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Service Manual GMX X-Ray Generator

CMR X-Ray, LLC 2000 Pewaukee Road, Suite H Waukesha, Wisconsin 53188

Copyright CMR X-Ray, March 2015

GMX X-RAY GENERATOR SERVICE MANUAL

©

CONTENTS 1)  

PRE-­‐INSTALLATION  ........................................................................................................  1  

1.1  Introduction  ..........................................................................................................................................  1   1.2  Dimensions,  Weight  and  Cable  Access   ..................................................................................................  1   1.3  Environmental  Requirements  ...............................................................................................................  3   1.4  Packaging   .............................................................................................................................................  3   1.5  Electrical  Requirements,  208  to  480  Volt  Lines  ......................................................................................  4   1.6  Electrical  Requirements,  Power  Assist  Units  ..........................................................................................  6   1.7  Safety  Devices  .......................................................................................................................................  6  

2)  

INSTALLATION  .................................................................................................................  8  

2.1  Introduction  ..........................................................................................................................................  8   2.2  Tools  and  Materials  ..............................................................................................................................  8   2.3  Measurement  Equipment  .....................................................................................................................  9   2.4  Pre-­‐Installation  Check  ...........................................................................................................................  9   2.5  Unpacking  .............................................................................................................................................  9   2.6  Power  Cabinet  Installation  /    power  assist  ..........................................................................................  10   2.7  Operator  Console  Installation  .............................................................................................................  10   2.8  Interface  Connections  .........................................................................................................................  11   2.8.1  Generator  Connections  Left  side  .........................................................................................................  11   2.8.2  Generator  connections  right  side  ........................................................................................................  12   2.8.3  T1  Voltage  Taps,  Rotor  and  Filament  ..................................................................................................  13   2.8.4  X-­‐Ray  Tube  Stator  Connections  ...........................................................................................................  14   2.8.5  DiGital  Interface,  2TS2  .........................................................................................................................  16   2.8.6  Relay  Board,  Bucky  Interface,  2TS3  .....................................................................................................  17   2.8.7  System  Connect,  2TS4  .........................................................................................................................  18   2.8.8T1  Power  Module  AUX  Power  ..............................................................................................................  19   2.8.9  T1  Taps  (Rotor  &  Filament)  and  Fuses  .................................................................................................  20   2.8.10  TS-­‐1-­‐1  Power  assist  transformer  input  ..............................................................................................  21  

i Copyright © CMR X-Ray, 2015

GMX X-RAY GENERATOR

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3)  GENERATOR  CONFIGURATION  ........................................................................................  22   3.1  Configuration  procedure  .....................................................................................................................  22  

4)  CALIBRATION  ........................................................................................................................  29   4.1  TRUE-­‐TRACK  Calibration  with  Computer  .............................................................................................  29   4.2  Typical  mA  and  kV  Wave  Forms  ..........................................................................................................  33  

5)  TROUBLESHOOTING  ...........................................................................................................  35   5.1  Introduction  ........................................................................................................................................  35   5.2  Service  RECOMMENDATIONs  ..............................................................................................................  35   5.3  Error  Codes  .........................................................................................................................................  36   5.3.1  ERROR  Code  Descriptions  ....................................................................................................................  37  

6)  RENEWAL  PARTS  .................................................................................................................  38   6.1  Power  Module  ....................................................................................................................................  38   6.2LINE  Inverter  ........................................................................................................................................  40  

7)  ACCEPTANCE  TESTING  .......................................................................................................  41   7.1  Introduction  ........................................................................................................................................  41   7.2  Preliminary  Testing  .............................................................................................................................  41   7.3  X-­‐Ray  Time  Measurement  ...................................................................................................................  42   7.8  kV/mA  X-­‐Ray  Measurement   ...............................................................................................................  44   7.8  Linearity   .............................................................................................................................................  46   7.8  Repeatability  ......................................................................................................................................  48  

SUPPLEMENT      B    POWER  ASSIST  .....................................................................................  50   SUPPLEMENT      C    USEFUL  TABLES  ....................................................................................  52   SUPPLEMENT      D    HV  CABLE  MAINTENANCE  ................................................................  53  

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PRE-INSTALLATION

1.1 INTRODUCTION

Planning and preparing the customer site. This list contains the main topics to consider during pre-installation planning: •

Equipment dimensions

•

Installation and sizing of the electrical supply

•

Installation of safety devices, Door Interlocks, X-Ray On-Lamps, Disconnect Circuit Breakers, etc.

1.2 DIMENSIONS, WEIGHT AND CABLE ACCESS

POWER MODULE DIMENSIONS: FRONT 23” SIDE 24” HEIGTH 19.5” WEIGHT 178 lbs. (Illustrated W/O covers)

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GMX X-RAY GENERATOR

BASIC RAD CONSOLE DIMENSIONS: FRONT 11.25” SIDE 9.75” HEIGTH 4.5” WEIGHT 4.75 lbs.

POWER ASSIST DIMENSIONS: FRONT 23” SIDE 24” HEIGTH 10.0” WEIGHT 98 lbs. (Illustrated W/O covers)

1.1 GENERATOR COMPONENTS

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GMX X-RAY GENERATOR

1.3 ENVIRONMENTAL REQUIREMENTS •

Temperature: 10ºC to 40ºC (50˚F to 104˚F).

•

Relative Humidity 0 to 90%.

•

Maximum Altitude: 2440 meters (8000 feet) above sea level.

Note: This X-Ray Generator will dissipate 544 btu/hr.

1.4 PACKAGING

1.7 SHIPPING CRATE

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1.5 ELECTRICAL REQUIREMENTS, 208 TO 480 VOLT LINES

Model

Power (kW) 30 kW

Supply Voltage (VAC) 1Ø 208/220,

Frequency (Hz)

GMX 325 RAD GMX 525 RAD

50 kW

220, 3Ø

50/60

GMX 625 RAD

60 kW

380, 3Ø

50/60

GMX 825 RAD

80 kW

480, 3Ø

50/60

50/60

1.2 LINE VOLTAGES

Power and Ground Wire Size (AWG): Model

Power

Ground

0 to 30m

Power

Ground

31 to 50m

Power

Ground

51 to 70m

Power

Ground

71 to 90m

Power

Ground

91 to 110m

Power

Ground

111 to 130m

GMX 325 RAD

1/0

6

1/0

6

2/0

2

3/0

2

4/0

1/0

250 MCM

1/0

GMX 525 RAD

1/0

6

1/0

6

2/0

2

3/0

2

4/0

1/0

250 MCM

1/0

GMX 625 RAD

2

6

1/0

6

2/0

2

3/0

2

4/0

1/0

250 MCM

1/0

GMX 825 RAD

2

8

1/0

6

2/0

2

3/0

2

4/0

1/0

250 MCM

1/0

1.31 POWER AND GROUND WIRE SIZING

4

GMX X-RAY GENERATOR electrical requirements continued.

Line Disconnect to Power Module Model

Power

Ground 0 to 10m

GMX 325 RAD

2AWG

2AWG

GMX 525 RAD

2AWG

2AWG

GMX 625 RAD

2AWG

6AWG

GMX 825 RAD

2AWG

6AWG

1.4 WIRE SIZING, TO POWER MODULE

Model

Power Transformer Capacity (kVA)

Main Disconnect Switch

GMX 325 RAD

40, 1Ø

100 Amp

GMX 525 RAD

50, 3Ø

100 Amp

GMX 625 RAD

65, 3Ø

100 Amp

GMX 825 RAD

80, 3Ø

100 Amp

1.5 WIRE SIZING TOLINE TRANSFORMER Note : Line voltage variations must not exceed ± 10% from nominal voltage. Note : Line voltage drop during X-Ray exposures must not exceed 10%.

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1.6 ELECTRICAL REQUIREMENTS, POWER ASSIST UNITS Power assist Generators require 115 VAC, 20 Amps, supplied from a standard wall outlet or 220VAC, 30 Amp. The Power assist Line Voltage is configured by taping its input transformer (located in the Power Assist Chassis) to the appropriate Line Voltage. See page 22, this manual.

1.7 SAFETY DEVICES •

Door safety switch: Prevents X-Ray exposures when the room door is open. Check local requirements.

•

X-Ray On lamp: Installed outside the X-Ray suite, (typically above the room door). Check local requirements.

Note: The GMX X-Ray Generator provides a switching function to activate the X-Ray On Lamp, the lamp voltage is supplied by the customer. Note: The GMX X-Ray Generator is not configured to supply any voltage or currents that may be required to interface other ancillary devices that may be installed with the X-Ray generator. Grounding and or load issues to the GMX circuits may result in faulty operation and function during X-Ray generation.

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2)

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INSTALLATION

2.1 INTRODUCTION This chapter describes procedures used to install the GMX X-Ray Generator. The installation process will depend on Generator type and ancillary equipment configuration: •

Check for transportation damage. Report shipping damage to the Freight Company or CMR X-Ray.

•

Check that supplied components and cables match what was ordered system.

NOTE: Power Assist Generator installation is covered in Appendix PA

2.2 TOOLS AND MATERIALS Required tools and materials: •

Hand tools. (Service Engineers Tool Kit)

•

Terminal Crimp Tool (Wire sizes 12 through 22)

•

Power Drill Motor, Drill Bit Index

•

Rotary Hammer, Concrete Bits

•

Extension cord.

•

Soldering iron, 60 Watts.

•

Silicone Insulating Grease – DC4 Vapor Proofing Compound or Equivalent.

•

Degreasing/Cleaning agent.

•

Dielectric Oil.

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GMX X-RAY GENERATOR

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2.3 MEASUREMENT EQUIPMENT •

Fluke 177 or equivalent digital multimeter.

•

Tektronix TDS 2002 or equivalent oscilloscope.

•

mAs meter.

•

KVP Meter

•

Dose Meter

2.4 PRE-INSTALLATION CHECK Prior to installation, inspect the site and verify that the X-Ray room complies with Preinstallation requirements: Incoming Line, voltage and current capacity. Main Switch and Safety Devices. Conduit, size and location. Space Requirements. Note: Refer to Pre-Installation Chapter (1)

2.5 UNPACKING TWO PEOPLE ARE REQUIRED FOR MOVEMENT AND PLACEMENT OF THE HV TRANSFORMER AND POWER MODULE and/or POWER ASSIST. IT’S HEAVY, DON’T RISK AN INJURY! During the equipment unpacking, inspect all items for visible damage. • • •

After unpacking, verify the following: All items on the customer order are present. All hardware and internal wiring is secure.

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2.6 POWER CABINET INSTALLATION / POWER ASSIST TWO PEOPLE ARE REQUIRED FOR MOVEMENT AND PLACEMENT OF THE HV TRANSFORMER AND POWER MODULE and/or POWER ASSIST. IT’S HEAVY, DON’T RISK AN INJURY! Power Cabinet Installation: 1. After unpacking, remove Power Module trim covers. 2. Remove the shipping screws that attach the Power Module to the pallet. Place the Power Module chassis near to its final position in the room. Two people are required for this operation. 3. Do not install HV Transformer wires, HV cables and covers until instructed to do so in this Manual.

4. Power Cabinet may be freestanding or located on a platform or shelf or bolted to the room floor.

NOTE: Local requirements apply.

2.7 OPERATOR CONSOLE INSTALLATION 1. Place the Operator Console at its final location. 2. Connect provided interconnect cable, the other end will terminate at the Power Module.

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2.8 INTERFACE CONNECTIONS

The following drawings show the connections between the generator and peripherals, ie.: Table Bucky, Wall Bucky, Safety Lamp, Door Switch, etc.

2.8.1 GENERATOR CONNECTIONS LEFT SIDE

2TS1 Rotor AUX Voltages See pp 14

2TS2 Digital Interface

2TS3 Relay Board, Bucky Interface See pp 17

11

2TS4 System Connect Jumper 4 and 10 to enable Service Mode See pp 18

GMX X-RAY GENERATOR

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2.8.2 GENERATOR CONNECTIONS RIGHT SIDE

1TS1 Pre Charge Functions & ON/OFF Functions MAKE NO CHANGES

F6, F7 ON/OFF 1TS2 T1 Primary Tap

1TS3 Rotor Start & Run Taps

FUSE F8, 15A Pre Charge

Filament Inverter Volts Tap

F9, 15A T1 F10, 15A RTR Start F11, 15A RTR Run F12, 15A Filament F14, 15A Filament

12

10

9

8

1TS2

0V BLK

208V BRN

220V RED

T1

13 0V VIO

270V GRY

310V WHT

220V BLU

130V YEL

100V ORN

60V RED

40V BRN

0V BLK

10

9

8

7

6

5

4

3

2

1

1TS3

* Al l Fuses a re 15 A / 2 50 VAC

Tapfor Filament Inverter Voltage

Tapfor RotorRun Voltage

Tapfor Rotor Start Voltage

Stator Common

A3002-79, J18

A3002-84, J11

A3002-84, J1-3

A3002-79, J11

Fluoro Only

1F15*

1F14*

Fluoro Only

1F13*

1F12*

1F11*

1F10*

2TS1-1

GMX X-RAY GENERATOR

2.8.3 T1 VOLTAGE TAPS, ROTOR AND FILAMENT

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Generator

2TS1 X-Ray Tube/ Stator Interface

** ChassisGround added byinstaller **

Descriptio 14 10

9

8

7

6

5

4

3

3

1 2

2C1*

0 VAC

1TS3

to

X-RayTube

Will not support more than 500 mA Load

AUX +24 Common

AUX +24, < 500mA

Tie Point (Open)

Tie Point (Open)

Thermo Switch RTN

Thermo Switch

Housing Ground

Main BLK

Phase Shift RED or GRN

Common WHT

2TS1

1

Closes at Power UP NO Contact: UL Rating: 5 A at 30 VDC 5 A at 125 VAC

Low Speed Rotor Control A3002-84-02

J3

Value as/per X-Ray Tube Stator

*2C1 Phase ShiftCapacitor

GMX X-RAY GENERATOR

2.8.4 X-RAY TUBE STATOR CONNECTIONS

20702-85 Wall Bucky Suppl Cable.

Table

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GMX X-RAY GENERATOR

Varian Color

Description

Black

Main

Red

Auxiliary

White

Common

Orange-Brown

Thermal switch

Brown-Orange

Thermal switch

Green-Yellow

Ground

TOSHIBA Color

Description

Black

Main

Red

Auxiliary

White

Common

Yellow

Thermal switch

Blue

Thermal switch

Green-Yellow

Ground

KAILLONG Color

Description

Black

Main

Red

Auxiliary

White

Common

Blue

Thermal switch

Blue

Thermal switch

Green-Yellow

Ground

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GMX X-RAY GENERATOR

2.8.5 DIGITAL INTERFACE, 2TS2

2TS2 Digital Interface Used for Software based interfaces

16

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21236-02

4 6 8 10

3

5

7

9

+24 V

2

1

J15

17 Room Light

Bucky4

Bucky3

Bucky2

Bucky1

A3002-02 AncillaryInterfaceBoard

D5

K5

D4

K4

R5

R4

R3

D3

K3

D2

K2

R2

D1

K1

R1

Bucky/Tomo EXP

LED5

LED4

LED3

LED2

LED1

K5B

K5C

K4B

K4C

K3B

K3C

K2B

K2C

K1B

K1C

2TS3

P15

P13

P12

P10

P9

P7

P6

P4

P3

P1

P14

P11

P8

P5

P2

12

11

10

9

8

7

6

5

4

3

2

1

TS1

Tie Point (Open)

Tie Point (Open)

Tie Point (Open)

EXP Start Return

EXP Start CMD

Room Light Return

Room Light

Spare 2 Start CMD

Spare 1 Start CMD

Bucky 2 Start CMD

Bucky 1 Start CMD

CMDReturn

GMX X-RAY GENERATOR

2.8.6 RELAY BOARD, BUCKY INTERFACE, 2TS3 ©

GMX X-RAY GENERATOR

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2.8.7 SYSTEM CONNECT, 2TS4

2TS4 1 2 3 4 5 6 7 8 9 10

2

127 VAC and Descriptio

Tie Point (Open) Tie Point (Open) Tie Point (Open)

*Jumper to GND for Service Mode

*SERVICE MODE Spare Interlock

** Must be LOW for EXP

**DOOROPEN

Through Door Switch or Jumper to GND

*** X-Ray Tube Thermo Switch

*** Must be LOW for EXP Connects to Tube at 2TS1-5

Tie Point (Open)

GND GND

2TS4 A3002-56-01 System Connect

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GMX X-RAY GENERATOR

2.8.8T1 POWER MODULE AUX POWER

19

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20

10

9

8

1TS2

0V BLK

208V BRN

220V RED

T1

0V VIO

270V GRY

310V WHT

220V BLU

130V YEL

100V ORN

60V RED

40V BRN

0V BLK

10

9

8

7

6

5

4

3

2

1

1TS3

* All Fuses are 15A / 250 VAC

Tap for Filament Inverter Voltage

Tap for Rotor Run Voltage

Tap for Rotor Start Voltage

Stator Common

A3002-79, J1-8

A3002-84, J1-1

A3002-84, J1-3

A3002-79, J1-1

Fluoro Only

1F15*

1F14*

Fluoro Only

1F13*

1F12*

1F11*

1F10*

2TS1-1

GMX X-RAY GENERATOR

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2.8.9 T1 TAPS (ROTOR & FILAMENT) AND FUSES

GMX X-RAY GENERATOR

2.8.10 TS-1-1 POWER ASSIST TRANSFORMER INPUT

Descriptio

Generator 21

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GMX X-RAY GENERATOR

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3) GENERATOR CONFIGURATION The following procedure describes the initial configuration for the GMX X-Ray Generator. Generator calibration follows in chapter 4. In order to successfully complete configuration and calibration you must observe the following:

Required Hardware / Software: Computer, Laptop Windows 7 or higher Service Interface Box, CMR part Number G4001-01, with USB cable. Service Software (A4000-xx), CMR CD provided. Software Driver, USB to UART bridge (silicon labs CP 2102 USB to UART); available at Silicone Labs website :http://www.silabs.com/products/mcu/Pages/USBtoUARTBridgeVCPDrivers.aspx

(also available on the CD provided with the CMR X-Ray Generator).

3.1 CONFIGURATION PROCEDURE 1. Verify that the Mains Power breaker is Off; Generators with Power Assist (PA) verify that the PA power cord is disconnected. 3. Connect the USB cable between your laptop computer and the Service Interface Box. 4. Connect the Generator to Operator Console cable (DB-15), from the Power Module front panel to the Service Interface Box. 5. Place a jumper between 2TS4-4 and 2TS4-10 on the A3002-56-01 board located in the power module (see page 11 and page 18 in this manual). .

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GMX X-RAY GENERATOR

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6. Turn the Mains wall breaker On, or connect the Power Assist unit to outlet power. Turn the Generator On with the ON switch located on the Service Interface Box. Close the toggle switch on the PA unit. 7. Insert the installation CD or flash drive into your PC. 8.

Open Folder A4000-13v4, in that Folder find Folder ”Software”, copy and paste “Software” to “C” Drive

9. 10. Open A4000-13v4 found on the installation disk or flash drive 11. Double click “setup.exe”, follow instructions, this will install the generator calibration program ion c:\Program Files (x86)\A4000-13 12. On your PC, Click Windows “Start” 13. Click on “Control Panel” 14. Click on “Device Manager” 12. Select “Ports (COM & LPT)”, this will indicate which COM Port connects to the X-Ray Generator. Note and remember this number. If you don’t see a comport that is connected to the generator via the service box then you don’t have the UART bridge driver installed. Most of the time your computer will search for this driver and find it on the supplied CD. However if that does not work you must go online to the silicone labs website, this will allow your computer to download and install the correct USB two UART driver. This operation is extremely critical to the successful and functional application of the configuration and calibration features of this generator.

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12 COM Port #

13. Run program A4000-13v4, accessible fron Windows “Start” or “Program Files” (x86)\A4000-13. Or create a shortcut from “Program Files”

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GMX X-RAY GENERATOR 15. The next screen should look like this. Select the ON button.

14, ON

16. You will see this window displayed for approximately 10 seconds

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17. Next, the Main screen will display. Note: Status box reflecting possible problems or errors. Note: that various selections located at the bottom of this window.. Select Configuration button.

11, Configuration

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18. In configuration mode, the following screen is visible. System ID and System Ratings cannot be changed. 100 Amp Line Power is default it when 1 Tube Rad is selected Rather than defining and repeating the selections on this screen, you as the installer should be able to configure and select the various functions presented. If you have trouble recognizing these choices you may want to enlist a more experienced service engineer to help (call a friend). The selection of the correct X-Ray Tube Type is extremely important.

20, Close

18, SAVE

19. Once configuration selections have been made use the Save button to move these settings into Generator memory .

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20. During Configuration Save you will see this screen

21. After saving the configuration settings , Select Close,, the software will return to the Main screen. NOTE: If you are not moving to Calibration Mode, remove the Service enable jumper on 2TS4 (see page 11 in this manual). If you are proceeding to the Calibration Mode, select mA Calibration ,continue as follows.

20, mA Calibration

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4) CALIBRATION 4.1 TRUE-TRACK CALIBRATION WITH COMPUTER TRUE-TRACK insures that X-Ray parameters calibrate to required specifications. If you have just finished Configuration, connect your scope and start at step # 6, this chapter. If you are checking Calibration only, install the software and setup as per Chapter 3.1 (pp 22 this manual), steps 1-13.

The following procedure will ensure compliance. Connect scope Channel 1 to TP12 (mA test point) on the PWM A2002-46 board, Set Amplitude: 500mV per division Set .Time 5ms per division. Use channel 1 trigger in normal mode. Connect scope Channel 2 to TP3 (kV test point) on the PWM A2002-46 board, Set Amplitude: 1V per division.

PULSE WIDTH MODULATOR A3002-85 TEST POINTS TP3, kV Test Point, Chanel 1 TP12, mA Test Point, Chanel 2 TP 23, kV and mA signal common 29

GMX X-RAY GENERATOR

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1. Connect the USB cable between your laptop and the SERVICE BOX, connect the Generator cable to the SERVICE BOX . 2. Place a jumper between 2TS4-4 and 2TS4-10 on the A3002-56-01 board located in the power module (see page 11 in this manual).

4

10

3. Install the .exe file found in the A4000-13 folder. This software is compatible with Windows XP and Windows 7. 4. Turn the Mains breaker On 5. Turn the Generator On with the ON switch located on the OPERATOR CONSOLE SIMULATOR BOX 6. From the Main screen, access Calibration mode.

7, Calibration

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7. Calibration screen. Note the Status window, if any of these are highlighted you will not be able to make an exposure. Repair or reconfigure as needed to satisfy all parameters in the Status window.

16, Status Window

8, Closed Loop. True-Track

NOTE: When True Track is selected the software will default to the starting technique setting, 80 kV, 10 mA, at 40 ms 8. Insure that Closed Loop and True-Track are selected. 9. To start (10 mA at 80 kV) make sure that the Filament Demand set point is at least 2200 but not greater than 2400 (for most x-ray tubes). Note: Filament Demand Limit and starting Set Point are set relative to the X-Ray Tube selected during Configuration.

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GMX X-RAY GENERATOR

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With a Hand switch connected to the service box make an exposure, the Filament Demand number will change.

11. Continue to hold exposure switch, X-Ray exposures will automatically continue, until a green highlight annotated with Calibration successful appears 12. Release the Expose and Prep switch, Note the WAIT indication in the STATUS Box, You must wait for the indicator to change to “Ready to expose” before continuing with the next mA Calibration. True-Track automatically saves the data and advances to the next station. 13. Continue to initiate the exposure switch until the next station is calibrated. 14. Repeat until all mA stations are calibrated. 15. A green indication of Cal complete will present when each station is calibrated. 12, WAIT Will Change to “Ready to

expose”

16, OFF 10, Filament Demand

11, 15, Green

16. When all mA stations are Calibrated, Select OFF. 32

GMX X-RAY GENERATOR

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Note: to recalibrate a specific mA station select the MA value and select 80 kVA , initiate the calibration process, after the 45 kVA station is calibrated you must manually select the 125 kV station and then initiate the Cal process.

4.2 TYPICAL MA AND KV WAVE FORMS

80 kV

10 mA

80 kV

100 mA

80 kV

300 mA

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You have just installed the Medical Imaging industry’s most cost effective High Performance High Frequency X-Ray Generator. Thanks’ for your wise choice.

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5) TROUBLESHOOTING 5.1 INTRODUCTION The generator includes self-diagnostic routines to facilitate troubleshooting. When in the unlikely event there is an error, the Operator console displays an error code. This chapter lists the errors, with corresponding corrective actions.

5.2 SERVICE RECOMMENDATIONS CAUTION: This X-Ray Generator has components that maybe damaged by electrostatic discharges (ESD). Use ESD precautions when working with the printed circuit boards. WARNING THE HIGH VOLTAGE INVERTER CAPACITORS RETAIN A LARGE PORTION OF CHARGE FOR APPROXIMATELY 2 MINUTES AFTER THE UNIT IS TURNED OFF. Auto-DISCHARGE CIRCUITS ARE IN PLACE BUT ALWAYS CHECK FOR BUS VOLTAGE WHEN WORKING IN THIS AREA.

Do not produce Radiation without cause When making exposures during service activities, be mindful of the expected path of the primary X-ray beam. Keep all parts of your body outside of this path. Exposure to X ray radiation may be harmful, care must be taken to avoid direct exposure to the primary X Ray beam.

Always Collimate the x-ray beam to as small an area as possible

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Do not defeat or override any safety features on the GMX X-Ray generator.

Note: In the unlikely event of a blown fuse: To insure the continued protection against fire replace uses only with the same type and ratings as supplied and specified by CMR X-Ray.

After service, insure that all protective panels and covers are in place. 5.3 ERROR CODES Error codes, provided for troubleshooting. There are two categories (1) recoverable and (2) non-recoverable. A recoverable error prevents exposures until the conditions generating the Fault have been repaired, does not require a Generator restart. A non-recoverable error requires the Generator to be repaired and restarted. For the Basic RAD Console, the lamp of the selected function key will flash. When that key is pressed, the kV indicator displays the error code. To check if more than one error occurred, keep the function key pressed and simultaneously press one of the kV keys.

For the Touch Screen Console, Error/Fault Codes display on the Operator Counsel using text, not numbers.

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GMX X-RAY GENERATOR

5.3.1 ERROR CODE DESCRIPTIONS Non-Recoverable Errors, Requires repair and Restart E02

Battery Fault (Battery Systems Only)

E07

X-Ray Tube Thermal Switch Fault.

E10

Bucky Signal Fault

E19

Rotor Signal Fault

E27

Communication Fault (Console to Power Module)

E36

Inverter Bus Voltage Low

E38

IPM Fault

E39

Filament Fault

E44

Console Pushbuttons activated during Power UP

E46

Microprocessor Battery Fault

E47

Tube Data Fault

E49

mA Station Not Calibrated

E52

kV Unbalanced

E53

Checksum Error, Flash Memory

E56

AEC No Calibration Data

E57

High Speed Rotor Fault

E58

Microprocessor Not Initialized

Recoverable Error, Re-Start Not Required E18

X-Ray Room Door Open

E29

Exposure Back Up Time

E32

Selected AEC Technique greater than 650 mAs

E33

Selected Technique Exceeds Available Heat Units

E51

Pre-Charge Error

E51

Exposure Hand switch released before End of Exposure

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6) RENEWAL PARTS

6.1 POWER MODULE Low Voltage Power Supplies 20500-00,24,25

Low Voltage Distribution A3002-75-

IPM

Line Fuses

Contactors, Line & Pre Charge

Filament Driver A3002-79-01

Inverter Module

Low Speed Rotor Control A3002-84-02

HV Transformer

(CONT. Next Page)

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GMX X-RAY GENERATOR

Digital I/O A3002-74-01

Micro Controller A3002-80-04 Analog I/O A3002-28-03

Pulse Width Modulator A3002-85-02

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6.2LINE INVERTER Assembly Number: A1003-40-00, Inverter Module, 1 Phase 240 VAC A1003-41-00, Inverter Module, 3 Phase 240 VAC A1003-43-00, Inverter Module, 3 Phase 480 VAC

IPM 21105-06 30 kW 21105-10 50 kW 21105-07 80 kW

Snubber Caps 30932-1MF 20932-2MF

IPM Driver A3002-93-01

Input Filter/Charge Monitor A3002-88-01 (240V 1P) A3002-89-01 (240V 3P) A3002-91-01 (480V 3P)

Line Rectifiers, (2 or 3 each) 21100-24

(Not Visible)

Capacitor, 4 each 20931-3700MF (Not Visible)

240 VAC Fuses (480V 3P Only)

Resistor, Pre- Charge 20822-25E 30 kW 20822-100E 80 kW

Pre-Charge Contactor 20304-00

Line Contactor 20304-00

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Line Fuses 20310-02

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7) ACCEPTANCE TESTING 7.1 INTRODUCTION This chapter defines the tests used to ensure that the calibrated operation of this equipment meets performance requirements set by the FDA in 21CFR, Sub Chapter J. Make these checks after installation calibration or any maintenance that would affect Generator calibration.

7.2 PRELIMINARY TESTING These procedures confirm the operation and calibration of the generator. 1. Turn the generator ON and note the operator console startup routine. The control console indicators will display the last mA, kV, and time 2. Change the technique factors and verify they are updating relative to operator input. 3. Press the prep pushbutton and make sure the X-Ray tube rotor is turning and the Ready Lamp illuminates. 4. Release the prep pushbutton and make sure the prep lamp turns off and the X-Ray Tube rotor is no longer powered.

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7.3 X-RAY TIME MEASUREMENT Test Equipment Oscilloscope.

Method Connect the oscilloscope at test point TP3 (KV test point), on the PWM board.

Acceptance Limit Set time

Acceptance limit

1ms at 5s

+/- (1%+0.1ms)

Procedure

1.

Make an exposure at 80kV, 100mA, using the exposure times specified in table 6.1.

2. Measure the exposure time with oscilloscope.

3. Record the measurement information Measurement (chapter 5, in this manual).

in

form

6

Time

The measured results must be within the indicated limits, see table 6.1.

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GMX X-RAY GENERATOR Exposure time

Limits

(s)

(s)

0.001

0.00089-0.00111

0.005

0.00485-0.00515

0.010

0.00980-0.01020

0.025

0.02465-0.02535

0.100

0.09890-0.10110

0.200

0.19790-0.20210

0.500

0.49490-0.50510

1.000

0.98990-1.01010

2.000

1.97990-2.02010

4.000

3.95990-4.04010

5.000

4.94990-5.05010

Table 6.1 Time Measurements.

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7.8 KV/MA X-RAY MEASUREMENT

Test Equipment •

Non-invasive kV meter.

•

mAs meter.

•

Connect the kV meter as indicated by the manufacturer.

•

Connect the mAs meter to the red and black test terminals located on the high-voltage transformer.

Method

Acceptance Limits

Factor

Acceptance limit

kV

+/- (5% of kV + 1 kV)

mA

+/- (5% of mA + 1 mA)

Table 6.2 kV and mA Measurements.

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kV/mA Measurement (continued)

Procedure

1. Select 50kV, 100ms and the lowest station in the set scale.

2. Make an exposure and record the measured values in Form 7 or Form 8 (Chapter 5, in this manual). 3. Select 80kV, 100ms

4.

Make an exposure and record the readings for kV/mA in form 7 or 8, as applicable.

5. Select 120kV, 100ms

6.

Make an exposure and record the readings for kV/mA in Form 7 or 8, as applicable.

7. Repeat until you are finished with the mA values and record in Form 7 or 8, as applicable. Note: Observe X-Ray Tube rating limitations during this procedure

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7.8 LINEARITY

Test Equipment

•

Dosemeter.

•

Handheld Calculator.

•

mAs meter.

•

Aluminum Filter.

•

Place the X-ray tube at a focus-film distance of 100cm (40”).

•

Place the dosemeter in the middle of the radiation field and a distance of 50cm (20”) from tube focal point.

•

Adjust the collimator as per the size of the radiation area.

•

Place an aluminum filter over the image reception to minimize “secondary radiation”.

•

Connect the mAs meter in the red and black terminals aon the high-voltage transformer. Remove the shorting link located between the red and black terminals.

Method

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Linearity (Continued)

Specifications

The linearity coefficient (CL) or difference between two radiation averages and the mAs obtained for an two consecutive readings of the tube current, must not exceed 0.1 times the sum.

That is:

___

___

___

___

___

CL = ( X 1 − X 2 ) ≤ 0.1( X 1 − X 2 )

___

Where X 1 and X 2 are the mR/mAs averages obtained from two consecutive tube current values.

Procedure

Select 80kV, 200mA, and 100ms. Perform a series of 5 exposures and record them in form 9 Linearity (chapter 5, in this manual).

Select 80kV, 250mA y 100ms. Perform a series of 5 exposures and record them in form 9 Linearity (chapter 5, in this manual).

Estimate the generator linearity with the data from the table and test its linear behavior.

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7.8 REPEATABILITY Test Equipment

Dosemeter. Calculator. Aluminum filter.

Method Place the X-ray tube at focus-film distance of 100cm (40”).

Place the dosemeter in the middle of the radiation field and at a 50cm (20”) distance from tube focal point.

Adjust the collimator based on the size of the radiation area.

Place an aluminum filter over the image reception to minimize “secondary radiation”.

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Specifications

The radiation coefficient of variability (CV) must not exceed 0.05 for any specific combination of technical factors.

That is:

CV =

s mR

Where: CV = Coefficient of variability.

s = The simple standard deviation (σ (n-1)) or the square root of the differences and the square of the total of 5 exposures divided by 4(n-1).

mR = Is the average doses for 5 exposures.

Procedure

Select 80kV, 100mA, and 200ms. Perform a series of 5 exposures and record the results in Form 10 Repeatability (Chapter 5, in this manual), for estimating the Repeatability. Repeatability must have a coefficient less than 0.05.

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GMX X-RAY GENERATOR

SUPPLEMENT

B

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POWER ASSIST

The Optional CMR Power Assist allows CMR X-Ray Generators to operate from 115VAC, 20 Amp outlets. Once installed mimimal Service or Operator interaction is required. Power outages will necessitate the Operator to push the Reset Push Button when power is restored.

POWER ASSIST MODULE

POWER ASSIST INVERTER, LOCATED IN POWER MODULE 50

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Service Switch

POWER ASSIST SERVICE SWITCH Located under the front cover of the Power Assist module. When Closed (Down Toggle) the Service Switch, will discharge the capacitor banks. Discharge may take up to 20 minutes,

SWITCH, Push to reset PA Module

LAMP, Indicates a Charge on PA Bus

SWITCH, UP Position (ON), enables PA function

SWITCH, UP Position (ON), enables power to Generator Power Module

POWER ASSIST CONTROL PANEL LAMP, Indicates PA Module is connected to power

LAMP, indicates Reset pushbutton must be activated

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GMX X-RAY GENERATOR

SUPPLEMENT

Selected mA Linear Scale 10 15 20 25 30 35 40 50 75 100 150 200 250 300 350 400 500 600 700 800

C

USEFUL TABLES

Selected mA Renard Scale 8 10 12.5 16 20 25 32 40 50 64 80 100 125 160 200 250 320 400 500 640 800

Voltage at TP 12, PWM 1.0 1.5 2.0 2.5 0.75 0.875 1.0 1.25 0.75 1.0 1.5 2.0 2.5 0.75 0.875 1.0 1.25 1.5 1.75 2.0

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I

Linear mA Scale

Voltage at TP 12, PWM 0.81 1.0 1.25 1.6 2.0 2.5 0.80 1.0 1.25 1.6 0.8 1.0 1.25 1.6 2.0 2.5 0.80 1.0 1.25 1.6 2.0

Renard mA Scale

Note: See page 11 for Test Point locations

Selected KV

40

50

60

70

80

90

100

110

120

130

140

150

Voltage at TP 12 PWM

1.33

1.66

2.00

2.33

2.66

3.00

3.33

3.66

4.00

4.33

4.66

5.00

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GMX X-RAY GENERATOR

SUPPLEMENT

D

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HV CABLE MAINTENANCE

If required, remove old insulating grease from cable ends and receptacles. Clean cable ends and receptacles with a hydrocarbon cleaning solvent. Avoid touching the cleaned areas with your hand to avoid leaving perspiration or skin oil on the insulating surfaces. Inspect cable ends and cables for evidence of arching, carbon tracking, burnt or pitted areas, and/cracked conditions. If any of these conditions cannot be cleaned it may be necessary to replace the cable or receptacle. Insure that the cable ends have a rubber sealing-ring and that the rubber ring is correctly positioned and clean. At the HV transformer, insulating oil (Shell Diala X or equivalent) may be used in the HV receptacles to provide insulation and vapor displacement. After cleaning, insert approximately ¼ inch of oil in the receptacle. Insert the cable(s) and tighten the spanner ring. At the X-Ray Tube, apply a fresh layer of insulating grease to the cable ends. Use a wooden or plastic spatula to apply the grease, avoid using fingers. On the side of the cable ends apply a 1 to 2mm layer of grease. At the cable end cover the cable pins with insulating grease. Insert the cable(s) and tighten the spanner ring. NOTE: after the XRay Tube has been heated recheck the tightness of the spanner ring; during the thermal cycling of the X-Ray tube the grease has melted and repositioned, causing the cable to loosen

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END OF DOCUMENT

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