Waveguide Flexible

Flexible/Twistable Flexible Only Twistable Hybrid Flexible Only Hybrid FT SERIES FO SERIES TH SERIES FH SERIES

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.

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.

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 CORE
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

THE JACKET
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. 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.

HYBRID ASSEMBLIES
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 flange interfaces Proving gas tight joints Lower overall mass and lower profile Lower insertion loss with

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).

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.

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

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 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 Assemblies

and

Flexible

Waveguide

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.

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.

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.

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.

Table 1. Thermal characteristics of Core Jacket and Solder.

Core Type Operating Temp Range -55 to +145 -55 to +145 -70 to +260 -55 to +145 -55 to +145, -70 to + 145 Fluid / Environmental Protection

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.

Flexible/Twistable Flexible Only Side Seam Brass / BeCu Side Seam Silver Plated Seamless Brass / BeCu Seamless Electroformed Nickel Jacket Type Neoprene Silicone Fluoro-Silicone Fluoro-Carbon (Viton) Cold Cure Silicone Cold Cure Urethane or (Devcon) Solder Type Kp 60/40 (Melting Point 188 deg C) 96S (High Melting Point 210 deg C) Silver Solder

-55 to +100 -70 to +200 -100 to +200 -10 to +200 -65 to +260 -25 to +100

Oil, Ozone Skydrol Skydrol Oil, Exhaust gas Good environmental Good environmental

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

-55 to +145 -55 to +181 -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.

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.

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.

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.

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.

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.

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.

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

DESIGN APPLICATIONS, INSTALLATION AND HANDLING INSTRUCTIONS

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.

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.

General Properties of Flexible Waveguides

A flexible waveguide is capable of being formed into a complicated shape using only moderate force. TWSFlex 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.

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.

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.

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).

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.

"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.

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

TESTING
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 090dB 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.

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. 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

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.

RF Leakage Formula 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. 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.

RECTANGULAR FLEXIBLE/TWISTABLE WAVEGUIDE

Operating Frequency Band (GHz)

Waveguide Designation UK WG IEC R E.I.A. WR TWS PART NUMBER Attenuation dB/m 300mm

Electrical specification V.S.W.R. & (Return Loss dBs) 600mm 900mm

2.60 -3.95 2.60 - 3.95 3.30 - 4.90 3.95 - 5.85 4.90 - 7.05 5.85 - 8.20 7.05 - 10.0 8.20-12.40 10.0 - 15.0 12.4 - 18.0 15.0 - 22.0 18.0 - 26.5 22.0 - 33.0 26.5 - 40.0 33.0 - 50.0 40.0 - 80.0

10 10H 11A 12 13 14 15 16 17 18 19 20 21 22 23 24

32 40 48 68 70 84 100 120 140 180 220 260 320 400 500

284 229 187 158 137 112 90 75 62 51 42 34 28 22 19

FT 10 PVZ-(***)-(***) /M(**) FT 10H PVZ-(***)-(***) /M(**) FT 11A PVZ-(***)-(***) /M(**) FT 12 PVZ-(***)-(***) /M(**) FT 13 PVZ-(***)-(***) /M(**) FT 14 PVZ-(***)-(***) /M(**) FT 15 PVZ-(***)-(***) /M(**) FT 16 PVZ-(***)-(***) /M(**) FT 17 PVZ-(***)-(***) /M(**) FT 18 PVZ-(***)-(***) /M(**) FT 19 PVZ-(***)-(***) /M(**) FT 20 PVZ-(***)-(***) /M(**) FT 21 PVZ-(***)-(***) /M(**) FT 22 PVZ-(***)-(***) /M(**) FT 23 PVZ-(***)-(***) /M(**) FT 24 PVZ-(***)-(***) /M(**)

0.11 0.12 0.15 016 0.18 0.28 0.30 0.40 0.50 0.80 1.00 1.20 1.50 2.0 N/A N/A

1.055 1.055 1.058 1.058 1.058 1.064 1.064 1.064 1.07 1.07 1.100 1.152 1.170 1.195 N/A N/A

(31.4) (31.4) (31.0) (31.0) (31.0) (30.2) (30.2) (30.2) (29.4) (29.4) (26.4) (23.0) (22.1) (21.0) (N/A) (N/A)

1.070 1.070 1.070 1.075 1.080 1.085 1.090 1.092 1.094 1.100 1.120 1.170 1.195 1.300 N/A N/A

(29.5) (29.5) (29.5) (28.8) (28.3) (27.8) (27.3) (27.1) (27.0) (26.4) (25.0) (22.1) (21.0) (17.1) (N/A) (N/A)

1.070 1.070 1.075 1.080 1.085 1.090 1.092 1.094 1.100 1.105 1.120 1.170 1.195 1.300 N/A N/A

(29.5) (29.5) (28.8) (28.3) (27.8) (27.3) (27.1) (27.0) (26.4) (26.0) (25.0) (22.1) (21.0) (17.7) (N/A) (N/A)

DOUBLE RIDGE FLEXIBLE/TWISTABLE WAVEGUIDE

Operating Frequency Band (GHz) Waveguide Designation Waveguide Designation TWS PART NUMBER Attenuation dB/m 300mm Electrical specification V.S.W.R. & (Return Loss dBs) 600mm 900mm

4.75 - 11.0 5.8 - 16.0 6.5 - 18.0 7.5 - 18.0 11.0 - 26.5 18.0 - 40.0

WRD475 D24 WRD580 D28 WRD650 D24 WRD750 D24 WRD110 C24 WRD180 C24

FT 475 PVZ-(***)-(***) /M(**) FT 580 PVZ-(***)-(***) /M(**) FT 650 PVZ-(***)-(***) /M(**) FT 750 PVZ-(***)-(***) /M(**) FT 110 PVZ-(***)-(***) /M(**) FT 180 PVZ-(***)-(***) /M(**)

0.65 1.20 1.31 1.31 3.61 2.79

1.110 1.180 1.200 1.200 1.220 1.375

(25.7) (21.5) (20.8) (20.8) (20.0) (16.0)

1.150 1.250 1.250 1.250 1.350 1.500

(23.1) (19.1) (19.1) (19.1) (16.6) (14.0)

1.150 1.300 1.350 1.300 1.350 1.500

(23.1) (17.7) (16.6) (17.1) (18.6) (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.

Electrical Specification Power Power RF Average Peak Leakage KW max MW max dBs

Sheath Dimension mm

Weight Unflanged Kg/m

Maximum Operating Pressure lb/in sq

Mechanical specification Minimum Bend Radius

Static E Plane mm Static H Plane mm Repeated E Plane mm Repeated H Plane mm

Twisting Rating
Static deg/m Repeated deg/m

2.2 N/A 1.8 1.4 0.6 0.56 0.33 0.20 0.18 0.12 0.085 0.045 0.031 0.022 N/A N/A

2.2 N/A 1.8 1.4 0.6 0.56 0.33 0.22 0.18 0.12 0.085 0.045 0.031 0.022 N/A N/A

50 50 50 50 50 50 50 50 50 50 50 50 50 50 N/A N/A

86X48 85X24 74X43 61X36 53X36 48X25 38X20 31X15 23x15 23X15 23x15 18X13 18X13 13 dia 13 dia 13 dia

0.803 0.658 0.729 0.560 0.533 0.331 0.274 0.226 0.186 0.162 0.120 0.078 0.078 0.057 0.057 0.057

20 20 30 30 30 30 35 45 45 45 45 45 45 45 45 45

180 150 165 165 125 100 75 85 85 50 50 30 30 25 25 25

355 405 330 330 255 205 150 125 115 100 100 85 85 50 50 50

710 810 880 880 610 405 305 255 255 205 205 125 125 100 100 100

1420 1625 1320 1320 1020 815 810 510 510 405 405 255 255 205 205 205

105 105 130 155 185 210 260 315 365 445 445 630 630 920 920 920

25 25 35 40 45 52 68 76 92 112 112 157 157 230 230 230

Electrical Specification Power Average KW max Power Peak MW max RF Leakage dBs Sheath Dimension mm Weight Unflanged Kg/m Maximum Operating Pressure lb/in sq

Mechanical specification Minimum Bend Radius

Static E Plane mm Static H Plane mm Repeated E Plane mm Repeated H Plane mm

Twisting Rating
Static deg/m Repeated deg/m

N/A N/A N/A N/A N/A N/A

N/A N/A N/A N/A N/A N/A

50 50 50 50 50 50

36X20 26X15 25X15 19X13 19X13 13 dia

0.274 0.186 0.186 0.078 0.078 0.057

30 45 45 45 45 45

89 76 76 50 50 25

180 155 155 100 100 50

355 305 305 205 205 100

915 510 510 405 405 205

295 490 390 490 590 720

98 130 115 130 196 246

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.

RECTANGULAR FLEXIBLE ONLY WAVEGUIDE

Waveguide Designation UK WG IEC R E.I.A. WR TWS PART NUMBER Attenuation dB/m 300mm Electrical specification V.S.W.R. & (Return Loss dBs) 600mm 900mm

Operating Frequency Band (GHz)

2.60 -3.95 2.60 - 3.95 3.30 - 4.90 3.95 - 5.85 4.90 - 7.05 5.85 - 8.20 7.05 - 10.0 8.20-12.40 10.0 - 15.0 12.4 - 18.0 15.0 - 22.0 18.0 - 26.5 22.0 - 33.0 26.5 - 40.0 33.0 - 50.0 40.0 - 80.0

10 10H 11A 12 13 14 15 16 17 18 19 20 21 22 23 24

32 40 48 58 70 84 100 120 140 180 220 260 320 400 500

284 229 187 159 137 112 90 75 62 51 42 34 28 22 19

FO 10 PVZ-(***)-(***) /M(**) FO 10H PVZ-(***)-(***) /M(**) FO 11A PVZ-(***)-(***) /M(**) FO 12 PVZ-(***)-(***) /M(**) FO 13 PVZ-(***)-(***) /M(**) FO 14 PVZ-(***)-(***) /M(**) FO 15 PVZ-(***)-(***) /M(**) FO 16 PVZ-(***)-(***) /M(**) FO 17 PVZ-(***)-(***) /M(**) FO 18 PVZ-(***)-(***) /M(**) FO 19 PVZ-(***)-(***) /M(**) FO 20 PVZ-(***)-(***) /M(**) FO 21 PVZ-(***)-(***) /M(**) FO 22 PVZ-(***)-(***) /M(**) FO 23 PVZ-(***)-(***) /M(**) FO 24 PVZ-(***)-(***) /M(**)

0.11 0.12 0.14 016 0.18 0.25 0.28 0.40 0.50 0.68 1.00 1.00 1.50 1.8 N/A N/A

1.055 1.055 1.058 1.058 1.058 1.064 1.064 1.064 1.07 1.07 1.100 1.152 1.170 1.195 N/A N/A

(31.4) (31.4) (31.0) (31.0) (31.0) (30.2) (30.2) (30.2) (30.0) (30.0) (28.4) (23.0) (22.1) (21.0) (N/A) (N/A)

1.070 1.070 1.070 1.075 1.080 1.085 1.090 1.092 1.094 1.100 1.120 1.170 1.195 1.300 N/A N/A

(29.5) (29.5) (29.5) (28.8) (28.3) (27.8) (27.3) (27.1) (27.0) (26.4) (25.0) (22.1) (21.0) (17.1) (N/A) (N/A)

1.070 1.070 1.075 1.080 1.085 1.090 1.092 1.094 1.100 1.105 1.120 1.170 1.195 1.300 N/A N/A

(29.5) (29.5) (28.8) (28.3) (27.8) (27.3) (27.1) (27.0) (26.4) (26.0) (25.0) (22.1) (21.0) (17.1) (N/A) (N/A)

WG23/24 Electrical specifications available on request.

DOUBLE RIDGE FLEXIBLE ONLY WAVEGUIDE

Operating Frequency Band (GHz)

Waveguide Designation Waveguide Designation TWS PART NUMBER Attenuation dB/m 300mm

Electrical specification V.S.W.R. & (Return Loss dBs) 600mm 900mm

4.75 - 11.0 5.8 - 16.0 6.5 - 18.0 7.5 - 18.0 11.0 - 26.5 18.0 - 40.0

WRD475 D24 WRD580 D28 WRD650 D24 WRD750 D24 WRD110 C24 WRD180 C24

FO 475 PVZ-(***)-(***) /M(**) FO 580 PVZ-(***)-(***) /M(**) FO 650 PVZ-(***)-(***) /M(**) FO 750 PVZ-(***)-(***) /M(**) FO 110 PVZ-(***)-(***) /M(**) FO 180 PVZ-(***)-(***) /M(**)

0.65 1.20 1.31 1.31 3.61 2.79

1.110 1.180 1.200 1.200 1.220 1.375

(25.7) (21.5) (20.8) (20.8) (20.0) (16.0)

1.150 1.250 1.250 1.250 1.350 1.500

(23.1) (19.1) (19.1) (19.1) (16.6) (14.0)

1.150 1.300 1.350 1.300 1.350 1.500

(23.1) (17.7) (16.6) (17.1) (18.6) (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.

Electrical Specification Power Power RF Average Peak Leakage KW max MW max dBs

Sheath Dimension mm

Weight Unflanged Kg/m

Maximum Operating Pressure lb/in sq

Mechanical specification Minimum Bend Radius

Static E Plane mm Static H Plane mm Repeated E Plane mm Repeated H Plane mm

2.2 N/A 1.8 1.4 0.6 0.56 0.33 0.20 0.18 0.12 0.085 0.045 0.031 0.022 N/A N/A

2.2 N/A 1.8 1.4 0.6 0.56 0.33 0.22 0.18 0.12 0.085 0.045 0.031 0.022 N/A N/A

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

86X48 85X24 74X43 61X36 53X36 48X25 38X20 31X15 23x15 23X15 23x15 18X13 18X13 13 dia 13 dia 13 dia

0.803 0.658 0.729 0.560 0.533 0.331 0.274 0.226 0.186 0.162 0.120 0.078 0.078 0.057 0.057 0.057

20 20 30 30 30 30 35 45 45 45 45 45 45 45 45 45

180 150 165 165 125 100 75 85 85 50 50 30 30 25 25 25

355 405 330 330 255 205 150 125 115 100 100 85 85 50 50 50

710 810 880 880 610 405 305 255 255 205 205 125 125 100 100 100

1420 1625 1320 1320 1020 815 810 510 510 405 405 255 255 205 205 205

Electrical Specification Power Average KW max Power Peak MW max RF Leakage dBs Sheath Dimension mm Weight Unflanged Kg/m Maximum Operating Pressure lb/in sq

Mechanical specification Minimum Bend Radius

Static E Plane mm Static H Plane mm Repeated E Plane mm Repeated H Plane mm

N/A N/A N/A N/A N/A N/A

N/A N/A N/A N/A N/A N/A

N/A N/A N/A N/A N/A N/A

36X20 26X15 25X15 19X13 19X13 13 dia

0.274 0.186 0.186 0.078 0.078 0.057

30 45 45 45 45 45

89 76 76 50 50 25

180 155 155 100 100 50

355 305 305 205 205 100

915 510 510 405 405 205

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.

Ordering Information
TWS FLEXIBLE AND FLEXIBLE/TWISTABLE WAVEGUIDES
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)

TWS FLEXIBLE AND FLEXIBLE/TWISTABLE

FH 16 *****
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)

Notes: 1) Waveguides with miniature Flanges (UER/CMR etc) cannot be supplied with a moulded jacket as standard.

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: enquires@waveguidesolution.co.uk 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.