlock switch and door alignment
should be checked.

• When removing the old switch just take a precaution to see that to which wire
switch is connected.

• Check the embossed marking on the old switch doesn’t depend on location as
replacement might just have a different arrangement.

• Make sure the new switch aligns correctly with the actuating mechanism and
then check for correct electrical operation with an ohmmeter before applying
power.

4.5.6 Wiring And Connections

Causes
Main causes are burning of wires, loose connection, cutting of wires, bad
soldering, melting of wires due to excessive heat, it may scrap with the sharp metal
sheet.

Testing
• Inspect the wiring especially between the magnetron, the transformer and other
components of high voltage circuits for sign of arching and excessive heating or
burning.

• Arcing may be the result of the wire scraping a sharp sheet metal edge due to
poor placement or vibration.

• Since the magnetron filament in particular uses high current any resistance at
the press connections will result in heating, weakening of the lug, more heating

54
 and eventual failure or erratic operation.

• Check for loose, burnt, or deteriorated lugs in the filament circuit, if we find
evidence of this remove the plug and clean the terminals with fine sand paper or
file. If they are not too badly deteriorated, they will still work even if they are
somewhat ugly.

• If the lugs and their wire connections appear to be in good connections but come
off their terminals easily, try squeezing them a little tighter with a pair of pliers
and reinstall. Otherwise cut off the old ones and replace them.

• If any connections between the lug and the wire or HV diode are loose, solder
it with wattage soldering iron or soldering gun.

• Alternatively, use a drill to make a hole in each terminal and then faster the wire
directly a new lug to the terminal with a machine screw, nut and lock washer.
Soldering is also an option.

• These approaches will work, as ion gas there is enough metal remaining for a
solid connection and may permit to salvage magnetron or HV transformer that
would otherwise need to be replaced.

• Also check for bad solder connection between terminals on the high voltage
transformer and the enameled wire used for its winding.

• If found anything suspect scrap away the enamel surface corrosion resolder with
a high wattage soldering iron or soldering gun.

4.5.7 Thermal Protectors And Fuses

Causes
• Thermal protection is thermostats that open setoff high current contacts at
apressure temperature. They should reset when cool off However like a relay
or switch these sometime deteriorate.

• Thermal fuses will open at present temperature but do not reset. They blow
need to be replaced. At room temperature, both type should read as a dead
short with an ohmmeter.

55
Testing
• Disconnect one terminal, as there may be low resistance components or wiring
which may confuse reading.

• Ifthe resistance is more than a small fraction of an ohm, the device is bad. Ifwe
suspect a bad thermal protection HV transformer primary, clip a 100 W light
bulb or a.c. voltmeter across it and operate the source.

• If the thermal protector is functioning properly, there should never be any voltage
across it unless there is actual overheating.

• If the bulb lights up or the meter indicates approximately line voltage- there is no
sign of over heating, the thermal protector is defective and will need to be
replaced.

4.5.8 Power Relay

Causes
• A relay with its contacts welded stuck closed would result in the oven coming
on as soon as the door is closed or the power being stuck on high, no matter
what the touch pad setting.

• A relay that doesn’t close due to defective contacts or a bad coil would result in
no heat and possibly other things like the fan and tumable not working as well.

Testing
• If the relay is totally in operative, test for voltage to the coil. If the voltage is
correct, the relay may have a coil.

• If the voltage is low at zero, the coil may be shorted or the driving circuit may be
defective. Ifthe relay makes the normal switching sound doesn’t correctly control
its output connections - the contacts may be corroded, dirty, worn, welded closed,
binding or there may be other mechanical problems.

• Remove the relay from the circuit if possible and measure the coil resistance.
Compare the reading with marked or specified value an compare with an known
working relay of the same type.

56
 • An open coil obviously defective’s but sometimes the break is right at the terminal
connections and can be repaired easily.

• If the resistance is too low, some of the winding are probably shorted. This will
result in overheating as well as no erratic operation. Replacement will be required.

4.6 CONCLUDING REMARKS

It has been observed that the practical radiation efficiency of the magnetron is
52.26 % against the theoretical efficiency of 62% (given). The power radiated is
calibrated in terms of radiated time in seconds so as to suit the instrument for general
use. The microwave source is used for seed testing in chapter 5.

57