Modification of Kiffer Industries 1.5kW Microwave Generator
Initial Problem
Although this generator is rated for 1.5 kilowatts of output power, the installed magnetron tube is capable of delivering up to 1.9 kilowatts. The limiting factors for output power include the tube type, high-voltage transformer, and the value of the high-voltage capacitors.
In some instances, the power supply enters a runaway condition, during which the magnetron outputs its full capacity. The high-voltage transformer attempts to meet the magnetron’s current demands but is unable to dissipate the excess heat. This leads to overheating of the transformer windings and ultimately causes premature power supply failure.
Objective
-
Prevent premature failure of the high-voltage transformer.
-
Improve overall system reliability and stability.
-
Ensure power output remains within safe design limits.
-
Reduce costly generator downtime and repairs.
MES Solution
-
Replaced the high-voltage capacitors with components of a different value, limiting the magnetron output to 1.5 kilowatts maximum.
-
Installed a single dual-package capacitor with higher specifications to replace the previous two-capacitor setup.
-
Replaced the existing filament transformer and capacitor arrangement with a modernized transformer design that does not require a capacitor.
-
Replaced all internal electrical wiring and neatly organized wire routing for improved serviceability and airflow.
-
Installed an elapsed time meter to track magnetron operating hours for proactive maintenance.
Results
-
Improved operating efficiency and system stability.
-
Increased reliability of the microwave generator.
-
Reduced downtime and failure rates across the generator fleet.
-
Improved internal airflow for better cooling of sensitive components.
-
Extended lifespan of high-voltage and critical electrical components.
Before
After
