Philips Optimus User manual

Philips Medical Systems
Converter test kit OPTIMUS
for OPTIMUS 50/65/80 generators
release 3.x with converters 4512 104 7231x
4512 104 91681
Level 1 Documentation
This document and the information contained in it is strictly reserved for current Philips Medical Systems ("Philips") personnel, Philips licensed
representatives and Philips customers who have purchased a valid service agreement for use by the customer's designated in-house service
employee on equipment located at the customer's designated site. Use of this document by unauthorized persons is strictly prohibited. This
document must be returned to Philips when the user is no longer licensed and in any event upon Philips' first written request.
Printed in Hamburg
Federal Republic of Germany
© 2008 Koninklijke Philips Electronics N.V.
ALL RIGHTS RESERVED
Manual Order No. 4512 984 22723 Vers. 00

Proprietary Notice:
This document and the information contained in it is proprietary and confidential information of
Philips Healthcare (”Philips”) and may not be reproduced, copied in whole or in part, adapted,
modified, disclosed to others, or disseminated without the prior written permission of the Philips
Legal Department. Use of this document and the information contained in it is strictly reserved
for current Philips personnel and Philips customers who have a current and valid license from
Philips for use by the customer’s designated in house service employee on equipment located
at the customer’s designated site. Use of this document by unauthorized persons is strictly
prohibited. Report violation of these requirements to the Philips Legal Department. This docu‐
ment must be returned to Philips when the user is no longer licensed and in any event upon
Philips’ first written request.
Warranty Disclaimer Language:
Philips provides this DOCUMENT without warranty of any kind, implied or expressed, including,
but not limited to, the implied warranties of merchantability and fitness for a particular purpose.
Limitations of Liability Language:
Philips has taken care to ensure the accuracy of this document. However, Philips assumes no
liability for errors or omissions and reserves the right to make changes without further notice to
any products herein to improve reliability, function, or design. Philips may make improvements
or changes in the product(s) or program(s) described in this document at any time.
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4512 984 22723 Vers. 00

SERVICE MANUAL - Unit
Converter test kit OPTIMUS for OPTIMUS 50/65/80 gener‐
ators release 3.x with converters 4512 104 7231x
Author: Th. Frenschek
Type no: 4512 104 91681
List of Pages and Drawings
Manual Order No. 4512 984 22723
released: 05/2008
1 ...3
4 ...53 (08.0)
Converter test kit OPTIMUS for OPTIMUS 50/65/80 gen‐
erators release 3.x with converters 4512 104 7231x
4512 984 22723 Vers. 00 CSIP Level 1
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3

CONVERTER TEST KIT OPTIMUS
Contents
1Introduction ............................................................................................................................ 6
1.1 Scope of delivery .................................................................................................................................. 6
1.2 Tools ..................................................................................................................................................... 6
2Generator condition after failure event .................................................................................. 7
2.1 Special case ......................................................................................................................................... 7
2.2 All other cases ...................................................................................................................................... 7
2.3 Prerequisites before checking the generator ........................................................................................ 7
3Check of generator mains supply parts ................................................................................. 8
3.1 Condition(s) when the service comes to the site .................................................................................. 8
3.1.1 ENF2 tripped, possibly in combination with ENF1 and mains fuses .................................................... 8
3.1.2 ENF1 tripped, possibly in combination with mains fuses ..................................................................... 9
3.2 Check for open springs at damping resistors ....................................................................................... 9
3.3 Check for contacts that are welded at breakers and contactors .......................................................... 9
4Converter checks (EQ frontal and E2Q rear) ...................................................................... 11
4.1 Visual converter check ....................................................................................................................... 11
4.2 Measuring of converter parts .............................................................................................................. 11
4.2.1 Rectifier check .................................................................................................................................... 11
4.2.2 IGBT check ......................................................................................................................................... 11
4.2.3 Overvoltage diode check .................................................................................................................... 12
4.2.4 Resistor check (PCB versions 4512 108 0862x / 0934x) ................................................................... 12
4.2.5 Power cable harness check ............................................................................................................... 13
4.2.6 Resonance capacitor check ............................................................................................................... 13
5Check of the high-voltage transformer ................................................................................ 14
5.1 Analysis .............................................................................................................................................. 14
6Visual check of the X-ray tube ............................................................................................. 16
7Interim results ...................................................................................................................... 17
8Tube check with Rotor Control Part 1 .................................................................................. 18
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9kV-driver test ....................................................................................................................... 19
10 Tube check with Rotor Control Part 2 .................................................................................. 24
11 Tube and high-voltage cable test with high voltage ............................................................. 25
12 Measuring of primary currents ............................................................................................. 29
12.1 Measuring of the resonance frequency .............................................................................................. 33
12.2 Measurement of kV behavior with an adapted tube ........................................................................... 34
12.3 Measuring of kV behavior with a non-adapted tube (Optimus 65/80) ................................................ 35
13 Reconditioning of the tube(s) ............................................................................................... 37
14 Final system test .................................................................................................................. 40
15 Appendix .............................................................................................................................. 41
15.1 Alignment of function unit kV .............................................................................................................. 41
15.1.1 General information ............................................................................................................................ 41
15.1.1.1 Connecting and setting the scope ...................................................................................................... 42
15.1.1.2 Deactivating the kV controller ............................................................................................................. 43
15.1.1.3 Setting of exposure data .................................................................................................................... 43
15.1.1.4 Adjustment of the factor for duty cycle ............................................................................................... 43
15.2 Tube conditioning ............................................................................................................................... 45
15.2.1 General Information ............................................................................................................................ 45
15.2.2 Preconditions / Program settings ....................................................................................................... 46
15.2.3 Procedure ........................................................................................................................................... 47
15.3 List of checked parts of generator S/N ............................................................................................... 51
15.4 List of checked parts of generator S/N ............................................................................................... 52
15.5 List of checked parts of generator S/N ............................................................................................... 53
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5

1INTRODUCTION
With this document it should be possible to determine which part of kV units of an Optimus generator is still
operational and which part is defective and has to be replaced.
1.1 SCOPE OF DELIVERY
– 2 current transformers
(ratio 1:1000, 20Ω resistors at the secondary coil give a ratio of 50A primary / 1V secondary)
– Test cable with resistor
– Test cable with diode
– This documentation
1.2 TOOLS
– Standard tools
– Extension boards C (96-pin)
– Dual trace oscilloscope with:
– 2 probes for signals
– 1 probe for external triggering
– Multimeter with diode test option
– 1 battery 1.5V D cell (R20) preferred
C cell (R14) or AA cell (R6) possible
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2GENERATOR CONDITION AFTER FAILURE EVENT
ENF1 and/or ENF2 and/or ENF3 tripped.
Mains fuses might have additionally tripped.
2.1 SPECIAL CASE
ENF3 tripped, possibly in combination with ENF2 and ENF1 and mains fuses:
Problem most likely caused by rotor control unit EY (high speed) or EYA (low speed).
Solutions for rotor control problems are not part of this document.
2.2 ALL OTHER CASES
The generator has to be kept in this condition to discover the cause of the problem.
A non-qualified person (e.g. hospital technician not familiar with Optimus) should not be asked to just turn the
fuses back on to prevent further damage.
A qualified person like a Philips field engineer (trained on Optimus) must visit the site.
2.3 PREREQUISITES BEFORE CHECKING THE GENERATOR
CAUTION Do not remove PCB kV-power from the IGBT transistors.
Electrostatic discharge and mobile phone waves can damage and destroy IGBTs
when gate connections are open.
WARNING The generator must be switched OFF and must be completely cut from mains (e.g.
room mains switch or earth leakage current breaker).
All following checks must be made without mains power
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7

3CHECK OF GENERATOR MAINS SUPPLY PARTS
▪ Measure DC voltage at auxiliary contacts 41-42 of ENK2.
(Converter DC discharging contact, max voltage can be 750VDC.)
If 0V is measured:
– the contact is closed (and the converter DC is discharged within 1 minute)
or
– the contact is open and the converter DC is discharged and safe.
WARNING In case one of the ENK2 main contacts is welded the converter DC discharge time is
much longer as the discharging auxiliary contact ENK2 41-42 cannot be closed.
600VDC discharge time to < 60VDC normally 40 seconds.
With open contact > 11 minutes to be < 60VDC.
▪ Check if any main contact of contactor ENK2 is welded:
Mechanical check: If snap-on auxiliary contacts or auxiliary contact block cannot be removed from the main
contactor at least one contact is welded.
ENK2 phase 1 1 - 2 contactor ENK2 2422 132 06621
phase 2 3 - 4 + 3 aux. contacts NO 2422 135 04355
phase 3 5 - 6 + 1 aux. contact NC 2422 135 04023
or
successor contactor 2422 132 07381
+ succ. aux. cont. block 2422 135 04464
+ succ. R/C circuit 2422 135 04661
▪ Record the conditions in the checklist (last pages).
▪ If contacts are found welded, replace contactor, its auxiliary contacts or contact block and the R/C circuit.
3.1 CONDITION(S) WHEN THE SERVICE COMES TO THE SITE
3.1.1 ENF2 tripped, possibly in combination with ENF1 and mains fuses
Problem might be caused by any of the:
– internal generator units (Optimus RAD + R/F)
or
– external units (Optimus RAD only) connected to breaker ENF2 :T1 :T2 :T3.
Solutions for such a case are not part of this document.
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3.1.2 ENF1 tripped, possibly in combination with mains fuses
Problem most likely caused by kV unit malfunction (kV-control, kV-power, converter(s), HV transformer) or external
parts e.g. HV cable(s) or tube.
WARNING Make sure that the DC voltage in the converter is discharged.
▪ Open the cover of the frontal (and rear where present) converter.
▪ Measure DC at PCB kV-power EQ100 at E2 – C1 (at both converters, see layout drawings attached).
The measured DC must be < 10VDC.
3.2 CHECK FOR OPEN SPRINGS AT DAMPING RESISTORS
EN :R1 safety resistor 47Ω 100W 4512 100 45441
:R2
:R3
▪ Record the conditions in the checklist (last pages).
▪ Check for open springs at damping resistors.
Springs might be open if all breakers are ON when the service comes to the site.
In this case the generator must have been switched ON after all fuses and breakers were reactivated. Short-
circuit in the converter or its mains rectifier/filter could have happened.
Springs can be resoldered. If the springs have to be resoldered, use as little solder as possible.
▪ Check that the ceramic resistor bodies do not have cracks. In case of cracks the springs must be resoldered.
3.3 CHECK FOR CONTACTS THAT ARE WELDED AT BREAKERS AND CONTACTORS
▪ Switch OFF breakers ENF1 and ENF2.
ENF1 L1 – T1 automatic circuit-breaker ENF1 Optimus 50 2422 129 15514
L2 – T2 or successor 2422 129 16291
L3 – T3 Optimus 65/80 2422 129 15513
or successor 2422 129 16292
ENF2 L1 – T1 automatic circuit-breaker ENF2 Optimus 50/65/80 2412 129 00341
L2 – T2 or successor 2422 129 16288
L3 – T3
ENK1 phase 1 2 – 1
phase 2 4 – 3
phase 3 6 – 5
contactor ENK1 Optimus 50 2422 132 06625
or successor 2422 132 07382
+ R/C circuit 2422 135 04662
Optimus 65/80 2422 132 06624
or successor 2422 132 07383
+ R/C circuit 2422 135 04662
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▪ Record the conditions of the breakers in the checklist (last pages).
▪ Check for contacts that are welded at breakers and contactors.
If contacts are found welded, replace breaker(s) and/or contactor(s).
▪ Remove the converter mains lines (frontal and rear converter) from contactor ENK1 :1 :3 :5.
Measure with an ohmmeter each line against the others (of each converter).
There should be no short-circuit, the meter should display 2MΩ ±5% after at least 20 seconds
(filter resistors).
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4CONVERTER CHECKS (EQ FRONTAL AND E2Q REAR)
4.1 VISUAL CONVERTER CHECK
▪ Check the converter visually.
The entire converter chassis must be replaced if cracks are visible at the white IGBT body
(looking through the converter cage grid) or if the kV-power PCB Q100 is bent towards the cover plate.
4.2 MEASURING OF CONVERTER PARTS
Use an ohmmeter that has a diode test feature.
▪ Check the polarity of the meter (for ohm and diode testing):
Anode of diode symbol on meter = positive voltage >> PLUS (see measurement)
Cathode of diode symbol on meter = negative voltage >> MINUS (tables)
Ω= Normal ohm measurements
➜= Diode test option of meter
4.2.1 Rectifier check
▪ Open the right side of the converter(s) to get access to the mains rectifier.
L1 □ □ –
L2 □ □ –
L3 □□ +
Rectifier EQV5 layout
MINUS PLUS
→
PLUS MINUS
→
L1 / L2 / L3 □ □ – □ + L1 / L2 / L3 □ □ – □ +
450mV ±10%
∞ ∞
450mV ±10%
(Fig. 1)
▪ Record the conditions in the checklist (last pages).
4.2.2 IGBT check
Legend Typical values when part is OK
Typical values of defective parts
If at least one test fails, the converter must be exchanged.
Proceed with chapter 5.
The table below shows results of IGBT emitter - collector measurement.
Converter working OK and completely assembled.
Q100 kV-power PCB 4512 108 0862x / 0934x
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MINUS PLUS Ω ➜PLUS MINUS Ω ➜
E1
E2,3,4
C1
C2,3,4
21.5 - 22kΩ ∞ E1
E2,3,4
C1
C2,3,4
16.5kΩ ±10% 300mV ±10%
Ex Cx 0Ω < 200mV Ex Cx 0Ω < 200mV
The table below shows values of IGBT gate - emitter resistances.
Converter working OK and completely assembled.
Q100 kV-power PCB 4512 108 0862x / 0934x
MINUS PLUS Ω PLUS MINUS Ω
G1
G2,3,4
E1
E2,3,4
3.8kΩ ±10% G1
G2,3,4
E1
E2,3,4
4.2kΩ ±10%
Gx Ex 0Ω Gx Ex 0Ω
▪ Record the conditions in the checklist (last pages).
4.2.3 Overvoltage diode check
Cathode = heat sink plate
MINUS PLUS ➜PLUS MINUS ➜
Cathode
V500
V501,2,3
Anode
V500
V501,2,3
310mV ±10% Cathode
V500
V501,2,3
Anode
V500
V501,2,3
∞
Cathode V5xx Anode V5xx 0 Cathode V5xx Anode V5xx 0
▪ Record the conditions in the check list (last pages).
4.2.4 Resistor check (PCB versions 4512 108 0862x / 0934x)
▪ Check 2 groups of 3 parallel resistors:
R506 / 507 / 508
and
R509 / 510 / 511
With 39Ω ±5% per group. Each resistor must have a resistance of 13Ω ±5%.
▪ Record the conditions in the checklist (last pages).
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4.2.5 Power cable harness check
▪ Check internal converter power cable connections
at resonance capacitors C3:2 and C13:2.
If the connectors look like (2) no additional action
is necessary.
If one of the connectors looks like (1) and if signs
of overheating are visible replace the converter.
▪ Record the conditions in the check list (last pages).
1 2
(Fig. 2)
4.2.6 Resonance capacitor check
▪ Remove primary lines from resonance capacitors C3:1 and C13:1 of frontal (and rear) converter.
▪ Check both capacitors for:
– short-circuit
– open connection
As it is not possible to measure the capacitance with an ohmmeter it is sufficient to see a variable resistance value
for a certain time and finally a high resistance or open connection.
Once a high resistance or open connection is displayed reverse the measuring lines. If it comes again to an
unstable resistance display with a high resistance or open connection display at the end, the capacitor should be
OK.
If a capacitance measuring device is available it should display 8µF ±5% (apart from the meter tolerance).
If a capacitor is defective (short or open) and no other part of the converter is defective which requires a converter
unit exchange, replace the capacitor (2019 321 00016).
▪ Record the conditions in the checklist (last pages).
NOTE Leave the primary lines disconnected from the capacitors for further tests.
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13

5CHECK OF THE HIGH-VOLTAGE TRANSFORMER
▪ Remove PCB EZ130 kV-control.
▪ Insert an extender PCB at EZ130 X1 (or use the backpanel connections, which is less convenient).
▪ Establish oscilloscope connections:
channel 1 =anode EZ130 X1:C17 10 or 20mV/div
channel 2 =cathode EZ130 X1:C16 10 or 20mV/div
ground =EZ130 X1 :A17 :A16
trigger =positive slope anode ch1 or negative slope cathode ch2
trigger level according to signal level
time base =500ms/div or 1s/div
Signal amplitudes might look different depending on the battery type, connection cables used and the ”contact
force” at the battery.
(Fig. 3)
▪ Measure
1. with high-voltage cables and tube connected.
2. with high-voltage cables only.
3. without high-voltage cables connected.
5.1 ANALYSIS
(1) and (2) have to look almost the same (symmetry and amplitude).
When (1) has a lower amplitude or a different kV behavior compared to (2) and (3) the tube might be defective.
(3) should have a steeper (faster) discharging ramp as the capacitance of the HV cable is missing (tank only 3nF,
20m cable typically 1.5nF) assuming amplitude and symmetry are the same.
When (2) and (3) look different (amplitude and symmetry) and if (3) is symmetric the HV cable(s) might be de‐
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fective.
When (3) shows an asymmetric amplitude the HV tank must be replaced.
▪ Check against the following chart:
(Fig. 4)
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15

6VISUAL CHECK OF THE X-RAY TUBE
▪ If possible remove the collimator and the X-ray tube window assembly.
Is there any visible damage?
▪ A cracked tube or the loss of its vacuum could be a reason to destroy the converter.
▪ Record the conditions in the check list (last pages).
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7INTERIM RESULTS
At this point
– generator parts and units
– tube(s)
– HV cables
have been checked.
Something might have been exchanged or all tests came to an OK-result.
▪ Remove the extender PCB and reinsert kV-control EZ130.
WARNING All followings checks must be made with mains power.
Check that the converter mains lines still have no connection
to mains at ENK1 :1, :3, :5
▪ Switch ON all generator breakers and the mains supply.
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17

8TUBE CHECK WITH ROTOR CONTROL PART 1
In case the tube was rotating during tripping of mains breakers the CPU remembers that the brake process has
not been carried out (high-speed rotor control only).
About 40 seconds after switch-ON the tube brakes.
NOTE If the anode disk is not rotating before switch-ON it sounds like an acceleration
process.
▪ Switch ON the generator and perform an audible check at the tube housing during the generator start-up
(for further explanations see chapter 10.)
As the mains lines are not connected to the converters, error messages 02HI and 02HJ come up
(converter DC is 0V, therefore out of range).
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9KV-DRIVER TEST
CAUTION Before this driver test can be carried out the kV power unit(s) must be disconnected
from the mains supply (leads of unit(s) EQ/E2Q to ENK1 :1, :3, :5)
This safety measure is also valid for the chopper test
to guarantee that the measurements can be carried
out without any risks involved.
1 3 5
ENF 1 ENK 1
2Q X1103
Q X1103
2Q X1102
Q X1102
2Q X1101
Q X1101
Z X47
X1
EN100
(Fig. 5)
▪ Switch ON the generator.
Ignore error codes 02HI and 02HJ now, the DC supply is off and these errors must come up.
▪ Check whether the gate voltage is about -14.2 V ±0.3V against emitter for every IGBT.
▪ Check the ±15 V supply for the IGBT drivers. Drivers 1 and 2 are supplied by chopper 1 while drivers 3 and 4
are supplied by chopper 2. The common zero point is the emitter.
Emitter +15 V supply at heat sink -15 V at resistor
E1, X101 A100 : 3 X102
E2, X201 A200 : 3 X202
E3, X301 A300 : 3 X302
E4, X401 A400 : 3 X402
The kV driver test is software-controlled via PC. Due to the missing PREP and exposure requests the signals
EN_X_C/ and CTRL_X_C/ have to be set low–active at the backpanel at locations X76 and X74
(see drawing Z2-5.1/2).
CAUTION Do not forget to remove these connections after the test. Otherwise kV start immedi‐
ately with the PREP command in normal application mode.
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Test of control signal(s) and driver(s) behavior:
The range of the control signal is + 3.7 V ± 0.2 V for the ON condition and + 1.2 V ± 0.2 V for the OFF condition
at the specified measuring point against generator ground (see schematic diagrams and PCB layout).
The range of the driver signal (gate against emitter) is - 14.2 V ± 0.3 V for the OFF condition and + 13.5 V ± 0.3 V
for the ON condition.
▪ Select menu ”FU_kV/ Faultfind/ Functional Test/ Test Converter” at the service PC.
The question [power supply mains - E disconnected ?:] comes up.
Answer with ”yes” (type Return twice) and transmit with [F2].
If the test takes longer than 10 minutes it may happen that the test is denied by the kV control. This happens if
the DC voltage = E–value is ≥ 5 V (the DC capacitors are slowly charged by the ±15 V of the drivers). Then short–
circuit the DC at collector C1 and emitter E2.
Do not establish a constant short–circuit to avoid problems after the test!
The test itself is short. The pulse time is 2.5 s long, but the PC screen displays [completed] after 5 s.
kV_control sends pulses for 5 s, but the hardware timer on the kV_control inhibits more pulses after 2.5 ms. Within
this time the actual kV must be on the nominal value.
Test 1: Optical coupler / activation of the gate
Test 1: Input and output:
▪ Put a 2–beam oscilloscope to every measuring
point of the control signals (channel A) and to every
gate belonging to the inputs (channel B).
Measuring points X6...X10 are present at the
kV power unit.
▪ Trigger with the negative slope of channel A, take
10..50ms/div.
IGBT
V1...V4
emitter
on = +13.5V
off = -14.2V
gate
kV -power EQ 100
kV -control
EZ 130
off=0V
on=5V
off=5V
on=0V
R#
X#
X10
channel A: X6
X7
X8
X9
against chassis/X10
channel B: X100
X200
X300
X400
(Fig. 6)
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