Xray Generation Troubleshooting

e GE Healthcare Canada
Diagnostic Imaging Service Operations
Xray Generation T/S

LightSpeed (1x,2x,3x,4x) & HighSpeed_QXi (3x)
with Performix Adv/Ultra Tube (MX200MCT)
Author: Mike MacNeil

Service Operations Canada, NSE – CT
Revision History:
9/27/04 rev 0 Initial release.
11/15/04 rev 1 Flowcharts and Diag Functions improved for Main T/S, Filament, & kV/mA
11/21/04 rev 2 Flowchart improvements and kV/mA Test sequence improvements.
11/22/04 rev 3 Audio files added
05/30/05 rev 4 Updates; Rotor workflow; KV loop values correct with HV cables pulled
Contents
Sec 1 Overview ............................................................................................................................................. 1
Sec 2 Troubleshooting Flow Diagrams ......................................................................................................... 2
Sec 2.1 Main T/S Work Flow................................................................................................................. 2
Sec 2.2 Rotor T/S Work Flow................................................................................................................ 3
Sec 2.3 Filament T/S Work Flow........................................................................................................... 4
Sec 2.4 kV/mA TS Work Flow (page1 of 2) .......................................................................................... 5
Sec 2.4 kV/mA TS Work Flow (page 2 of 2) ......................................................................................... 6
Sec 3 Troubleshooting Methodology ............................................................................................................ 7
Sec 4 Diagnostic Functions........................................................................................................................... 8
Sec 4.1 HVDC ....................................................................................................................................... 8
Sec 4.2 Rotor ........................................................................................................................................ 9
Sec 4.3 Filament ................................................................................................................................. 12
Sec 4.4 kV/mA..................................................................................................................................... 16
Sec 5 HV Bleeder Usage ............................................................................................................................ 25
Sec 6 Power & Grounding........................................................................................................................... 25
Sec 7 Typical Diag Results ......................................................................................................................... 26
Rotor Diag – Typical results screens .................................................................................................. 26
Filament Test – Typical results screens.............................................................................................. 35
KV Loop Diag – Typical results screens ............................................................................................. 37
KV/MA Diag – Typical results screens ................................................................................................ 42
Audible Results: .................................................................................................................................. 47
Sec 8 Quick Review Highlights: .................................................................................................................. 50
Sec 1 Overview
The purpose of this document is to provide a convenient guide to defining Xray Generator problems and
identifying root cause. The goal is to correctly identify the failing part in one hour to avoid costly and time-
consuming miss-diagnosis of components, particularly HV Tanks and Xray Tube. This has a big impact
on Customer downtime and it is difficult to retrieve parts and reinstall originals if a wrong diagnosis is
made. Xray tube life is also a significant consideration for Customers when comparing CT scanners.
Please forward suggestions or corrections to michael.macneil@med.ge.com
05/30/05 Rev 4 MMN PROPRIETARY 1 of 50 Xray Gen TS LS_1x-4x rev4.doc

Sec 2 Troubleshooting Flow Diagrams

Sec 2.1 Main T/S Work Flow
Customer description, aborts,
Define sounds, smells, smoke, etc
Prodiags or logsummary
reports
AutoSC logsummary report

Check gesyslog for Gen errs
Measure
Check tubespit stats
Determine error freq. & trend
HVDC or low mains

Re-define Rotor, mA, or kV pbm
& Filament Lg, Sm, or Both
Select best test/s Anode, Cathode or Both
High kVA, Low kVA, or Both
Y Rotor or kV/mA N HVDC

HVDC errors
overloads ? Testing
N Y
Y Rotor
Rotor errors
Flowchart
Y Filament
Filament errors
Flowchart
Y kV / mA
kV / mA errors
Flowchart
Analyze all test results

Analyze combined with error log
Part cost information, etc.
(in decending order)
Tube Note: Contact Support
HEMRC AC drive resources for a second
mA Cont Bd Improve
opinon if a logical root cause
Anode HV Tank diagnosis cannot be found
Cathode HV Tank
HV Inverter
kV Cont Bd Follow-up:
Control logsummary.xxx sweep or
manual error log analysis

Sec 2.2 Rotor T/S Work Flow

Rotor
Sample errors
Errors
Rotor Control
1 Diag Typical results
(Stationary Gantry)
Load Problem?
Accelerate rotor
Y Output Amps High Y
Listen at Gantry Rotor
Failure ? Accel Freq Low Relpace Tube
during rotor brake dragging ?
Brake Freq Low
& coast to stop
Internal DC bus low
N N
Optional:
HVDC Supply Low? Accelerate rotor
Output Amps Low Gantry 120V OFF Power OFF HVDC
Accel Freq Low Let rotor coast to & 120 VAC
HVDC errors stop - unpowered
HEMIT Xfmr
Secondary
Ohm Check
L to C ~1.2 ohms
TS HVDC HEMIT (rotor Xfmr)
S to C ~1.2 ohms
Pri: J10 Anode tank
L to S ~1.3 ohms
Sec: Anode HVcable
Drive Problem? Y
Replace HEMRC AC Replace HEMIT
Output Amps Low HEMIT bad?
Drive Anode tank
Accel Freq Low
N
Tube Stator
Rotor Control HVDC Warning Ohm Check
L to C ~2.3 ohms
2 Diag Lock Out Tag Out Tube stator
S to C ~2.3 ohms
system power input windings at Anode
(Rotating Gantry) L to S ~2.3 ohms
HV well
IF rotor only fails Y

Y Tube
consistently at faster Replace Tube
Failure? Stator bad?
gantry speeds then
Replace Tube
N
N
Temporarily connect
Return System to new tube & retest
operation (Orig. tube still
or installed)
Consider repeating
tests
Y
Fail? Replace HEMIT
Replace Tube

Sec 2.3 Filament T/S Work Flow

Filament
Sample errors
Errors
Filament
Typical results
Diag
Ohm Check A
Filament Xfmr Primary
Ohm Check A
Y any test lead polarity OK
Filament Power OFF HVDC Remove J2 on
XS1: TP12-13 ~ 0.3 ohm
Open errors ? & 120 VAC Cathode Tank
XS2: TP12-11 ~ 0.3 ohm
Measure at CA
XL1: TP15-16 ~ 0.3 ohm
Tank Meas Bd.
N XL2: TP15-14 ~ 0.3 ohm
Y Check/Replace High Y Replace Cathode

Filament
Filament PS Resistance ? Tank
PS errors ?
(In HEMRC Assm)
N N
Ohm Check B & C
Ohm Check B HV Cable / Xray Tube
Pull HV cable at note test lead polarity
Replace mA Bd
Cathode Tank +C to -S ~ 0.1 ohms
Measure at HV +C to -L ~ 0.2 ohms
cable pins -C to +S ~ 0.7 ohms
& bang on tube -C to +L ~ 0.7 ohms
Problem
resolved ?
Ohm Check C
High Y High Y
Measure in Xray Replace Tube
N Resistance ? tube well Resistance ?
& bang on tube
N N
Ohm Check D
Phone for Support
HV Cable Ohm Check D
Reinstall HV cable C to C ~ 0 ohms HC Cable Y
Measure HV cable Replace HV cable
at Cathode tank S to S ~ 0 ohms Bad ?
continuity (tighten
L to L ~ 0 ohms HV cable end pins)
N
Ohm Check E - Check condition of collars on HV cable pins
Ohm Check E & F
Remove HV cable Filament Xfmr Sec. - Check condition of springs in cable well pin sockets
at Tube Cathode - Reconnect cable at Tube Cathode & Repeat Ohm Check B
Measure at C to S ~ 0.3 ohms - IF Tube well connection can't be resolved Replace the Tube
HV cable pins C to L ~ 0.3 ohms
(tube end)
Ohm Check F
High Y High Y Replace Cathode
Measure in CA
Resistance ? tank well Resistance ? Tank
(filament xfmr sec)
N
N
Ohm Check D
- Check cable continuity from
Measure HV cable HC Cable Y
OBC backplane to CA tank Replace HV cable
continuity (tighten Bad ?
- Check or replace K78 relay
on the OBC backplane HV cable end pins)
- IF the problem persists N
Replace the Tube - Check condition of collars on HV cable pins
- Check condition of springs in cable well pin sockets
- Reconnect cable at Cathode Tank & Repeat Ohm Check E
- IF Tank well connection can't be resolved Replace the Tank

Sec 2.4 kV/mA TS Work Flow (page1 of 2)

kV / mA
Sample errors
Errors
~ 1.5 minutes
1
No load kV
Basic Test Typical results
(kV Loop Diag)
HVDC Warning
AN or CA Y Lock Out Tag Out
kV=0V ? Check fuse in
HV Inverter
Amplify sound with a
N stethoscope if possible
Repeat Failing
HV Spits Y Test while
or overcurrent Typical results
Listening to HV
errors?
Tanks
N
~ 10 minutes
2
Xray Test HV Tank Y
Low, Med, Hi Pwr Typical results Internal Replace HV Tank
(kV mA Diag) Arcing ?
kV values Y Remove HV Note: Fill vacant HV cable wells with

abnormal ? A Cables from both HV oil. CT eng. is developing a new HV
HV Tanks & Rerun cable termination tool to make this
kV Loop Diag easier. Hopefully sometime in 2005
N
mA values Y
abnormal ? B Y Remove input to
Fail ? suspect HV Tank
(P1, P2 conn)
N
~ 15-30 minutes N
3 While testing:
No load kV Inspect HV cable Rerun kV Loop
Position HV Tanks
140 kV 30sec and tube well for Diag on failing side
upside down and rotate
(kV Loop Diag) signs of arcing. (Anode or Cathode
gantry back & forth a bit
Clean tube well only mode)
HV Spits Y
or overcurrent HV Cable Y Replace HV
errors ? Fail ?
OK? Inverter
N ~ 10 minutes
Y N
4 While testing:
Xray Test Keep gantry in the same
Re-install HV HVDC Warning
140 kV 100mA cable & retest Lock Out Tag Out
position as the previous Replace HV tank
(kV mA Diag) IF still failing: system power input
No Load test
Replace Tube
HV Spits Y
or overcurrent C
errors ? Optional: Optional:
Suspect Return system to
Repeat testing For Intermittent Spits
intermittent tube Customer use or
N Scope Tanks (TP1) Try 2 Heat Soak &
problem replace Tube
Scope & HV Bleeder Seasoning cycles

Sec 2.4 kV/mA TS Work Flow (page 2 of 2)

2 Note: Logic conditional upon: LightSpeed Scanner
Xray Test a) Performix Tube; b) Common inverter 2208852 for AN & CA
(kV mA Diag) c) KV bds 46-321198G1-F or 2143147; d) mA Bd 2154834 for Performix tubes
Low, Med, Hi Pwr Old original 46-321064G1 kV Bds. (HSA-CTI ) require unique AN & CA inverters so can't swap inverters.
Review diag 5 Check/Replace:

VCNT Y Run Fiber Y
results screen and 1) Fiber cables
A compare to typical
( & Frequency ) Fiber Optics Test Optics test
2) kV Bd.
Low ? (in kV Loop Diag) failed ?
results section 3) OBC backplane
N
kV values N
abnormal
Review prev. kV/mA Previous results:
Inverter I Y Recheck mA results: Suspect Scroll back or see
Abnormal ? values side with lowest kV /usr/g/service/state/
& high duty cycle ssw.diagSession.hist
Suspect: Swap Inverters

Recheck results HVDC Warning
1) HV Tanks; &
and phone for Lock Out Tag Out
2 2)Tank meas Bd; Rerun kV mA Diag
support system power input
Xray Test 3) mA Bd. at failing kv & mA
(kV mA Diag)
Low, Med, Hi Pwr
Did
Perform mA Meter check Replace Inverter
the problem Y
Suspect: on the side with
mA move to the
Y 1) HV Tanks; the lowest kV and
B imbalance ? other side?
2)Tank meas Bd; high duty cycle
only
3) Cables (Tanks to OBC backplane)
N
3) mA Bd.
mA values N
Replace HV Tank
abnormal on the side with
Perform high IF an Inverter
AN & CA Y power test 120kV current is high the lowest kV and
mA low ? 400mA before suspect the HV high duty cycle
making diagnosis tank for that side
Make a note if Heater/

failing on one Filament
filament only Diag.
Xray Test
(kV mA Diag)
140 kV 100mA
Y Suspect Cathode Tank

Cathode
C overcurrent ?
(Tube overcurrents typically report as
Anode overcurrent )
N
kV arcing or
overcurrent Suspect Anode Tank or Tube EHS Warning: The presence of Xray limits our
Anode Y More likely the Anode Tank, since errors ability to listen for arcing within the HV Tanks.
overcurrent ? only occur with Xray load at the same A remote audio recorder may be a solution.
stationary gantry position as no load test
EHS Policy requires avoiding unnecessary
N Xray exposure. If you must enter the room
Suspect AN or CA Tanks or Tube during Xray, ensure the aperture/filter is closed
Y More likely a Tank, since errors only and wear Personal Protective Equipment, to
HV Spits? include a lead apron and lead collar throat
occur with Xray load at the same
stationary gantry position as no load test protection.

Sec 3 Troubleshooting Methodology

Sec 3.1 Define
Determine all the symptoms from operators, logsummary reports or prodiags alerts.
o i.e. Scan aborts with sounds of tube arcs, smoke, oil spill, power loss after a tube arc heard, .
Sec 3.2 Measure
Investigate generator related errors, frequency and trends
o Check the gesyslog for all generator related error trends over the past several days.
o AutoSC “logsummary.ls” sweep is the easiest method [AutoSC Website]
o Manually review gesyslog for Generator errors (1831xx; 1832xx; 1833xx;1855xx; 219800)
o NOTE: When the older Zeus tubes were arcing across the insert (Anode to Cathode) there
would be some mix of Anode and Cathode overloads in the error log. However when
Performix tubes arc across the insert (Anode to Cathode) there are typically only Anode
overloads in the error log. This seems to be a characteristic of the Performix tube.
o Check the HV spit history over the past several days.
o AutoSC “logsummary.ls” sweep is the easiest method
o To manually see HV spit history: “getStats TUBE_SPITS xx” where xx= numbers of days
o NOTE: A brief period of heavy spitting may simply mean a floating particle got vaporized in
the beam resulting in a bit of gas that gets absorbed by the getter action of the big anode
mass over time. This is not a problem as long as it does not continually re-occur. A heat soak
can speed up the absorption of gas molecules by the tubes anode mass.
Sec 3.3 Redefine to select and perform the best generator test sequence
Based on Customer input and error log results, select the Generator test sequence.
IF: HVDC errors are present
IF: Corresponding HVDC load overcurrents (HEMRC or Inverters), troubleshoot the load problem
ELSE: Troubleshoot the HVDC power supply
IF: Rotor errors are present
Troubleshoot the Rotor problem
A failing rotor can often include or lead to kV mA errors or failures, so address rotor failures first
IF: Filament errors are present
Note if errors on Small or Large filament or Both
Troubleshoot the Filament problem.
A failing filament circuit can include or lead to kV mA errors or failures so address filament
failures before kV mA errors.
IF: kV or mA errors are present without rotor or filament errors
Note if errors at higher kVs only or high/low mA only
Address the kV/mA problem MAIN TS WORK FLOW
Tip: To monitor error logs during testing.
1) In Service desktop, open 2 Unix windows on the left hand monitor.
2) Adjust size and position so the 2 windows are side by side equally sharing the screen.
3) Window 1: tail –f /usr/g/service/log/gesys_hostname.log [substitute actual hostname]
4) Window 2: tail –f /usr/g/service/state/ssw.diagSession.hist
5) When complete, to end the tail –f processes type Ctrl-C in the unix windows.
Sec 3.4 Analyze
Analyze test sequence results together with error log results and determine the problem root cause.
Sec 3.5 Improve
Take the necessary service actions or replace parts as guided by the flowcharts.
Contact Support resources for a second opinion if a logical root cause diagnosis cannot be found.
Sec 3.6 Control
Follow-up on results of service actions using tools such as a logsummary.ls autoSC sweep.

Sec 4 Diagnostic Functions
Sec 4.1 HVDC

Test Objective
Determine if HVDC errors are caused by excessive load, poor facility regulation, or HVDC supply failure.
Test sequence
1. IF Line Loss error and PDU fuses blown.
o Power OFF; Warning: Lock Out Tag Out system power input
o Ohm check HVDC PS output. +(Red) to –(Black); +(Red) to Ground; –(Black) to Ground;
o Ohm check the HVDC bridge rectifier
2. IF 183182 errors occur with very low HVDC Rail voltage, check for a failed softstart resistor on
the PDU control board.
3. Check gesyslog for any correlation of HVDC errors to Anode, Cathode, or Rotor overcurrent
errors. If load overcurrents return to the respective Rotor or kV/mA troubleshooting.
4. Check regulation of the mains input at the PDU control Bd.
(This validates the PDU Xfmr output as well )
5. IF mains regulation at PDU control is out of spec. check facility line regulation at the input to the
PDU
Return to work flow for decision path
Theory
Advanced system service manuals provide a good description of HVDC power supply operation.
Sample Errors
183262 OBC Generator hemrc_manager.c 1.14 XRAY GENERATION : HVDC Backup
Contactor Intlk Pri/Most Severe Backup contactor opened without firmware command.
183182 OBC Generator gen_rotor.c 1.39 SYSTEM POWER CONTROL : HVDC

Control Pri/Most Severe I/O board pilot relays are closed. PDU pilot relay not energized.
BCSTAT = 0 HVDC Rail voltage = 192V
183338 OBC Generator gen_power.c 1.13 SYSTEM MONITORING : HVDC

Monitor Primary/Most Severe The maximum allowable HVDC Rail voltage drop has been exceeded.No
load HVDC value: 717V 1st HVDC sample: 16004V HVDC 15mS later: 16004V Rotor LOV bit value: 0
185553 OBC Generator The HEMRC drive has detected a Line Loss. This can occur
when the input power to the drive falls below 85% of the nominal Bus voltage. Possible causes: HEM-IT,
HEMRC/AC Drive, or X-Ray tube stator drawing too much current therefore loading down the HEMRC
input power.

Sec 4.2 Rotor

Test Objective
Determine if the rotor function is failing and isolate the root cause
Components include: HVDC; HEMRC Cont Bd in the OBC; H-CAN Buss; HEMRC I/F bd;
HEMRC AC Drive; HEMIT Anode Tank; Xray Tube
Run diagnostics to evaluate if the problem is the HVDC supply, control, drive circuits, or load
Rotor Test Sequence (1): Stationary Gantry

Diag > X-Ray Generation > Rotor Control [ TYPICAL RESULTS ] [ ROTOR T/S WORK FLOW ]
Test Selection:HEMRC Manual Rotor Speed:Low(only selection) Test Duration(sec):10
Gantry Enable: Disabled
A. Monitor gesyslog for HEMRC/Rotor errors
B. Compare test results to typical results
o Note the times posted to know at what point in each phase the results represent
o Is the drive output current too high for the control phase (Accel, Run) indicating a load problem
o Is the HVDC supply to the drive failing with a normal or lower than normal drive output load
o Is the drive output current too low for the control phase time point indicating a drive problem
st
o Has the drive frequency reached 280Hz (Performix Ultra& Adv) at the 1 RUN phase results
o Check the drive frequency on the last BRAKE cycle results. Lower than normal (33Hz Performix
Ultra/Adv) may indicate bad bearings slowing the rotor down more quickly
C. Return to work flow for decision path
NOTE 1: Results-frequency output If the rotor is open or frozen the frequency output may still increase to
180-190 during acceleration before it drops back and the test fails. Remember the diagnostic can only
measure output frequency, not the actual frequency of the rotor itself.
Typical Rotor diag results for an open rotor, cable, etc.
Diag results during accel show a higher than normal output current but the output frequency remains
around 100 Hz. After about 5 results output the drive goes directly to the IDLE mode without a BRAKE
cycle and the output frequency is 0 Hz. This is a good indication the tube rotor was not spinning at all,
because it would not be 0 Hz output freq so quickly unless the rotor was extremely bad or never spinning
in the first place. Don’t confuse the high freq sound from the drive with the sound of actual rotor rotation.
Failure or abnormal results

HEMRC Drive problem: [HEMRC AC Drive Assm]
Load problem: [Tube; HEMIT HV Tank; HV Cable]
No Drive output current at all. > Check continuity to HEMIT Tank primary
Drive output current too high for the control phase
HVDC supply problem: [HVDC Supply; Facility AC Mains; slipring]
Note 2: When evaluating the HEMIT using resistance checks, the workflow indicates to only check the
HEMIT secondary because this easy to do and a more likely failure point. The primary can checked if
desired at J10 of the HEMIT Anode transformer but it is difficult to do and may not be worth the effort in
typical cases. [Typical readings: J10 1 to 2 ~1.2 ohms; J10 2 to 3 ~1.2 ohms; J10 1 to 3 ~1.2 ohms]
IF test results indicate a load problem (HERMIT or Tube); At the gantry listen for noise or vibration that
might indicate tube rotor bearing problems. After the rotor completes the braking cycle try and determine
if the rotor comes to a stop too quickly. An optional test is to run up the rotor then turn off the gantry 120
VAC power so all fans are quiet and the rotor will coast freely with no brake cycle. If the rotor stops too
quickly there is likely rotor bearing problems. Don’t do this too often though, because the braking cycle is
designed to decelerate quickly thru the rotors resonant frequency zone to avoid the extra vibration that is
not good for long term tube life.

TIP: If a tube replacement is decided as the best action but there is still some uncertainty the tube is
causing the rotor problems, then first hang the new tube from the hoist with the original tube still installed.
Switch over the cables and retest the rotor on the new tube. It may save the time to realign and calibrate
a new tube if the problem is elsewhere.
Rotor Test Sequence (2): Rotating Gantry

Diag > X-Ray Generation > Rotor Control [ TYPICAL RESULTS ] [ ROTOR T/S WORK FLOW ]
Test Selection:HEMRC Manual Rotor Speed:Low(only selection) Test Duration(sec):10
Gantry Enable: Rotation
Gantry Speed: Select gradually increasing speeds to determine if the rotor only fails at faster speeds.
A. Monitor gesyslog for HEMRC/Rotor errors
IF the rotor shows consistent signs of problems only at the faster axial rotation speeds then the tube rotor
bearings are the most likely cause.
Theory
Advanced service manuals contain good theory on the HEMRC operation.
Sample Errors
183316 OBC Generator The HEMRC failed to reach the Run speed in the allotted time.
183318 OBC Generator The HEMRC output current is out of 35.0 percent Warning tolerance
183319 OBC Generator The HEMRC output current is out of 55.0 percent MAXIMUM tolerance
185505 OBC Generator Could not send HEMRC message in the allotted time. HEMRC serial link
is down. HEMRC_ISO_+24V indicates OK possible causes: HEMRC CAN jumper, interconnects, CAN
devices
185548 OBC Generator The HEMRC operating frequency is below the minimum value.
185553 OBC Generator The HEMRC drive has detected a Line Loss. This can occur when the
input power to the drive falls below 85% of the nominal Bus voltage. Possible causes: HEM-IT,
HEMRC/AC Drive, or X-Ray tube stator drawing too much current therefore loading down the HEMRC
input power.
219800 OBC Generator The HEMRC AC Drive reported fault code: F2 - Auxiliary Fault. The
interlock between the Chopper Control circuit on the HEMRC I/F Board and the Drive is open. Possible
Chopper Control fault or connections to the I/F board. Also check the fuse on the chopper resistor pan.
219800 OBC Generator The HEMRC AC Drive reported fault code: F4 - Undervoltage Fault The
Drive internal DC bus voltage dropped below 325V. Possible low voltage condition on 120 VAC in gantry
or power interruption. Also, may indicate excessive run or braking power required due to sluggish tube.
Problem/Solution
1) Rotor failure rate on Performix Ultra tubes increases when used heavily at 0.5 sec scanning
183553 183318 183319 Errors
The Performix Ultra tube used LightSpeed Plus, Ultra, and 16 systems have larger rotor bearings than the
Performix ADV tube. A trend observed in July 2002 showed a higher percentage of bearing failures on the
Ultra tubes when 0.5 second gantry rotation scan techniques are used frequently. The trend was only
seen on tubes with > 100 million mAs or 8 months life and high use of 0.5 sec gantry rotation speeds. Do
Not jump to this conclusion without adequate investigation and testing.
2) Risk of misdiagnosed Performix Tubes due to Anode(HEMIT) Tank failure

Date: 01/11/2000
System: QX/i with Performix Tube
Re: Anode HV Tank (HEMIT) T3109CD (model #2161307)
PROBLEM:

Rotor errors failing to reach run speed and rotor output current high combined with Anode overcurrents
and HV Spits. With ear to a screwdriver pressed on the tube, could hear the rotor trying to spin up during
manual rotor diags. HEMRC appeared not to get the rotor above 96Hz. Seemed likely the tube (rotor
seizing causing spits?).
Excerpt from logsummary tool:
183109 7 Jan10x7 OBC:Generator KV fault detected: Anode overcurrent.
183258 5 Jan10x5 OBC:Generator KV board MAXIMUM spit rate exceeded.
183316 2 Jan10x2 OBC:Generator HEMRC failed to reach Run speed in the allotted time.
183319 1 Jan10 OBC:Generator HEMRC output current out of 55.0 % MAXIMUM tolerance.
SOLUTION:
Replacing the Anode Tank resolved the problem. Found it surprising a bad tank can look so much like a
tube going bad. The clue here is the combination of Anode Overcurrent errors along with the HEMRC
errors. The one part in common with Anode Overcurrents and HEMRC Rotor problems is the Anode Tank
since the Rotor Isolation Transformers are located inside the Anode HV tank.
This illustrates the need to follow the main TS flowchart to resolve Rotor errors before kV, mA errors.
[ ROTOR T/S WORK FLOW ]

Sec 4.3 Filament
Test Objective
Exercise the filament control function and isolate the root cause of failures.
Components include: Filament PS; mA Control Bd; Relay K78 (on OBC backplane); Cable (OBC to CA
tank); Cathode Tank; CA HV Cable; Tube
Test Sequence
Diag > X-Ray Generation > Filament [ TYPICAL RESULTS ] [ FILAMENT T/S WORK FLOW ]
1. Focal Spot:Small Fil Current(Amps):1.5 Test Duration(sec): 0.2
2. Focal Spot:Small Fil Current(Amps):1.5 Test Duration(sec): 2.0
3. Focal Spot:Large Fil Current(Amps):1.5 Test Duration(sec): 0.2
4. Focal Spot:Large Fil Current(Amps):1.5 Test Duration(sec): 2.0
A. Monitor gesyslog for Filament errors

B. Return to work flow for decision path
New to consider adding filament diag test with Tube at 4 quadrants. If the filament diag fails at only one of the 4 positions then it is
most likely the filament inside the tube is sagging/opening/shorting with gravity. If error is not tube position dependent problem is
more likely a connection problem somewhere in cables pins, etc.
Need to check for diag delays etc. to see cost of perfoming this axtra testing here.
IF: Filament Open errors; Follow the flowchart to perform the sequence of ohm checks
IF: Filament power supply errors; Check the filament power supply located in the HEMRC assembly.
IF: Other filament errors i.e. filament inverter errors; Replace the mA Control Bd
Filament open errors: Resistance tests

Filament transformer windings and filaments in the tube are low resistance < 1 ohm so we will consider >
1.0 ohm as high resistance. Also the filaments have a diode like effect with slightly different ohm readings
when the meter lead polarity is reversed. Typical values are listed as a guide but keep in mind these low
meter readings can vary a bit with lead resistance and probe connection quality. Filament shorts are very
difficult to distinguish with our typical DVM setup, but most filament errors encountered are open filament.
1. Power OFF HVDC and 120 VAC
2. Ohm Check A: Filament transformer primary
o Remove J2 on the cathode tank measurement bd.
o Measure resistance at the cathode tank measurement bd. test points.
o Polarity of meter test leads has no effect on these readings.
o Disconnecting the HV cathode cable has no effect on readings on a good system.
XS1: TP12-13 ~ 0.3 ohm
XS2: TP12-11 ~ 0.3 ohm
XL1: TP15-16 ~ 0.3 ohm
XL2: TP15-14 ~ 0.3 ohm
o Reconnect J2 on the cathode tank measurement bd after measurements complete
IF: Ohm Check A; resistance is high, replace the Cathode HV Tank, otherwise continue with Ohm
Check B to test the HV cable connections and tube filament.
3. Ohm Check B: Filament resistance measured thru HV cable
o Pull the HV cable from the cathode HV tank and ohm check at the HV cable pins.
o While measuring bang the tube with your hand to try and reproduce a potential intermittent.
o Readings vary with meter test lead polarity. There is somewhat of a diode effect between the
filaments and the cathode cup assembly.
+C to -S ~ 0.1 ohms
+C to -L ~ 0.2 ohms
-C to +S ~ 0.7 ohms

-C to +L ~ 0.7 ohms
Note: L to Gnd, C to Gnd, & S to Gnd should all measure open circuit
o Reinstall the HV cable in the cathode HV tank after measurements are complete.
IF: Ohm Check B is high, continue with Ohm Check C to isolate the tube from HV cable and tube
well connections. Otherwise reinstall the HV cable in the cathode tank and continue with Ohm
Check E to check the Cathode tank HV cable connection and filament transformer secondary.
4. Ohm Check C: Filament resistance measured direct at tube well
o Pull the cathode HV cable from the tube and ohm check at pin sockets in the tube well
o While measuring bang the tube with your hand to try and reproduce a potential intermittent.
o Readings vary with meter test lead polarity. There is somewhat of a diode effect between the
filaments and the cathode cup assembly.
+C to -S ~ 0.1 ohms
+C to -L ~ 0.2 ohms
-C to +S ~ 0.7 ohms
-C to +L ~ 0.7 ohms
IF: Ohm Check C is high, replace the tube. Otherwise continue with Ohm Check D to isolate
between the HV cable and tube well connections.
5. Ohm Check D: HV cable resistance
o Measure the HV cable resistance from end to end. Pins on newer HV cables are screwed into
the cable end and could be making a loose connection so be sure to check that cable end
pins are securely screwed into their sockets.
C to C = 0 ohms
S to S = 0 ohms
L to L = 0 ohms
IF: Ohm Check D is high, replace the HV cable.
IF: Ohm Check D is good, the problem is a poor connection of the HV cable pins to the HV cable
well sockets. Check the condition of the collars on the HV cable pins and the springs in the cable
well pin sockets. Reinstall the HV cable and retest connection quality. It is a good idea to connect
the meter and watch the readings as the cable is inserted and tightened in the well. Torque HV
cables to 11 ft lbs initially then back off and torque to 7 ft lbs. If the connection problem can’t be
resolved replace the HV Tank or Tube with the bad cable well sockets. Some ZSEs may have a
custom cable well spring removal and insertion tool and spare springs.
6. Ohm Check E: Filament transformer secondary measured thru HV cable
o Pull the HV cable from the tube cathode and ohm check at the cable pins.
C to S ~ 0.3 ohms
C to L ~ 0.3 ohms
IF: Ohm Check E is high, continue with Ohm Check F
IF: Ohm check E is good
• Check or replace relay K78 on the OBC backplane
• Check cable continuity from the OBC backplane to the cathode tank
• IF: All resistance checks are good the problem is likely an intermittent open filament
inside the tube. Replace the tube.
7. Ohm Check F: Filament transformer secondary measured directly at tank well
o Pull the HV cable from the cathode HV tank and ohm check at pin sockets in the tank well.
C to S ~ 0.3 ohms
C to L ~ 0.3 ohms

IF: Ohm Check F is high, replace the cathode tank. Otherwise continue with Ohm Check D to
isolate between the HV cable and tank well connections.
Theory
The mA Control Board contains an inverter to produce filament heating current. Do not confuse tube mA
with filament current. Tube mA is a result of tube KV and filament heating current, so the bd. also has
feedback circuits for closed loop tube mA control. The filament/mA control function provides 10 - 440 mA
capability with 5% accuracy. Protection circuitry for; filament open circuit, mA imbalance, over-current,
and inverter faults is provided in addition to monitoring of mA by firmware during exposures.
Filament Current:
The filament inverter is a parallel resonant AC current supply with a 16KHz switching frequency to provide
a current source for the tube filaments. The inverter output current is commanded by FILDE produced on
the mA control bd. The inverter maintains output current equal to FILDE by using closed loop filament
current feedback sensed by T1 at the output of the mA circuit board. Inverter output is connected to a
relay located on the OBC backplane to select either the small or large tube filament. The filament select
relay output is connected to a filament isolation transformer in the Cathode tank by a cable harness from
the OBC backplane to the Cathode tank. The Cathode tank large and small focal spot filament
transformers provide HV isolation between the HV Filaments and the Low Voltage Filament Inverter.
Cathode tank filament transformer output is connected to the tube filaments by the Cathode HV cable.
Open loop tube mA

Filament current is determined from a generator calibration table lookup based on the prescribed tube
mA. This digital command word FID is sent from the OBC to the mA bd where it is converted to the
analog filament current command FILDE without any tube mA feedback. This mode is used for the first
4ms of every exposure. Open loop mode is also available as an option in the kV/mA diagnostic tool , as
well as a manual filament current selection in Filament Diagnostic tool.
Closed loop tube mA

st
After the 1 4 ms of every exposure the mA bd switches to closed loop mA control. In this mode the same
filament current command FID, is received from the generator calibration lookup table as for open loop,
but now compensation is added for closed loop mA control. The mA bd receives the tube mA command
word, MAD from the OBC, and converts it to analog for comparison to measured tube mA, MAFB. The
result is a correction value, Filament Error that is then added to the filament current command from the
OBC before producing the final filament current command FILDE. Tube mA is measured at the cathode
HV tank measurement bd sensor resistor (10 Ohms), through which the actual tube mA flows.
Note: An older mA bd 46-288886G1 T3202BM used on HSA and CTi systems used Anode mA for
feedback control for use with Zeus tubes only.
Generator calibration
The generator calibration table contains open loop kV and filament current command values, sometimes
referred to as pre-scan values. Generator calibration tool adjusts these pre-scan values to produce
correct tube mA and KV for the first 4ms of exposure before closed loop mA and kV takes over. If pre-
scan values are too far out of calibration the result can be excessive kV or damaging filament current or
tube mA before closed loop feedback brings the values under control.
The two utilities for generator calibration Auto mA Cal and New Tube Seed Shift are often misunderstood.
These two utilities perform the same generator calibration with only one difference. Auto mA Cal uses
existing calibration values as a starting point for calibration. New Tube Seed Shift replaces existing
values with known safe starting values before calibration. Whenever a tube or HV component is replaced,
New Tube Seed Shift should be used to protect components from potentially damaging starting values.

Sample Errors
183119 OBC Generator FIL/MA fault detected: Filament current limit exceeded.
183121 OBC Generator FIL/MA fault detected: Open filament circuit.
183124 OBC Generator FIL/MA fault detected: Inoperative filament inverter.
183125 OBC Generator FIL/MA fault latch 1 would not reset.
214335 OBC diagExec Diagnostics XRAY GENERATION : MA Loop A filament inverter error
has been detected
[ FILAMENT T/S WORK FLOW ]

Sec 4.4 kV/mA
Test Objective
Isolate a failing kV / mA component by running diagnostics to exercise all modes of generator operation.
For intermittent HV spits or overcurrents perform extended tests at high kV no load and medium load.
Components include: HV inverters, HV tanks, HV Cables; Tube; kV Control bd., mA Control Bd;
Test sequence: kV/mA
Sequence (1) No Load kV - Basic Test; >> Check for 0kV, HV spits, or Inverter overcurrents.
Sequence (2) Xray Test - Low, Med, High Power; >> Compare results to typical values.
Sequence (3) No Load kV - Extended Test 140kV 30sec; >> Check for HV Spits or overcurrents
Sequence (4) Xray Test - Extended 140kV 100mA; >> Check for HV Spits or overcurrents
Sequence (5) Fiber Optics Test; >> If directed by flowchart
Sequence (6) Optional; Scope HV Waveforms
Sequence (7) Optional; Heat Soak and Seasoning
Sequence (1): No Load kV - Basic Test (1.5 min.)
Start with low kV and increment up as instructed to minimize damage from major failure.
Diag > X-Ray Generation > KV Loop [TYPICAL RESULTS] [KV/MA TS WORK FLOW]
Note: Log To File:True [default selection] Must always be “True”
Common Selections: Test Selection:HV Manual HV Inverter Enable:Both Gantry Enable:Disabled
1. HV DC Bus:Test Mode kV:80 Test Duration: 2 sec
2. HV DC Bus:Normal Mode kV:80 Test Duration: 2 sec
A. Monitor gesyslog during testing for HV Spits or other generator errors

(Note: Diag. results screen may not post an error for HV spits if below the Max spit level)
NOTE 1: kV Loop Diag - kV accuracy On many systems the KV Loop Diag results can show incorrect
measured AN or CA kV values, usually Anode kV 5-30% low. The purpose here is only to test if there is 0
kV, HV spits, or inverter overcurrents with no load kV. The kV/mA Diag Xray Test performed later will
produce accurate readings for evaluation and decisions.
Running the test with HV cables pulled from the tube will report correct values as will running anode or
cathode only mode, but it is important to run both anode and cathode together at this point in the testing.
NOTE 2: ~13 kV is the normal result for Anode and Cathode in HV DC Bus:Test Mode. (HVDC=50V).
Test steps 2-4 must select HV DC Bus:Normal Mode.
IF: Anode or Cathode kV=0V; Check HV inverter fuse Warning: Lock Out Tag Out system power input
IF: No HV spits or inverter overcurrents occur move on to the Xray Test sequence 2.
IF: HV spits or inverter overcurrents do occur, repeat the test at the failing kV while listening to the HV
tank/s to determine the source of arcing. If an overcurrent occurs, the error message will indicate which
HV tank (anode or cathode) to listen to, otherwise listen to both HV tanks one at time.
IF: sizzling or arcing is heard from within a HV tank replace that HV tank [Audible Results]
IF: spits or overcurrents occur but no sizzling or arcing is heard in either tank, or the source of
arcing is uncertain, retest with the HV cables removed from the Anode & Cathode HV tanks.
Remember to fill the Tank HV wells with oil to about 3 cm from the top to prevent arcing during
the test and don’t rotate the gantry.
IF: spits stop with only the HV tanks in the circuit, inspect the HV cable/s for arcing and
inspect the tube HV cable well/s for arcing and clean if necessary. Reinstall HV cable/s
and repeat the test at the failing kV to confirm the problem still occurs only with the tube
in circuit before replacing the Tube.

Sequence (2): Xray Test – Low Medium & High Power (10 min.)
Testing must include generator operating modes (low, med, & high power) and both filaments
Start with low power as instructed to minimize damage from major failure
Identify the problem type: mA/kV out of tolerance, mA imbalance, certain power range, or certain filament
Diag > X-Ray Generation > KV mA [ TYPICAL RESULTS ] [KV/MA TS WORK FLOW]
Note: Log To File:True [default selection] Must always be “True”
Common Selections: Xray Test Type:Manual Gantry Enable:ON Gantry Speed: 2 sec
1. kV:80 mA:40 Exp Time(sec):2 Focal Spot:Small
2. kV:120 mA:200 Exp Time(sec):2 Focal Spot:Small
3. kV:120 mA:200 Exp Time(sec):2 Focal Spot:Large

IF: Anode or Cathode kV = 0 then Lock Out Tag Out power and check HV Inverter fuse.
Note 1: For Performix Adv/Ultra tubes, Anode mA will normally be 5-10% less than Cathode mA.
Note 2: Watch Exposure duration time on the results screen. Results for less than 1 second of
exposure duration may be un reliable, especially if the exposure was aborted early due to errors. Also
keep in mind the first 4 ms of exposure is open loop kV and mA control that depends entirely on stored
generator calibration pre-scan values.
Note 3: kV measured is only what the system thinks the kV is via the HV tank internal bleeders,
measurement bds, and feedback gain adj. on the kV bd. In closed loop mode the system feedback circuit
will attempt to keep this measured value equal to the kV commanded. It is uncommon, but possible to get
the kV gain pots out of adjustment as much as ± 15kV.
Note 4: Compare Test results to T/S. Compare VCNT, Inverter frequency, duty cycle, & measured kVs
to T/S KV. Compare mA measured, filament current, and inverter currents to T/S MA
Sequence (3): No Load kV – Extended Test 140kV 30sec (15-30 min.)

Diag > X-Ray Generation > KV Loop [KV/MA TS WORK FLOW]
Note: Log To File:True [default selection] Must always be “True” to review previous results
Common Selections: Test Selection:HV Manual HV Inverter Enable:Both Gantry Enable:Disabled
1. HV DC Bus:Normal Mode kV:140 Test Duration:30 sec
Position the gantry with HV tanks upside down. While running 140kV test, manually rotate the
gantry back and forth a few feet, while listening very carefully to the tanks for arcing. Use a
stethoscope to amplify sound within a HV tank if available. Otherwise a screwdriver with the blade
held to a tank and the handle to your ear will help amplify sound from inside the tank.
2. Repeat this test at least twice for each side if no spits occur and an intermittent is suspect.

(Note: Diag. results screen may not post an error for HV spits if below the Max spit level)
IF: No HV spits or inverter overcurrents occur move on to the Xray Test sequence 4. (140 kV 100mA)
IF: HV spits or inverter overcurrents occur, repeat the test at the failing kV while listening to the HV tank/s
to determine the source of arcing. If an overcurrent occurs, the error message will indicate which HV tank
(anode or cathode) to listen to, otherwise listen to both HV tanks one at time.
IF: sizzling or arcing is heard from within a HV tank replace that HV tank [Audible Results]
IF: spits or overcurrents occur but no sizzling or arcing is heard in either tank, or the source of
arcing is uncertain, retest with the HV cables removed from the Anode & Cathode HV tanks.

Remember to fill the Tank HV wells with oil to about 3 cm from the top to prevent arcing during
the test and don’t rotate the gantry.
IF: spits stop with only the HV tanks in the circuit, inspect the HV cable/s for arcing and
inspect the tube HV cable well/s for arcing and clean if necessary. Reinstall HV cable/s
and repeat the test at the failing kV to confirm the problem still occurs only with the tube
in circuit before replacing the Tube.
NOTE 1: Always run KV loop initially with Both selected ( Anode and Cathode ).
It is just as important while listening to HV tanks to know if a tube spit occurs without any audible arcing
from the tanks to help identify a bad tube, as it is to hear an arc within a tank to identify a bad tank.
Both: Tests Tube , HV Tanks, and HV Cables
Anode only: Tests Tube-Anode to Casing only, Anode tank, Anode HV cable,
Cathode only: Tests Tube-Cathode to Casing only, Cathode tank, Cathode HV cable
Sequence (4): Xray Test – Extended 140 kV 100 mA (5 min.)

Check for spits at 140 kV 100mA.
Diag > X-Ray Generation > KV mA [KV/MA TS WORK FLOW]
Note: Log To File:True [default selection] Must always be “True” to review previous results
Xray Test Type:Manual Gantry Enable:Disabled
Maintain the same gantry position as for the previous Sequence 3, 140 kV no load test with HV
Tanks upside down. The initial goal is to determine if spits will occur only under load with the
same stationary tank and tube positions.
2. Repeat this test at least three times if no spits occur and a stubborn intermittent is suspected.

IF: HV spits or overcurrents occur with Xray load at the same stationary gantry position with tanks upside
down, but can’t be reproduced in the same position with extensive testing at 140 kV no load, then the HV
tanks are the most likely failure.
IF: HV spits can only be produced with normal rotating Xray scans, then the problem may still be in a HV
tank or Tube. However at this point in the troubleshooting process a reasonable effort has been made to
isolate the root cause without success. Replace the tube as the most likely failing item.
Sequence (5): Fiber Optic Test (15 min.)

Diag > X-Ray Generation > KV Loop [KV/MA TS WORK FLOW]
Note1: The original old 46-321064G01 KV Bd does not support this fiber optic diagnostic
Note2: The LEDs can be viewed without removing the inverter covers with some difficulty, but it is easier
with covers removed. Covers need to be removed for later steps anyway.
1. Test Selection:HV Fiber Optics HV inverter Enable:Both [Both(default)]; Anode; Cathode]
Select test duration 15 [5sec(default);1-3600 seconds;]
The fiber optic drivers will be enabled one at a time.
Check the KV inverter LEDs for the following sequence:
1. Anode - Left Upper 5. Cathode - Left Upper
2. Anode - Left Lower 6. Cathode - Left Lower
3. Anode - Right Upper 7. Cathode - Right Upper
4. Anode - Right Lower 8. Cathode - Right Lower
A. Return to work flow for decision path

IF: All inverter fiber LEDS light OK continue to isolate the problem between a failing Inverter or HV tank
IF: an Inverter LED does not light in sequence;
o Check the fiber optic cable connections at inverter and OBC backplane.
IF the fiber cable connections were not fully inserted
o Push the connectors in properly and rerun the fiber optic test.
IF the LEDs are now OK; Return to the Xray Test to verify operation
IF the fiber cable connections were already OK continue below to swap fiber cables
o Swap the suspect fiber cable with one of the good ones and rerun the fiber test
IF the fiber cable is bad replace it and rerun the fiber optic test
IF the fiber cable & connections are good replace the kV bd and rerun the fiber optic test
IF the problem continues replace the OBC backplane
Sequence (6): Optional: Scope HV waveforms

Scope the kVp waveform to look for instability
• Scope TP-1 to TP-18 on the measurement board of each HV Tank. This is a 10,000/1 divider, so
2VDC Vertical and 50msec/div Horizontal are good starting points. Typically there may be some
kV ripple from 3kVP under no-load to 6 kVp under high load.
• Scope the KVp waveform using the HV Bleeder. Be sure to follow proper Bleeder, Belden cable,
and Scope connections to minimize excess noise and aliasing. (always use only 100 KV 50 mA
when checking accuracy or adjusting feedback resistors for kV Cal)
Sequence (7): Optional: Heat Soak and Seasoning
For intermittent spits try 2 heat Soak and Seasoning cycles to see if HV spits will clear up
Theory
HV Spits: This system doesn’t distinguish between HV tank, cable, or tube arcs so we should never
assume spits are “Tube spits” as is reported in some error messages. HV Spits are counted by the kV
control bd when measured kV drops faster than a specified rate indicating a “spit” and can be caused by
HV tanks, HV cables or the tube. Of course the spit counter on the kV bd could also be defective although
I believe this is rare. One difference we can observe is that spits in the tube can sometimes be improved
by running a heat soak and seasoning cycle. HV cable arcs will generally just get worse and more
frequent quickly as a carbon track forms from the arcs. With HV tanks, carbon tracks from arcs may get
diluted in the HV oil allowing intermittent arcs to go on for a long time, however a heat soak and
seasoning will not improve intermittent spits caused by tanks like it sometimes can with a tube.
[ KV/MA T/S WORK FLOW ]

KV Control:
There are 3 versions of kV Control Bds – Latest ver. 2143147 required for unreg HVDC supplies
KV bd. types used in the HSA-CTi-LS product line. New bds. are backward compatible:
2143147: Latest version uses Total kV plus unreg HVDC compensation to produce VCNT
Refer to explanation for KV Control Bd (2143147 or 46-321198G1) below.
nd
46-321198G1-F:. 2 Version Total kV used to produce VCNT
Refer to explanation for KV Control Bd (2143147 or 46-321198G1) below.
46-321064G1.:Original Bd. Cathode kV used to produce VCNT - Upgrade recommended

Cathode kV feedback only is compared to KVCMD to produce VCNT that determines the
frequency for both Cathode and Anode inverters, plus the phase shift for Cathode only. Anode kV
feedback is only used to control Anode phase shift. This old control requires different Anode and
Cathode inverters with a small difference in inverter base frequency.

Failure Notes: Cathode side failures affect both anode and cathode because of the cathode
controlled VCNT. Anode side failures affect anode only output, inverter current, duty cycle, and
total KV. The VCNT and Cathode side is unaffected although tube current could be low.
On these Bds. the good side can sometimes have a higher than expected kV
1/25/2005: DOA kV Board notice, P/N 2143147

Rev#?? Identifying features ?? Error codes ?
Please be advised that a batch of new kV boards have entered the parts pool that will not work properly
when installed. These new boards were incorrectly calibrated for an Anode inverter frequency of 48kHz
rather than 39kHz. This may cause problems with kV / mA test problems at higher power levels above
24kW. Typically seen with 140 kV and use of AutoMa or SmartMa. MA variation within the scan causing
the kV bd to go into oscillation resulting in HV spits being reported.
These defective parts will be removed from all stocking locations as soon as possible.
Note: TS flowcharts in this document apply only to the 2 newer kV Bd versions. Older HSA or CTi
scanners should upgrade to one of the 2 newer versions.
KV Control Bd (2143147 or 46-321198G1)

The requested kV command word is sent to the kV control bd where it is decoded and converted to an
analog command, KVCMD. Actual Anode kV and Cathode KV feedback from the HV tank measurement
bds. are sent independently to the kV control bd where kV feedback adj. gain compensation is added to
calibrate kV control and produce CAKV & ANKV. These two are summed to produce total kV that is
compared to KVCMD to produce KVERR. Before KVERR becomes VCNT, on Version 2143147 bds
KVERR goes to a variable loop gain control where compensation is added for unregulated HVDC from
the PDU. VCNT controls the common operating frequency for both AN and CA inverters. (0V=19.5kHZ
100% duty cycle; 1.5V=22.8 kHz 100% duty cycle; 5.0V=30.5 kHz 0% duty cycle) ANKV is combined
with VCNT to produce the final APH Anode phase or duty cycle control. CAKV is combined with VCNT to
produce CPH Cathode phase or duty cycle control.
o Lower VCNT = lower frequency = higher kV
o Higher duty cycle = higher kV
o Maximum output command measured: VCNT ~0.09V; Frequency ~19.7 kHz.; Duty Cycle 100%
Inverters
The Inverters are designed to invert the HVDC from the PDU to provide a high frequency output to the
anode and cathode HV transformers (Tanks). The inverters and tanks form a tuned circuit where
maximum VAC is output to the tanks at approximately 19.0 kHz. Individual inverter output capacitors are
adjusted at the factory to tune the inverter for 19.0 kHz. Actual base frequency and adjusted frequency
are recorded on a label in the inverters. Inverter IGBTs are controlled entirely by the frequency and duty
cycle of fiber optic signals received from the kV control Bd. For medium to high power exposures the
inverters are designed to operate at 100% duty cycle with kV controlled by frequency. However in practice
one inverter and tank combination will always produce a bit more kV for the same frequency than the
other side, so the higher output side will have to reduce duty cycle a bit to keep its kV correct. In our
system with a Performix tube this is typically the Anode side that is a bit higher output so it runs at a
slightly lower duty cycle (appx. 85%). However this is not always the case and with a slight difference in
inverter factory tuning and HV tank combination the Cathode output can sometimes be higher and run at
the lower duty cycle with no problems. For low power exposures frequency alone is not enough to keep
the kV under control and both inverters will have to run at a much lower duty cycle.
While inverter frequency and duty cycle control kV, inverter current is mostly a function of tube mA and
can be used to help decide the true mA in situations where a mA metering circuit failure is in question.
Failure Notes

A failure on either cathode or anode side will affect both sides because they both contribute to VCNT that
sets the common frequency for both inverters.
Anode side failure: Anode inverter duty cycle will be higher than normal to try and compensate to keep
kV at the requested value. If the problem is not too serious an increase in the duty cycle may be enough
to produce the desired kV and the cathode side will be relatively unaffected. However if duty cycle is not
enough then VCNT will compensate to lower the frequency and the cathode side will be affected as well.
The good cathode side will then have to compensate by lowering its duty cycle. If VCNT and duty cycle
for the failing Anode side has reached its limit (VCNT 0.09 V and 19.7 kHz) then the Anode kV will be low
especially at higher mA loads. As the problem gets more severe at higher loads then the cathode kV may
also be low but not as low as the anode kV.
Cathode side failure: Same as Anode failure description, just reverse the names (anode and cathode)
[KV/MA TS WORK FLOW ]

mA Control:
Performix tube Anode mA is typically 5-10% less than Cathode mA

Since mA is measured at the HV output of each HV Tank and the current from each tank supplies the
same load, Anode and Cathode mA should theoretically be the same. However due to a characteristic of
the Performix tube the Anode mA will be 5-10% less than the Cathode. This is caused by absorption of
scatter electrons from the target by the metal insert frame.
Cathode mA measured is the true tube current in a Performix tube so Cathode mA feedback is
used for closed loop mA control on 2154834 mA Bds mandatory for Performix tubes (MX200) .
Note: Older HSA or CTi scanners with Zeus tubes (MX165) used Anode mA for closed loop control on
46-288886G1 mA Bds. For Zeus tubes Anode mA and Cathode mA are equal so it doesn’t matter if
Anode or Cathode mA is used for the closed loop mA control. These scanners can use either type mA
control bd.
Warning: Some, older schematics, theory diagrams and/or troubleshooting directions have the anode vs.
cathode feedback control confused because of the mA bd differences.
Procedure to check the mA bd installed.
• Perform a Scan HW reset; (bd rev info in the log will get overwritten during normal scanning)
• rsh sbc; nbsClient obcr; y (to see log) ; Control-C (to exit nbsClient)
Example: > 3472<t7: =====| MA Board Revision: 2154834-01 C
> 3472<t7: =====| KV Board Revision: 2143147-01 B
mA Bd. 46-288886G1 T3202BM for ZEUS(MX165) Tube only. Uses Anode mA feedback for
closed loop mA control. It must not be used for Performix tubes (MX200). As these Bds went out
of stock they were replaced by the newer, backward compatible 2154834 Bd.
mA Bd. 2154834 for Performix or Zeus tubes uses Cathode mA feedback for closed loop mA
control. This change is required for compatibility with the Performix X-Ray Tube (MX200). Also
backward compatible with Zeus tubes.
For additional mA control board theory refer to Filament Theory Section
Sample Errors
183109 An OC OBC Generator gen_abort.c 1.31 Function: XRAY GENERATION
: KV Loop Scan: 493/2/2 Type: Helical Exception Level: Secondary Time: 11:40:49:970
Log Series: 132 KV fault detected: Anode overcurrent. Fault latch address = ffcff3 hex, Bit = D4
MA out of tolerance >10% or 4mA

183342 OBC Generator Function: XRAY GENERATION : MA Loop Scan:
50080/1/1 Type: Axial Exception Level: Pri/Most Severe Time: 12:14:02:785 Log Series: 41
Two consecutive anode mA samples out 10.0 % or 4 mA tolerance. Selected technic: 80 kV, 50 mA
Sample1: Anode = 76.1 mA Cathode = 49.7 mA. Sample2: Anode = 76.1 mA Cathode = 50.1 mA.

Possible cause: mA monitoring circuit failure.
MA imbalance > 10% or 2mA

50080/1/1 Type: Axial Exception Level: Sec/Soft Time: 12:14:02:810 Log Series: 41
mA imbalance over 10 % or 2 mA tolerance. Selected technic: 80 kV, 50 mA
Imbalance threshold = 5.0 mA. Average anode mA = 76.1 mA. Average cathode mA = 49.9 mA.
[KV/MA TS WORK FLOW]

Problem/Solution
1) Arcing between inverter plate and HV tank
Report # 1260003 GEWINS # 1026214
Issue type Product Quality Report
Report title H1: Arcing between inverter and HV tank
Status Closed September 3, 2002 0:00:00 PDT
Created date June 10, 2002 0:00:00 PDT Created by System Administrator
Problem:
Intermittent backup timer errors along with HV spits, attempted heat soak but problem got worse with
constant tube spits.
Solution:
Found cathode HV tank bad, but when removing inverter from tank mount position, noticed a high amount
of arcing had been going on between inverter and tank chassis due to concentration of carbon tracking on
both assemblies. Carbon tracks extended from right upper bolt hole over to center of mounting position
and back to lower right bolt hole, forming a 'V' pattern between the two bolt positions.
Srv Eng Review enclosure from CTCge66828
Lots of arcing found between the inverter plate and HV tank. The arcing was produced due to space
created between the two surfaces. The inverter was tested and it worked correctly. The Tank had a bad
cathode as described by the FE. It is a manufacturing requirement to loc-tite (242) the bolts that hold the
inverter to the HV tank. This is to prevent the bolts from getting loose. Proper manufacturing procedure
must be followed in the field as well when replacing this component.
Marcela Gonzalez CT Xray Gen Eng.
2) mA imbalance Problem – Performix Tube – 2154834 mA Bd.

gesyslog errors
50080/1/1 Type: Axial Exception Level: Pri/Most Severe Time: 12:14:02:785 Log Series: 41
Two consecutive anode mA samples out 10.0 % or 4 mA tolerance. Selected technic: 80 kV, 50 mA
Sample1: Anode = 76.1 mA Cathode = 49.7 mA. Sample2: Anode = 76.1 mA Cathode = 50.1 mA.
Possible cause: mA monitoring circuit failure.

50080/1/1 Type: Axial Exception Level: Sec/Soft Time: 12:14:02:810 Log Series: 41
mA imbalance over 10 % or 2 mA tolerance. Selected technic:80 kV,50 mA
Imbalance threshold = 5.0 mA. Average anode mA = 76.1 mA. Average cathode mA = 49.9 mA.
kV/mA Diag 80kV/40mA Average Selected Last

No. Device Value Value Sample
---------------------------------------------------------------------
1. Total KV: 79.9KV 80.0KV 79.9KV
2. Cathode KV: 40.1KV 40.0KV 40.1KV
3. Anode KV: 39.8KV 40.0KV 39.8KV
4. Cathode MA: 39.7mA 40.0mA 39.7mA
5. Anode MA: 59.6mA 40.0mA 59.6mA
6. Cathode inverter current: 10.325A (typ 6.8)-- 10.325A
7. Anode inverter current: 9.575A (typ 6.5)-- 9.575A
8. Approx. KV inverter frequency(VCNT):( 3.47V)(typ 3.59) 27.1KHz(typ 27.4)
9. Cathode inverter duty cycle: 46% (typ 41)
10. Anode inverter duty cycle: 40% (typ 36)
11. Filament current: 5.792A(typ 5.6) 5.465A 5.792A
12. HVDC Bus voltage: 659V -- 660V
13. Exposure duration: -- 1000mS 167mS
14. Exposure number: -- 1 1

The above problem was caused by a faulty Cathode tank. The Cathode tank mA measurement circuit
was measuring lower than actual mA, but since the Cathode mA controls closed loop feedback it will
adjust filament current until the cathode mA as measured equals the selected value. The Anode mA was
simply reporting the true tube mA that was driven too high due to the failing cathode measurement.
Note that both Inverter currents are similar indicating the true Anode and Cathode mA should be similar.
3) Cathode only or Anode only mA overloads on higher mA only. Not related to kV.
This was a known problem seen on the original old KV cont bd ( 46-321064G1 T3202BP )
Failure only occurs at higher mA at any kV. This problem has often been seen with the older KV control
bds, and is caused by KV bd diode failures in the rectification of the Anode or Cathode Inverter current
feedback to the KV bd. The KV bd reports a higher current than actual. If these old style bds fail they
should be replaced with one of the newer versions.

Sec 5 HV Bleeder Usage

46-154966G1 HV Bleeder
46-219921G2 Cable (17.5 ft. Bleeder to Scope)
When measuring kV be sure to use the bleeder, scope, and cable setup. The 100 kV 50 ma technique is
selected to minimize high frequency kV ripple and scope aliasing effects, without being so low as to
produce high overshoot.
The HV bleeder is most accurate at 100 kV. It was also designed for older 3 phase 12 pulse generators
with a KV ripple of only 720 Hz. The high frequency generator operates from 19 to 32 KHz and when a
scope is connected directly to the bleeder it has a tendency to amplify the high frequency kV ripple
producing aliasing on the scope waveform. To minimize this effect the capacitance of the bleeder to
scope cable is needed to attenuate the higher frequency. The low 50 mA also minimizes ripple without
being so low as to cause too much kV overshoot.
Sec 6 Power & Grounding

Power
Because Xray generation requires high current demands it is important the facility power supply meets
GEMS input power specs for line regulation published in the pre-install manuals.
• Test the line regulation by performing a maximum power Xray scan while monitoring the line to line
input VAC using a Fluke DVM in the Min/Max record mode for each line combination (A-B; B-C; A-C).
• Check all HVDC power source connections from the PDU through to the HV inverters
o PDU connection
o Gantry base connection
o Slipring power brush block connection
o Slipring HV power rings and brushes
o Slipring rotating HVDC connection
o HVDC connections at HV inverters and HEMRC
Grounding
Tube and HV component life for HSA, CTi, LS is not as dependent on hospital grounding as older 9800,
HLA scanners. However grounding within the CT System itself remains critical for tube life, and is
necessary to protect other sensitive electronics from HV disturbances caused by the tube and/or
generator.
HV Ground Path Connections:
Tube – Rotating slipring ground ring –Stationary SR brush block – Stationary Gantry frame –
Table/Gantry raceway ground buss – PDU

Sec 7 Typical Diag Results
Rotor Diag – Typical results screens
[ ROTOR TEST SEQUENCE ] [ ROTOR T/S WORK FLOW ]
Tube Type Test Results

Performix Ultra LS_2x
Performix Adv CTi
Typical Results Summary

Delta Mode I I I degC V V V Freq V
Time output flux torque temp hvdcbus input output output ref
(sec)
0 IDLE 0.00 0.00 0.00 47 672 677 0 0.00 9.99
3 ACCEL 10.13 3.07 5.04 47 657 656 97 88.00 9.99
6 ACCEL 11.56 5.27 8.47 47 650 648 195 157.00 9.99
10 ACCEL 11.39 5.53 10.13 47 648 647 311 257.33 9.99
13 RUN 2.20 2.09 6.11 47 669 674 99 281.33 9.99
16 RUN 2.30 0.76 3.12 47 669 674 99 280.00 9.99
19 RUN 2.29 0.92 2.47 47 669 674 99 280.00 9.99
23 BRAKE 2.22 0.78 2.38 47 436 438 199 279.67 9.99
26 BRAKE 5.98 3.66 2.80 47 189 564 251 238.00 9.99
29 BRAKE 7.04 5.71 3.24 47 88 481 183 175.67 9.99
32 BRAKE 7.49 6.64 2.91 47 42 448 105 111.33 9.99
35 BRAKE 7.15 6.19 3.46 47 21 428 35 40.67 9.99
38 IDLE 0.00 0.00 0.00 47 13 483 0 0.00 9.99
604520QXI LS_2x Performix Ultra

Wed Feb 4 13:29:20 2004 HEMRC Drive Status
No. Device Expected Present
---------------------------------------------------------------------
1. Rotor operating mode: IDLE
2. Drive output current -- 0.000A
3. Drive flux current -- 0.000A
4. Drive torque current -- 0.000A
5. Drive temperature -- 48C
6. HVDC Bus voltage: -- 687V
7. Drive input voltage -- 691V
8. Drive output voltage -- 0V
9. Drive output frequency -- 0Hz
10. Rotor reference voltage: 10.000V 10.008V
11. Drive status bit map -- 0E0CH
12. Drive fault code -- 00
13. Status register (Address = FFB829H): -- 22H
14. Fault register (Address = FFB82BH): 00H 00H

---------------------------------------------------------------------
1. Rotor operating mode: ACCEL

11. Drive status bit map -- 0E1FH

---------------------------------------------------------------------

---------------------------------------------------------------------

---------------------------------------------------------------------
1. Rotor operating mode: RUN

11. Drive status bit map -- 0F0FH

---------------------------------------------------------------------

---------------------------------------------------------------------

---------------------------------------------------------------------
1. Rotor operating mode: BRAKE


---------------------------------------------------------------------

---------------------------------------------------------------------

---------------------------------------------------------------------


---------------------------------------------------------------------

---------------------------------------------------------------------
604682CTI CTi Performix

Tue Feb 17 13:02:53 2004 HEMRC Drive Status
---------------------------------------------------------------------


---------------------------------------------------------------------

---------------------------------------------------------------------

---------------------------------------------------------------------


---------------------------------------------------------------------

---------------------------------------------------------------------

---------------------------------------------------------------------


---------------------------------------------------------------------

---------------------------------------------------------------------

---------------------------------------------------------------------


---------------------------------------------------------------------

---------------------------------------------------------------------

---------------------------------------------------------------------
Tue Feb 17 13:03:33 2004 Testing has completed.

Filament Test – Typical results screens

[ FILAMENT TEST SEQUENCE ] [ FILAMENT T/S WORK FLOW ]
Tube Type Small Fil Large Fil

Performix Ultra LS_2x Small Fil Large Fil
Performix Adv CTi Small Fil Large Fil
Small filament; 604520QXI LS_2x Performix Ultra

Wed Feb 4 13:47:37 2004 MA/Filament board status
---------------------------------------------------------------------
1. MA/Filament mode: STANDBY
2. Filament demand DAC: 1.500V 1.507V
3. Filament current: 1.500A 1.512A
4. MA reference: 5.000V 5.009V

5. Filament power supply: 32.000V 30.635V
6. Filament center tap voltage: -- 1986mV
7. Control register (Address = FFDF41H): -- 06H

---------------------------------------------------------------------
1. MA/Filament mode: OFF
Average run current 1.500A 1.512A
Large filament; 604520QXI LS_2x Performix Ultra

---------------------------------------------------------------------


---------------------------------------------------------------------

Small filament; 604682CTI CTI Performix Adv

Tue Feb 17 13:20:04 2004 MA/Filament board status
---------------------------------------------------------------------


---------------------------------------------------------------------
Large filament; 604682CTI CTI Performix Adv

---------------------------------------------------------------------


---------------------------------------------------------------------

KV Loop Diag – Typical results screens

[ KV LOOP TEST SEQUENCE ] [ KV MA T/S WORK FLOW ]
Tube Type Test Mode Normal Mode

Performix Ultra LS_2x 80kV 2s 80kV 2s 120kV 2s 140kV 10s
Performix Ultra LS_4x 120kV 2s 140kV 10s
Performix Adv CTi 80kV 2s 80kV 2s 120kV 2s 140kV 10s
Many systems may report inaccurate AN or CA kV values, often Anode kV 5-30% low.
For kV or mA accuracy decisions use kV/mA Diagnostic results.
HV Manual; Both; Test Mode; 80kV 2 sec - 604520QXI LS_2x Performix Ultra
Wed Feb 4 13:31:39 2004 High voltage status
Average Selected Last
---------------------------------------------------------------------
1. Total KV: 25.8KV 80.0KV 26.1KV
3. Anode KV: 13.0KV 40.0KV 13.1KV
5. Anode MA: 0.1mA 0.0mA 0.1mA
6. Cathode inverter current: 0.375A -- 0.375A
7. Anode inverter current: 0.550A -- 0.550A
8. Approx. KV inverter frequency (VCNT): ( 0.09V) 19.7KHz
9. Cathode inverter duty cycle: 100%
10. Anode inverter duty cycle: 100%
14. Status register (Address = FFCFF9H): -- 88H
HV Manual; Both; Normal Mode; 80kV 2 sec 604520QXI LS_2x Performix Ultra
---------------------------------------------------------------------
1. Total KV: 77.3KV 80.0KV 78.4KV
3. Anode KV: 39.9KV 40.0KV 40.9KV

---------------------------------------------------------------------
1. Total KV: 115.6KV 120.0KV 117.5KV
3. Anode KV: 59.9KV 60.0KV 61.1KV
HV Manual; Both; Normal Mode; 120kV 2 sec 418862LS LS_4x Performix Ultra
Thu Nov 27 16:10:00 2003 High voltage status
---------------------------------------------------------------------
1. Total KV: 115.3KV 120.0KV 114.1KV
3. Anode KV: 55.0KV 60.0KV 54.7KV
---------------------------------------------------------------------
1. Total KV: 134.1KV 140.0KV 133.8KV
3. Anode KV: 69.6KV 70.0KV 70.0KV

HV Manual; Both; Normal Mode; 140kV 10 sec 418862LS LS_4x Performix Ultra
140KV 15s Average Selected Last
---------------------------------------------------------------------
1. Total KV: 135.2KV 140.0KV 136.1KV
3. Anode KV: 65.4KV 70.0KV 64.1KV
HV Manual; Both; Test Mode; 80kV 2 sec 604682CTI CTi, Performix Adv, KV Bd.
2143147
Tue Feb 17 13:06:03 2004 High voltage status
---------------------------------------------------------------------
1. Total KV: 26.4KV 80.0KV 26.4KV
3. Anode KV: 13.3KV 40.0KV 13.2KV
HV Manual; Both; Normal Mode; 80kV 2 sec 604682CTI CTi, Performix Adv, KV Bd.
2143147
---------------------------------------------------------------------
1. Total KV: 68.4KV 80.0KV 69.0KV

3. Anode KV: Normal result > 27.4KV 40.0KV 27.7KV
2143147
---------------------------------------------------------------------
1. Total KV: 110.1KV 120.0KV 112.7KV
2143147
---------------------------------------------------------------------
1. Total KV: 130.8KV 140.0KV 132.9KV

HV Manual; Both; Normal Mode; 140kV 2 sec 604727CT CTi Performix Adv
Wed May 29 09:26:26 2002 High voltage status
140KV Average Selected Last
---------------------------------------------------------------------
1. Total KV: 120.6KV 140.0KV 120.5KV
11. HVDC Bus voltage: 541V 550V 540V

KV/MA Diag – Typical results screens

[ KV/MA TEST SEQUENCE ] [ KV MA T/S WORK FLOW ]
Tube Type Low KVA Med KVA Med KVA High KVA
Small Fil Small Fil Large Fil Large Fil
Performix Ultra LS_2x 80kV 40mA 120kV 200mA 120kV 200mA 120kV 400mA
Performix Ultra LS_4x 120kV 200mA 120kV 200mA 120kV 400mA
Performix Adv CTi 80kV 40mA 120kV 200mA 120kV 200mA 120kV 400mA
Performix: Anode mA is normally 5-10% lower than Cathode; Cathode mA = true tube mA;
Low power; Small filament; 80kV 40mA 2s 604520QXI LS_2x Performix Ultra
---------------------------------------------------------------------
1. Total KV: 79.7KV 80.0KV 79.7KV
3. Anode KV: 39.9KV 40.0KV 39.8KV
5. Anode MA: 37.3mA 40.0mA 37.3mA
11. Filament current: 5.573A 5.482A 5.568A
13. c: -- 2000mS 2007mS
Med power; Small filament; 120kV 200mA 2s 604520QXI LS_2x Performix Ultra
---------------------------------------------------------------------
1. Total KV: 119.5KV 120.0KV 119.6KV
3. Anode KV: 60.0KV 60.0KV 60.0KV
5. Anode MA: 184.3mA 200.0mA 184.3mA
Med power; Small filament; 120kV 200mA 2s 418862LS LS_4x Performix Ultra

---------------------------------------------------------------------
1. Total KV: 119.5KV 120.0KV 119.4KV
3. Anode KV: 59.8KV 60.0KV 59.7KV
5. Anode MA: 185.2mA 200.0mA 185.2mA
Med power; Large filament; 120kV 200mA 2s 604520QXI LS_2x Performix Ultra
---------------------------------------------------------------------
1. Total KV: 119.5KV 120.0KV 119.6KV
3. Anode KV: 60.0KV 60.0KV 60.1KV
5. Anode MA: 185.1mA 200.0mA 185.1mA
Med power; Large filament; 120kV 200mA 2s 418862LS LS_4x Performix Ultra
---------------------------------------------------------------------
1. Total KV: 119.5KV 120.0KV 119.5KV
3. Anode KV: 59.8KV 60.0KV 60.1KV
5. Anode MA: 185.8mA 200.0mA 185.9mA

High power; Large filament; 120kV 400mA 2s 604520QXI LS_2x Performix Ultra
---------------------------------------------------------------------
1. Total KV: 119.5KV 120.0KV 119.9KV
3. Anode KV: 60.5KV 60.0KV 60.7KV
5. Anode MA: 368.8mA 400.0mA 368.6mA
High power; Large filament; 120kV 400mA 2s 418862LS LS_4x Performix Ultra
---------------------------------------------------------------------
1. Total KV: 119.6KV 120.0KV 119.9KV
3. Anode KV: 60.1KV 60.0KV 60.4KV
5. Anode MA: 369.6mA 400.0mA 369.3mA
Low power; Small filament; 80kV 40mA 2s 604682CTI CTi Performix Adv
---------------------------------------------------------------------
1. Total KV: 79.9KV 80.0KV 79.7KV
3. Anode KV: 39.9KV 40.0KV 40.0KV
5. Anode MA: 36.8mA 40.0mA 37.0mA

Med power; Small filament; 120kV 200mA 2s 604682CTI CTi Performix Adv
---------------------------------------------------------------------
1. Total KV: 119.8KV 120.0KV 119.6KV
3. Anode KV: 59.9KV 60.0KV 59.7KV
5. Anode MA: 182.8mA 200.0mA 182.9mA
Med power; Large filament; 120kV 200mA 2s 604682CTI CTi Performix Adv
---------------------------------------------------------------------
1. Total KV: 119.9KV 120.0KV 119.8KV
3. Anode KV: 59.9KV 60.0KV 59.8KV
5. Anode MA: 183.5mA 200.0mA 183.2mA
High power; Large filament; 120kV 400mA 2s 902496CTIP CTi Performix Adv
Thu Apr 15 10:55:13 2004 High voltage status
---------------------------------------------------------------------
1. Total KV: 119.3KV 120.0KV 119.8KV
3. Anode KV: 59.9KV 60.0KV 60.3KV

5. Anode MA: 369.6mA 400.0mA 369.1mA

Audible Results:
[ KV MA T/S WORK FLOW ]
Often listening closely to HV tanks can help diagnose generator problems. While major HV transformer
breakdowns can usually be heard when standing beside the gantry some intermittent or less serious
problems may require a stethoscope to amplify the sound. There is usually one available in most CT
rooms. If a stethoscope is not available a screwdriver blade held to a tank with the handle held to your ear
will help amplify sound within HV tanks.
Before you perform “No Load HV” testing, first use the stethoscope to listen to the HV tanks and become
accustomed to the normal background noises. Rotate the gantry a bit while listening to hear some of the
normal results below.
Normal Results
Under no load kV testing the tanks should be silent except for the background noises listed below
o Noise from tube fans if they are on.
o May hear occasional popping noises especially if rotating the gantry a bit.
o May hear some sloshing of the oil inside the tank when rotating the gantry a bit.
o Noise from the stethoscope tube rubbing on the gantry components
Failure results
HV Tanks:
Arcs are typically audible
o Typical HV tank arcing will sound like bacon frying, hissing with some arcing pops. (some
high freq content but predominantly <100 hz content) If there is only a very faint high
frequency (>1kHz) hissing sound it may just be a reflection from the tube.
o Multiple spits can sound like a rapid fire arcing sound.
Minor transformer breakdown or partial winding short
o Subtle humming during HV ON
Major transformer defects such as winding shorts can often be easily heard without any aid.
o Loud humming sound or even loud sound of oil bubbling.
Tube anode to casing or cathode to casing:

Arcs are typically audible as a relatively loud crack.
Tube anode to cathode spits:

Arcs in a vacuum are silent or at least much more difficult to hear.
HV cables
Warning: Never directly contact a HV cable to listen for arcs. Arcing in HV cables will not be
difficult to find because a carbon track will build with each arc, very quickly leading to either
constant arcing or a hard short. You also will be able to detect a burning smell. Years ago arcing
would occasional occur in a HV cable either at the end of the flexible cable under the horn or in
the termination. Since cable manufacturing was improved a long time ago HV cable arcs have
become very rare.
Site Examples:
There is a project underway to record audio samples as heard using a stethoscope to include in future
revisions.

403492LSP1 UAH Edmonton 10/28/04

Site down with very frequent spits and several Cathode OC errors. KV loop OK and Kv/MA results OK.
Using a stethoscope no spits heard in kV Loop no load testing. However in kV/mA Diag spits seemed to
occur under load and higher kVs. Using a stethoscope no spits heard at either AN or CA HV tanks and no
spits heard at Tube anode end but spits could be heard at the tube cathode end with pickup placed
against the round flat plate on the cathode end of the tube casing. Sounded like a muffled metallic "tink,
tink, tink" as if a metal hammer was hitting a metal surface. Spits heard correlated with the spit count
reported by the system error messages. Conclude tube is spitting but suspicious there may be some
other root cause for poor tube life and history of generator problems. Will install bleeder to check HV
waveform first. Original kV bd bleeder and scope measurements @100 kV/50mA; AN 55.6 kV w/ 3.6 kV
overshoot; CA 52.4 kV w/ 0 kV overshoot. At a 140 kV technique this translates to a total KV 151 and if
you include the overshoot 156 kV. This could definately have a serious impact on HV component life.
Tube replaced 10/29/06 16:25 but spits and Cathode OC continued.
Cathode Tank replaced 10/29/04 17:30 and problems resolved but only for a short time before this new
CA tank also failed with spits, Cathode OC and mA kV out of tolerance. Hard failure with loud humming
from tank like oil boiling.
604520QXI RCH; LS_2x; 112304;

Intermittent Anode OC only, 4x 11/20/04 3day ago and none since, no max spits or other kVmA errors,
one rotor error ~24 days ago
Tube 18 months old with 168 kAs Suspect Failing Tube
Location Test Normal HV Spits KVA fail
Anode Tank Kv Loop 140kV 30s
Cathode Tank Kv Loop 140kV 30s
Tube-cathode end Kv Loop 140kV 30s
Anode Tank kV/mA 140 kV 100mA 10 sec Low

Anode Tank kV/mA 140 kV 100mA 10 sec High
Cathode Tank kV/mA 140 kV 100mA 10 sec Low
Cathode Tank kV/mA 140 kV 100mA 10 sec High
Tube-cathode end kV/mA 140 kV 100mA 10 sec Low
Tube-cathode end kV/mA 140 kV 100mA 10 sec High
Anode Tank Rotor Diag

Tube-cathode end Rotor Diag
604434AQXI BGH; LS_2x; 112404;

Intermittent Anode OC, AN tank was replaced already but failed hard within 12 hours and original
nd
replaced. Tube then replaced but AN OC continued. 2 Anode tank replaced 112404
o Metallic “ting” can sometimes be heard at a tank or tube when the HV comes up at the start of an
exposure. Since the Anode tank failed hard the next day it is not certain if this was an early
indication of problems.
Location Test Normal HV Spits KVA fail
Anode Tank Kv Loop 140kV 30s
Cathode Tank Kv Loop 140kV 30s
Tube-cathode end Kv Loop 140kV 30s
Anode Tank kV/mA 140 kV 100mA 10 sec Low

Anode Tank kV/mA 140 kV 100mA 10 sec High
Cathode Tank kV/mA 140 kV 100mA 10 sec Low
Cathode Tank kV/mA 140 kV 100mA 10 sec High
Tube-cathode end kV/mA 140 kV 100mA 10 sec Low
Tube-cathode end kV/mA 140 kV 100mA 10 sec High
Anode Tank Rotor Diag

Tube-cathode end Rotor Diag

Sec 8 Quick Review Highlights:

Xray Generator Troubleshooting Flow Diagrams
• All problem diagnosis should begin on the Main Troubleshooting Flow Diagram
• Return to Flow diagrams after each action to keep focused on workflow and next steps
• Logic flow represents field experience best practices at the time of publishing
Standardized test sequences:

• Designed to exercise all generator modes of operation
• Optimum chance of uncovering intermittent failures
• Allows for comparison to typical results if exact techniques are followed
• Provides support resources with the right data to give a second opinion
KV or mA error test sequence

Sequence (1) No Load kV - Basic Test; >> Check for 0kV, HV spits, or Inverter overcurrents.
Sequence (2) Xray Test - Low, Med, High Power; >> Compare results to typical values.
Sequence (3) No Load kV - Extended Test 140kV 30sec; >> Check for HV Spits or overcurrents
Sequence (4) Xray Test - Extended 140kV 100mA; >> Check for HV Spits or overcurrents
Sequence (5) Fiber Optics Test; >> If directed by flowchart
Sequence (6) Optional; Scope HV Waveforms
Sequence (7) Optional; Heat Soak and Seasoning
Milwaukee Learning Solutions

An Xray Generation troubleshooting simulator is available based on this document.
Vist the MyLearning site to take the simulation test. (2 fault scenarios )

Xray Generation Troubleshooting

Uploaded by

Copyright:

Available Formats

You might also like

Xray Generation Troubleshooting

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Xray Generation Troubleshooting

Uploaded by

Copyright:

Available Formats

e GE Healthcare Canada

Diagnostic Imaging Service Operations

Xray Generation T/S

Author: Mike MacNeil

05/30/05 Rev 4 MMN PROPRIETARY 1 of 50 Xray Gen TS LS_1x-4x rev4.doc

Sec 2 Troubleshooting Flow Diagrams

AutoSC logsummary report

HVDC or low mains

Y Rotor or kV/mA N HVDC

Analyze all test results

05/30/05 Rev 4 MMN PROPRIETARY 2 of 50 Xray Gen TS LS_1x-4x rev4.doc

Sec 2.2 Rotor T/S Work Flow

IF rotor only fails Y

05/30/05 Rev 4 MMN PROPRIETARY 3 of 50 Xray Gen TS LS_1x-4x rev4.doc

Sec 2.3 Filament T/S Work Flow

Y Check/Replace High Y Replace Cathode

05/30/05 Rev 4 MMN PROPRIETARY 4 of 50 Xray Gen TS LS_1x-4x rev4.doc

Sec 2.4 kV/mA TS Work Flow (page1 of 2)

kV values Y Remove HV Note: Fill vacant HV cable wells with

05/30/05 Rev 4 MMN PROPRIETARY 5 of 50 Xray Gen TS LS_1x-4x rev4.doc

Sec 2.4 kV/mA TS Work Flow (page 2 of 2)

Review diag 5 Check/Replace:

Suspect: Swap Inverters

Make a note if Heater/

Y Suspect Cathode Tank

05/30/05 Rev 4 MMN PROPRIETARY 6 of 50 Xray Gen TS LS_1x-4x rev4.doc

Sec 3 Troubleshooting Methodology

05/30/05 Rev 4 MMN PROPRIETARY 7 of 50 Xray Gen TS LS_1x-4x rev4.doc

Sec 4 Diagnostic Functions

Sec 4.1 HVDC

Return to work flow for decision path

183182 OBC Generator gen_rotor.c 1.39 SYSTEM POWER CONTROL : HVDC

183338 OBC Generator gen_power.c 1.13 SYSTEM MONITORING : HVDC

05/30/05 Rev 4 MMN PROPRIETARY 8 of 50 Xray Gen TS LS_1x-4x rev4.doc

Sec 4.2 Rotor

Rotor Test Sequence (1): Stationary Gantry

Failure or abnormal results

05/30/05 Rev 4 MMN PROPRIETARY 9 of 50 Xray Gen TS LS_1x-4x rev4.doc

Rotor Test Sequence (2): Rotating Gantry

2) Risk of misdiagnosed Performix Tubes due to Anode(HEMIT) Tank failure

05/30/05 Rev 4 MMN PROPRIETARY 10 of 50 Xray Gen TS LS_1x-4x rev4.doc

05/30/05 Rev 4 MMN PROPRIETARY 11 of 50 Xray Gen TS LS_1x-4x rev4.doc

A. Monitor gesyslog for Filament errors

Filament open errors: Resistance tests

05/30/05 Rev 4 MMN PROPRIETARY 12 of 50 Xray Gen TS LS_1x-4x rev4.doc

05/30/05 Rev 4 MMN PROPRIETARY 13 of 50 Xray Gen TS LS_1x-4x rev4.doc

Open loop tube mA

Closed loop tube mA

05/30/05 Rev 4 MMN PROPRIETARY 14 of 50 Xray Gen TS LS_1x-4x rev4.doc

[ FILAMENT T/S WORK FLOW ]

05/30/05 Rev 4 MMN PROPRIETARY 15 of 50 Xray Gen TS LS_1x-4x rev4.doc

A. Monitor gesyslog during testing for HV Spits or other generator errors

05/30/05 Rev 4 MMN PROPRIETARY 16 of 50 Xray Gen TS LS_1x-4x rev4.doc

A. Monitor gesyslog during testing for HV Spits or other generator errors

Sequence (3): No Load kV – Extended Test 140kV 30sec (15-30 min.)

A. Monitor gesyslog during testing for HV Spits or other generator errors

05/30/05 Rev 4 MMN PROPRIETARY 17 of 50 Xray Gen TS LS_1x-4x rev4.doc