Generator

Introduction

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Agenda
1. Overview

2. Main component introduction

3. Diagram

4. Hardware settings

5. Service Tool

6. Adjustment and replacement

7. Known issues

8. Group B new design

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Product Specs
Official Product Name:
– CARESTREAM X-ray Generator
Model Number:
– 65kW : CGF-65
Dimensions*:
– Width: 25.6 inches (650 mm)
– Depth: 13.5 inches (343 mm)
– Height: 24.1 inches (612 mm)
Weight
– 154 lbs.(70kg)

* Same dimension with CPI CMP200 and mechanical compatible with DRX Evolution PDU
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Product Specs
• Specs:
– Rated power : 65kW
– Input power: 380VAC 3 phase, no neutral wire
– KV: 40 to 150kV, variable in 1 KV step, Rise time (10~90%): < 1.5ms
– KV accuracy: ± 5 % +1kV
– mA: 10 to 800mA, follow R’20 serial
– mAs: 0.1 to 800 mAs
– mAs accuracy: ± (10 % + 0.2) mAs
– Exposure time : 1 to 6300ms, Time accuracy: ± (10%+1 ms)
– Technique setting: 2 knobs(kV, mAs)/ 3 knobs(kV, mA, ms)
• Interface
– AEC interface: 2 channel, support 3 fields chamber
– DR Room interface: door interlock, room light, bucky start/enable, 24VDC output, 26VAC
output
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Main Components_1

1. HV tank
1
3 2. AEC (Automatic Exposure Control)
2 3. MCB (Main Control Board)
4. FCB (Filament Control Board)
5. RCB (Rotor Control Board)

4 6. Inv_B (Inverter Assembly B)

7. Inv_A (Inverter Assembly A)

7 5

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Main Components_2

10 8. Mains Input Cable Access

8 9 12 9. Main Circuit Breaker
10. Cable Access
13 11. Filter
12. RIB(Room Interfact Board)
14
13. LS (Low Speed) Phase-shift Capacitor
14. HS (High Speed) Phase-shift Capacitor
17 15. Rectifier
16. Main Contact
18 11
17. Fuse
16 18. Auxiliary Transformer
15

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Main control board

• Communication with console(RS-232)

• Regulates multiple DC switching power supplies 12 v, 5 v, 3.3 v and 1.8v

• Initiates Generator Power up

• Controls Exposure kV, mA, time, Dual Speed Starter, focal Spot

• Monitors the interlocks

• Starts and stops exposure

• Error handling

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Auxiliary transformer
• L2 and L3 supply the Auxiliary transformer with Mains AC

• Passes the 380 VAC to the Aux Transformer and returns with the following
voltages: 220 VAC, 110 VAC 26 VAC and 18 VAC

• Input mains power supply jumper setting:380V,400V,480V

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Auxiliary transformer

Auxiliary Transformer
Connection:
• Connect to the 380
V tap if the line
voltage is nominally
380 VAC.
• Connect to the 400
V tap if the line
voltage is nominally
400 VAC.
• Connect to the 480
V tap if the line
voltage is nominally
480 VAC.

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Filament control board

• PWM (pulse-width modulator) U303 drives MOSFETS Q2, Q4, Q6, and Q8. The
MOSFETS convert the + and - 35 V supplies to high frequency AC to drive the
primary of the filament transformers in HV-tank,

• large / small filament select relay K1

• Convert AC voltage from Aux transformer 25v,18v to DC voltage +35v,-35v and

+24v. LED DS3,DS2,DS1 indicate exist of these voltage respectively. +/-35v is
fed to filament power supply,24v is fed to MCB power regulator and RIB for
auxiliary equipment(brake).

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Rotor control board(dual speed)

• The dual-speed starter contains IGBT Q1 to Q4, which produces the required
stator current by precisely switching the DC bus voltage.

• K2 is the switch between high speed capacitor and low speed capacitor

• DC bus pre-charge circuit and voltage detection

• LED DS1(red) indicate the high DC voltage on DC bus

• Main contactor K1 driver and feedback

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Inverter
• The pulses from the VCO are fed to NAND gates which are held low to allow an
X-ray exposure. The drive pulses are applied to the gates of the MOSFET
inverter Q401-Q404 on the main control board. These MOSFETS form a full
bridge inverter circuit that outputs high frequency gate pulses to the power
MOSFETS on the inverter board(s) via P40 and / or P41 on the main control
board.

• Two modules used for 65kW,each module with 40kw capability

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HT tank
• The HT tank has similar anode and cathode sections. The cathode and anode
sections have their own high voltage transformer and high voltage multiplier
board. The anode section generates 0 to +75 kV. The cathode section
generates 0 to -75 kV. The anode and cathode sections contain voltage dividers
that supply kV anode and cathode feedback voltages.

• Remove jumper between E1 and E2 to measure mAs with serial connected

meter

• Oil fill port, also used as air pressure balance port during installation

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HT tank

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Room interface board

• Provide output contactor for Room-light, 24vDC,26vAC.

• Provide input contactor for door interlock, tube thermal switch.

• Provide two channel for bucky start/ready signal.

• Provide connector to tube rotor.

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Room interface board

Stator connection:
The tube rotor cable is connected to the connectors on RIB (Room Interface Board).

Designator Connect to
Common P8-1
Main P8-2
Shift P8-3
Ground GND
Thermal switch (terminal1) J4-1
Thermal switch (terminal2) J4-2

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Room interface board

Pin Definition Description

J1/2-1 BUCKY1/2_START Bucky enable signal .

J1/2-3 BUCK1/2_OUT 24 VDC, 110V/220 VAC out(short connect cable

selected)
J1/2-5 BUCK1/2_RTN Bucky power and signal return

J1/2-7 BUCK1/2_READY Bucky 1/2 ready. A contact closure from pin7 to pin8
Indicates Bucky 1/2 READY. Low level active.
J1/2-8 GND

J3-1 DOOR_INTERLOCK Door interlock. A contact closure from pin1 to

pin3 indicates the room door is closed. Low level
J3-3 GND active.
J5-1&3 ROOM_LIGHT Relay contactor output. Max load capacity 250Vac,
8A.
J6-1 24VDC 24Vdc output for system use

J6-3 GND

J7-1 26VAC 26Vac output for collimator use

J7-3 26VAC_RTN 26Vac output for collimator use

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AEC board
• The chamber-select signals originate on the main control board. Only one
chamber can be active at one time, and the active channel is indicated by DS1
or DS2 on the AEC board.

• The AEC ramp from U6A,U6B and U6Cis fed to comparator U7 on the AEC
board where it is compared to the AEC reference voltage.

• The AEC chambers are connected to J1 and J2 on the AEC board. Jumper
JW1 and JW2 are designed to interchange the left/right chamber selection
signal for J1. JW3 and JW4 are for J2 connector accordingly.

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AEC board

Jumper

LED

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Circuit breaker

AC Main Cable Connction:

1. Pass the AC mains cable through the cable clamp at the upper rear of the generator
cabinet.
2. Connect the ground wire to the chassis ground connector.
3. Connect the mains power wires to the terminals on the main circuit breaker 1L1, 3L3, and
5L5.
4. Tighten the clamps to secure the cable.
5. Verify the main circuit breaker is set to the ON position

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System Diagram

Interconnect

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Power Distribution

power
distribution

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System on

system on

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Exposure Control

exposure

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Filament Control

filament

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Rotor Control

rotor

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Self-diagnostics

The generator contains self-diagnostic routines which greatly facilitate troubleshooting.

Self-diagnostic functions require that DSP’s function correctly. If error occurs, the error
code will be displayed on console. Trouble shooting guide can help the engineers to solve
the problem.

troubleshooting

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Hardware Settings

DIP Switch Setting:

S101:
• Power rating setting

Generator Power Rating S101-1 S101-2 S101-3

32KW/400mA OFF ON ON

40KW/500mA OFF ON OFF

50KW/630mA ON ON OFF

65KW/800mA ON OFF ON

80KW/1000mA ON OFF OFF

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Hardware Settings

DIP Switch Setting:

S101:
• Input voltage setting
• Factory defaults configuration recovery(EEPROM)

S101-7 S101-6 Definition

0 0 380V

0 1 400V

1 0 480V

1 1 Invalid

S101-8 ON: Load factory defaults OFF: Defaults disabled

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Hardware Settings

DIP Switch Setting:

S102:
• Tube type select

MFG Code Model Code

MFG Model
S102-8 S102-7 S102-6 S102-5 S102-4 S102-3 S102-2 S102-1

E7252_AL OFF OFF OFF OFF ON OFF OFF ON

Toshiba
E7252-RA OFF OFF OFF OFF ON OFF ON OFF

Varian RAD60 OFF OFF OFF ON OFF OFF OFF ON

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Hardware Settings

Shift Capacitor Configuration:

Match with the tube used
• LS (Low Speed) Phase-shift Capacitor
• HS (High Speed) Phase-shift Capacitor

Dual Speed Starter Tube Select Table

H.S. Shift L.S. Shift
Tube Type Rotor type
CAPAC CAPAC

Toshiba E7252X XS-AL 6 uF 44 uF

Toshiba E7252X XS-R 3 uF 24 uF

Varian RAD60 20 uF 65 uF

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Service Tool
GUI Overview:
Setting
• kV, mA, mAs, ms
• Exposure Technique
• Focal
• Station selection
Monitor
• Prep,Exp
• HU
• Exposure Info
Tool bar
Status
• Service tool version
• Firmware version
• Communication status

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Service Tool
File/Serial Port
1. From the File menu, select Serial Port.
2. Select Com Port via arrow buttons.
3. Press OK.
File/Reconnect
From the File menu, select Reconnect to
reconnect the generator.
File/Login
1. From the File menu, select Login.

2. Enter the password:62335

3. Press OK.
File/Exit
From the File menu, select Exit to exit the
software

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Service Tool
File/Backup Generator Setting

From the File menu, select Back

Generator Setting to back up the generator
setting

File/Restore Generator Setting

From the File menu, select Restore

Generator Setting to restore the generator
setting

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Service Tool

Upgrade Firmware *
Open CodeSkin Chip Programmer to upgrade firmware.

1. Shut down the generator, change the jumper JW101 position

to 2 & 3.

2. Turn on the generator.

3. From the File menu, select Upgrade Firmware to run

CodeSkin Chip

4. Click "Configure ports" to configure serial port.

5. Click "Select File" button to select the firmware file.

6. Click "Program" to start download the firmware

7. Shut down the generator, change the jumper JW101 position

to 1 & 2.
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Service Tool

Tools/Tube Statistics*

From the Tools menu, select Tube

Statistics. Checking the tube

exposure count

number.

Tools/View DC Bus Voltage

From the Tools menu, select View DC

Bus

Voltage. Monitoring the DC bus

voltage.

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Service Tool
Tube Calibration

• Select focus, press and hold exposure

switch to complete tube auto calibration.

View Calibration Data

Review tube calibration curve.

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Service Tool
AEC setting*

KV compensation

• Set correct compensation value

according to different kv

Density Setup

• Set up the density step (by %) according

to system requirement

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Service Tool

Setting/Generator Limitation*

1. From the Setting menu, select

GeneratorLimitation.

2. Set the value wanted

3. If the value larger than the

generator hardware setting, it will
be forcely limited by hardware
settings.

Setting/Generator Date

This function is disabled.

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Service Tool
Tools/Station Setting*
Supports six
independent stations

Enable Station

Hangover time setting

Auto Focus selection

Input/Output setting

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Service Tool
Setting/Tube Setting*
• Tab Filament
Parameter
All settings are fixed
• Tab Anode Setting
Warning threshold and
limitation threshold setting
for anode heat capacitor
• Tab Tube Setting
Maximum tube voltage
Maximum small focus
current
Additional rotor boost time
• Tab Tube Files
Tube file download, align
with the hardware setting

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Service Tool

Setting/Set Capacitance

From the Setting menu, select

Set Capacitance.

1. Select the cable type used

2. Input the cable length

3. Input the tank capacitance,

the present design is 166

4. Input the cofficient, the

default value is 0

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Service Tool

Setting/Set Log Level

From the Setting menu, select

Set Log Level.

Select Log Level, the “Error”

is the lowest level and the
“Verbose” is the highest level .
The high the level, the more
information is saved.

Log file location in console harddisk: Group A: C:\log, will transfer to

D:\log in Group B
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Adjustment

During manufacture, system installation or specific parts replacement, there parameters

need to be adjusted.
• Filament current (only adjusted in manufactury)
• kV
• High mA (when mA is larger than100mA, it is considered to be high mA)
• Low mA (when mA is smaller than100mA, it is considered to be low mA)
The equipment needed:
• Oscilloscope
• Dynalyzer or Dosemeter

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Filament Current Adjustment

1. Insert the test
fixture
between
generator and
tube
2. Measure the
filament
current from
test fixture by
oscilloscope
3. Adjust the
potentiometer
R319 to
eusure the
filament
current
between 2.4A
to 2.6A
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kV adjustment

1. Set 100kV/100ms, large focus, then select the

Tools/CalibrationMA.
2. Input filament current 3.3A.
3. Then exposure.
4. Adjust the potentiometer R444 to eusure the
kV value measured by Dynalyzer or
Dosemeter is between 99 and 101.

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High mA adjustment

1. Set 100kV/100ms, large focus, then select the

Tools/CalibrationMA.
2. Adjust filament current to ensure measured
mA between 195 and 205
3. Adjust the potentiometer R488 to eusure the
difference between measured mA and
feedback mA value in tolerance +/- 5.

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Low mA adjustment

1. Set 100kV/100ms, large focus, then select the

Tools/CalibrationMA.
2. Adjust filament current to ensure measured
mA between 15 and 25
3. Adjust the potentiometer R497 to eusure the
difference between measured mA and
feedback mA value in tolerance +/- 1.

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Calibration
1. Select the Tools/Tube Calibration.
2. Select large focus.
3. Press handle switch to start calibration
4. Release handler switch if the calibration
status display complete
5. Select small focus
6. Press handle switch to start calibration
7. Release handler switch if the calibration
status display complete
8. OK

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Replacement

Related adjustment need to be performed after parts replacement.

Component replaced Adjust Items

MCB kV, High_mA, Low_mA, tube calibration
HV Tank kV, High_mA, Low_mA, tube calibration
Tube tube calibration

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Tips

1. Log file archived in console hard disk will not be deleted by generator.

• Log file size is quite small, increase rate is slow. Risk: low.
2. When entering download firmware phase by set JW101 to pin 2 and 3, sometimes
generator will jump from download mode to normal initialization.

• Solution: Restart generator. New download method is developed for Group B that without changing
jumper setting.

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