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Instruction Sheet: Flexwell Waveguide Flaring and Connector Assembly

1. The document provides assembly instructions for flaring and connecting a flexwell waveguide. 2. Key steps include cutting the waveguide to length, removing the jacket, flaring the waveguide over an insert plate, and attaching a backnut and connector body using screws and gaskets. 3. The proper gasket configuration depends on the type of flange installation and includes options for full, half, and O-ring gaskets.

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106 views

Instruction Sheet: Flexwell Waveguide Flaring and Connector Assembly

1. The document provides assembly instructions for flaring and connecting a flexwell waveguide. 2. Key steps include cutting the waveguide to length, removing the jacket, flaring the waveguide over an insert plate, and attaching a backnut and connector body using screws and gaskets. 3. The proper gasket configuration depends on the type of flange installation and includes options for full, half, and O-ring gaskets.

Uploaded by

sami
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Instruction Sheet No.

412445
Rev. B

Flexwell Waveguide Flaring and Connector Assembly


Tools Required 5. Grease the outside of the threaded gasket. Slide the
1. Fine Toothed Hacksaw 6. Screwdriver, 3/16" Blade gasket onto the waveguide tapered end first. Position the
2. Rule, 6 inch 7. Allen Wrench, 3/16" gasket up against the backnut. Be sure threaded gasket
3. Knife 8. Electrical Tape seats into the waveguide corrugation. Use care to keep
4. Light Metal Snips 9. Clean Rag grease away from the copper waveguide. See Figure 3.
5. Ball Peen Hammer 10. Heat Gun or Torch

1. Disassemble the connector and identify all parts as shown


in Figure 1. A plastic trim guide (not shown) may be
supplied.
Figure 1.

Figure 3.

6. Slide the backnut forward as far as possible over the


threaded gasket. Assemble the insert plate with screws to
the face of the backnut, compressing the threaded gasket.
See Figure 4.

2. Cut the waveguide to the required length with a hacksaw.


Position the waveguide downward to prevent metal chips
from entering the waveguide, or stuff a clean cloth inside
the wave guide just beyond the final cut point.
Figure 4.
3. Remove the waveguide jacket 2-1/2 inches from the end
with a knife. Use caution to minimize scoring the
waveguide. To insure the waveguide jacket is cut
7. If supplied, slide the plastic trim guide over the waveguide
perpendicular to the waveguide axis, temporarily wrap a
and snap it onto the backnut face. The trim guide must be
turn of electrical tape around the jacket to serve as a
guide. See Figure 2. flush to the backnut mounting flange. See Figure 5.

Trim the waveguide with a hacksaw flush to the plastic


Figure 2. trim guide. The resulting cut should be 3/16 inch. See
Figure 6.

4. Slide the heat shield boot onto the waveguide jacket and
out of the way. Slide the backnut onto the waveguide until
it bottoms against the trimmed jacket. See Figure 3.

Figure 5. Figure 6.
8. Make longitudinal cuts in the waveguide down to the 12. To complete installation, slide the heat shrink boot into
backnut face with light metal snips. Space the cuts 1/8 to place over the backnut. Use a heat gun or apply a light
1/4 of an inch apart, with the narrower spacing being on flame to the boot until it shrinks smoothly forming a
the small radii of the ellipse. See Figure 7. weatherproof seal. See Figure 10.

Figure 10.

Figure 7.

9. With a ball peen hammer, flare the waveguide over the


insert plate. Start the flare from the inside and work
outward. Lift with a knife and snip any tab that protrudes
over the gasket groove.
NOTE: The waveguide connector is supplied with two flange
gaskets, one or both of which are used depending on
10. When completed,
the type of interface the connector will be mated to.
the flare should be
CPR series connectors are supplied with a rectangular
smooth and flat and
shaped full gasket and similar but thinner half gasket.
must not protrude
An O-ring and a round flat gasket are supplied with
over the gasket
UG series connectors.
groove. Clean the
backnut face and
waveguide flare of Figure 8. The following table identifies the proper gasket configuration
any grease, dirt or
to be used with different types of flange installations:
metal chips. See
Figure 8.

11. Insert the four screws and lockwashers into the backnut's FLANGE GASKET(S)
four thru-holes. Place the flat gasket over the screws and COMBINATION REQUIRED
into the backnut gasket groove. Attach the connector
body to the backnut and tighten the screws securely, CPR (G) Contact Flange with
alternating crosswise to insure the body seats even to the gasket groove mated to an Full Gasket
backnut. See Figure 9. identical flange.

CPR (G) Contact Flange with


gasket groove mated to CPR (F) Half Gasket
Contact Flange or Pressure
Window without gasket groove.
UG Cover Flange with gasket
groove mated to an identical Half Gasket
flange or UG Choke Flange with + O-Ring
gasket groove.
UG Cover Flange with gasket
groove mated to a UG Cover O-Ring
Flange or Pressure Window
without gasket groove.*
Figure 9. * UG flanges are available in rectangular or round configurations
dependent on frequency.

NOTE: WE191 gasket has two


flats that must be
matched to the two flats
of the backnut gasket
groove.

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