Golden engineering XRS4 User manual

X-RAY
Golden Engineering, Inc.
6364 Means Road, Box 185
Centerville, IN 47330 USA
Phone: [phone]
Golden Engineering
Portable X-ray Technology
18-20V X-RAY GENERATORS
OPERATOR’S
MANUAL
XRS3
XRS4
XR200
XR150
JULY 2021
ORIGINAL INSTRUCTIONS

1
CONTENTS
INTRODUCTION____________________________________________________________________ 3
WARNINGS _______________________________________________________________________ 4
PHYSICAL DESCRIPTION _____________________________________________________________ 5
CONTROL MODULE ____________________________________________________________ 7
REAR VIEW ___________________________________________________________________ 8
PHYSICAL DESCRIPTION _____________________________________________________________ 9
REMOTE CABLE CONNECTOR____________________________________________________ 11
DESCRIPTION OF OPERATION _______________________________________________________ 12
OPERATING INSTRUCTIONS _________________________________________________________ 13
RECOMMENDED PULSE SETTINGS ____________________________________________________ 15
NAVIGATING THE MENU____________________________________________________________ 16
HOME SCREEN - PULSES, DELAY, TRAINS ___________________________________________ 16
BASIC NAVIGATION ___________________________________________________________ 16
PULSE COUNT EXCEEDS DUTY CYCLE______________________________________________ 17
MANUALLY ENTERING PULSE TRAINS______________________________________________ 18
MULTIPLE PULSE TRAINS EXCEED DUTY CYCLE _______________________________________ 18
WORKING WITH PRESETS ______________________________________________________ 19
DEFINE PRESETS ___________________________________________________________ 19
RECALL PRESETS ___________________________________________________________ 19
RENAME PRESETS __________________________________________________________ 20
MENU SCREEN________________________________________________________________ 21
DISABLE DUTY CYCLE WARNING______________________________________________ 21
EXTRA SETTINGS __________________________________________________________ 21
VIEW LIFETIME PULSES______________________________________________________ 22
RESET PULSE COUNTERS ____________________________________________________ 22
ERROR MESSAGES_________________________________________________________________ 23
TROUBLESHOOTING _______________________________________________________________ 24
MAINTENANCE ___________________________________________________________________ 25
X-RAY DOSE MEASUREMENT ____________________________________________________ 25
TUBE REPLACEMENT ___________________________________________________________ 25
BATTERY DISPOSAL ____________________________________________________________ 25
INSTRUCTIONS FOR REPAIR _________________________________________________________ 26
DISASSEMBLY INSTRUCTIONS____________________________________________________ 26
REMOVING THE CONTROL MODULE __________________________________________ 26
INSTRUCTIONS FOR REPAIR _________________________________________________________ 27
REMOVING THE MAIN CONTROL BOARD_______________________________________ 27
REMOVING THE HEAD ______________________________________________________ 27
REMOVING THE OSCILLATOR BOARD AND ISOLATING THE HEAD ___________________ 27
CE CERTIFICATES __________________________________________________________________ 29
SPECIFICATIONS __________________________________________________________________ 31
SPARE PARTS AND ACCESSORIES _____________________________________________________ 32

2
WARRANTY ______________________________________________________________________ 34
RETURNING UNIT FOR REPAIR________________________________________________________ 34

3
X-ray generators from Golden Engineering are industrial type open beam X-ray generators intended to
radiograph inanimate objects. The devices are a pulsed X-ray device that produces X-ray pulses of very short
duration (10-50 nanoseconds). The energy produced by the X-ray generator varies from model to model, and
can be up to 370kVp, which makes it possible to radiograph up to one (1) inch (2.54 cm) of steel.
Each unit ships with two keys, two 20V battery packs, and one battery charger.
Many users choose to add other accessories like a Remote Cable or Carrying Case. Refer to the Spare Parts and
Accessories section for more details.
INTRODUCTION
RADIATION WARNING
The X-ray generator produces high levels of radiation and must be operated by qualied personnel
who have read the WARNINGS and OPERATING INSTRUCTIONS sections of the manual before
operating the device.

4
The X-ray generators from Golden Engineering are pulsed X-ray generators that emit hazardous ionizing
radiation when pulsing. The unit should only be operated by authorized personnel who are properly trained to
safely operate the X-ray generator. The X-ray generator must be registered with proper authorities prior to use
and should not be used to intentionally expose humans.
Develop and closely follow a safe operating system for using the X-ray generator. The safe operating system
must ensure that no one is exposed to radiation above the permissible limits which are 2 mR (0.02 mSv) per hour
for a member of the public. The safe operating system must ensure the X-ray generator is used within federal
and state guidelines.
All operators and users of the X-ray generator must wear a personal radiation monitoring
device, such as a TLD (thermoluminescent dosimeter), lm badge, and/or a pocket dosimeter
consistent with the appropriate federal, territorial or provincial standards. If an operator or
bystander is exposed to an unacceptable level of radiation
contact your Radiation Safety Ofcer and/or appropriate
health care provider.
Due to the short pulse width of the pulsed X-ray, survey meters of the Geiger-
Mueller and scintillator type do not accurately detect the radiation emitted
from pulsed X-ray generators.
Survey meters should be of the ionization chamber (ion chamber) type and should be used in the integration
mode. Survey meters must not be used in the rate mode because the pulsed X-ray generator does not produce
constant radiation. Pulsed X-ray generators produce very high rates of radiation for very short periods of time
resulting in either unrealistically high readings or no readings for a survey meter in rate mode.
The X-ray generators have no explosion proof rating and should not be used in an explosive atmosphere. The
Spark Gap could be a source of ignition.
WARNINGS
NOTE: Electronic dosimeters
and survey meters of the
Geiger-Mueller and scintillator
types may not detect the X-ray
Generator’s radiation pulses.

5
BEAM ANGLE
LABEL
COLLIMATOR
HANDLE
HIGH VOLTAGE PULSER/TUBEHEAD
The main body of the X-ray Generator
is the tube head. The head contains the
tube cavity, cold cathode type X-ray tube,
spark gap, high voltage capacitor, and
transformer.
The standard collimator
located on the front of the
head limits the X-ray beam to
40 degrees. Special order
collimators up to 85 degrees
are available.
PHYSICAL DESCRIPTION
The handle of the XR200 and XRS3 is attached
to the front and back of the Control Module.
The handle of the XRS4 is integral to the body.
XRS3
XR150 20V

6
BATTERY
RADIATION WARNING LABEL CONTROL MODULE
PICATINNY RAIL
The base of the unit contains an
identication label and a ¼-20
brass insert compatible with
standard camera tripods. The
base also accommodates a quick
release external tripod mount. The
identication label located on the
bottom of the generator lists the
manufacturer’s name and address,
model number, serial number,
weight, volt, amp, and production
date.
BATTERY PACK. The standard
battery pack is a DeWalt®
20V 2 amp hour Li Ion battery
(DCB203).
The X-ray generator is equipped a 21 mm
picatinny rail located on each side of the
housing.
BASE
XR200
XRS4
The main user interface for the
X-ray generator located on top of
the unit.

7
The 80 character LCD is the main
interface with the unit. See the
Operating Instructions for more details
on the various control screens.
X-RAY PULSING LIGHTS
ENTER / EMERGENCY STOP
KEY
POWER ON LIGHT
LIQUID CRYSTAL DISPLAY (LCD)
MODEL
IDENTIFICATION
DIRECTIONAL BUTTONS
DELAY SWITCH Stops the unit before it begins
pulsing or stops the unit in the
middle of a pulse train.
Also used as the enter button to
select desired option.
Pressing both Left and Right arrow
buttons simultaneously initiates
the delay mode, allowing the
operator to use the unit without
the remote cable.
Left, Right, Up and Down
buttons used to navigate
through the menu.
Blinks once per second after time
delay button or remote cable button
is pressed to warn that the X-ray
Generator is going to pulse. The light
stays on continuously while the unit is
pulsing.
This is a failsafe warning light. If the
light does not work the X-ray unit will
not pulse. See settings menu for fail-
safe override in emergency situations.
Illuminates when battery voltage
is applied to control module.
Main power switch to turn
the unit on and off.
CONTROL MODULE
BEAM ANGLE
LABEL
Top View
Control Module

8
REAR VIEW
POSITIVE +
BATTERY
TERMINAL
BLOCK
TEMPERATURE
SENSOR
NEGATIVE -
Rear View
BATTERY PACK
The standard battery pack is a DeWalt® 20V 2 amp-
hour Li Ion battery (DCB203). The units are compatible
with batteries up to 12 amp-hours.
BATTERY CHARGER
The standard battery charger is the DeWalt® DCB115
charger for both 110V and 220V. (Note: DeWalt
model numbers may change). Battery charge time is
typically less than one hour.
See battery charger manual for additional instructions
and warnings.
REMOTE CABLE
CONNECTOR

9
QUICK RELEASE
TRIPOD MOUNT
TRIPOD MOUNT
RELEASE TAB
PHYSICAL DESCRIPTION
XRS3 - bottom
The nameplate identication
label located on the bottom
of the generator lists the
manufacturer’s name, model
number, serial number, weight,
volt, amp, and production date.
NAMEPLATE LABEL

10
The base of the unit contains an
identication label and a ¼-20
brass insert compatible with standard
camera tripods. The XR150, XR200,
and XRS3 bases also accommodate a
quick release external tripod mount.
All units feature rubberized non-skid
feet for stability when not using a
tripod.
BASE
XR150-20V - bottom

11
REMOTE CONNECTOR: LEMO EEG.0K.305.CLN
MATING CABLE PLUG: LEMO FGG.305.CYCC50Z
GROUND PIN
REMOTE SWITCH PIN
Remote switch inputs are activated when connected to ground pin.
34
5
2
1
PIN # 5 PIN K CONNECTOR 7 PIN K CONNECTOR
1 +5 VOLTS 100 mA MAXIMUM +5 VOLTS 1 A MAXIMUM
2 REMOTE SWITCH (5 sec delay) REMOTE SWITCH (5 sec delay) (+3V)
3 REMOTE SWITCH – NO DELAY REMOTE SWITCH – NO DELAY (+3V)
4X-RAY ON / FEEDBACK SIGNAL X-RAY ON / FEEDBACK SIGNAL (+5V)
5 GROUND (COMMON 0 VOLTS) RS232-RX
6 RS232-TX
7 GROUND (COMMON 0 VOLTS)
5 PIN K REMOTE CABLE CONNECTOR 7 PIN K REMOTE CABLE CONNECTOR
5
1
2
34
6
7
REMOTE CONNECTOR: LEMO EGG.0K.307.CLN
MATING CABLE PLUG: LEMO FGG.0K.307.CYCC50Z
The X-ray Generator is equipped with Lemo “K” series connector located on the lower left corner of the back of
the control module. This is where the remote cable or imaging system cable is attached. Depending on the options
of the unit, this may either be 5 pin or 7 pin connector.
See the diagrams and table below for the details of each conguration.
REMOTE CABLE CONNECTOR
SERIAL INFORMATION
Baud Rate: 57600
8 – bit data
1 stop bit
Hardware ow control: None
Parity: none
Voltage Input: +/- 25V
Voltage Output: +/- 6V

12
The block diagram below illustrates how the X-ray generator functions. The following sequence of events takes
place each time the unit is red:
PULSE DETECTOR
USER INTERFACE
X-RAY TUBE
HIGH VOLTAGE
CAPACITOR
CONVERTER
BATTERY
SPARK GAP
CONTROLLER
BLOCK DIAGRAM
DESCRIPTION OF OPERATION
1. User initiates operation of the machine.
2. The controller sends a signal to the converter to begin oscillating.
3. Once oscillating, the converter section changes the DC battery voltage to 22Khz AC.
4. The transformer charges the High Voltage Capacitor to about 9000 volts.
5. The spark gap arcs after the High Voltage Capacitor reaches peak voltage.
6. The pulse detector signals the control block that the unit has pulsed.
7. As the High Voltage Switch is closed, a high voltage transient of between 150,000 and 370,000
volts (depending on the model and 10-30 nanoseconds in duration is applied across the X-ray
tube generating X-rays.
The closing of the High Voltage Switch produces an audible pulsing sound. The X-ray generator cannot produce
X-rays without the pulsing sound so it serves as an additional warning the unit is functioning.
This unit generates X-rays through high voltage bombardment of a tungsten target.
The X-ray generator does not contain radioactive materials.
All the high voltage is contained within the aluminum canister and as long as the canister is not punctured the
operator is not exposed to dangerous voltages.

13
DR Remote Cable Time Delay
Determine Pulse
Initiation Method
Position X-ray Generator*
Attach Battery
Connect System
Turn on X-ray Generator
using key and turning
clockwise 1/4 turn
Set pulse count to 100
View Image
Retreat to imaging system
controller (computer)**
Follow imaging system
instructions to set pulses
and initiate pulse train
Turn off X-ray generator
Position X-ray Generator*
Attach Battery
Attach Remote Cable
Turn on X-ray Generator
using key and turning
clockwise 1/4 turn
Set pulse count
View Image
Retreat length of cable
behind X-ray generator
Press and hold cable
button down to initiate and
complete pulse train
Turn off X-ray generator
Retrieve image plate or
lm cassette
Position X-ray Generator*
Attach Battery
Turn on X-ray Generator
using key and turning
clockwise 1/4 turn
Set pulse count
View Image
Press left and right arrow
buttons simultaneously to
initiate time delay
Retreat safe distance
behind X-ray generator
Turn off X-ray generator
Retrieve image plate or
lm cassette
Set delay time
OPERATING INSTRUCTIONS

14
24 - 72 IN
(60 - 180 CM)
X-ray generator Object Imager
X-ray Beam
a
** The operator should always stand outside of the exclusion zone. The exclusion zone (below) should be a
controlled area free of all personnel while X-ray pulses.
* The X-ray generator should be positioned directly in front of the object to be X-rayed and the imager placed
directly behind the object to be X-rayed. Imager should be placed as close to the object as possible. Distance
between X-ray generator and imager is usually 24 to 72 inches (60 to 180 cm). During operation the unit should
be stabilized on a at surface, a tripod, or a custom xture suitable for holding the weight of the device. Refer
to the Specications table for details.
The following are basic operation instructions to take an X-ray image using the X-ray generator. Certain
applications may require modications to these basic procedures.
a
a
b
b
EXCLUSION ZONE
XR150-20V XR200 XRS3 XRS4
a 10’ (3 m) 10’ (3 m) 10’ (3 m) 20’ (6 m)
b 20’ (6 m) 20’ (6 m) 25’ (7.6 m) 36’ (11 m)
c 100’ (30 m) 100’ (30 m) 100’ (30 m) 113’ (35 m)
c
X-ray Beam

15
RECOMMENDED PULSE SETTINGS
The chart below lists approximate pulses necessary to penetrate various materials. Settings vary depending on
imaging system used. Refer to imaging system instructions for more information.
Underexposed
Overexposed
Correct Exposure
MATERIAL PULSE SETTING
XR150 20V XR200 XRS3 XRS4
Cardboard, light wood, plastic 2-5 2-5 2-5 1-2
Light metal 10 10 10 5-10
Steel ¼” (6 mm) 25 25 25 25
Steel ½” (13 mm) 50 50 50 35-40
Steel 1” (25 mm) - - 99 50
Steel 1½” (25 mm) - - - 99
Brass ⅛” to ¼” (3-6 mm) - - 99 50-99
If the radiograph is too light the lm is overexposed.
Overexposure can be corrected by reducing the number of pulses and/
or increasing the distance between the imaging medium and X-ray
generator.
Underexposure can be corrected by increasing the number of pulses
and/or decreasing the distance between the imaging medium and the
X-ray generator.
If the radiograph is too dark, the lm is underexposed.
Correct Exposure

16
NAVIGATING THE MENU
HOME SCREEN - PULSES, DELAY, TRAINS
This is the HOME screen. From here you can set the
number of pulses, delay in seconds, and adjust the
trains settings. See MANUALLY ENTERING PULSE
TRAINS.
Pulses: Number of consecutive pulses that will be
sent when the unit is red.
Delay:
Number of seconds after the Delay
sequence is activated by pressing BOTH
the left and right arrows simultaneously
Trains: Number of GROUPS of Pulses that will
be sent when the unit is red
BTWN: Number of seconds between TRAINS
BASIC NAVIGATION
Press LEFT or RIGHT to change position.
The underlined character has the focus.
Press ENTER to select - cursor will blink between
current setting and all segments on (black cursor).
Press UP or DOWN to change value of the selected
character.
Press ENTER to accept.
Use directional buttons to navigate to all settings on
the HOME screen. See below changing the Delay
setting.
OR
to change
cursor position
OR
to change valueto switch to edit
mode. Change
cursor position
with left/right
arrows
to accept
Press the DOWN arrow
to navigate to the PULSES
settings.

17
PULSE COUNT EXCEEDS DUTY CYCLE
If the number of pulses exceeds 200, the unit
will automatically attempt to split the pulses into
consecutive pulse trains with a delay between
them. See the below example of setting 500
pulses.
DUTY CYCLE WARNING
The 20V family of X-ray generators are light duty machines that are not made to pulse continuously. The maximum
duty cycle for the units is 200 pulses every four minutes. In temperatures above 90°F (32.22°C) or continual use
situations, rest a minimum of 30 sec every 50 pulses and 4 min after every 200 pulses. Exceeding the duty cycle
will shorten the life of the tube and head, and may also cause thermal damage to the circuit boards.
Set PULSES higher than 200,
press Enter.
ASTERISK (*) APPEARS
WHEN WARRANTY HAS
BEEN VOIDED

18
THE UNIT WILL FIRE 50
PULSE TRAINS OF 25 PULSES
EACH, WITH A 4 MINUTE
REST PERIOD BETWEEN
TRAINS FOR A TOTAL OF
1250 PULSES
Arrow down on the HOME screen to
adjust Trains and BTWN settings.
Trains indicates the number of
consecutive pulse groups that will be sent.
BTWN indicates the number of seconds
between pulse trains.
CANCELLING SETS
TRAINS = 1
BTWN = 240
ASTERISK (*) APPEARS
WHEN WARRANTY HAS
BEEN VOIDED
Set PULSES and Delay, then
adjust Trains and BTWN.
Pulse train settings that exceed the duty cycle of 200
pulses in a 4 minute period will result on the following:
MULTIPLE PULSE TRAINS EXCEED DUTY CYCLE
Operator may manually
adjust settings and try again
MANUALLY ENTERING PULSE TRAINS

19
NAVIGATING THE MENU
WORKING WITH PRESETS
Presets allow the operator to save settings that are commonly used, so they can be recalled when needed. This is
useful for changing between different pulse train setups.
DEFINE PRESETS
The settings you wish to save
as a preset must rst be loaded
on the home screen. See HOME
SCREEN - PULSES, DELAY,
TRAINS for more information.
THIS SCREEN SHOWS WHAT
IS PRESENTLY STORED IN
SELECTED PRESET
RECALL PRESETS
LOADS WHAT IS SHOWN ON
THE PRESET SCREEN TO THE
HOME SCREEN