Spellman XRV320P&N4500, Instruction Manual

Page 1: ...igh Voltage Power Supply MODEL SERIAL DATE SPELLMAN HIGH VOLTAGE ELECTRONICS CORPORATION 475 Wireless Blvd Hauppauge New York 11788 1 631 630 3000 FAX 1 631 435 1620 E mail sales spellmanhv com Website www spellmanhv com X RAY INSPECTION GENERATOR XRV SERIES ...

Page 2: ...Load 0 1 of rated output voltage for a full load change Line 0 1 of rated output voltage over specified input voltage range Output Polarity See model selection table Output Current See model selection table Ripple See model selection table Temperature Coefficient 1 8kW 3 0kW 4 0kW and 4 5kW models 50ppm C 6 0kW models 50ppm C Emission Current Accuracy 0 25 Stability 100ppm C 1 8kW 3 0kW 4 0kW and ...

Page 3: ...8kW 3 0kW 4 0kW 6 0kW 1 8kW 4 5kW Ripple Noise p p 0 025 0 05 0 1 0 25 0 025 0 1 Dimensions 10 5 H x 17 W x 24 D 10 5 H x 17 W x 24 D 10 5 H x 17 W x 24 D 10 5 H x 17 W x 24 D 2 x 10 5 H x 17 W x 24 D 2 x 10 5 H x 17 W x 24 D Weight 150 lbs 68kg 150 lbs 68kg 150 lbs 68kg 155 lbs 70 3kg 300 lbs 136 kg 300 lbs 136 kg Output Connector R24 R24 R24 R24 Two R24 Two R24 XRV225 450 SPECIFICATIONS XRV225 1...

Page 4: ...tor 50V 10mA max 20 X Ray ON X Ray ON status low X Rays are ON open collector 50V 10mA max 21 Interlock Status Low interlocks are closed can enable HV open collector 50V 10mA max 22 GND Digital ground 23 X Ray ON Pre Warn Pre warning low before X Ray ON open collector 50V 10mA max 24 Reset Active low minimum 10mS transition 25 Arc fault Low arc fault the HVPS has detected an arc open collector 50V...

Page 5: ...R VIEW REAR VIEW POWER ON POWER SUPPLY READY FILAMENT ON X RAY ON PRE WARNING POWER SUPPLY FAULT INTERLOCK OPEN FAULT ON FAULT UV FAULT DC FAULT L C FAULT OVER POWER FAULT FILAMENT FAULT MVMW FAULT OVER TEMP FAULT MA DIFF FAULT KV DFF FAULT ARC CATHODE ARC ANODE TEMP APPCH WARNING POWER ON POWER SUPPLY READY FILAMENT ON X RAY ON PRE WARNING POWER SUPPLY FAULT INTERLOCK OPEN FAULT ON FAULT UV FAULT...

Page 6: ... aware of the electrical hazards WARNING note in the text call attention to hazards in operation of these units that could lead to possible injury or death CAUTION notes in the text indicate procedures to be followed to avoid possible damage to equipment Copyright 2000 Spellman High Voltage Electronics Corporation All Rights Reserved This information contained in this publication is derived in par...

Page 7: ...spannungsnetzteiles benötigen ca 5 Minuten um sich zu entladen Erden Sie sich nicht und arbeiten Sie nicht in feuchter oder nasser Umgebung Notwendige Reparaturen können es erforderlich machen den Gehäusedeckel während des Betriebes zu entfernen Reparaturen dürfen nur von qualifiziertem eingewiesenem Personal ausgeführt werden WARNING im folgenden Text weist auf gefährliche Operationen hin die zu ...

Page 8: ...de l alimentation Ne vous mettez pas à la masse ou ne travaillez pas sous conditions mouillées ou humides La maintenance peut nécessiter l enlèvement du couvercle lorsque l alimentation est encore allumée Les réparations doivent être effectuées par une personne qualifiée et connaissant les risques électriques Dans le manuel les notes marquées WARNING attire l attention sur les risques lors de la m...

Page 9: ...carica della capacità interna dell alimentatore ad alta tensione Non mettere a terra il proprio corpo oppure operare in ambienti bagnati o saturi d umidità SICUREZZA NELLA MANUTENZIONE Manutenzione potrebbe essere richiesta rimuovendo la copertura con apparecchio acceso La manutenzione deve essere svolta da personale qualificato coscio dei rischi elettrici Attenzione alle AVVERTENZE contenute nel ...

Page 10: ...ERCONNECTIONS AND SETUP SINGLE ENDED 12 4 10 SYSTEM INTERCONNECTIONS AND SETUP BI POLAR 13 4 11 HV CONNECTOR J1 14 4 12 HV CABLE INSTALLATION INSTRUCTIONS 14 5 USER INTERFACE AND CONTROL 16 5 1 COMPUTER INTERFACE 16 5 1 1 RS 232 Digital Interface J3 9 pin D female connector 16 5 1 2 Ethernet Digital Interface J4 8 pin RJ45 connector 17 5 1 3 USB Digital Interface J5 4 pin USB B connector 18 5 2 AN...

Page 11: ...ing limits 28 7 2 APPLICATION SOFTWARE INSTALLATION 31 7 2 1 Installing GUI Software from the CD provided 32 7 2 2 Downloading Application Software via FTP Site 32 8 MAINTENANCE RECOGNIZING FAULTS AND FILAMENT ADJUSTMENTS 32 8 1 MAINTENANCE 32 8 2 RECOGNIZING FAULTS 33 8 2 1 Front Panel Faults 33 8 2 2 Front Panel LED Summary 34 8 3 FILAMENT ADJUSTMENTS 38 9 FIELD REPLACEABLE ITEMS 42 10 SCHEMATIC...

Page 12: ...gned to meet the FDA safety requirements Title 21 part 1020 section 20 21 CFR 1020 40 Cabinet X ray Systems as used in the NDT application 1 3 Interferences Between Equipment The device was designed and manufactured to minimize electromagnetic or other interferences Tests have been performed to evaluate potential risks that could originate from the device itself or the surrounding environment All ...

Page 13: ... to personnel Always shut off the supply circuit breaker s and follow an appropriate grounding procedure to discharge the output before touching any exposed connections DO NOT rely on the unit s instrumentation or controls to determine that the output is safely discharged The sensors are driven by amplifiers which are powered by an internal low voltage power supply as are the indicator LEDs There ...

Page 14: ...AFETY SYMBOLS The following safety related symbols are found on the unit Caution consult operation manual High voltage connection dangerous Voltage 1000V Ground connection XRV SERIES Page 5 118116 001 REV C ...

Page 15: ...amage which may have occurred during shipping In the unusual event that shipment damage has occurred contact the transportation company and the manufacturer immediately If additional materials have been enclosed in the shipping crate such as cables etc inspect them as well Then put them aside and DO NOT proceed until the operation manual has been completely read and understood XRV SERIES Page 6 11...

Page 16: ...e procedure Only persons who are properly trained are allowed to carry out the installation 4 1 Overview of the Connections Cathode 160kV User I O Connections J7 Anode Inverter Control Bipolar J6 Anode Feedback Bipolar JB1 Main AC Input JB2 Main AC Output Anode Bipolar J1 High Voltage connector Ground Stud XRV 160kV Cathode XRV SERIES Page 7 118116 001 REV C ...

Page 17: ...4 2 Overview of the Connections Anode 160kV XRV 160kV Anode Ground Stud AC Input JB1 J2 Feedback J3 Inverter Control J1 High Voltage connector XRV SERIES Page 8 118116 001 REV C ...

Page 18: ...ions Cathode 225kV User I O Connections J1 High Voltage connector JB2 Main AC Output Anode Bipolar J7 Inverter Control Bipolar Ground Stud J6 Feedback Bipolar JB1 Main AC Input XRV 225kV Cathode XRV SERIES Page 9 118116 001 REV C ...

Page 19: ...4 4 Overview of the Connections Anode 225kV XRV 225kV Anode J1 High Voltage connector Ground Stud AC Input JB1 J2 Feedback J3 Inverter Control XRV SERIES Page 10 118116 001 REV C ...

Page 20: ...ired 4 6 Main and Aux AC Input Power JB1 Connector 4 6 1 Main AC input Power Voltage 180VAC 264VAC 50Hz 60Hz Current 30 Amp max Pin D Line 1 Pin F Neutral Line 2 US Pin E Ground NOTE Use 3 conductor cable or single isolated wires rated no less than 600VAC 30 Amps wire size 10 AWG 4 6 2 Aux AC Input Power Voltage 180VAC 264VAC 50Hz 60Hz Current 5 Amp max Pin A Line 1 Pin C Neutral Line 2 US Pin B G...

Page 21: ...re are three different interlock functions and if any one of the three operates the HV output will cease These three functions are summarized below All the critical cable connection are interlocked so disconnecting any of these cables from the PCBs will immediately turn off the HV output Interlock 1 customers external interlocks Interlock 2 second customer s external interlock 4 9 System Interconn...

Page 22: ...4 10 System Interconnections and Setup Bi Polar XRV SERIES Page 13 118116 001 REV C ...

Page 23: ... and plug tip using lint free cloth and isopropyl alcohol Insert the high voltage cable plug into the HVPS receptacle Adjust flange to achieve a gap of 4 5mm between the cable mounting flange and the Receptacle Remove plug from the receptacle Wearing latex gloves apply silicone compound to the rubber area of the connector Apply 0 1 mm thick layer to the entire exposed area but don t apply any sili...

Page 24: ... This procedure should be followed whenever the cable plug is removed from the cablewell Silicone Compound Area Tip Mounting Flange XRV SERIES Page 15 118116 001 REV C ...

Page 25: ... unit to J2 a manual analog controller The Analog controller must meet the interface requirement as indicated on page 18 J2 I O PINOUT for both analog and digital logic signals 5 1 Computer Interface 5 1 1 RS 232 Digital Interface J3 9 pin D female connector Pin Signal Parameters 1 NC 2 TX out Receive data user 3 RX in Transmit data user 4 NC 5 SGND Ground 6 NC 7 NC 8 NC 9 NC Communication Paramet...

Page 26: ...be set by the system integrator RJ 45 connector Network attachment via Crossover and Standard Ethernet cables Supported Operating System Windows XP Professional The Ethernet RJ 45 has two LED indicators as shown in Figure 5 The left LED LED1 indicates that the network processor has a valid network link The right LED LED2 indicates network activity 8 7 6 5 4 3 2 1 LED 2 LED 1 Pin Signal Parameters ...

Page 27: ...d USB 2 0 specifications Type B male connector Included driver can be communicated with via standard Windows serial communications methods Pin Signal Parameters 1 VBUS 5 VDC 2 D Data 3 D Data 4 GND Ground 5 2 Analog Interface User I O J2 25 Pin D female connector See Data Sheet for Pin Out XRV SERIES Page 18 118116 001 REV C ...

Page 28: ...red voltage magnitude A current limiting resistor is located at the HV output to limit to the arc current when the electron source arcs A compensated HV divider is located at the output of the multiplier to provide voltage feedback The feedback signal from the HV divider is fed into a summing junction of an error amplifier two pole two zero configuration in the system control board The program or ...

Page 29: ...diate This enable signal will also enable disable the PWM or the drive inverter for the high voltage The kV error amplifier system is connected to PWM Controller The PWM outputs are used to drive the gates of the HV inverter The regulator inputs outputs are normalized to 10V Full scale These circuits should be able to operate linearly with 11V range for testing and burn in purposes 110 full scale ...

Page 30: ...ill rise but then be limited to the Filament Current Limit setting In this case a Filament Regulation Error will occur and a Filament Fault will occur Lastly the maximum filament current is set by design and factory settings The mA error Filament control loop amplifier system is connected to the PWM Controller The PWM outputs are used to drive the gates of Filament inverter The PWM Controller and ...

Page 31: ...e DSP 10 mA Diff Bipolar units compares Cathode Anode DSP 5 Digital logic functions are implemented in the DSP All of the fault latching is done in the DSP The DSP is field programmable An array of Fault Status LED s located on the front panel provided a visual indication of the status of the HVPS and to identify fault conditions The DSP supports remote communications and diagnostics over RS 232 E...

Page 32: ...nected Green ON if USB is connected DS5 HV in current limit Red OFF DS6 Filament in current limit Red OFF DS7 Over temp cathode inverter Red OFF DS8 Over temp cathode inverter Red OFF DS9 Cable connection Cathode Red OFF DS10 Cable connection Anode Red OFF DS11 Local Control selected Green OFF ON if Local Control selected X ray ON OFF timing Sequence XRV SERIES Page 23 118116 001 REV C ...

Page 33: ...577 XXX Power Inverter Board 460156 XXX which includes Power Factor Correction PFC Circuits DC rail voltage filter caps 304440 XXX L1 PFC Boost Choke and Temperature Switch SW1 and cooled by Fan B1 When the nominal 230VAC power is applied to the Power Supply it proceeds to EMI filter then arrives to the Inverter Power Board where a Line Voltage Detector monitors the AC input line which will issue ...

Page 34: ...ormer and a RMS converter that is calibrated to provide actual filament current that is scaled 10VDC maximum specified Amps If Filament Current fails to be regulated to the programmed Filament current Filament regulation error will occur and a filament fault will be issued by the DSP Filament selection L S is monitored by a filament confirm signal to the DSP and if filament selected is not equival...

Page 35: ... HV Multiplier Assembly located in the HV Assembly Section 6 6 HV Assembly 6 6 1 HV Multiplier Assembly The HV Section contains HV Multiplier Assembly Current Limiting Assembly HV Divider and HV Output Cablewell J1 All these components are encapsulated in silicon rubber The Current Limiting Resistors limit the X Ray Tube arcing current The HV Divider provides a HV Feedback Signal for the feedback ...

Page 36: ... HVPS control using the X Ray Power Supply Controller software Check all connections interlocks and grounds Check that the Tube Cooling System is On and functioning normally Turn On the mains power to the System See Manual for installation and control instruction HVPS control using Analog Control The Analog controller must meet the interface requirement as indicated on page 20 J2 Analog I O for bo...

Page 37: ...erating limits Connect the RS 232 cable from PC to J3 of HVPS Turn ON power to the HVPS Start the GUI software and establish communication with HVPS select User Configs Tab which is password protected contact factory for password Enter power limit for small large filament Enter filament limit small large Enter pre heat current small large XRV SERIES Page 28 118116 001 REV C ...

Page 38: ...s related to a full scale reading of analog converter on the system control board The default setting for all units is 87 this value should not be changed without consulting the factory XRV160 100 192kV 87 167kV XRV225 100 270kV 87 234kV XRV320 100 384kV 87 334kV XRV450 100 540kV 87 469kV XRV SERIES Page 29 118116 001 REV C ...

Page 39: ...e values to the power supply all user parameter are saved in memory inside the HVPS Recall user parameters click in box click here to request user parameters all user parameters are recalled from HVPS memory to GUI controller for viewing Filament Parameters Large Power Limit This is maximum power that can be set product of kV multiplied mA when Large Filament is selected Over power fault will occu...

Page 40: ...Amps Cal Current with actual load Filament Preheat Current Large 0 6 Amps 2 Amps Typical value Current Limit Large 2 Filament Preheat Current Small 0 6 Amps 2 Amps Typical value Current Limit Samll 2 Arc Trip Counter 0 30 1 Arc Quench Time 10msec 1sec 50 msec Counter will reset in 100X set value 100sec max kV Slew Time 100 msec 10sec 5 sec Typical 5 sec mA Slew Time 100 msec 10sec 5 sec Typical 5 ...

Page 41: ... MAINTENANCE RECOGNIZING FAULTS AND FILAMENT ADJUSTMENTS 8 1 Maintenance Very little maintenance is required since there are no serviceable parts inside Keep fan filter clean and all vents free from obstruction or dirt build up There are two Warnings that must be checked periodically The first is Temp Approach Warning indicates that ambient temperature is above 45 C and a latch Over Temp Fault wil...

Page 42: ... 8 2 1 Front Panel Faults During normal operation only Green LEDs should be illuminated on the front panel Any red LED indicates a fault or incorrect operation LED s on the control board report any faults or incorrect operation that the XRV recognizes and that occur during normal operation XRV SERIES Page 33 118116 001 REV C ...

Page 43: ...rlock fault has occurred Red OFF OV Fault Over Voltage Fault Red OFF UV Fault Under Voltage Fault Red OFF OC Fault Over Current Fault Red OFF UC Fault Under current Fault Red OFF Over Power Fault Over power Fault Red OFF Filament Fault Filament Fault Red OFF HV Inv Fault HV Inverter Fault Red OFF Over Temp Fault Over Temperature Fault Red OFF mA Diff Fault mA Difference Fault Bi polar Red OFF kV D...

Page 44: ...ximum allowable current This may be caused by X Ray tube HV cable Regulator PWA failure Low End PWA Diagnosis The OVER CURRENT FAULT LED will illuminate HV output will be disabled Temperature Fault This fault occurs when a high temperature condition is detected on the inverter assembly The system control board then latches the temperature fault to prevent damage to the inverter This may be caused ...

Page 45: ... detected via the interface issue a reset and set Maximum rated kV output Listen again for multiple arcs and attempt to localize the problem to X Ray Tube or HVPS For X ray tube problems refer to the appropriate documentation Filament Fault This fault occurs when the system detects a problem with the filament selection or filament current regulation This may be caused by System control board PWA f...

Page 46: ...ol interface issue a reset If HV Inverter LED is still illuminated then If the problem appears to be in the HVPS verify on Power Inverter input line is 230 AC 10 If not Check Main AC Line Verify that DC BUS is at 400VDC Interlock Open Fault This fault occurs when the system does not detect the proper External interlock signal This may be caused by Problem with the cool or door interlock Failure of...

Page 47: ...ctly in the high voltage cable connected to the tube The filament current limit data for small and large can be found in the Tube Specification Data Sheet Test equipment required 1 Measuring Adapter for high voltage socket 2 Measuring Adapter for high voltage cable plug 3 Digital Multimeter set for DC Current 10 Amps Max 1 2 Trained personnel only 3 Safety Ground Wire C Common Connection L Large F...

Page 48: ...ting from zero current slowly increases filament large pre heat setting and at the same time monitoring the actual current from the digital multimeter Never exceed maximum tube current Increases actual filament current till 10 below the maximum filament current as specified in the tube data sheets The actual filament current and the monitored current that is read by either GUI or Analog Control sh...

Page 49: ...led Discharge cable by grounding the high voltage tip of cable to the power Supply chassis ground Connect common wire of measuring adapter 1 to ground E1 of HVPS and also common of measuring adapter 2 of on the high voltage cable side Connect small filament wire of measuring adapter 1 to small filament wire of measuring adapter 2 To measure DC current in large filament connect digital multimeter 3...

Page 50: ...ime monitoring the actual current from the digital multimeter Never exceed maximum tube current Increases actual filament current till 10 below the maximum filament current as specified in the tube data sheets The actual filament current and the monitored current that is read by either GUI or Analog Control should be within 1 tol If reading is not at spec readjust R36 SMALL FIL I CAL on Filament F...

Page 51: ...20 407003 001 HV Assembly Anode 160 320 407111 001 Inverter Module Assembly 160 320 407105 001 HV Transformer 160 320 407006 001 HV Assembly Cathode 225 450 406996 001 HV Assembly Anode 225 450 407108 001 Inverter Module Assembly 225 450 407000 001 HV Transformer 225 450 406999 001 System Control Board 460130 001 Front Panel LED Display 460124 001 24V LVPS LLP 150 24 EMI Filter 10KE1 XRV SERIES Pa...

Page 52: ... Assy ANODE 460158 001 460158 001 460158 001 460158 002 460158 001 460158 002 Fil FDBK Bd Schematic 441170 001 441170 001 441170 001 441170 001 Inverter Module Assembly 407105 001 407000 001 407105 001 407000 001 Power Inverter Bd Assy 460156 002 460156 001 460156 002 460156 001 Power Inverter Bd Sch 441164 001 441164 001 441164 001 441164 001 System Control Assy 460130 001 460130 001 460130 001 4...

Page 53: ...lleged breach of this warranty No modification amendment supplement addition or other variation of this warranty will be binding unless it is set forth in a written instrument signed by an authorized officer of Spellman Factory Service Procedures For an authorization to ship contact Spellman s Customer Service Department Please state the model and serial numbers which are on the plate on the rear ...