Mega Industries, LLC RF Solutions - A leader in the manufacture of Microwave Transmission Equipment

Waveguide

Waveguide Dummy Loads

Mega Dummy Loads are high power single terminal device intended to terminate a transmission line. Three types of dissipative material are employed in Mega Industries’ dummy loads: lossy plastic, refractory ceramic, and liquid. Three methods of heat transfer are employed: free air convection, forced air cooling, and liquid cooling. While dummy loads can be supplied to operate over full waveguide bands, generally faster delivery and a more efficient unit can be furnished for use over narrower frequency ranges.

The power rating of a dummy load is a complex function dependent upon many parameters. Average and peak power, guide pressure, external temperature, guide size, air flow, and availability of auxiliary coolant all play factors in the final power rating of a dummy load. The average and peak powers are interrelated in that the peak power capacity is a function of the operating temperature which in turn is a function of the average power. These are then impacted by the ambient temperature of the cooling medium (air or liquid). The tables on the following pages provide power ratings for each model. The independent average power rating assumes CW operation. The independent peak power rating assumes negligible average power. The typical combined average and peak power ratings should be employed in combination. Our application engineers will readily assist in determining proper loads for a particular application.

Air cooled high power dummy loads have high surface temperatures and must be finished in such a manner as to increase heat transfer. Mega employs a heat resistant black silicone-based paint (>525°C) for most applications, although custom finishes are available for even higher surface temperatures.

Unfinned Dummy Loads 1.12 - 40 GHz
WE Series


WE Series Unfinned Dummy Load
  • Extremely Rugged High Power Loads
  • High Temperature Refractory Load Elements
  • Economic Convection Design
  • Available with most Common Flanges

Mega WE series dummy loads are rugged high power units designed to satisfy minimum cost and weight objectives. Models are designed for bands from 1.12 to 40.0 GHz.

The WE loads employ high temperature refractory load elements designed to meet the requirements of MIL-D-3954A. These load elements are in direct contact with the waveguide walls for optimum heat transfer. They can withstand extremely high temperature, temperature gradients and thermal shocks. For additional cooling fins see the WF series.

These loads can be supplied to operate over the full indicated waveguide frequency band. Generally faster delivery and a more efficient unit can be furnished for use over narrower frequency ranges. Always specify your frequency and VSWR requirements.

The table below provides power ratings for each model. The independent average power rating assumes CW operation, and the independent peak power rating assumes negligible average power. The combined average and peak power ratings should be employed together.

Designs to meet special requirements for bandwidth, size, flanges, etc., are available on request. (4/14)

General Specifications
Load Material: Refractory
Test Pressure: 35 psig. max.
Housing Finish: Black, Silicone-based
Pyromark 1200
>525°C (1,000°F)
Material: Aluminum
Flange Finish: Iridite Per
MIL-C-5541
Model Frequency
Range
Waveguide
Size
Power Ratings VSWR
Max.
Approximate Dimensions
Inches/Ounces
Independent Combined
RG WR W Avg. kW‡
peak
W Avg. KW†
peak
L in. W in. H in. Wt
(lbs.)
WE-0005 1.12-1.70 103 650 2250 65,000 1500 20,000 1.15 32.9 6.9 8.7 67.0
WE-00151.70-2.60105430150030,000100010,0001.1521.86.06.421.0
WE-00252.60-3.9575284120012,5007504,0001.1014.05.35.37.5
WE-00353.95-5.85951878005,2505001,8001.109.83.73.73.9
WE-00455.85-8.201061375002,7503001,0001.107.93.23.22.3
WE-00507.05-10.0681123001,7501757501.106.31.92.21.0
WE-00558.20-8.80
8.80-12.4
67902501,2501503501.15
1.10
5.71.71.90.8
WE-006512.4-18.0349621506501002501.104.11.31.70.4
WE-007518.0-26.512142125225751001.154.11.01.30.2
WE-008526.5-40.096†287512550751.204.20.81.00.2
†Aluminum Equivalent
‡at pressure of 35psig †at pressure of 10 psig

Finned Dummy Loads 1.12 – 40.0 GHz
WF Series

  • Extremely Rugged High Power Load
  • High Temperature Refractory LoadElements
  • Transverse Cooling Fins
  • Available with most Common Flanges
WF Series Finned Dummy Load

Mega WF series dummy loads are the commercial equivalent of the standard military DA loads. Models are designed to meet the requirements of MIL-D-3954C in all electrical and mechanical respects for bands from 1.12 to 40.0 GHz.

The WF loads employ transverse cooling fins and high temperature refractory load elements designed to meet the requirements of MIL-D- 3954C. These load elements are in direct contact with the waveguide walls for optimum heat transfer. They can withstand extremely high temperature, temperature gradients and thermal shocks. The WG series is a similar finned design, but with enhanced heat transfer. For lower powers unfinned models may meet the need, see the WE series.

These loads can be supplied to operate over the full indicated waveguide frequency band. Generally faster delivery and a more efficient unit can be furnished for use over narrower frequency ranges. Always specify your frequency and VSWR requirements with any request.

Designs to meet special requirements for bandwidth, size, flanges, etc., are available on request.

General Specifications
Dissipative Material: Refractory
Test Pressure: 35 psig. max.
Housing Finish: Black, Silicone-based
Pyromark 1200
>525°C (1,000°F)
Flange Type:< 2.6 GHz:> 2.6 GHz:
Contact
Flange Cover
Material: Aluminum
Flange Finish: Iridite Per
MIL-C-5541
Model Frequency
Range
JAN
Equivalent
Waveguide
Size
Rated Power* VSWR
Max.
Approximate Dimensions
Inches/lbs.
RG WR W
Avg.
Test
kW pk
L in. W in. H in. Wt
lbs.
WF-00051.12-1.70DA-147/U103650800022001.1532.98.911.490.0
WF-00252.60-3.95DA-145/U75284450032001.1014.04.96.411.5
WF-00353.95-5.85DA-149/U95187200010001.109.83.64.15.1
WF-00455.85-8.20DA-144/U10613710007101.108.03.13.93.3
WF-00507.05-10.0DA-148/U681126004601.106.32.53.11.5
WF-00558.20-8.80
8.80-12.4
DA-146/U67905002901.15
1.10
5.72.82.81.3
WF-006512.4-18.0DA-159/U349622501601.154.32.42.40.75
WF-007518.0-26.5DA-160/U12142150801.154.22.22.20.37
WF-008526.5-40.0DA-158/U96†28751001.204.22.02.00.37
†Aluminum Equivalent
*When tested in accordance with MIL-D-3954A

Super High Power Dummy Loads 1.12 – 40.0 GHz
WG Series

  • Highest Power Air Cooled Loads
  • High Temperature Refractory Load Elements
  • Transverse Cooling Fins
  • Available with most Common Flanges
WG Series Super High Power Dummy Load 1.12 - 40.0 GHz WG Series Super High Power Dummy Load Types

Mega WG series dummy loads are designed to offer superior performance that exceeds that offered by the standard military DA loads. Improved fin location, slight physical size alterations, and other enhancements make this increase in performance possible.

The WG loads employ transverse cooling fins and high temperature refractory load elements that are designed to conform to the requirements of MIL-D-3954C. These load elements are in direct contact with the waveguide walls for optimum heat transfer. They can withstand extremely high temperature, temperature gradients and thermal shocks.

These loads can be supplied to operate over the full indicated waveguide frequency band. Generally faster delivery and a more efficient unit can be furnished for use over narrower frequency ranges. Always specify your frequency and VSWR requirements with any request.

Designs to meet special requirements for bandwidth, size, flanges, etc., are available on request.

Power Ratings: The Independent Average Power ratings assume CW operation and the Independent Peak Power ratings assume negligible average power. The Combined Power ratings should be employed together. Forced air cooling is necessary to reach the highest levels listed.

General Specifications
Dissipative Material: Refractory
Test Pressure: 35 psig. max.
Housing Finish: Black, Silicone-based
Pyromark 1200
>525°C (1,000°F)
Flange Type:< 2.6 GHz:> 2.6 GHz:
Contact
Flange Cover
Material: Aluminum
Flange Finish: Iridite Per
MIL-C-5541
Model Frequency
Range
Type Waveguide
Size
Absolute Max
Independent
Power Rating
Typical Combined
Power Rating
VSWR
Max.
Approximate Dimensions
Inches/Ounces
RG WR W
Avg.
Peak @
45psig
(kW)
W
Avg.
Peak @
30psig
(kW)
L in. W in. H in. Wt
(lbs.)
WG-00051.12-1.70I1036509000100,000600020,0001.1537.68.911.491.0
WG-00151.70-2.60II105430650045,000500010,0001.1524.46.78.830.0
WG-00252.60-3.95II75284500019,00040004,0001.1016.65.46.412.0
WG-00353.95-5.85II9518725007,75018001,8001.1012.23.64.15.5
WG-00455.85-8.20II10613715004,25010001,0001.109.53.13.93.5
WG-00507.05-10.0II681127502,7506007501.107.92.53.11.7
WG-00558.20-12.40II67906501,7505003501.106.72.82.81.4
WG-006512.40-18.00II91†624001,0002502501.104.72.42.40.75
WG-007518.00-26.50III121423003501501001.154.52.22.20.37
WG-008526.50-40.00III96†28300175100751.154.52.02.00.37
†Aluminum Equivalent
*When tested in accordance with MIL-D-3954A

Liquid Cooled High Power Dummy Loads 1.12 – 18.0 GHz
WL Series

  • Maximum Power Liquid Cooled Loads
  • High Temperature Refractory Load Elements
  • Mounts in Any Position
  • Available with most Common Flanges
WL Series Dummy Load

Mega WL series dummy loads are the highest power liquid cooled dry loads available in this product family. They are available in the 1.12 to 18.0 GHz region.

The WL dummy loads employ high temperature refractory load elements designed to meet the requirements of MIL-D-3954C. Load elements are in direct contact with waveguide walls for optimum heat transfer. They can withstand extremely high temperature, temperature gradients, and thermal shocks. They are designed to operate at the rated power without coolant for sufficient time to permit detection and correction of coolant system failure.

The units utilize a cylindrical aluminum, copper or stainless steel cooling jacket. Stiffening ribs are employed for mechanical rigidity, improved heat transfer, and optimum coolant flow. Standard NPT female pipe threads are provided for coolant connections. Coolant flow rates shown are the minimum recommended for proper cooling for peak power values. These units may be mounted in any position.

These loads can be supplied to operate at set frequencies over the full indicated waveguide frequency band. Generally faster delivery and a more efficient unit can be furnished for use over narrower frequency ranges. Always specify your frequency and VSWR requirements.

The table provides power ratings for each model. The independent average power rating assumes CW operation, and the independent peak power rating assumes negligible average power. The combined average and peak power ratings should be employed together.

Power Ratings: The Independent Average Power ratings assume CW operation and the Independent Peak Power ratings assume negligible average power. The Combined Power ratings should be employed together. Additional water flow volumes may be necessary to reach the highest levels listed or if inlet temperatures are above 20 degrees C.

General Specifications
VSWR: 1.10:1 max.
Dissipative Material: Refractory
Coolant:Max. Inlet Temp:Test Pressure:Pressure: Liquid
150°F
50 psig. max.
100 psig max.
Coolant Connector:WL-0025,-0035,-0045:WL-0050,-0055,-0065: NPT, female¾ - 14 ¼ - 18
Finish: Black
Silicone-based
Pyromark 1200
>525°C (1,000°F)
Flange Material: Aluminum
Flange Finish:Iridite
per MIL-C-5541
Model Frequency
Range
Waveguide
Size
Absolute Max
Independent
Power Rating
Typical Combined
Power Rating
Min
Flow
Rate
(gpm)
VSWR
Max.
Approximate Dimensions
Inches/Ounces
RG WR W
Avg.
Peak @
45psig
(kW)
W
Avg.
Peak @
30psig
(kW)
L in. Diam.
in.
Wt
(lbs.)
WL-00051.12-1.7010365025,000100,00012,00020,00081.1540.09.595
WL-00151.70-2.6010543018,00045,00010,00010,00071.1528.57.745
WL-00252.60-3.957528415,00019,0007,5004,00051.1017.55.919
WL-00353.95-5.859518710,0007,7504,0001,80041.1012.64.810
WL-00455.85-8.201061375,0004,2502,0001,00021.109.03.44
WL-00507.05-10.0681124,0002,7501,50075021.108.13.13
WL-00558.80-12.40†67903,0001,7501,00035011.107.02.92.3
WL-006512.40-18.00349621,5001,00050025011.105.82.51.3
†Operation to 8.2 GHz with reduced VSWR of 1.15:1

Dummy Loads and Load Inserts 7.50 – 11.50 GHz
WD and WZ Series

  • Extremely Rugged High Power Loads
  • High Temperature Refractory Load Elements
  • WD Series Dummy Load - Mega Industries
  • WZ Series Dummy Load- Mega Industries
  • WZ Series Dummy Load Scale- Mega Industries

Mega WD series dummy loads are low cost, miniaturized units with moderate power handling capacity. Models are designed for bands from 7.50 to 11.50 GHz.

The WD loads employ tapered refractory load elements which are capable of withstanding extremely high temperature. These loads are sometimes used as 1 Watt terminations at ambient temperatures as high as 600°F. They are designed to provide optimum performance over approximately 12% frequency bands. Cover flanges are supplied.

The Mega WZ series consists of the tapered refractory load elements as used in the WD series. They can be cemented by the user into a section of waveguide to meet particular requirements.

The table provides power ratings for each model. Independent average power rating assumes CW operation, and independent peak power rating assumes negligible average power. The combined average and peak power ratings should be employed together.

General Specifications
Load Material:Refractory
Test Pressure:35 psig. max.
Housing Finish:Black, Silicone-based
Pyromark 1200
>525°C (1,000°F)
Material:Aluminum
Flange Finish:Iridite Per
MIL-C-5541
*RoHS compliant coating available
Model Frequency
Range
Waveguide
Size
Power Ratings Approximate Dimensions
Inches/Ounces
Independent Combined
RG WR W
Avg.
kW‡
peak
@40 psig
W
Avg.
KW†
peak
@ 30 psig
L in. W in. H in. Wt
(lbs.)
WD series Mini Load
WD-00527.50-8.506811215010060602.21.91.92.5
WD-00538.50-9.60
WD-00568.50-9.6067901007540401.91.71.72.5
WD-00579.50-10.60
WD-005810.30-11.50
WZ series Load Insert
WZ-00527.50-8.506811210015†152.01.220.4970.5
WZ-00538.50-9.60
WZ-00568.50-9.6067906010†101.60.9000.4000.2
WZ-00579.50-10.60
WZ-005810.30-11.50
† at 0 psig

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