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.
Converter test kit OPTIMUS for OPTIMUS 50/65/80 gen‐
erators release 3.x with converters 4512 104 7231x
2 CSIP Level 1
© 2008 Koninklijke Philips Electronics N.V.
ALL RIGHTS RESERVED
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
© 2008 Koninklijke Philips Electronics N.V.
ALL RIGHTS RESERVED
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
Converter test kit OPTIMUS for OPTIMUS 50/65/80 gen‐
erators release 3.x with converters 4512 104 7231x
4 CSIP Level 1 (08.0)
© 2008 Koninklijke Philips Electronics N.V.
ALL RIGHTS RESERVED
Conv test Optimus

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
Converter test kit OPTIMUS for OPTIMUS 50/65/80 gen‐
erators release 3.x with converters 4512 104 7231x
Conv test Optimus CSIP Level 1 (08.0)
© 2008 Koninklijke Philips Electronics N.V.
ALL RIGHTS RESERVED
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
Converter test kit OPTIMUS for OPTIMUS 50/65/80 gen‐
erators release 3.x with converters 4512 104 7231x
6 CSIP Level 1 (08.0)
© 2008 Koninklijke Philips Electronics N.V.
ALL RIGHTS RESERVED
Conv test Optimus

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
Converter test kit OPTIMUS for OPTIMUS 50/65/80 gen‐
erators release 3.x with converters 4512 104 7231x
Conv test Optimus CSIP Level 1 (08.0)
© 2008 Koninklijke Philips Electronics N.V.
ALL RIGHTS RESERVED
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.
Converter test kit OPTIMUS for OPTIMUS 50/65/80 gen‐
erators release 3.x with converters 4512 104 7231x
8 CSIP Level 1 (08.0)
© 2008 Koninklijke Philips Electronics N.V.
ALL RIGHTS RESERVED
Conv test Optimus

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
Converter test kit OPTIMUS for OPTIMUS 50/65/80 gen‐
erators release 3.x with converters 4512 104 7231x
Conv test Optimus CSIP Level 1 (08.0)
© 2008 Koninklijke Philips Electronics N.V.
ALL RIGHTS RESERVED
9

▪ 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).
Converter test kit OPTIMUS for OPTIMUS 50/65/80 gen‐
erators release 3.x with converters 4512 104 7231x
10 CSIP Level 1 (08.0)
© 2008 Koninklijke Philips Electronics N.V.
ALL RIGHTS RESERVED
Conv test Optimus