System Setup Procedure_V9
- 1. System Setup Procedure_V9.docx 1 ******** System Setup Procedure Dual FC320 with Shared Cooler 12/2015 1.0 Part Designation Labeling All components of the system must be labeled. Use the label printer to create the following designation labels: Qty Label Location 1 V LAB IO IO Box door above knob 1 H LAB IO IO Box door above knob 2 OFF AUX MAIN IO Box key switch 2 POWER CROSS COOLER SAFETY LIGHT GEN IO Box inside bottom plate 2 GEN NC PC IO Box inside bottom plate 2 VERTICAL tube and generator 2 HORIZONTAL tube and generator 2 V V V V H H H H Cooler hoses Labels for cooler hoses are to be attached to small plastic tags, then zip-tied to each end of the cooler hoses. 1.1 Part Number Labeling In addition to part designations, all primary components must be labeled with the appropriate ******** part numbers. Labels should be placed near existing manufacturer part number labels. Use the label printer to create the following part number labels: Qty Model Description ******** PN 4 FC320 Generator Set 13112608 2 RS1200SP RS232 Lab IO box with light monitor modification 42112802 2 NDI-320/26FB 320 kV Fan Beam Tube 13112609 4 AS2122/05 R24-R24RA HT cable, 5 meter 21112613 1 OL4503DV cooler with dual I/O modification 13112612 2 52039 Null Modem cable, 10 ft. 21114422 2 GIDB10 Data Cable, Heavy Gauge, 10ft. 21114421 Labels for the high tension cables are to be attached to large plastic tags, then zip-tied to the generator end of the high tension cables. Tags are to be readable while holding cable in left hand with tip pointing right. 2.0 Cooler A modified Kluver oil cooler is used for dual oil in / dual oil out. Two flow switches must be added for this purpose. Black FLOW line from Lab IO box is terminated with MOLEX two position plug along with lead from cooler terminal 6
- 2. ******** System Setup Procedure System Setup Procedure_V9.docx 2 Conduit from cooler contains two additional 18 awg wires. These have MOLEX two position sockets at each end. Conduit from cooler is run to H LABIO box. Two flow switches are installed on cooler return line. They are designated ‘V Flow’ upper and ‘H Flow’ lower. The leads from the V Flow switch are heat shrunk and terminated into a MOLEX two position plug. The leads from the H Flow switch are heat shrunk and terminated into a MOLEX two position socket. The MOLEX connections from the flow switches are then connected to the MOLEX connections from the conduit. Record cooler serial number on both system setup sheets. 3.0 Lab IO Two custom boxes are used, labeled ‘V LAB IO’ and ‘H LAB IO’. H LAB IO is primary, conduit from the cooler is terminated here. In the V LAB IO box, a jumper is ran between TB3-D and TB3-F. Record serial number of each box on appropriate setup sheet. Key switch positions should be labeled ‘OFF’, ‘AUX’, and ‘MAIN’. A label should also be placed on inside bottom of box to identify conduit ports and RS232 connections. It should be noted that the FLOW indicator LED (D16) on the RS232 I/O PCB does not indicate flow, it indicates 12V supply to lamp circuit (from PSU-2).
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- 4. ******** System Setup Procedure System Setup Procedure_V9.docx 4 3.1 Current Monitor The current monitor is located at the bottom right of the IO box, next to PSU1. Verify that it is set correctly. 3.2 Crossover Cable A ten foot crossover conduit is used to connect H LAB IO to V LAB IO. This conduit contains a ten conductor 22 awg cable. Only four of these wires will be used. Orange and violet wires are attached to MOLEX two position male plug (orange next to clip). The remaining six wires are coiled together. Origin Color Destination Description V TB3-D ORG H MOLEX PIN 1 24V V TB3-G VIO H MOLEX PIN 2 Flow V TB4-H BRN H TB4-J Lamp Sense V TB4-J BLU H TB4-L Lamp Sense 3.3 Lamp Out Sense For testing purposes, a 133 ohm (ideal value) load is placed between TB4-K and TB4-H in the H LAB IO box. Four 470 ohm 0.5 W resistors placed in parallel can be used for this (117.5 ohm). For testing of a single IO Box, a jumper should be placed between TB4-J and TB4-L.
- 5. ******** System Setup Procedure System Setup Procedure_V9.docx 5 4.0 Generator System uses two FC 320 (dual vertically stacked FC 160’s) generators running EPROM Build 362. Attach the connector cable from the rear of the anode to the receptacle on the rear of the cathode. Record serial number of system and individual generators on appropriate setup sheet. Circle appropriate letter (‘V’ or ‘H’) on setup sheet to indicate whether system described is setup as vertical or horizontal. 5.0 High Tension Cable Ensure each cable is marked with the manufacturer part number and label each HT cable with the ******** part number. Labels for the high tension cables are to be attached to large plastic tags, then zip-tied to the generator end of the high tension cables. Tags are to be readable while holding cable in left hand with tip pointing right. Record cable serial numbers on appropriate setup sheet. Compression is to be set for 4-5mm dry with firm pressure. DO NOT EXCEED 5MM as this will cause ridging and rubber deformation. 6.0 X Ray Tube System uses two tubes. Print labels and mark one tube ‘Vertical’ and the other ‘Horizontal’. Mark each tube with ******** part number. Verify cooler lines are properly attached to IN (blue line) and OUT (red line) connections and labeled, ‘V’ or ‘H’. Record tube serial number on appropriate setup sheet. 7.0 RS232 Parameters Open Gulmay Logging Client (v4.23 or later). Verify that all parameters match those listed in attached log file. Print log file. Write system serial number on printout and keep with system setup sheet. Record RS232 Control PCB serial number (displayed at top of log) on appropriate setup sheet. 7.1 Programming the RS232 Control PCB If the parameters in the Gulmay Logging Client do not match those displayed in this document, then they must be manually programmed. Please note that this is necessary only if the parameters are not pre-set to those highlighted in the example log file (following page). Key switch on IO boxes must be in ‘Standby’ position. Open a terminal emulator (Putty, HyperTerminal, etc.) on a PC. Verify that PC is connected to IO box with DB9. Enter super user mode to modify limits (!P992). !P902 !P956,20 !P957,31 !P959,3 !P992,295,013 Exit terminal emulator.
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- 7. ******** System Setup Procedure System Setup Procedure_V9.docx 7 8.0 System Test Key switch on IO boxes must be in ‘MAIN’ position. Repeat this procedure for both systems. Use DMM (set to VAC) to check voltage between TB2-B and TB2-C (MAINS) in IO box. Record this value on system setup sheet. Locate build number on EPROM located on Control PCB. Version information can be found using HyperTerminal or Putty. Enter query ?P910, the response will be in the format of ?P910,<software revision>. Record these numbers on appropriate setup sheet. Crimp cooler hose and verify that contactor K2 in IO box releases. Check appropriate line on setup sheet. Set oscilloscope for 5 S/div and 10 V/div. Attach oscilloscope to Filament PCB TP6 wrt TP1. Attach DMM (set to VDC) to cathode of D15 (located between RV1 and RV2) wrt TP1 (TP1 on control PCB can also be used as reference point). Adjust RV1 (standby) clockwise until DMM voltage is 1.45 V (± 0.01 V). Observe the waveform at this point, it should resemble figure below. Peak plateau pulse width on oscilloscope should be approximately 2.1 S. Record voltage from DMM on system setup sheet for ‘V_CONTROL’ next to ‘Filament Standby’. Place Ohm meter on IO Box TB4-f and TB4-G. In x ray off state, resistance should be infinite. Turn on x rays and verify that x ray on state drops resistance low. Check appropriate line on setup sheet. Connect a DMM (set to VDC) to TP7 (mA MON) wrt TP1 on the RS232 Control PCB. If using a terminal emulator, turn on Engineering switch with “!P902”. If using Panel.Net, click on the ‘Engineering Mode’ checkbox. Set V to 180 and I to 013 (1.3 mA). Turn x rays on. Voltage should go to 180 kV, current should stay at 0 mA. Adjust RV2 (limit) clockwise until current reaches 013 (1.3 mA). This will be indicated by the DMM on TP7 reading 291 mV. When complete rotate RV2 one more half revolution clockwise. Peak plateau pulse width on oscilloscope should be approximately 5 S. While making 1.3 mA of tube current, the voltage on the Cathode of D15 wrt TP1 should be 1.85 V (± 0.15 V)on the setup sheet for ‘V_CONTROL’ next to ‘Limit’.
- 8. ******** System Setup Procedure System Setup Procedure_V9.docx 8 9.0 System Warmup Using two PCs, run a long warmup (P101) on both systems. Long warmup takes 60.5 minutes. Upon completion of warmup, set voltage to 295 kV and current to 1.3 mA. Turn x rays on. Check kV feedback. Attach a DMM (set to VDC) to Control PCB TP2 (kV MON) wrt TP1. At 295 kV, this value should be 3.69 V (±0.01 V). Record this values on setup sheet. Check mA feedback. Attach a DMM (set to VDC) to Control PCB TP7 (mA MON) wrt TP1. At 1.3 mA, this value should be 0.29 V (±0.01 V). Record this values on setup sheet. Check DC rail. Attach a DMM (set to VDC) to Power board, TP11 wrt TP10. This value is the DC voltage being supplied to the tank. At 295 kV and 1.3 mA, this value should be 214 V (± 1 V). Record this values on setup sheet. 10.0 Included Documentation One 8.5” by 11” laminated copy of G:Technical DocumentsFCFC320_Doc FC320_Technical_Manual ******** PROV WIRING.pdf should be attached to the inside door of each IO Box before shipping. Clear, UL listed double- sided tape is to be used for this. The system setup sheets for each system must be scanned and saved under G:Technical ServicesSystem Setups********, using the RA number as the filename. The RS232 IO Box Evaluation form must be completed and shipped with each IO box.
- 9. ******** System Setup Procedure System Setup Procedure_V9.docx 9 System Setup and Test Verification ******** Customer: ******** PO#____________ Ship to: ************ RA#____________ ************* ************** System Type: FC320 RS# 13112608 SN:______________ Generators: FC167-1/1 Cathode Assy SN:______________ _____ FCA167/1 Anode Assy SN:______________ _____ RS232 Control PCB SN:____________Sys Config: V H IO RS232 PCB SN:_____________ Tube: NDI 320/26 FB RS# 13112609 SN:__________________ _____ Cooler: OL4503/DV RS# 13112612 Hose / Cable Lengths: 5M SN:_______________ _____ I/O Box: RS1200RP RS# 42112802 Cable Length: 3M SN:__________________ _____ Cable PN: A2122/05 RS# 21112613 Desc: R24-R24 RA Length: 5M SN:____________ _____ Cable PN: A2122/05 RS# 21112613 Desc: R24-R24 RA Length: 5M SN:____________ _____ Flanges: A1578-05 x 2 and T20045/D x 2 _____ DB25: GIDB10 RS# 21114421 Length: 10FT _____ DB9: 52039 RS# 21112622 Length: 10FT _____ Mains________ Tap Selected 220 Version/Build _______/_______ Gen / Tube 20 / 31 Flow Check______ Filament Standby __________ V_CONTROL __________ X RAY ON Status Check ______ Limit 180 kV / 1.3 mA V_CONTROL __________ Max kV 295 kV TP2 __________ Max mA 1.3 mA TP7__________ TP10 wrt TP11__________ Tested by:___________________________________ Date:________________________ ___________________________________
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