WHat is a system upgrade?
When we talk about system upgrades, we principally mean one of two things:
- Upgrades to the Microwave Generator
- Upgrades to the PLC Control System
Technically, the upgrade could be to any of the microwave equipment. It could be that a customer is changing the product makeup and requires more belt support to handle the added weight. Or, it could be that the door to the microwave cavity has seen better days and needs replacing and strengthening. However, these upgrades are much less common. There are just a lot more old generators out there than applicators or cavities. Technological advances also bring more benefit at less cost to generators than they do to the microwave cavities. Upgrades make the most financial sense for generators which may be working less efficiently due to an outdated transformer or poor heat exchangers.
What Are The Different Types Of Upgrades I Should Consider?
Consider these different options as you evaluate your current generator and control unit. Often, an older unit can be salvaged, saving you tens of thousands of dollars. If you are unsure what you need or just want a professional opinion to back up your hunch, have one of our professional technicians visit your facility.
Don’t Wait To Upgrade!
Regular maintenance and an on-site supply of spare parts can keep your microwave generator up and running for decades. However, no matter how disciplined the maintenance schedule, efficiency loss and obsolescence are inevitable. But, that does not mean that you have to throw out your investment and purchase a replacement. Consider an upgrade instead. Are you ready for an upgrade? Let our trained technicians walk you through your options!
Our most expensive upgrade, this upgrade involves a full rebuild of your existing microwave generator. This enables better performance through longer tube life, more control, better efficiency and easier troubleshooting.
Our new cooling components are less expensive and more efficient than the old tube-and-shell style heat exchangers — we now use flat plate heat exchangers. See below the old (left) versus the new (right)
On certain generators, we can upgrade the power output from 50 kW to 60 kW by replacing the transformer to a higher voltage unit with concurrent wiring. See below a picture of an old transformer (left) versus a new one (right).
We can also upgrade the filament and/or the solenoid to enable better control over the magnetron performance.
Having inrush issues on your 6 pulse transformers or Amana or Raytheon Generators? Add a step start circuit.
Having lots of diode failures? Consider upgrading to our higher current capacity diode.
Older control setups may be obsolete and need switching to ethernet I/O to be compatible with new displays. We’re currently standardized on Allen Bradley Ethernet I/O infrastructure.
Any older system can be upgraded to the latest touchscreen, assuming it’s using ethernet I/O protocols. We’re currently standardized on Allen Bradley PanelView Plus 6 touchscreens.
A water pump upgrade can increase pressure from 35PSI to 65PSI which increases cooling and flow to the magnetron tube for better performance.. See below the old (left) and the new (right).
Unsure about precisely how much energy you will need for your particular microwave system application?
Download this guide to understand the simple calculation and more.
- Learn to calculate your energy requirements for drying your material
- Know your power needs upfront for success with potential suppliers
- Learn how accurate energy estimates are essential for ROI