Flexible Waveguide

The Waveguide Solution flexible and flexible/ twistable waveguide is used in a wide variety of military and commercial applications. It is designed to isolate vibration, to eliminate installation difficulties caused by misalignment and to provide a simple aid to positioning and alignment of parabolic reflectors in line of sight, microwave radio links. Both flexible / twistable and flexible only are made from a helically wound waveguide core. Additional mechanical support is offered through the availability of a variety of protective jacket materials such as Neoprene, Silicone, Viton, Devcon etc.

The Waveguide Solution flexible waveguide is produced to

IEC636 and regular testing confirms the product is capable of

repeated flexures to the order of 1,000,000 cycles. All waveguides are available with a choice of protective finishes such as electroplated Tin, Nickel, Gold, Silver, chromated aluminium or epoxy paint. As well as a full range of rectangular flexible waveguides from 1-75GHz, The Waveguide Solution also manufacture a range of high performance Broad Band Double Ridge Flexible and Flexible / Twistable waveguides. The Waveguide Solution's design and manufacturing facility

is approved to ISO 9001.

Waveguide Flexible

Flexible/Twistable FT SERIES

Flexible Only FO SERIES

Flexible Only Hybrid FH SERIES

Twistable Hybrid TH SERIES

Fig 1, A photograph showing a sectional view of The Waveguide

Solution Flex non-twistable core, with detail of the vulcanized rubber jacket.

Mechanical Construction

The waveguide core for TWS Flexible / Twistable and Flexible Only waveguides is manufactured by a process of helical winding a silver coated, brass strip to form a continuous, uniform rectangular tube. Flexible Only core is wound with a solder fillet in the Interlock (as shown in illustration 2), thus eliminating RF and Pressure Leakage. In a Flexible / Twistable waveguide core the solder wire is replaced with the Grounding / sealing wire where necessary (see Illustration 3) to facilitate twisting while maintaining Minimum RF Leakage. The above photograph shows a detailed section of a TWS Flexible Only (non-twistable) core. Controlled construction of the waveguide core to the Optimum form provides a repeatable return loss and Insertion loss performance during flexing. The Waveguide Solution Provides a precision controlled process capable of Manufacturing flexible / twistable waveguides at millimetric Frequencies up to 40GHz operating frequency.

Double Ridge The Waveguide Solution precision Flexible / Twistable and Flexible Only core is also manufactured for all double ridge waveguide sizes up to 40GHz. Repeated bending and/or twisting is possible, but care Must be taken not to overstress the waveguide, as this will cause permanent and severe damage. TWS carries

out life flex testing to IEC636 standards on their waveguides. From these tests it is known that applications where the waveguide maybe subject to repeated flexing to the minimum repeated bend radius, are acceptable. Test results are available to show that TWS waveguides will survive 1,000,000 flexures to the minimum repeated bend radius (in line with IEC636). It must be remembered that Flexible waveguides are not as robust as their rigid counterparts and also that

excessive internal or external pressure can markedly alter the return loss. Flexible waveguides are generally used to compensate for mechanical misalignment, thermal expansion, or to facilitate ease of installation and to decouple the effects of vibration. Long lengths of flexible waveguide are not generally recommended due to the inherently higher attenuation values when compared with rigid waveguide. For long length, narrow band assemblies, The Waveguide Solution has developed a low insertion loss, twistable waveguide. Flexible Only and Flexible / Twistable waveguides may be bent to fit from the straight condition. However if it is to be optimized in the bent condition, it is often better to perform the waveguide to the required shape during the manufacturing process.

THE CORE

RF Tight Flexible/Twistable Waveguide The Waveguide Solution has developed a high performance conductive silicone rubber jacket, unique to The Waveguide Solution, for use on all standard flexible/twistable waveguides. This guarantees RF leakage as better than –90dB. (Tested using The Waveguide Solution test method and procedure detailed on page seven.) Defined as the EMC jacket, this product is available as standard on Flexible/Twistable waveguides simply by requesting the letter “E” under the field for the jacket in the TWS part number i.e. FT 20 P E B 402-402/M300. This is not approved for use on Hybrid waveguides and is not yet available for Double Ridge Waveguides.

A jacket will provide environmental and mechanical protection to the precision performance core as well as mechanical support. The Waveguide Solution offers a range of different protective coverings to suit most needs. Neoprene, Silicone and Viton are vulcanized to the waveguide using thermal compression techniques. These Vulcanized jackets provide support to the convolutions during flexing and in TWS-Flex Flexible / Twistable waveguides, the pressure seal is provided by the jacket (see illustration 4). Thermal compression is used in the majority of low volume production runs due to the flexibility and fast set uptimes. Also available is Polyolefin heat jacket.

4. Illustration showing moulded neoprene rubber jacket.

Where preformed flexible waveguides are required and Where vulcanizing is not viable, The Waveguide Solution offers a variety of cold cure jackets in both silicone or (Urethane) Devcon. All jackets are resistant to oil and other fluids as given in the specification for the appropriate jacket material. The silicone and neoprene used by The Waveguide Solution has a high resistance to ozone attack (enamel or epoxy painting may be offered as an alternative to a moulded jacket if required, but should be offered only after consulting the factory).

Flanges A full range of flange styles is available with each Waveguide size as defined in the 1999 The Waveguide

Solution Flange catalogue. Flanges are offered to UK WG, IEC-R, American E.l.A., WR and WRD specifications with a variety of surface treatments. The standard flange is offered unplated and unpainted, however the flanges may be Alochromed Aluminium or Electroplated Tin, Nickel, Copper, Silver or Gold. The back faces of the flange can be epoxy painted Upon request.

Flexible Only and Flexible/Twistable core may be used in Conjunction with rigid waveguide to produce Hybrid Assemblies. Many of these designs may be complex Multiple bends and twists, with the flexible section Included to eliminate vibration or misalignment. The Waveguide Solution incorporates flangeless low profile joints in their Hybrid assemblies. By eliminating flanges the hybrid Assembly offers the following advantages:

• Eliminating EMC problems associated with flange interfaces

• Proving gas tight joints

• Lower overall mass and lower profile

• Lower insertion loss

A range of protective jackets and finishes are available. These include cold cure jackets such as Silicone and (Urethane) Devcon for the flexible section. These may be combined with a range of electroplated and epoxy paint finishes for the assembly. It is recommended that the flexible section is offered with a suitable form of jacket to offer the necessary mechanical support and protection. As a manufacturer of both precision rigid and flexible waveguide, The Waveguide Solution is able to offer the precise control over tolerances and performance of the individual Sections to achieve the highest microwave specifications for hybrid combinations. Wherever possible The Waveguide Solution will use formed sections (as Preferred to machined or cast bends and twists) to ensure the best possible insertion loss, return loss and PIM (passive inter-modulation) performance. Individual tuning of rigid and flexible waveguide sections maybe used to guarantee stringent return loss specifications. Each waveguide assembly is tested electrically on completion. All test results are recorded in line with ISO 9001 procedures. Test results or test plots are available with each waveguide on request. The Waveguide Solution is the leading supplier of Double Ridge Flexible/Twistable Hybrid Assemblies in Europe, and has Successfully manufactured many assemblies in WRD180, WRD580, WRD650 and WRD750.

THE JACKET

HYBRID ASSEMBLIES

The nature of all hybrid assemblies makes them specific to the individual customer. The Waveguide Solution therefore has constructed its part numbering system to accommodate this. All hybrid assemblies are redrawn onto the TWS CAD system and provided with an individual 5 digit Number proceeded by the product descriptive code and Waveguide size (e.g. FH1681342 as shown in the Ordering information).

Pre-formed Hybrid and Flexible Waveguide Assemblies “Preformed” is a term for a waveguide assembly that is formed into a desired shape during the manufacturing process. Preforming can reduce the stress on the waveguide and the joints, and it is recommended in waveguides that will be bent close to the minimum static bend radius. Preforming may be carried out on all TWS Flexible Waveguides and on Side Seam and Seamless waveguides. Preforming is not currently offered on the Seamless Flexible/Twistable waveguides. If a permanent twist is required the TWS Flexible Only Waveguides may be manufactured with a set twist that will offer a more stable insertion loss than the equivalent Flexible/Twistable waveguide. Preformed waveguides offer a defined and measured electrical performance for the installed shape.

Jacketing of Preformed Flexible Waveguides In some cases, it is possible to use hot pressure cured rubbers to jacket waveguides that have been preformed, but this will require specific mould tooling. Generally cold cured rubbers offer satisfactory mechanical protection and support to the flexible section. Cold cured rubbers offer reduced pressure handling capability on Flexible / Twistable waveguides. Where maximum mechanical and environmental protection is required then vulcanized jackets are recommended. Internal operating pressure and hence peak power handling may be reduced where cold cure rubbers are used. Note that an RF Tight moulded jacket is not currently available with preformed waveguides.

Design Characteristics Average Power All High Power performance specifications in this data sheet have been calculated from existing data and are offered for advice only. High power test facilities are not available on site at TWS and High Power test results are only available on request at extra cost. Average power handling is estimated and based on figures derived from the peak power ratings shown in IEC 636. All flange to waveguide joint are soldered using 180 deg solder.

Peak Power The peak power handling capability is based on figures published in IEC636 for the lower end of designated frequency band. The figures shown are the theoretical breakdown value at a frequency of 1.5 times cut-off, assuming that breakdown in dry at normal temperature and pressure (N.T.P) occurs at 30,000 V/cm, a power safety factor of 2.25 and a

voltage reflection factor of 0.2 (V.S.W.R.= 1.5) in the system under test. The duty cycle must be less than 0.001. The values given in the tables shown on page 9 & 11 are for information only. The complex construction of the flexible profile will reduce the peak power handling of all flexible waveguides. Due to the close pitch ratio and the repeated joints we would suggest that Flexible/Twistable is the least suitable of all TWS flexible waveguides for High Power applications.

Environmental Characteristics The Waveguide Solution flexible waveguide may be considered suitable for use in most environments, provided the correct protective jackets are requested.

Operating Temperature In general the maximum operating temperature of a Flexible waveguide should be kept below 100 deg C. Operating temperatures may in some cases be increased up to 254 deg C but this may compromise certain electrical properties. When operating at elevated temperatures care should be taken to ensure that the correct jackets and solders have been requested. The minimum standard operating temperature is -25 deg C, but the waveguides may operate in temperatures as Low as -196 deg C (check with the factory for details). The table shown below gives the thermal characteristics for the different jackets and cores available with WS flexible waveguides.

Table 1. Thermal characteristics of Core Jacket and Solder.

Core Type Operating Fluid / Environ-

Temp Range mental Protection

Flexible/Twistable -55 to +145

Flexible Only -55 to +145

Side Seam Brass / BeCu -70 to +260

Side Seam Silver Plated -55 to +145

Seamless Brass / BeCu -55 to +145,

Seamless Electroformed

Nickel -70 to + 145

Jacket Type Neoprene -55 to +100 Oil, Ozone

Silicone -70 to +200 Skydrol

Fluoro-Silicone -100 to +200 Skydrol

Fluoro-Carbon (Viton) -10 to +200 Oil, Exhaust gas

Cold Cure Silicone -65 to +260 Good environmental

Cold Cure Urethane

or (Devcon) -25 to +100 Good environmental

Solder Type

Kp 60/40 (Melting

Point 188 deg C) -55 to +145

96S (High Melting

Point 210 deg C) -55 to +181

Silver Solder -196 to +254

Note: As standard, flanges are attached using Kp 60/40

solder. For certain side seam waveguides and the RF/tight Flex/Twist 96S solder is used as standard.

Vibration Vibration of flexible waveguides should be kept to a minimum if the unit is in a stressed (tensile) condition as the rubber jacket may be come more susceptible to "ozone" and general environmental attack. Flexible waveguides have a low spring stiffness, and as such, a low first resonant frequency. If this resonant frequency is excited, then violent oscillation may occur.

Humidity Humidity in general will not affect a flexible waveguide, although low surface temperatures may cause condensation, which may penetrate non-sealed flanges through capillary action. Also non-jacketed Flexible/ Twistable waveguide may be prone to condensation. Long lengths of waveguide should be sealed or regularly purged with dry air, where they may be used in areas of high humidity, to prevent moisture buildup.

Climatic Treatment of brass flanges with Tin or Silver is recommended where a corrosive environment is envisaged. Aluminium flanges should, as a minimum requirement, be coated with a chromate conversion finish. Where maximum protection is required, aluminium flanges should be coated with a nickel/silver finish. Passivation of flanges is only recommended for mild climatic conditions. In all conditions, added protection may be derived from painting the flanges with a DTD5555A epoxy paint. Note Cadmium Plating is no longer offered on TWS

waveguides.

Plating Finishes Available Tin Tin is offered as a corrosion resistant material finish and is used on brass flanges to improve compatibility with Aluminium by reducing the differential electrode potentials. On brass flanges, a basecoat of copper is deposited prior to the tin. On aluminium, a base of nickel is made first, followed by the tin.

Silver Silver is deposited directly on brass and copper unless a solder joint is present, where a copper flash will be deposited first.

Gold Gold may be offered on brass flanges only.

Chromated Conversion This is offered as standard on Aluminium and is equivalent to Alochrome. Note: As standard, brass flanges are offered unplated and

Aluminium flanges are offered with a chromate conversion.

Flanges, Fixing Kits and Sealing Rings TWS part numbers for the full range of standard flanges to the respective international flange specifications are shown in the 1999 Flange data sheet.

Plain Flanges Offer the best V.S.W.R. performance but are only suitable for unpressurised systems.

Choke Flanges The choke flange is used to reduce RF leakage (typically- 80dB). Recommended for mating with plain flanges for field installations where RF leakage may be a problem.

Flanges for Pressurisation Both choke and plain flanges may be offered with "0" Ring or Gasket grooves to maintain a pressure tight joint. These joints provide a pressure seal and prevent the ingress of moisture.

PIM Flanges Low Passive Intermodulation generation flanges may be offered on waveguide on request. These flanges are not offered with "0" Ring grooves.

This information is intended to provide waveguide system designers and users with the information that they require to incorporate successfully TWS Flexible/Twistable waveguide, hybrids and Rigid waveguide assemblies.

General Properties of Flexible Waveguides A flexible waveguide is capable of being formed into a complicated shape using only moderate force. TWS- Flex is the most flexible of all the TWS range of waveguide due to its helically wound form. Repeatable Bend performance to IEC636 is achieved through careful control of the convolution shape and results in good life, electrical and pressure handling performance. Flexible only waveguide has a continuous solder seam and is therefore only flexible in the E and H plane. This construction is pressure and RF tight. Flexible/Twistable is sealed electrically via a friction joint. This construction has the best twistable performance of all TWS waveguides. The Twistable waveguide will hold limited pressure, but it is not sealed against RF leakage. For pressure handling, the waveguide is sealed with a rubber jacket. To provide an RF tight Flexible/Twistable waveguide, TWS has developed a conductive jacket to use in conjunction with the standard Flexible/Twistable core.

DESIGN APPLICATIONS, INSTALLATION AND HANDLING INSTRUCTIONS

Flexible waveguides are not designed to be dimensionally equivalent to rigid waveguide, but they are designed to be electrically equivalent and compatible with the equivalent waveguide size. For all moulded flexible waveguides the length dimension is subject to a tolerance 1.5% (-+2mm min) to allow for contraction of the rubber after moulding. Flexible and Twistable waveguides maintain their Return Loss and Insertion Loss through flexing. Due to their design, Flexible Waveguide cannot be considered Phase Stable when flexed, since this will alter the electrical length of the assembly. RF power can be transmitted across the whole band of the equivalent rigid waveguide size, and it is usually possible to optimally tune the return loss of the waveguide, so to improve the performance over a narrow bandwidth if required.

Installation and use of Flexible Waveguides Flexible waveguides are manufactured for optimum performance. It is essential that their internal dimension and shape is maintained. PLEASE INSTALL WAVEGUIDES WITH GREAT CARE

Handling and Storage All waveguides should be transported and stored in their original packing until they are installed. TWS packing is appropriate for normal shipment, and it incorporates a sealed polythene enclosure to protect the internal waveguide surfaces from corrosion and oxidation. The sealed enclosure is also necessary to exclude humidity and moisture ingress. The protective end caps fitted to the waveguides should be routinely used to prevent damage to the flange faces and to keep out dirt etc. End caps should be kept in place until joined to the mating half. Waveguides intended for high power applications should be pressurized with dry air at all times to exclude humidity and reduce high power sparking.

Installation Sufficient bulkhead clearance should be allowed for the flanges and for spanner access. Clearance must not be created by bending or twisting the rigid section. All flanges or seatings must be correctly aligned before clamping. Waveguides Should not be stretched or forced to mate with a bracket, flange or clamp

Pressure seals should be used on all flanges where dry air pressure is applied.

Flexible Waveguide Handling Particular attention must be paid to minimum bend radius quoted in this datasheet.

The Static Bend Radius The minimum bend that an assembly may be subject to without repeat movement (except as a consequence of small vibrations or axial expansions). TWS designs its flexible waveguide with additional support at the flange to flexible joint. However, care should be taken not to subject this area at the back of the flange to the minimum static bend radius. Where a flexible waveguide is subject to intermittent or continuous cycles or

movement during operation, then the minimum repeat bend radius will apply. When using clamps with flexible waveguides care must be taken not to crush the waveguide core.

Servicing Waveguides should not be used to support any other component or equipment. If waveguides are dismantled for any reason, protective end caps should be used to prevent damage to the flange faces or ingress of moisture or dirt. Never use the waveguide as a hand or foot hold.

Hardware / Fixing Kits Sets of nuts, bolts and washers can be provided in fixing kits under TWS part number FK* *-* ** as appropriate for a pair of mated flanges. The fixing kits will include rubber "0" rings or gaskets to allow for a standard Plain flange to Seal flange assembly. If requested, shims or metal gaskets maybe included. Fixing kits are provided in individual bags / boxes and may be packaged with waveguides as required. One fixing kit will provide all the nuts, bolts, washers and "0" rings to assemble one end. (As shown below).

"0" Rings or Gaskets Gaskets or "0" Rings are offered on request with flanges where a suitable groove is made in the flange. These gaskets / ”O” rings are normally made from either silicone, nitrile, neoprene or EPDM. In most applications where the temperature range is within –10 to +100 deg C, neoprene or EPDM are satisfactory. Outside of this temperature range silicone is recommended. Metal gaskets or shims can be used for RF and pressure sealing on plain flanges, sometimes in conjunction with rubber gaskets or "0" rings. This type of joint is not recommended for use in ultra high power applications unless the assembly has been designed for that purpose.

Test Equipment Swept Synthesized Source and scalar analyzer with a dynamic range of 0-70dB at a frequency of up to 50 GHz. Vector Network Analyser with a dynamic range of up to 0-90dB at frequency range up to 75 GHz. Spectrum Analyser dynamic range of 104dB frequency ranges up to 40 GHz. All Flexible and Twistable waveguide products are tested 100% for Insertion and Return Loss swept over the stipulated frequency band using scalar network analyzer test equipment up to a maximum frequency of 50 GHz. Flexible waveguides may be tuned to give improved Return Loss performance over specified narrow frequency bands. Flexible/Twistable waveguides are tested for RF Leakage where requested in the specification. All RF Tight Flexible/Twistable waveguide products are tested 100% for RF Leakage. Unless otherwise requested The Waveguide Solution test for RF Leakage using the following TWS Inspection Procedure IP1504.

RF Leakage Test Procedure (based on IP1504). The industry has not yet decided on a standard test method for RF Leakage within Flexible Waveguides. The method of test and the interpretation of the data can severely affect the results. At TWS we have produced the following test method that is accurate and repeatable for Flexible waveguides and can be cross-related to other more conventional methods. All figures quoted for RF Leakage are based on the TWS test method.

Test Method Connect the test waveguide onto the test port and terminate with a load (F). Run the waveguide to coax adaptor (G) around the flanges of the test waveguide and ensure that the leakage from the flange is at least 5 dB down on the test requirement. With the test waveguide static and roughly horizontal move the waveguide to coax adaptor (G) along the 4 sides of the waveguide, with the coax adaptor in contact with the waveguide surface as shown in fig. 5. The alignment of the waveguide to coax adaptor (G) dimension (A) aperture of is always to be the same as that of the test waveguide broadwall. NB Movement of the detector must be regular and smooth to avoid spurious signals due to tribo electric or other effects.

The leakage is then measured and the worst value recorded. The results of the measurements obtained are converted by using the 'x' values given in table in 1, to their equivalent values when the measurements are made with a 10dB gain horn placed one metre from the waveguide. The waveguide is flexed and twisted to the minimum static bend and twist specifications.

If a hardcopy of the results is required, a plot of the swept response at the worst position is recorded.

Fig 5. RF leakage detection set up.

RF Leakage value The RF leakage value offered in our quoted specifications is based on the following calculation derived from the test results. The formula is used to calculate the equivalent RF Leakage Value if the device under test were measured using a 10dB Gain Horn placed one metre from the device under test.

RF Leakage Formula V =-A-X V = Value of RF Leakage at 1m from waveguide. A = Measure of RF Leakage of the device under test. X = The value from table

1 shown opposite for the appropriate waveguide size.

Note if the flexible/twistable waveguide is bent or twisted beyond the minimum recommended specification for the flexible section, then the RF leakage and other electrical performance characteristics may be affected. No guarantee can be offered for products installed beyond their recommended operating parameters. In many RF Leakage tests the majority of the leak is experienced at the flange interface, between the waveguide flange and the test equipment. Care must be taken to ensure that this joint is leak tight before testing. For TWS RF Tight Flexible/Twistable assemblies, the length of the solder joint of the flange is extended along the waveguide to prevent leakage. This has the effect of reducing the flexible section by a further 10mm.

Table 1

Waveguide Size X= Waveguide Size X=

8 13.3 15 25.0

9A 16.9 16 26.9

10 16.9 17 28.5

11A 18.8 18 30.1

12 20.5 19 31.8

13 22.0 20 33.5

14 23.3 21 33.5

15 25.0 22 37.0

TESTING

Waveguide Designation Electrical specification

V.S.W.R. & (Return Loss dB’s) Operating Frequency Band (GHz)

UK WG

IEC R

E.I.A. WR

TWS PART NUMBER Atten-uation dB/m

300mm 600mm 900mm

2.60 -3.95 10 32 284 FT 10 –PVZ-(***)-(***) /M(**) 0.11 1.055 (31.4) 1.070 (29.5) 1.070 (29.5)

2.60 - 3.95 10H FT 10H –PVZ-(***)-(***) /M(**) 0.12 1.055 (31.4) 1.070 (29.5) 1.070 (29.5)

3.30 - 4.90 11A 40 229 FT 11A –PVZ-(***)-(***) /M(**) 0.15 1.058 (31.0) 1.070 (29.5) 1.075 (28.8)

3.95 - 5.85 12 48 187 FT 12 –PVZ-(***)-(***) /M(**) 016 1.058 (31.0) 1.075 (28.8) 1.080 (28.3)

4.90 - 7.05 13 68 158 FT 13 –PVZ-(***)-(***) /M(**) 0.18 1.058 (31.0) 1.080 (28.3) 1.085 (27.8)

5.85 - 8.20 14 70 137 FT 14 –PVZ-(***)-(***) /M(**) 0.28 1.064 (30.2) 1.085 (27.8) 1.090 (27.3)

7.05 - 10.0 15 84 112 FT 15 –PVZ-(***)-(***) /M(**) 0.30 1.064 (30.2) 1.090 (27.3) 1.092 (27.1)

8.20-12.40 16 100 90 FT 16 –PVZ-(***)-(***) /M(**) 0.40 1.064 (30.2) 1.092 (27.1) 1.094 (27.0)

10.0 - 15.0 17 120 75 FT 17 –PVZ-(***)-(***) /M(**) 0.50 1.07 (29.4) 1.094 (27.0) 1.100 (26.4)

12.4 - 18.0 18 140 62 FT 18 –PVZ-(***)-(***) /M(**) 0.80 1.07 (29.4) 1.100 (26.4) 1.105 (26.0)

15.0 - 22.0 19 180 51 FT 19 –PVZ-(***)-(***) /M(**) 1.00 1.100 (26.4) 1.120 (25.0) 1.120 (25.0)

18.0 - 26.5 20 220 42 FT 20 –PVZ-(***)-(***) /M(**) 1.20 1.152 (23.0) 1.170 (22.1) 1.170 (22.1)

22.0 - 33.0 21 260 34 FT 21 –PVZ-(***)-(***) /M(**) 1.50 1.170 (22.1) 1.195 (21.0) 1.195 (21.0)

26.5 - 40.0 22 320 28 FT 22 –PVZ-(***)-(***) /M(**) 2.0 1.195 (21.0) 1.300 (17.1) 1.300 (17.7)

33.0 - 50.0 23 400 22 FT 23 –PVZ-(***)-(***) /M(**) N/A N/A (N/A) N/A (N/A) N/A (N/A)

40.0 - 80.0 24 500 19 FT 24 –PVZ-(***)-(***) /M(**) N/A N/A (N/A) N/A (N/A) N/A (N/A)


V.S.W.R. & (Return Loss dB’s)

Operating Frequency Band (GHz) Waveguide Designation TWS PART NUMBER

Atten-uation dB/m

300mm 600mm 900mm

4.75 - 11.0 WRD475 D24 FT 475 –PVZ-(***)-(***) /M(**) 0.65 1.110 (25.7) 1.150 (23.1) 1.150 (23.1)

5.8 - 16.0 WRD580 D28 FT 580 –PVZ-(***)-(***) /M(**) 1.20 1.180 (21.5) 1.250 (19.1) 1.300 (17.7)

6.5 - 18.0 WRD650 D24 FT 650 –PVZ-(***)-(***) /M(**) 1.31 1.200 (20.8) 1.250 (19.1) 1.350 (16.6)

7.5 - 18.0 WRD750 D24 FT 750 –PVZ-(***)-(***) /M(**) 1.31 1.200 (20.8) 1.250 (19.1) 1.300 (17.1)

11.0 - 26.5 WRD110 C24 FT 110 –PVZ-(***)-(***) /M(**) 3.61 1.220 (20.0) 1.350 (16.6) 1.350 (18.6)

18.0 - 40.0 WRD180 C24 FT 180 –PVZ-(***)-(***) /M(**) 2.79 1.375 (16.0) 1.500 (14.0) 1.500 (14.0)

** Insert flexible Waveguide length in mm *** For 3 digit Rectangular Waveguide or Double Ridged Waveguide flange part number, refer to the TWS Flange catalogue, or consult the factory. H = Half Height Waveguide

Notes

1. RF Leakage specification based on the TWS method of test detailed in this data sheet. 2. V.S.W.R. figures are based on Plain to Plain flanges. Degraded figures can be expected with Plain to

Choke flanges. 3. Power specifications are based on figures published in IEC 636 for complete jacketed assemblies.

The figures used are the maximum recommended for the lowest frequency in the designated waveguide band.

RECTANGULAR FLEXIBLE/TWISTABLE WAVEGUIDE

DOUBLE RIDGE FLEXIBLE/TWISTABLE WAVEGUIDE

Electrical Specification Mechanical specification

Minimum Bend Radius Twisting Rating Power Average KW max

Power Peak

MW max

RF Leakage dB’s

Sheath Dimen-sion mm

Weight Unflang-ed Kg/m

Maximum Operating Pressure lb/in sq

Static E Plane mm

Static H Plane mm

Repeated E Plane mm

Repeated H Plane mm

Static deg/m

Repeated deg/m

2.2 2.2 50 86X48 0.803 20 180 355 710 1420 105 25

N/A N/A 50 85X24 0.658 20 150 405 810 1625 105 25

1.8 1.8 50 74X43 0.729 30 165 330 880 1320 130 35

1.4 1.4 50 61X36 0.560 30 165 330 880 1320 155 40

0.6 0.6 50 53X36 0.533 30 125 255 610 1020 185 45

0.56 0.56 50 48X25 0.331 30 100 205 405 815 210 52

0.33 0.33 50 38X20 0.274 35 75 150 305 810 260 68

0.20 0.22 50 31X15 0.226 45 85 125 255 510 315 76

0.18 0.18 50 23x15 0.186 45 85 115 255 510 365 92

0.12 0.12 50 23X15 0.162 45 50 100 205 405 445 112

0.085 0.085 50 23x15 0.120 45 50 100 205 405 445 112

0.045 0.045 50 18X13 0.078 45 30 85 125 255 630 157

0.031 0.031 50 18X13 0.078 45 30 85 125 255 630 157

0.022 0.022 50 13 dia 0.057 45 25 50 100 205 920 230

N/A N/A N/A 13 dia 0.057 45 25 50 100 205 920 230

N/A N/A N/A 13 dia 0.057 45 25 50 100 205 920 230


Minimum Bend Radius Twisting Rating Power Average KW max

Power Peak

MW max

RF Leakage dB’s




Static E Plane mm

Static H Plane mm

Repeated E Plane mm

Repeated H Plane mm

Static deg/m

Repeated deg/m

N/A N/A 50 36X20 0.274 30 89 180 355 915 295 98

N/A N/A 50 26X15 0.186 45 76 155 305 510 490 130

N/A N/A 50 25X15 0.186 45 76 155 305 510 390 115

N/A N/A 50 19X13 0.078 45 50 100 205 405 490 130

N/A N/A 50 19X13 0.078 45 50 100 205 405 590 196

N/A N/A 50 13 dia 0.057 45 25 50 100 205 720 246

Length of Flexible Twistable Assemblies

This overall length of waveguide assemblies, is measured as the distance between the front face of both flanges. The maximum length of flexible and flexible twistable waveguide is dictated by the mechanical strength of the waveguide and the production tooling available. The following is a list of the standard recommended length for the various waveguide sizes. Other lengths may be available on request but may be subject to tooling and design charges. MM: 75, 150, 230, 300, 380, 460, 500, 600, 650, 760, 900, 1000, 1250 and 1500 INCHES: 12, 24, 36 and 48.

All lengths are subject to a tolerance on the length of 1.5% or ±2mm or whichever is greater.


V.S.W.R. & (Return Loss dB’s) Operating Frequency Band (GHz)

UK WG

IEC R

E.I.A. WR

TWS PART NUMBER Atten-uation dB/m

300mm 600mm 900mm

2.60 -3.95 10 32 284 FO 10 –PVZ-(***)-(***) /M(**) 0.11 1.055 (31.4) 1.070 (29.5) 1.070 (29.5)

2.60 - 3.95 10H FO 10H –PVZ-(***)-(***) /M(**) 0.12 1.055 (31.4) 1.070 (29.5) 1.070 (29.5)

3.30 - 4.90 11A 40 229 FO 11A –PVZ-(***)-(***) /M(**) 0.14 1.058 (31.0) 1.070 (29.5) 1.075 (28.8)

3.95 - 5.85 12 48 187 FO 12 –PVZ-(***)-(***) /M(**) 016 1.058 (31.0) 1.075 (28.8) 1.080 (28.3)

4.90 - 7.05 13 58 159 FO 13 –PVZ-(***)-(***) /M(**) 0.18 1.058 (31.0) 1.080 (28.3) 1.085 (27.8)

5.85 - 8.20 14 70 137 FO 14 –PVZ-(***)-(***) /M(**) 0.25 1.064 (30.2) 1.085 (27.8) 1.090 (27.3)

7.05 - 10.0 15 84 112 FO 15 –PVZ-(***)-(***) /M(**) 0.28 1.064 (30.2) 1.090 (27.3) 1.092 (27.1)

8.20-12.40 16 100 90 FO 16 –PVZ-(***)-(***) /M(**) 0.40 1.064 (30.2) 1.092 (27.1) 1.094 (27.0)

10.0 - 15.0 17 120 75 FO 17 –PVZ-(***)-(***) /M(**) 0.50 1.07 (30.0) 1.094 (27.0) 1.100 (26.4)

12.4 - 18.0 18 140 62 FO 18 –PVZ-(***)-(***) /M(**) 0.68 1.07 (30.0) 1.100 (26.4) 1.105 (26.0)

15.0 - 22.0 19 180 51 FO 19 –PVZ-(***)-(***) /M(**) 1.00 1.100 (28.4) 1.120 (25.0) 1.120 (25.0)

18.0 - 26.5 20 220 42 FO 20 –PVZ-(***)-(***) /M(**) 1.00 1.152 (23.0) 1.170 (22.1) 1.170 (22.1)

22.0 - 33.0 21 260 34 FO 21 –PVZ-(***)-(***) /M(**) 1.50 1.170 (22.1) 1.195 (21.0) 1.195 (21.0)

26.5 - 40.0 22 320 28 FO 22 –PVZ-(***)-(***) /M(**) 1.8 1.195 (21.0) 1.300 (17.1) 1.300 (17.1)

33.0 - 50.0 23 400 22 FO 23 –PVZ-(***)-(***) /M(**) N/A N/A (N/A) N/A (N/A) N/A (N/A)

40.0 - 80.0 24 500 19 FO 24 –PVZ-(***)-(***) /M(**) N/A N/A (N/A) N/A (N/A) N/A (N/A)

WG23/24 Electrical specifications available on request.

Waveguide Designation

Electrical specification

V.S.W.R. & (Return Loss dB’s)

Operating Frequency Band (GHz) Waveguide Designation TWS PART NUMBER

Atten-uation dB/m

300mm 600mm 900mm

4.75 - 11.0 WRD475 D24 FO 475 –PVZ-(***)-(***) /M(**) 0.65 1.110 (25.7) 1.150 (23.1) 1.150 (23.1)

5.8 - 16.0 WRD580 D28 FO 580 –PVZ-(***)-(***) /M(**) 1.20 1.180 (21.5) 1.250 (19.1) 1.300 (17.7)

6.5 - 18.0 WRD650 D24 FO 650 –PVZ-(***)-(***) /M(**) 1.31 1.200 (20.8) 1.250 (19.1) 1.350 (16.6)

7.5 - 18.0 WRD750 D24 FO 750 –PVZ-(***)-(***) /M(**) 1.31 1.200 (20.8) 1.250 (19.1) 1.300 (17.1)

11.0 - 26.5 WRD110 C24 FO 110 –PVZ-(***)-(***) /M(**) 3.61 1.220 (20.0) 1.350 (16.6) 1.350 (18.6)

18.0 - 40.0 WRD180 C24 FO 180 –PVZ-(***)-(***) /M(**) 2.79 1.375 (16.0) 1.500 (14.0) 1.500 (14.0)

** Insert flexible Waveguide length in mm *** For 3 digit Rectangular Waveguide or Double Ridged Waveguide flange part number, refer to the TWS Flange catalogue, or consult the factory. H = Half Height Waveguide

Notes

1. RF Leakage specification based on the TWS method of test detailed in this data sheet. 2. V.S.W.R. figures are based on Plain to Plain flanges. Degraded figures can be expected with Plain to

Choke flanges. 3. Power specifications are based on figures published in IEC 636 for complete jacketed assemblies.

The figures used are the maximum recommended for the lowest frequency in the designated Waveguide band.

RECTANGULAR FLEXIBLE ONLY WAVEGUIDE

DOUBLE RIDGE FLEXIBLE ONLY WAVEGUIDE


Minimum Bend Radius Power Average KW max

Power Peak

MW max

RF Leakage dB’s




Static E Plane mm

Static H Plane mm

Repeated E Plane mm

Repeated H Plane mm

2.2 2.2 N/A 86X48 0.803 20 180 355 710 1420

N/A N/A N/A 85X24 0.658 20 150 405 810 1625

1.8 1.8 N/A 74X43 0.729 30 165 330 880 1320

1.4 1.4 N/A 61X36 0.560 30 165 330 880 1320

0.6 0.6 N/A 53X36 0.533 30 125 255 610 1020

0.56 0.56 N/A 48X25 0.331 30 100 205 405 815

0.33 0.33 N/A 38X20 0.274 35 75 150 305 810

0.20 0.22 N/A 31X15 0.226 45 85 125 255 510

0.18 0.18 N/A 23x15 0.186 45 85 115 255 510

0.12 0.12 N/A 23X15 0.162 45 50 100 205 405

0.085 0.085 N/A 23x15 0.120 45 50 100 205 405

0.045 0.045 N/A 18X13 0.078 45 30 85 125 255

0.031 0.031 N/A 18X13 0.078 45 30 85 125 255

0.022 0.022 N/A 13 dia 0.057 45 25 50 100 205

N/A N/A N/A 13 dia 0.057 45 25 50 100 205

N/A N/A N/A 13 dia 0.057 45 25 50 100 205


Minimum Bend Radius Power Average KW max

Power Peak

MW max

RF Leakage dB’s




Static E Plane mm

Static H Plane mm

Repeated E Plane mm

Repeated H Plane mm

N/A N/A N/A 36X20 0.274 30 89 180 355 915

N/A N/A N/A 26X15 0.186 45 76 155 305 510

N/A N/A N/A 25X15 0.186 45 76 155 305 510

N/A N/A N/A 19X13 0.078 45 50 100 205 405

N/A N/A N/A 19X13 0.078 45 50 100 205 405

N/A N/A N/A 13 dia 0.057 45 25 50 100 205

Length of Flexible Twistable Assemblies

This overall length of waveguide assemblies is measured as the distance between the front faces of both flanges. The maximum length of flexible and flexible twistable waveguide is dictated by the mechanical strength of the Waveguide and the production tooling available. The following is a list of the standard recommended length for the various waveguide sizes. Other lengths may be available on request but may be subject to tooling and design charges. MM: 75, 150, 230, 300, 380, 460, 500, 600, 650, 760, 900, 1000, 1250 and 1500. INCHES: 12, 24, 36 and 48.

All lengths are subject to a tolerance on the length of 1.5% or ±2mm or whichever is greater.

The Waveguide Solution Limited

King Charles Business Park ● Old Newton Road ● Heathfield ● Newton Abbot Devon TQ12 6UT ● United Kingdom

T: +44 (0) 1626 835255 F: +44 (0) 1626 836166

E-mail: [email protected] www.waveguidesolution.co.uk

Specifications shown on this document are offered as a guide only. Components may be modified to suit the mechanical or electrical parameters requested, or may be optimized to suit the operating frequency range. Frequency range of operation shall be advised when ordering. Issue 1.0a

Information provided in this brochure is for reference only. Dimensions or specifications are typical values. All designs, specifications and availabilities of products and services

presented in this document may be subject to change without notice. For confirmation of details please consult your agent or manufacturer.

Ordering Information

FT 16 P V Z 402 402 M500

LENGHT

LENGTH IN mm PREFIXED BY THE LETTER ‘M’ E.g. M500 = 500 mm FLANGE Y

SELECT THE REQUIRED FLANGE BY SELECTING THE LAST 3 DIGITS

OF THE TWS FLANGE PART No.

E.g. 402= UBR FLANGE

FLANGE X

SELECT THE REQUIRED FLANGE BY SELECTING THE LAST 3 DIGITS OF THE TWS

FLANGE PART No.

E.g. 402= UBR FLANGE

FINISH

Z = UNPLATED (STANDARD FOR BRASS)

H = CHROMATE (STANDARD FOR ALUMINIUM)

A = TIN PLATE (OPTIONAL FOR BRASS ONLY)

B = SILVER PLATE (OPTIONAL FOR BRASS ONLY)

COVERING ON CORE V = VULCANISED NEOPRENE (STANDARD) [SEE NOTE BELOW]

I = VULCANISED RED SILILCONE (OPTIONAL) X = UNJACKETED (UNPAINTED)

E = EM TIGHT SPECIAL TWO LAYER SILICONE (OPTIONAL) A = ELASTROMETRIC PAINT

CORE TYPE

P = SILVER PLATED BRASS (STANDARD FOR FT &FO)

WAVEGUIDE SIZE USE THE BRITISH WG SIZE FOR RECTANGULAR WAVEGUIDE or THE MIL SPEC. WRD SIZE FOR DOUBLE RIGDE WAVEGUIDE

Eg. 16= WAVEGUIDE SIZE WG16

750 = WRD750

PRODUCT CODE

FT = FLEXIBLE TWISTABLE (STANDARD TYPE)

FO = FLEXIBLE ONLY (STANDARD TYPE)

Notes:

1) Waveguides with miniature Flanges (UER/CMR etc)

cannot be supplied with a moulded jacket as standard.

TWS FLEXIBLE AND FLEXIBLE/TWISTABLE WAVEGUIDES

TWS DRAWING NUMBER ALL ITEMS LISTED BELOW ARE CURRENTLY CLASSED AS SPECIFIC TO INDIVIDUAL CUSTOMER REQUIREMENTS AND SHOULD BE

ALLOCATED WITH A UNIQUE TWS 80,000 SERIES DRAWING/REFERENCE NUMBER

WAVEGUIDE SIZE USE THE BRITISH WG SIZE FOR RECTANGULAR WAVEGUIDE or THE MIL SPEC. WRD SIZE FOR DOUBLE RIGDE WAVEGUIDE

E.g. 16= WAVEGUIDE SIZE WG16 750 = WRD750 90 = NO RECOGNISED WG SIZE (E.g. COAX COMPONENTS or SPECIAL SIZES)

PRODUCT CODE FH = FLEXIBLE HYBRID (CUSTOM RIGID/FLEX WG ASSEMBLIES)

TH = TWISTABLE HYBRID (CUSTOM RIGID/FLEX TWIST WG ASSEMBLIES) TC = TRANSMISSION LINE COMPONENT FOR SPACE FLIGHT APPLICATIONS

TL = TRANSMISSION LINE (WAVEGUIDE RUN and/or SUB-SYSTEM)

TWS FLEXIBLE AND FLEXIBLE/TWISTABLE

FH 16 *****

Documents

Flexible Waveguide