Golden engineering XRS4 User manual

1
PAGE
1.0 INTRODUCTION 2
2.0 WARNINGS 2
ELEVATION WARNING 2
DUTY CYCLE 2
3.0 PHYSICAL DESCRIPTION 3
HIGH VOLTAGE PULSER/TUBEHEAD 3
BASE 3
BATTERY PACK 3
BATTERY CHARGER 3
CONTROLS 4
CABLE CONNECTOR DIAGRAM 5
4.0 DESCRIPTION OF OPERATION 6
BLOCK DIAGRAM 6
5.0 OPERATION INSTRUCTIONS 7
OPERATING PRECAUTIONS 8
EXCLUSION ZONE 8
SUGGESTED PULSE SETTINGS 9
NAVIGATING THE MENU 10
SET PULSE COUNT 11
TIME DELAY OPTION 12
MULTIPLE PULSE TRAIN OPTION 13
DUTY CYCLE 14
PULSE SETTINGS 14
6.0 MAINTENANCE 15
DOSE MEASUREMENT 15
TUBE REPLACEMENT 15
7.0 TROUBLE-SHOOTING 15
8.0 INSTRUCTIONS FOR REPAIR 16
FUSE REPLACEMENT 16
REMOVING BOARDS 17
BOARD INSTALLATION 17
STORAGE, TRANSPORT, DISPOSAL 17
9.0 WARRANTY 18
MANUFACTURER & EUROPEAN REPRESENTATIVE 18
RETURNING REPAIR INSTRUCTIONS 18
10.0 SPECIFICATIONS 19
PHYSICAL DIMENSIONS 19
X-RAY OUTPUT 19
ELECTRICAL & THERMAL CHARACTERISTICS 19
11.0 SPARE PARTS 19
TABLE OF CONTENTS

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1.0 INTRODUCTION
The XRS4 is an industrial type open beam X-ray generator intended to radiograph inanimate objects. The XRS4 is
a pulsed X-ray device that produces X-ray pulses of very short duration (10 nanoseconds). The energy produced
by the XRS4 is up to 370kVp, which makes it possible to radiograph up to one (1.5) inch (3.81 cm) of steel.
XRS4 standard accessories are two keys, two battery packs, and one battery charger. Remote cable, carrying case,
and lm developing equipment are also common accessories.
2.0 WARNINGS
The XRS4 is a pulsed X-ray generator that emits hazardous ionizing radiation when pulsing. The XRS4 should only
be operated by authorized personnel who are properly trained to safely operate the generator. The XRS4 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 XRS4. 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 XRS4 is used within federal and state guidelines.
All operators and users of the XRS4 X-ray machine must wear a personal radiation monitoring device, such as a
TLD (thermo luminescent dosimeter), lm badge, and/or a pocket dosimeter consistent with the appropriate fed-
eral, territorial or provincial standards (note: an electronic dosimeter will not detect the XRS4 radiation pulses). 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 XRS4, survey meters of the Geiger-Mueller and scintillator type do not accu-
rately detect the radiation emitted from the X-ray source.
Survey meters should be of the ionization type and should be used in the integration mode. Survey meters must not
be used in the rate mode because the XRS4 does not produce constant radiation. The XRS4 produces 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 XRS4 has no explosion proof rating and should not be used in an explosive atmosphere. The Spark Gap
is vented to the air and could be a source of ignition. THE STANDARD XRS4 WITHOUT A MODIFIED SPARK
GAP WILLL LIKELY FAIL PREMATURELY WHEN USED ABOVE 5000 ft. (1524 m) ELEVATION.
The XRS4 produces high levels of radiation and must be operated by qualied personnel who have read
the Warning and Operations section of the manual before operating the device.
DUTY CYCLE WARNING. The XRS4 is a light duty machine that is not made to pulse continuously. The maximum
duty cycle for the XRS4 is 200 pulses every four minutes (3000 pulses per hour). Additional 30 second rest every
50 pulses is suggested for applications requiring more than one hour continual use or in temperatures exceeding
90 degrees F. Exceeding the duty cycle will shorten the life of the tube and head.

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3.0 PHYSICAL DESCRIPTION
HIGH VOLTAGE PULSER/TUBEHEAD. The main body of the XRS4 is the tube head which contains the tube cavity,
cold cathode type X-ray tube, spark gap, high voltage capacitor, and transformer. The standard collimator locat-
ed on the front of the head limits the X-ray beam to 40 degrees. Special order collimators up to 85 degrees are
available.
BASE. The base of the XRS4 contains the identication label and a threaded ¼-20 insert that can be attached to
any standard camera tripod. Identication label indicates the model, manufacturer, and serial number is located
on the bottom of the XRS4 base.
BATTERY PACK. The standard battery pack is a DeWalt®18V nickel-cadmium battery. Optional battery chem-
istry or voltage may be available.
BATTERY CHARGER: The standard battery charger is the DeWalt®DW9116 110V charger or DE9108 220V
charger. Battery charge time is one hour. See battery charger manual for additional instructions and warnings.
TOUCH PAD KEY
RADIATION
WARNING LABEL
HOUSING
BATTERY
HEAD
BEAM ANGLE
LABEL
COLLIMATOR
HANDLE

4
CONTROLS
RED X-RAY PULSING LIGHT:
¾Blinks after time delay button or remote cable button is pressed AND between multiple pulse trains.
¾Stays on continuously while the XRS4 pulses.
¾Blinks at a slower rate between multiple pulse trains.
¾This is a failsafe warning light. If the light does not work the X-ray unit will not pulse.
LIQUID CRYSTAL DISPLAY (LCD): 32 character LCD. Home screen displays Pulse count (PC), Multiple pulse
trains (*), Time Delay (DEL), and Ready to Fire. See instructions for menu options.
DELAY SWITCH: Initiates time delay mode count down when left and right arrows pressed simultaneously.
POWER ON LIGHT: Illuminates when battery voltage is applied to control module.
ENTER/ EMERGENCY STOP SWITCH: ENTER used when menu options are selected.
EMERGENCY STOP stops the unit during delay count down mode or between multiple pulse trains.
DIRECTIONAL ARROWS: Left, Right, Up, Down used to navigate through LCD and menu options.
X-RAY PULSING
LIGHTS
LCD
DELAY SWITCH
KEY
DIRECTIONAL
ARROWS
ENTER /
EMERGENCY
STOP
POWER ON
LIGHT

5
XRS4 REAR VIEW/CABLE CONNECTOR
PIN 5
REMOTE CONNECTOR: LEMO EPG.0B.305.HLN
MATING CABLE PLUG: LEMO FGG.0B.305.CLAD 56Z
PIN 5
PIN 2
Remote switch inputs are activated when grounded.
3 4
5
2
1
CABLE CONNECTOR: Lemo “K” series ve pin connector located on the back of the control module beneath the
battery receives the remote cable or imaging system cable.
PIN # DESCRIPTION
1 +5 VOLTS 100 ma MAXIMUM
2 REMOTE SWITCH
3 REMOTE SWITCH - NO DELAY
4 X-RAY ON SIGNAL
5 COMMON 0 VOLTS
Remote cable connector

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4.0 DESCRIPTION OF OPERATION
The block diagram below illustrates how the XRS4 functions. The following sequence of events takes place each
time the XRS4 is red:
1. User initiates operation of the machine.
2. The control section sends a signal to the converter section to begin oscillating.
3. Once oscillating, the converter section changes the 18 volts DC to 22Khz AC.
4. The transformer charges the High Voltage Capacitor to about 10,000 volts.
5. The spark gap arcs after the High Voltage Capacitor reaches proper 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 approximately 370,000 volts and
10 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 XRS4 cannot produce x-rays with-
out the pulsing sound so it serves as an additional warning the XRS4 is functioning.
This unit generates X-rays through high voltage bombardment of a tungsten target. The XRS4 does not contain ra-
dioactive 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.
BLOCK DIAGRAM
PULSE DETECTOR
USER INTERFACE
X-RAY TUBE
HIGH VOLTAGE
CAPACITOR
CONVERTER
BATTERY
SPARK GAP
CONTROLLER

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5.0 OPERATING INSTRUCTIONS
The following are basic operation instructions to take an X-ray image using the XRS4. Certain applications may
require modications to these basic procedures.
DETERMINE PULSE INITIATION METHOD:
DR, REMOTE CABLE, TIME DELAY
DR REMOTE CABLE TIME DELAY
Attach Battery Attach Battery Attach Battery
Connect System Attach Cable Position XRS-4*
Position XRS-4* Position XRS-4*
Turn on XRS-4 using key and
turning clockwise 1/4 turn
Turn on XRS-4 using key and
turning clockwise 1/4 turn
Turn on XRS-4 using key and turning
clockwise 1/4 turn
Set Pulse Count (pg. 11)
Set pulse count to 200 (pg. 11) Set Pulse Count (pg. 11)
Set Delay Time (pg. 12)
Retreat to imaging system
controller (computer)**
Retreat length of cable behind the
XRS-4**
Press left and right buttons
simultaneously to initiate
time delay
Follow imaging system
instructions to set pulses and
initiate pulse train
Press and hold cable button down to
initiate and complete pulse train
Retreat safe distance
behind XRS-4**
View Image Retreive image plate or film cassette
Retreive image plate or film
cassette
Turn off XRS-4 View Image View Image
Turn off XRS-4 Turn off XRS-4

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*XRS-4 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 XRS-4
and imager is usually 24 to 72 inches (30 to 180 cm). XRS-4 should be stabilized during use on a at surface, a
tripod, or a custom xture suitable for holding the 22 pound (9 Kg) XRS-4.
**OPERATING PRECAUTIONS: The operator should always stand at least 20 feet (6m) behind the X-ray unit and
clear all personnel at least 20 feet (6m) behind the unit or at least 100 feet (30m) from the front of the unit before
pulsing. The exclusion zone (below) should be a controlled area free of all personnel while
X-ray pulses.
Figure 4: Exclusion Zone
24 to 72 inches (30 to 180 cm)
XRS4 OBJECT IMAGER
X-ray Beam
36’ (11m)
36’ (11m)
100’ (30m)
20’(6m)
20’(6m)
20’(6m)

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SUGGESTED PULSE SETTINGS
The chart below lists approximate pulses necessary to penetrate various materials. Settings vary greatly depend-
ing on imaging system used. Refer to imaging system instructions for more information.
The following is true when using lm or digital systems that generate a positive image. If the radiograph is too
dark, the lm is underexposed. If the radiograph is too light the lm is overexposed. Underexposure can be cor-
rected by increasing the number of pulses and/or decreasing the distance between the imaging medium and the
XRS4. Overexposure can be corrected by reducing the number of pulses and/or increasing the distance between
the imaging medium and XRS4.
MATERIAL PULSE SETTING (24” BETWEEN X-RAY & IMAGER)
CARDBOARD / LIGHT WOOD / PLASTIC 2
LIGHT METAL 5-10
STEEL 1/4” 25
STEEL ½” 50
STEEL 1” 99
BRASS 1/8” to ¼” 50-99
Underexposed Overexposed
Correct exposures (pulse setting)

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NAVIGATING THE MENU
Home Press Right Arrow to advance to next menu
Press Left Arrow to go back to home Press enter to view settings menu options
Down Arrow to scroll to next menu option Press enter to select option >

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SET PULSE COUNT
*Any pulse setting above 200 will automatically default to multiple pulse trains of 50 with 45 second delay be-
tween each pulse train.
Press Right Arrow button from home screen Press Enter button from Settings screen
Select Set Pulse Count and press Enter Button Use LEFT / RIGHT arrow to select Digit
Use UP / DOWN arrows to change number
Pulse setting from 001 to 999*
Press Right Arrow to Save and Press enter Home screen appears after pulse count is saved

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SET DELAY TIME (Before rst pulse)
¾Time delay is the delay time before the rst pulse only when ring the unit directly from the XRS4 control
panel by depressing left and right arrow buttons simultaneously.
¾Time delay does not affect delay time between multiple pulse trains and does not affect delay time
before the rst pulse when using a remote cable or when X-ray is red from a digital imaging system
controller.
Press Right Arrow button from home screen Press enter button from Settings screen
Select Set Delay Time press Enter button Use Left/Right arrows to select digit
Use UP/DOWN arrows to change number
Delay option from 5 to 240 seconds
Press Right Arrow to Save and Press Enter Home Screen appears when Time delay is saved

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MULTIPLE PULSE TRAINS
Option is used to enter multiple pulse trains and rest period between each pulse train.
¾If multiple pulse trains are entered Multi-Trains set Continue screen appears when unit is powered up.
¾Operator must select Y and press enter to continue with multiple pulse trains.
¾If operator does not select Y and press enter the unit will default to a single pulse train. This safety fea-
ture ensures operator’s knowledge that multiple pulse trains are set.
¾Red X-ray pulse light blinks between multiple pulse trains.
Multiple pulse train option can be used slow the pulse rate to one pulse per second by entering a pulse count of
one, enter desired number of pulse trains (pulses), and select one second between pulse trains.
Select Multiple Trains press Enter Select pulse trains 1 to 999
Select seconds between pulse trains and save Must select Y to continue
Home screen Appears with * to designate multiple pulse trains.

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DUTY CYCLE
If operator selects multiple pulse trains that exceed the duty cycle of 200 pulses in 4 minutes the LCD will display:
Setting exceed duty cycle for four seconds followed by Continue? Yes/No screen. If the operator selects No the
Unit will default to a single pulse train. If the operator selects Yes on the continue screen the LCD will display a
second warning May void Warnty Continue? If operator selects Y the pulse count will remain with the multiple
pulse trains in place. When the unit is returned for repair Golden Engineering can see how many times the duty
cycle had been exceeded. If the repairs required to the machine are caused by excessive use the warranty may
be voided.
PULSE COUNTERS
XRS4 contains two pulse counter options. The rst pulse counter can be reset to zero by selecting Pulse Counter
then pressing the UP ARROW to reset. This feature allows the operator to track the number of pulses red from
a desired event like the last tube change or total number of pulses for a specic job. The Lifetime Pulse option
displays the total number of pulses on the machine and cannot be reset. Unlike previous versions there is no multi-
plier – the number displayed on the LCD is the exact number of pulses on the machine.

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6.0 MAINTENANCE
X-RAY DOSE MEASUREMENT Using a dosimeter, the average X-ray dose for new tube can be established.
¾With the dosimeter located 1 foot from the front of the case and in line with the center of the beam an-
gle label, the reading for 10 pulses should be 40 mR to 70 mR.
¾The leakage sheet illustrates the X-ray dose and maximum allowable radiation leakage levels for each
X-ray unit. A completed copy of this form accompanies each X-ray.
TUBE REPLACEMENT If you have a tube replacement kit refer to instructional disk included with the kit. If you do
not have a kit the unit must be sent back to Golden Engineering or an Authorized Distributor for tube replacement.
Tube life is 50,000 to 100,000 pulses. Under normal conditions the tube’s output will decrease slowly with use. If
the tube is broken or the glass cracks the tube output will cease immediately.
7.0 TROUBLESHOOTING
SYMPTOM TEST ACTION
No “power on” light -Check battery voltage
-Check battery connection
- Replace or charge battery
- Make sure battery is securely
attached and battery clips are
not bent or broken.
Power on lights, but X-ray does not
pulse.
-Check the battery voltage.
-Check the 2amp fuse.
-Charge or replace the battery.
-Replace the fuse if necessary.
Power on lights, X-ray pulsing light
does not illuminate, X-ray dose not
pulse
- Replace the X-ray pulsing light
Low Battery
Please Charge
-Appears if battery is below 17V -Charge the battery
X-ray pulses, but no image or black
image.
-Test X-ray output. -Replace the tube.
Unit stops pulsing in the middle of a
pulse train and LCD displays 00.
-Check the battery voltage.
-Check 20 amp fuse.
- Charge battery if necessary.
- Replace the fuse if blown.
Unit makes loud popping noise
while pulsing.
- Stop immediately and return
for repair.
Oil leaking from unit. Return for repair.

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8.0 INSTRUCTIONS FOR REPAIR
STEP 4
STEP 1 STEP 2 STEP 3
KEY SWITCH
CONNECTOR
STEP 5
Counter Board
FUSE REPLACEMENT Requires T-10 Torx driver & needle nose pliers.
1. Remove the back plate. Remove the 5 screws in the back
plate then pull the back plate off slowly maneuvering the
battery terminal connecting wires through the opening in the
oscillator board.
2. The 20 amp fuse is the white one inch long fuse on the left side of the oscillator board. The 15 amp fuse
is a small green fuse in the center of the oscillator board. The 15 amp fuse is soldered in place and can
only be replaced using a soldering iron.
3. REMOVING THE BOARDS Refer to the diagram on page 17
4. Using T10 Torx Remove the 2 screws on both sides of the housing.
5. Using T10 Torx Remove the 5 screws holding the back plate in place.
3. Lift the top plate from the control module.

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INSTRUCTIONS FOR BATTERY DISPOSAL Follow all federal, state, and local laws for disposal of lithium-ion
batteries. Batteries may be returned to Golden Engineering.
4. Disconnect the Key Switch wires from the Oscillator Board.
5. Use at head driver to remove screws holding the Counter Board in place and remove the Counter Board.
6. There are three terminals on the lower left side of the Oscillator Board and one on the lower right.
Disconnect the two blue wires, one red wire, and one green signal wire using Philips driver.
7. There are three socket head cap screws holding the oscillator board in place. Two are in the middle of
the board and one is at the bottom. Remove these three screws then remove the Oscillator Board.
BOARD INSTALLATION
1. Install the Oscillator Board.
2. Put the three cap screws through the oscillator board and then put the ½” offsets on the back of the screws.
3. Attached the two blue feedback wires, one red feedback wire, and green signal line.
4. Attach the Counter Board to the top plate.
5. Attached key switch wires to the Oscillator board.
6. Set top plate back in place making sure Counter Board and Oscillator Board connect.
7. Reinstall the back plate.
8. Insert and tight the two screws on each side of the control module.
20 AMP
15 AMP
FUSE
STEP 6
STEP 7
POWER
TRANSISTOR
SIGNAL WIRE
STEP 6
Oscillator Board
LCD CONTRAST
ADJUSTMENT

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9.0 WARRANTY
Golden Engineering, Inc. warrants XRS4 X-ray unit made and sold by it or its authorized representatives to be free
of defects in materials and workmanship for a period of twelve (12) months from the date of shipment to the end
user. Warranty does not cover maintenance required due to life. To make a claim under this limited warranty,
customer must ship the entire unit (or the component believed to be defective) to Golden Engineering, post-paid.
Golden Engineering, Inc. assumes no liability for units or components shipped until they are actually in the custody
of Golden Engineering, Inc. Provided Golden Engineering, Inc. in its sole discretion, is satised that the failure is
not the result of excessive use, abuse, misuse, accident, modication or improper disassembly or repair, Golden
Engineering will provide parts and labor required to repair the unit. Golden Engineering reserves the right to use
reconditioned and remanufactured components that meet original specications. The unit or component will be
return shipped to customer at customer’s expense. THIS EXPRESS LIMITED WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES AND GUARANTEES, EITHER EXPRESS OR IMPLIED OR CREATED BY OPERATION OF LAW.
XRS4 Manufacturer European Representative
Golden Engineering, Inc. Certication Experts Europe
PO Box 185 Nieuwstad 100
Centerville, IN 47330 USA 1381 CE Weesp
Phone: [phone] The Netherlands
Fax: [phone]
Web: www.goldenengineering.com
RETURNING UNIT FOR REPAIR
¾Complete the repair form at www.goldenengineering.com/technical.html and include a copy of the
printed form with the repair. If you do not have internet access prior to sending repair then include a letter
containing a brief description of the problem, contact name, phone number, and return address.
¾Remove battery before shipping the unit.
¾Accessories are not required
¾Be sure the unit is securely packaged for shipment and wrap in plastic bag if there is an oil leak.
¾Ship to address:
The XR200 X-Ray Source is
manufactured by:
GOLDEN ENGINEERING, INC.
PO BOX 185
CENTERVILLE, IN 47330 USA
Phone: [phone]
Fax: [phone]
Web: www.goldenengineering.com
Email: [email protected]
Golden Engineering
6364 Means Road,
Centerville, IN 47330 USA
Serial Number:___________________ Delivery Date:____________________