OPERATION MANUAL

X2455
130KV, 200MA, 24KW
CT X-RAY GENERATOR

THIS INFORMATION CONTAINED HEREIN IS PROPRIETARY TO SPELLMAN HIGH

VOLTAGE ELECTRONICS CORPORATION AND IS TO BE USED ONLY FOR THE PURPOSES
INTENDED AND IS NOT TO BE REPRODUCED IN WHOLE OR IN PART WITHOUT EXPRESS
WRITTEN PERMISSION OF SPELLMAN HIGH VOLTAGE CORPORATION
I. INTRODUCTION:

1.1 WARNING: This equipment utilizes high voltage that could be LETHAL. Servicing and
operation should be done only by qualified personnel.

1.2 General: The X2455 is a High Voltage Power Supply for use in 3rd generation continuous
rotation CT scanners. The X2455 represents state of the art in power conversion technology. The
basis for this advanced technology is a patented resonant inverter. This inverter is coupled to a high
power high voltage multiplier which results in 24KW output power at greater than 87% efficiency.

1.3 Specifications: The specifications of the X2455 are detailed in appendix A. The basic
specifications are:

Output Voltage: +/-65KV (130KV tube voltage)

Output Current: 200mA
Input Voltage: 170-240VAC, 3 phase, 48-63Hz.
Filament: 15V, 5A rms, high frequency AC.
Configuration: Two assemblies: AC/Control Box and Inverter/HV Box.
Both designed for installation on the rotating portion of the
scanner. All system interconnect cables are included.
F.S.U.'s (Field Serviceable Units): Inverter/HV Box, AC/Control Box, AC PWB, System
Control PWB, System Cables.

2. Theory of Operation:

2.1 System Theory of Operation: (Refer to schematic diagram 440664-001 and outline
drawings 404526-001, 404631-001). Input voltage from the mains supply is connected to the AC
chassis. This input can be 170-230VAC. The AC chassis interfaces with the scanner via the Toshiba
XC PWB located in the AC box. The AC chassis outputs approximately 300VDC. This DC voltage
is supplied to the Inverter/HV Chassis. The DC voltage is used to power the inverter and filament
circuits. The output of the Inverter/HV Chassis connects to the X-ray tube via 2 Federal standard X-
ray connectors. The cathode output also connects to the floating filament in the X-ray tube.

All control functions for the generator are communicated through the XC PWB I/O.
Chassis frame for both the AC/Control Box and Inverter/HV Box must be connected to earth ground.

WARNING:
DO NOT REMOVE ANY CABLES OR COVERS UNTIL 5
MINUTES HAVE ELAPSED AFTER TURNING OFF POWER.
FAILURE TO COMPLY CAN CAUSE SERIOUS INJURY
OR DEATH.
WARNING:
THERE ARE UNINSULATED LIVE PARTS WITHIN THE AC/CONTROL AND INVERTER/HV.
EVEN THOUGH THE CONTACTOR IS OFF,

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 HAZARDOUS VOLTAGE MAY BE PRESENT.
ALLOW 5 MINUTES AFTER REMOVAL OF ALL POWER
BEFORE ACCESSING ANY INTERNAL PARTS.

2.2 AC/Control Theory of Operation: (Refer to schematic diagram 404672-001, 440633-001,

440673-001, outline drawing 404526-001).

The AC PWB and assemblies provide input power conditioning for the generator. The AC input has
three major sub-assemblies: The chassis assembly, system control PWB, and the AC PWB. At the
chassis level, the input mains are connected to contactor K1, rectifier CR1, and to the DC output
connector. Contactor K1 provides fail safe disconnection of the mains voltage.

CR1 is a three phase rectifier power module. The rectified line is filtered by C7-C16 on the AC
PWB. The output is a well filtered DC voltage. The DC voltage is approximately 300VDC, +/-10%
for a 220 volt mains. (Typically, the DC level will be 1.414 times the mains rms input voltage). The
output current of the IPC will vary with line voltage KV and mA selection.

2.2.1 AC PWB: (Schematic 440673-001, part number 404540-001). The AC PWB

provides filtering, soft-start, and monitoring functions for the IPC AC circuits.

NOTE: The conventions for identifying I.C.'s in this manual are U#, P#, where U# refers to the schematic
reference of the I.C., P# refers to the output pin of a particular gate within the U#.

2.2.1.1 DC Voltage Monitor: DC voltage on the AC PWB is monitored via R12 and
R13, and provides a scaled measurement of the DC voltage. The scale factor is
approximately 1V per 100V. This signal is used for start up timing and diagnostics as
described later. R9 and R10 provide discharge of the electrolytic capacitor C7-C16.
R11 and DS1 provide indication that >75 volts is present on the DC rail.

2.2.1.2 Contactor Control/Start Up: When a contactor on command is issued by the

system control PWB, K2 and K3 are energized. Initially K2 and K3 close which
applies the mains voltage to the rectifier and filter via R7 and R8. These resistors are
used to limit the inrush current due to the charging of capacitors C7-C16. At a set
delay, determined by the System Control PWB, K1 mains contactor is energized. This
contactor shorts out R7 and R8 and applies the mains directly to the rectifier/filter.
Fuses F1 and F2 protect against a failure of the timing circuit, which would cause
excessive heat in R7 and R8.

2.2.1.3 Diagnostic Circuitry: Circuitry on the System Control PWB provide

diagnostic and protection circuitry for the AC PWB. The System Control PWB will
not allow the main contactor to energize if:
a) Input voltage is not connected.
b) The DC rails are shorted. (Do not charge to a minimum voltage within 100 milli-
seconds.
If a fault occurs, The System Control will transmit an AC Fault to the XC PWB.

2.2.1.4 EMI Filter: The mains EMI filter is located on the AC PWB. This filter
is a line to line snubber, and X-Y type capacitors. The filter is shown in zone
C8, D8 of the schematic diagram.
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 2.2.1.5 Starter Circuits: The AC Chassis assembly and AC PWB contain all
power circuits to run the tube starter. Starter control is done by the System
Control PWB. K4 is a SSR which is used to turn on and off power to the starter.
K5 is used to switch between boost voltage (approximately 200VAC), and run
voltage (approximately 65VAC). F5 provides overcurrent protection for the
starter. The starter connects to TB1, 2, and 3 on the AC box. T1 and T2 monitor
boost and run currents.

2.2.1.6 Heat Exchanger: Heat exchanger power is available from the AC box on
TB4, 5 for 110V, TB4, 6 for 220V. F3 and F4 provide overcurrent protection for heat
exchanger voltages.

2.2.1.7 Tube Thermal Switch and Flow Switch: The X-ray tube thermal switch
connects to TB1 9,10. The X-ray tube flow switch connects to TB1 7,8. These
signals are sent to the System Control PWB for status monitoring.

2.2.2 System Control PWB: (Schematic 440672-001)

2.2.2.1 Low Voltage Power Supply: Sheet 1 of the System Control PWB contains
circuitry for the low voltage power supply used in the generator. CR1 rectifies the
auxiliary power. U1 is a "simple switcher" regulator. It provides +5VDC for digital
circuits. U2 provides +15VDC for analog circuits and gate drive power for the
Inverter IGBT drivers. U3 is a linear regulator which provides -15V for analog
circuitry. A useful connector legend is located on Sheet 1 of the schematic. This
legend shows connection locations for each of the System Control I/O connectors.

2.2.2.2 KV, MA Monitoring and Regulation Circuits: Sheet 2 of the System Control
PWB schematic shows the majority of the KV and mA monitoring and regulation
circuits. U4, P8, P7 buffers the anode and cathode KV feedback signals from the
Inverter PWB. U7, P2, P15 provides overvoltage protection for the system. If either
the anode or cathode voltages exceed 75KV, an overvoltage fault will be issued. U4,
P1 is a summing amplifier for the anode and cathode feedback. The output of U4, P1
is the total KV feedback which is used for regulation. U6, P7 is the buffered KV
reference (KVREF). This reference is used to program the set point for tube voltage.
U6, P8 is the error signal which programs the inverter drive signals. This signal will
regulate the KV output via closed loop feedback. A controlled KV ramp during initial
X-ray on command is done via the KV ramp signal. (Circuits on Sht. 4).
U7, P3 monitors the regulation of U6, P8. If the system cannot maintain regulation,
U7, P3 will indicate a "HV Abnormal" error. U8, P2 is used to inform the
PLD, U14, that a voltage is present on the output. This is used for safety functions
within the PLD, U14. U5, P7, P8 buffers anode and cathode mA feedback signals
from the Inverter PWB. U8, P14, P15 provides overcurrent protection from the
system. If the tube current exceeds 10% of set value, an overcurrent fault is issued.
U5, P14 buffers the mA reference signal (mA REF) used to set the tube current. This
signal is sent to sheet 3 of the system control PWB schematic. There it is compared to
the actual tube current by U13, P14. U13, P14 then programs the filament level in
order to regulate the tube current. U9, P14 monitors the regulation circuit. If tube
current is not regulated, a "HV Abnormal " error will be issued. Amplifier U13 is
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 used to program the filament level during preheating and to switch over to the
regulation amplifier during exposure. U12, P14 provides the buffered filament
program to the Inverter PWB. U6, P1 buffers the filament feedback signal, and
supplies this signal to the Analog I/O. U9, P15 indicates a filament fault has
occurred. (Additional circuits are shown for 48KW generator on Sht 2 and 3).

2.2.2.3 Phase/Frequency Controller: The inverter operates in 3 basic modes: out of

phase, in phase, or frequency mode. During both phase modes, the inverter phase
shift is changed from 180° to 0°, at approximately 20khz. During the frequency mode,
the inverter frequency is changed from 20khz to 30khz. As power is increased from
0 to max, the inverter will operate from the out of phase mode (180°), to the in phase
mode (up to 0°), then to the maximum frequency allowed (30khz). This "multi-
mode" of operation is accomplished on Sheet 3 of the system control PWB. U10 is a
conventional PWM I.C. From a varying pulse width, PLD U14 creates the phase shift
required for regulation. U9, P3 monitors the input voltage to U10. This signal is
used to linearize the transfer function as the inverter changes phase. This signal
defines the terms "In Phase" and "Out of Phase". U15 is a high current driver used
to drive optocouplers for the IGBT gate drivers.

2.2.2.4 Digital I/O: Sheet 4, 5, and 6 of the system control PWB schematic contain
XC I/O, PLD, and generator control circuits. (All digital and analog digital I/O's are
specified in Appendix A). Inputs for control of the generator are opto-coupled by
U16, U17, U18 and U19. Digital outputs from the generator are driven by U30 and
U33. PLD U14 processes all digital I/O signals. (Appendix F shows the internal
function blocks of PLD U14). U22 provides a redundant shutdown path for
the X-ray exposure control signal. In the unlikely event U14 should fail, causing an HV
ON signal to be generated internally, U22 will override this by an alternate shutdown of
U10, sheet 3.

2.2.2.5 System Control DC Voltage Monitor: Sheet 5 of the system control

PWB schematic shows the DC voltage and monitors. U28, P7
outputs a dc voltage of 1V per 33 Volts of the AC PWB dc rail. This signal is
buffered by U28, P8, and sent to the A/D, U26. The dc voltage monitor is also
applied to U29. U29, P2 is used by the PLD U14 to determine the applied
Dc input voltage. This is used to turn the mains contactor on and diagnostics for AC
faults. U23, U24, and U25 provide input control for the analog data acquisition
system. U26, U27 outputs the data from the serial A/D U26.

2.2.2.6 Diagnostics and Miscellaneous PLD Functions: Sheet 6 of the System Control
PWB contains the diagnostic sensor input connections to the PLD, U14. In
zone D7 of sheet 6, sensor inputs and fault alarm inputs to the PLD are shown. The
functions of these inputs are described in previous sections. Connector JB2 and JB3,
zone C8, are diagnostics from the AC PWB and Inverter PWB.

YI is a crystal oscillator. It operates at 1MHz . The 1MHz clock is used for a variety
of PLD functions. Typical functions for the clock are: IGBT gate drive on time
settings, fault detection delays, and synchronization of internal PLD logic blocks.
U22, P12 is a lower frequency clock which is used for longer delay requirements.
This is to minimize the number of counters which would be needed to divide down the
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 1Mhz clock if used for long delay times. JB7 is for in circuit programming of U14.
This connector is for factory use only.

Indicator LED's provide local indication of generator status.

POWER ON: Indicates +5V power is present on the System Control

PWB.
TEST MODE: Indicates SW1 switches is in the test mode.
FAULT: Indicates the generator is in a fault mode. The detailed
fault data is provided on the digital I/O.
HV ON: Indicates high voltage (greater than 10KV) is present on
the output of the generator.
SPARE: This is primarily used by the factory during trouble
shooting. It provides indication of the phase mode of
the inverter. LED on is out of phase mode.
FIL ON: Indicates the filament is on.
STARTER ON: Indicates the starter is on.
CONTACTOR ON: Indicates contactor is energized.

2.3 Inverter/HV Theory of Operation: (Refer to schematic diagrams 440661-001,

440653-001, outline drawing 404526-001).

The Inverter/HV consists of 3 major assemblies. The inverter assembly, the HV

multiplier, and the HV transformer. The Inverter/HV is basically a 24KW, DC to DC
converter. The DC input is applied to a resonant inverter. The inverter operates in a
phase modulation, and a frequency mode. The maximum operating frequency of the
inverter is 30khz. The output of the inverter is a high frequency current source. The
current drives a step-up transformer. The output of the step-up transformer is
approximately 5KV Pk ac. This is applied to two half-wave multipliers. The
multiplier is a diode capacitor charge pump. It successively doubles the input voltage
for each stage of diode capacitors used.

The output of the multipliers are dc voltages of +/-65KV. This is applied to the X-tube. The
Inverter/HV is connected to the AC/Control via a control cable and DC power cable.

2.3.1 Inverter Assembly/Inverter PWB: (Schematics 440661-001, 440653-001, Assembly

Drawing 4 04511-001). The inverter assembly contains the inverter heat sink, cooling fan,
DC input connections, IGBT's, and the inverter PWB. The majority of these functions can be
discussed by reviewing the inverter PWB schematic 440653-001.

IMPORTANT:

No field service calibration is required. The generators FSU's can be serviced without need
for re-calibration. The inverter assembly and the HV module are NOT FSU's. Calibration
for the HV module is accomplished on the inverter PWB. Therefore, the HV module and
inverter PWB CANNOT be replaced separately.

NOTE:

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Circuit descriptions for anode and cathode are identical except for component reference
designators. The anode reference designators will be used. Please refer to the schematic
for cathode reference designators.

2.3.2.1 KV, MA Feedback Amplifiers/Arc Sense: Sheet 1 of the inverter PWB

schematic show all KV and mA feedback calibration a buffer circuits.

T1 on Sheet 1 is used to sense a tube arc. This signal is sent to the system control board via
JB2, P33. A low (transistor on) on the collector of Q1 indicates a tube arc. This is a
momentary signal of <10 milliseconds. U1, P7 is the output for the mA feedback signal.
This amplifier scales and buffers the mA sense signal generated by current sense resistor R1.
Components CR2, C1, C97, R2, CR3, CR4, R3 provide transient protection and filtering.

U1, P1 is the output for the KV feedback monitor. This amplifier scales and buffers the
KV sense signal generated by the high voltage divider resistors located in the HV module.
R11, R12, C4, C5 are bandwidth compensation components. R13, R14, CR6, CR7 provide
transient protection.

2.3.2.2 Filament Inverter and Control Circuits: Sheet 2 of the Inverter PWB shows filament
power supply circuits. The filament inverter is a PWM controlled, series resonant circuit.
300VDC, from the DC input connector, is filtered by L1, C17, C18. MOSFET's Q3
and Q4 operates at approximately 60KHz. The on-time of Q3 and Q4 controls the current
supplied to the filament isolation transformer located in the HV module. This
current is outputted on E45, LRG FIL OUT E46, SML FIL OUT, and E47, E48 FIL INV
RET. T3 monitors the primary current which is used for regulation of the filament power
supply and for monitoring. U3 is a conventional PWM I.C. U5, P7 provides the pulse width
requirement signal by comparing the required filament program, FIL PROG IN JB2-28, to the
monitor signal generated by T3 and U4. U4 is a rms/dc converter. It converts the rms signal
sensed by T3 to a dc level. This level is scaled as 0-10VDC equals 0-5 amp rms of filament
output current. U5, P1 buffers this signal which is sent to the System Control PWB.

2.3.2.3 IGBT Gate Drive/Inverter Circuits: Sheet 3 of the inverter PWB show the inverter
power circuits, and gate drive circuits. Q7 and Q8 are IGBT power modules. Gating of Q7
and Q8 is done by U7, U8, U9, U10. These are hybrid I.C. circuits. U6 provide an isolated
power source of 28VDC for U7, U8, U9, U10.

WARNING:
GATE DRIVE CIRCUITS AND IGBT INVERTER CIRCUITS
ARE AT HIGH VOLTAGE. DO NOT ATTEMPT TO TROUBLE SHOOT,
PROBE, OR SERVICE THESE CIRCUITS

2.3.2.4 Miscellaneous Circuits: R99, DS1 provides visual indication that the rail dc voltage is
greater than 75 volts.

U12 provides -15 volts for circuits used on the inverter PWB. L4, C77, CR45 provide
filtering for the +15 volt power which is provided from the System Control PWB low
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 voltage power supply.

2.3.3 High Voltage Module: (Schematic 440659-001, Assembly 404508-001). The high voltage
module contains the high voltage multipliers, high voltage feedback dividers, filament transformers,
and anode/cathode connectors. The HV module utilizes solid encapsulation. As described in
previous sections, the HV module is not a FSU.