Instructions for Use

Air Purge Tool

For GE LightSpeed VCT series CT Scanners
Using the Reevo 240G X-ray Tube Assembly

453575086900 Rev A 01/11

 INSTRUCTIONS FOR USE

Table of Contents
1.0 SAFETY INFORMATION .......................................................................................... 4
1.1 General ...................................................................................................................... 4
1.2 Radiation Protection.................................................................................................. 5
1.3 Electrical Safety ........................................................................................................ 5
1.4 Disposal..................................................................................................................... 5
1.5 Transportation ........................................................................................................... 5
2.0 INSTALLATION & MAINTENANCE ....................................................................... 6
2.1 Installation................................................................................................................. 6
2.2 Planned Maintenance – General ............................................................................... 6
3.0 Damage & Return ......................................................................................................... 6
3.1 Carrier Damage ......................................................................................................... 6
3.2 Return Process .......................................................................................................... 6
4.0 Contents ........................................................................................................................ 7
5.0 Instructions .................................................................................................................. 10
5.1 Procedure ................................................................................................................ 11
5.1.1 Preparation ....................................................................................................... 11
5.1.2 Checking Pump and Heat Exchanger for Contaminants.................................. 13
5.1.3 Prepare the Purge Tool..................................................................................... 14
5.1.4 Connect Purge Tool to Heat Exchanger and Pump Assemblies ...................... 16
5.1.5 Connect Purge to Tube..................................................................................... 19
5.1.6 Heat Exchanger Compensation ........................................................................ 20
5.1.7 Check Tube Alignments .................................................................................. 25
6.0 Cleanup ....................................................................................................................... 26

2 453575086900 Rev A 01/11

Preface
The Dunlee Reevo 240G X-ray tube for GE 100 kW VCT systems was released at RSNA
2009. We have since developed several new tools to help our customers perform tube
changes on these very sophisticated systems.

It was discovered that the quick disconnects for the oil cooling system have a tendency to
leak oil and/or to admit air into the cooling system. After a few X-ray tube changes (3-5
tubes), there could be enough air in the system to induce image artifacts. The VCT Air
Purge Tool is designed to remove any air within the cooling system and replace any lost
oil. We highly encourage (and even insist) that all tube changes on VCT scanners be
checked for air using the Oil flow Check Tool. The Air Purge Tool includes the Oil Flow
Check Tool. Failure to perform the Purge once air is identified within the system can and
will result in image artifacts and, with enough air, could damage the oil pump. A failed
oil pump results in overheating and possibly destruction of the X-ray tube. The Oil Flow
Check Tool also includes a second hose assembly to verify the oil flow rate.

On occasion, the X-ray tube assembly may experience an anode failure. Such a failure
may result in compromising the insert. The Oil Flow Check Tool will allow you to verify
if anode particles have been released into the oil and cooling system. This is a situation
where the complete cooling system consisting of the X-ray tube, oil pump, and heat
exchanger must be replaced.

For additional information, please contact one of our Technical Service Engineers at 1-
800-238-3780 or +1-630-585-2000.

Copyright
© 2010 DUNLEE
All rights reserved. Reproduction in whole or in part is prohibited without the prior written consent
of the copyright-holder. DUNLEE reserves the right to make changes in specifications or to
discontinue any product, at any time without notice or obligation, and is not liable for any
consequences resulting from the use of this publication.

Subject to change without notice.

All changes will be in compliance with regulations governing manufacture of medical equipment.
Printed in the USA.
Document originally drafted in English.

3 453575086900 Rev A 01/11

1.0 SAFETY INFORMATION
1.1 General
This manual is designed to make it possible for you to work with the Air Purge Tool in a safe
manner. You may operate the X-ray tube housing assembly and the Air Purge Tool only in
compliance with the safety instructions in this manual and not use it for purposes other than for
which it is intended. The X-ray system may only be operated by persons who have the necessary
expertise in radiation protection and who have been instructed in how to operate the X-ray
system.

Potential for Burns. Severe personal injury via burns can occur

from contact with hot oil. Do not service while tube and oil are

hot (See required condition, below).

Potential for personal injury. Gantry oil pump should not be energized during air

removal process.

Personal injury or damage to unsecured hoses during gantry

rotation. Be careful of pinch points.

Tube temperature needs to be less than 200º C prior to proceeding with

Purge procedure.

It is always the user who is responsible for compliance with the regulations applying to installation
and operation of the X-ray unit
• You must never use the X-ray Tube Housing Assembly or any associated diagnostic
imaging equipment if it has any electrical, mechanical or radiological defects. This
particularly applies to faulty indicators, displays, warnings and alarms.
• If the assembler wishes to connect this product to other equipment, components or
assemblies and if it is not apparent from the technical data whether it can be safely
combined with such equipment, components or assemblies, the user must ensure that
the safety of the patient, operating staff, third parties and the environment is not affected
by the planned combination by consulting the manufacturers involved or by making
inquires from an expert.
• Dunlee and Philips are responsible for the safety features of its products only if persons
explicitly authorized to do so by Dunlee or Philips have performed maintenance, repairs
and modifications.
• As with any technical appliance, this equipment requires - correct operation - regular,
competent maintenance - care

4 453575086900 Rev A 01/11

 • If you operate the Air Purge Tool incorrectly or if the user fails to maintain it properly, Dunlee
and/or Philips cannot be held responsible for any malfunctions, damages or injuries.
• Safe operation of the Air Purge Tool is only guaranteed when it is used according to its
specification and instructions. In case the specification or instructions limits are
disregarded, there is the danger of oil leaks and expelled component parts as a result of
implosion/explosion. In such cases the manufacturer of the Air Purge Tool excludes any
liability. Any guarantee claims for this product are rejected.

1.2 Radiation Protection

Make certain that all necessary radiation precautions have been taken. You can find information
about radiation precautions in the instructions for use for the individual X-ray systems with which
you are using.

1.3 Electrical Safety

• Only trained maintenance staff may remove the covers from the X-ray system.
• This product may only be used in medical rooms which meet the requirements of relevant
national and international standards and laws.
• You must not use this product in areas where there is danger of explosion.

1.4 Disposal
• Take-back, proper disposal and recovery of this product must take place in accordance
with the European WEEE Directive (Waste Electrical and Electronic Equipment) and the
requirements of national legislation.
• Our state-of-the art X-ray equipment is manufactured according to safety and
environmental protection procedures. Under normal operation, there are no risks to
persons or the environment.
• To comply with regulations, it is necessary to use materials which may be harmful to the
environment and therefore have to be disposed of in a proper manner.
• Refer to the disposal section in this manual for details.
• CrossTrans 206 Oil does NOT contain Dioxin.
• Dunlee/Philips supports you in the recycling of the Air Purge Tool in accordance with
valid regulations and laws.
• Contact your Dunlee/Philips organization for proper handling and disposal.

1.5 Transportation
Extreme care must be taken when transporting the Air Purge Tool. It is recommended to transport
this product in the original packaging material. Transportation using other packaging material or in
any other way, may result in product damage

5 453575086900 Rev A 01/11

2.0 INSTALLATION & MAINTENANCE

2.1 Installation
Only trained and qualified service personnel must perform installation and operation of the Air
Purge Tool. The installation must be performed in accordance with the system documentation
provided. Consult the appropriate documentation for the removal and installation procedure.

2.2 Planned Maintenance – General

The Air Purge Tool is designed to aid in the diagnosis of X-ray Tube Cooling system problems
that may result in image artifacts and/or damage the X-ray tube housing assembly and
associated components. Should particulates be observed in the Clear Hose check, the hose
assembly must be returned to Dunlee for proper removal of the contaminated oil and refilled with
processed Crosstran 206. Contact Dunlee for details regarding the reconditioning of the Air Purge
Tool.

3.0 Damage & Return

3.1 Carrier Damage

In the unlikely event of damage due to handling by the carrier, it is important to follow a few
specific steps in order to receive proper credit:
1. Inspect the product immediately upon receipt. Check both the packing and the product for
physical damage.
2. If there is physical damage, call the carrier immediately and order a “Joint Inspection” of both
the packing and the product.
Within the United States:
3. If the product has been shipped freight pre-paid, return the product in accordance with the
instruction on the Return Form along with a copy of the Joint Inspection Report to Dunlee.
4. If the product has been shipped via the customer’s carrier, the customer must initiate the claim
process directly with the carrier.
Outside the United States:
5. Please consult your local sales and service office for instruction for return.

3.2 Return Process

Use the re-usable packaging for the return shipment of the defective product. This guarantees a
transport of the defective product in a packing which has been developed for this purpose.
Follow the instruction on the Return Form, fill in all required information and send it together with
the defective product.
Outside the United States:
If returning a product from outside the United States, please contact your local sales or service
representative for return instructions.

6 453575086900 Rev A 01/11

 4.0 Contents

Illustration 1: Oil Purge Tool

Drain Hose
with Male
Connector

12 VDC
Pump
Plastic
Funnel

Pump On/Off
rocker switch Oil outlet
pump –
female
disconnect
Oil/Air Return to Illustration 2: Oil Purge Tool
on blue hose
reservoir - male
disconnect on clear
hose

7 453575086900 Rev A 01/11

 Illustration 3: Oil Purge Tool

12 VDC
Pump

Reservoir

12 V, 120 W
50/60 Hz,
Single
output Reservoir
fill cap

Compensation
Tool

Clear Hose
Flow Meter
Hose

8 453575086900 Rev A 01/11

Oil Purge Tool Inventory

Qty Item Description

1 Power Purge Unit Assembly
1 Drain Hose w/ Male Connector
1 Operator Manual
1 Heat Exchanger Compensation Tool
1 Clear Hose w/ Quick Disconnects
1 Flow Meter w/ Quick Disconnects
1 Funnel
1 Heavy Duty Cleaning Wipes (Wet) /Canister
5 Absorbent Spill Pads
1 Oil Container filled with 2 gallons of CrossTran 206 oil
1 Empty Oil Container
2 Clear Plastic Bag
10 Cable Tie
10 Paper Towels
4 Container Cap (2 w/Red Dot for use during return shipment)

9 453575086900 Rev A 01/11

5.0 Instructions

This procedure is intended for use on GE CT Scanners using the GE Performix Pro 100 or
Dunlee Reevo 240G X-ray tubes.

LightSpeed VCT
LightSpeed VCT Select
LightSpeed TR16
LightSpeed Xtra
Discovery VCT
LightSpeed Pro 16 (100 kW version only)

This document provides the necessary steps to remove air from the CT tube oil cooling system.

The CT tube oil cooling system is a closed system. The system consists of the heat exchanger,
tube oil pump, and the CT tube as its main components. In the event that air is introduced into the
system, Image Artifacts and/or tube over heating issues can occur.

10 453575086900 Rev A 01/11

5.1 Procedure
5.1.1 Preparation
Prepare the Gantry
1. Ensure the gantry tilt is at 0 degrees.

2. Lower the table to the lowest position for front cover removal.

3. Remove right side cover to access service panel.

4. Power off the 120 VAC, Axial Drive Enable and HVDC Enable service switches.

5. Remove the Mylar window, covers from top, left side, and front of the gantry.
The front cover will need to be moved to the right side of the table so that the
electrical cables can be reconnected to the gantry. If there is no room for the front
cover to be placed on the right side of the table, the Gantry Display and Gantry
Control Panel will need to be put in the service positions. (See the Gantry Front
Cover Removal and Re-Install procedure located in the OEM service
documentation under Enclosure.)

6. Rotate the tube to the 2 o’clock position.

7. Unbolt the collars that secure the quick disconnects to the tube.

11 453575086900 Rev A 01/11

8. Decouple both hoses that connect the tube to the pump/heat exchanger.

9. Remove the hose bracket that secures the hose in a coiled position on the tube
housing.

12 453575086900 Rev A 01/11

5.1.2 Checking Pump and Heat Exchanger for Contaminants
1. Connect the Clear Hose to heat exchanger and pump assemblies.

2. Rotate Heat exchanger to 8 o’clock position.

3. Power on 120 VAC service switch, press reset on the Service Panel, and monitor
Clear Hose for air bubbles and particles circulating through hose. If no air
bubbles or particles are observed, tilt gantry to 30 degrees and monitor hose for
bubbles or particles.

If PARTICLES are observed, the pump, heat exchanger and tube

must be replaced as a complete set.
If ONLY AIR BUBBLES are observed, the air must be purged
from the system by following the rest of this procedure.

4. Power off the 120 VAC service switch.

5. Disconnect the Clear Hose from the heat exchanger and pump assemblies.
6. Disconnect the oil pump power connector, J52.

13 453575086900 Rev A 01/11

5.1.3 Prepare the Purge Tool
1. Place Purge Tool on the table towards the gantry so that the lid opens away from
the gantry.

2. Open the Purge Tool, remove the reservoir cap, and place rags or paper towels
around the opening to capture any oil spilled during the filling process.

NOTE: Set the voltage selector to the proper voltage for

your location before connecting to electrical outlet!

3. Place the funnel in the reservoir opening and fill reservoir with oil until at least
half full. (Put the reservoir cap in place to check oil level. Oil level should be at
least half full.)

14 453575086900 Rev A 01/11

4. Connect hoses, (outlet/return), quick disconnects to each other to purge air from
the Purge Tool BEFORE connecting the Purge Tool to the gantry.

5. Plug in the Purge Tool’s power cable into the service outlet on the gantry located
on the lower right side of the gantry. Power on the 120 VAC service switch on
the gantry and press the reset button on the Service Panel.

CAUTION: An Energized Gantry Presents Electrical and

Mechanical Hazards. Use extreme caution when rotating the
energized gantry by hand.

6. Once the gantry completes the boot up process, raise the table to a comfortable
working height. Do not advance the table into the gantry.

15 453575086900 Rev A 01/11

 7. Power on the Purge Tool and hold the quick disconnects overhead and observe
the oil flow through the hoses. Gently shake the hoses to help to remove trapped
air.

8. Once all of the air bubbles have disappeared from the hoses (about 2 minutes),
power off the Purge Tool and uncouple the quick disconnects.

9. Check oil level in reservoir and add if below half full.

5.1.4 Connect Purge Tool to Heat Exchanger and Pump Assemblies

1. Ensure Oil Pump’s power connector, J52, on gantry is disconnected.

16 453575086900 Rev A 01/11

2. Return the gantry tilt to 0 degrees.

3. With the Purge Tool’s power off, connect the Purge Tool’s hoses to the Pump and
Heat Exchanger assemblies (where the tube was connected).

4. Secure all of the hoses (loosely) to tube housing with cable ties to allow for
manual, unobstructed rotation of the gantry by hand.

5. Rotate the gantry clockwise until the heat exchanger is at 12 o’clock.

17 453575086900 Rev A 01/11

6. Power on the Purge Tool.

7. Leave heat exchanger in the 12 o’clock position for about 2 minutes, longer if air
bubbles are observed.

8. Rotate the heat exchanger, clockwise, to the 4 o’clock position for about 2
minutes, longer if air bubbles are observed.

9. Rotate the heat exchanger, clockwise, to the 8 o’clock position for about 2
minutes, longer if air bubbles are observed.

10. Tilt gantry to 30 degrees away from table with heat exchanger in the 8 o’clock
position for about 2 minutes, longer if air bubbles are observed.

11. Rotate the heat exchanger, counter-clockwise (to keep hoses from purge tool
untangled), to the 4 o’clock position for about 2 minutes, longer if air bubbles are
observed.

12. Rotate the heat exchanger to the 12 o’clock position for about 2 minutes, longer if
air bubbles are observed.

13. Tilt gantry to 30 degrees towards the table with heat exchanger in the 12 o’clock
position for about 2 minutes, longer if air bubbles are observed.

14. Rotate the heat exchanger, clockwise, to the 4 o’clock position for about 2
minutes, longer if air bubbles are observed.

15. Rotate the heat exchanger, clockwise, to the 8 o’clock position for about 2
minutes, longer if air bubbles are observed.

16. Power off Purge Tool and disconnect hoses from Heat Exchanger and Pump
assemblies.

17. Return gantry tilt to 0 degrees.

18 453575086900 Rev A 01/11

5.1.5 Connect Purge to Tube

NOTE: If the tube is being installed as new (never connected to a

gantry), it will not need to be purged.

1. With the Purge Tool’s power off, connect the Purge Tool’s hoses to the Tube.

2. Check the oil level in the Purge Tool and add if necessary.

3. Secure all of the hoses (loosely) to tube housing with cable ties to allow for
manual, unobstructed rotation of the gantry by hand.

4. Rotate the gantry until the tube is at 12 o’clock.

5. Power on the Purge Tool.

6. Leave tube in the 12 o’clock position for about 2 minutes, longer if air bubbles are
observed.
7. Rotate the tube, clockwise, to the 4 o’clock position for about 2 minutes, longer if
air bubbles are observed.

8. Rotate the tube, clockwise, to the 8 o’clock position for about 2 minutes, longer if
air bubbles are observed.

9. Rotate the tube, counter-clockwise, to the 4 o’clock position for about 2 minutes,
longer if air bubbles are observed.

10. Rotate the tube, counter-clockwise, to the 12 o’clock position for about 2 minutes,
longer if air bubbles are observed.

11. Power off the Purge tool and disconnect the hoses from the tube.

12. Reinstall the bracket to coil the Tube hose on the top rear of the tube housing.

13. Reconnect the tube hose to the heat exchanger.

19 453575086900 Rev A 01/11

5.1.6 Heat Exchanger Compensation

1. Remove rubber stopper from hose on Compensation tool.

2. Open valve on Compensation tool. Compensation

Tool
3. Place hose into oil container and draw oil into the Compensation tool by pulling
the handle. Hold tool vertical so that any air is at the top of the cylinder.

4. Position the Compensation tool so that the valve is higher than the handle. Push
the oil/air back into the oil container. This will help to rid the cylinder of
unwanted air.

5. Repeat step 3, drawing oil into the tool to the mark on the cylinder. If air is still
present in the cylinder, repeat step 4 to minimize the amount of air.

6. Close the valve.

20 453575086900 Rev A 01/11

7. Remove the hose from the oil container and wipe away excess oil. Place the
rubber stopper into the open end of the hose to prevent oil from dripping into the
gantry.

8. Power off the Axial Drive Enable and HVDC Enable service switches.

9. Position the Tube to the 4 o’clock position.

10. Power off the 120 VAC service switch.

11. Lock the gantry to prevent unwanted rotation.

12. Disconnect the Oil Pump hose from the Tube if not already done.

13. Connect the Compensation tool to the Tube.

14. Push the handle on the Compensation tool to force oil into the tube. Once you
feel resistance in the handle, stop.

21 453575086900 Rev A 01/11

15. If the handle is not fully depressed and there is oil still present in the cylinder,
disconnect the Compensation tool from the Tube.

16. Remove the rubber stopper from the hose on the Compensation tool and place
hose into oil container.

17. Open valve on tool and push handle in to force remaining oil out of tool. Do not
pull handle out at this time.

18. Close valve and wipe away oil from hose. Put rubber stopper back in hose.

19. Reconnect Compensation tool to tube.

22 453575086900 Rev A 01/11

20. Pull handle to draw 30 units of oil from the tube. Each gradicle, marked on the
cylinder, is 1 unit.

gradicles

Compensation Tool

21. Disconnect the tool from the tube.

22. Connect the Flow Rate Meter to the Tube and the Oil Pump.

23. Reconnect the power connector J52, on the Oil pump.

24. Power on the 120 VAC service switch.

23 453575086900 Rev A 01/11

25. After a minute, observe the Flow Rate Meter. It should read 4 GPM
(Gallons/Minute) or higher. If the rate is lower, the Oil Pump must be
replaced before system calibrations or clinical use. If the pump is not
replaced, this can cause thermal damage to the tube.

26. Power off the 120 VAC service switch.

27. Disconnect the Flow Rate Meter.

28. Connect the Tube and Oil Pump hoses.

29. Secure all cables and hoses on the gantry and check all plugs and connectors.

30. Unlock the gantry to allow rotation.

31. Manually rotate gantry to ensure no obstructions are present.

24 453575086900 Rev A 01/11

5.1.7 Check Tube Alignments
1. Power on the 120 VAC, Axial Drive Enable and HVDC Enable service switches
and press the reset button on the Service Panel.
2. Check BOW alignment.
3. Check ISO alignment.
4. Check CBF/SAG alignment.

If alignments are out of specification, perform corrective

actions according to the Tube Installation Manual.

5. Perform Hot ISO.

If overpressure errors occur during steps 2-5, more oil will need to
be removed from the tube. Repeat steps 1-21 and 28 of the Heat
Exchanger Compensation section and 1-5 of the Check Tube
Alignments section above. If no overpressure errors occur, proceed
with steps below.

6. Bolt the collars that secure the quick disconnects to the Tube.

7. Install covers, power on the 120 VAC, Axial Drive Enable, and HVDC Enable
service switches and press the reset button on the Service Panel.

25 453575086900 Rev A 01/11

6.0 Cleanup
1. Empty oil out of the Compensation tool by;
a. Removing rubber stopper in hose
b. Placing hose into oil container
c. Opening valve
d. Pushing handle completely in to force remaining oil from tool.
e. Close valve
f. Wipe away excess oil from tool and hose

2. Empty oil from Purge Tool reservoir by;

a. Attaching Drain Hose (open ended hose) to Purge Tool’s output hose via
quick disconnect
b. Place open end of Drain Hose into empty Oil Container marked “Off-Spec
Used Oil” on the red label.
c. With Tool on flat surface, elevate end of Purge Tool opposite the reservoir
pump a few inches to ensure oil flow to pump. (This helps to properly
drain the reservoir).
d. Power on the Purge Tool. Oil should flow into the oil container. Once
flow has minimized, power off Purge Tool and disconnect the open ended
hose from output hose.

e. Connect the Purge Tool’s output and input hoses together.

f. Unplug the Purge Tool, wipe away all excess oil and stow power cable
and hoses and funnel.

26 453575086900 Rev A 01/11

g. Replace the 2 black oil container caps with the Red Dot Caps.

Be sure to remove the old locking (tamper evident) band from the
container before screwing on the Red Dot Cap.

Once the Red Dot Caps are screwed on and locked on the containers, DO
NOT RE-OPEN them, as this will break the tamper evident band and
possibly lead to oil leakage during shipment.

END

27 453575086900 Rev A 01/11

 Service and Manufacturing Locations

Dunlee World Headquarters

555 North Commerce Street
Aurora, Illinois 60504 USA
Tel:
800.238.3780 (U.S. & Canada)
630.585.2100
Fax: 630.585.2125

Arlington Facility
2312 Avenue J
Arlington, Texas 76006 USA
Tel: 800.544.9729 (U.S. & Canada)
817.640.7666
Fax: 817.640.6644

28 453575086900 Rev A 01/11

29 453575086900 Rev A 01/11
30 453575086900 Rev A 01/11