Spellman XRB011 User manual

XRB011 User’s Manual 118148-001 Rev A
R
Instruction Manual
SPELLMAN
HIGH VOLTAGE ELECTRONICS
CORPORATION
One Commerce Park
Valhalla, New York, 10595
[phone]* FAX: [phone]*
E-mail: [email protected]
Website: www.spellmanhv.com
XRB011

118091-001 REV. B
IMPORTANT SAFETY PRECAUTIONS
SAFETY
THIS POWER SUPPLY GENERATES VOLTAGES THAT ARE DANGEROUS AND MAY BE FATAL.
OBSERVE EXTREME CAUTION WHEN WORKING WITH THIS EQUIPMENT.
High voltage power supplies must always be grounded.
Do not touch connections unless the equipment is off and the
Capacitance of both the load and power supply is discharged.
Allow five minutes for discharge of internal capacitance of the power supply.
Do not ground yourself or work under wet or damp conditions.
SERVICING SAFETY
.
Maintenance may require removing the instrument cover with the power on.
Servicing should be done by qualified personnel aware of the electrical hazards.
WARNING note in the text call attention to hazards in operation of these units
that could lead to possible injury or death.
CAUTION notes in the text indicate procedures to be followed to avoid possible
damage to equipment.
Copyright 2000, Spellman High Voltage Electronics Corporation. All Rights Reserved.
This information contained in this publication is derived in part from proprietary and patent data. This information has
been prepared for the express purpose of assisting operating and maintenance personnel in the efficient use of the
model described herein, and publication of this information does not convey any right to reproduce it or to use it for
any purpose other than in connection with installation, operation, and maintenance of the equipment described.

118091-001 REV. B
WICHTIGE SICHERHEITSHINWEISE
SICHERHEIT
DIESES HOCHSPANNUNGSNETZTEIL ERZEUGT LEBENSGEFÄHRLICHE HOCHSPANNUNG.
SEIN SIE SEHR VORSICHTIG BEI DER ARBEIT MIT DIESEM GERÄT.
Das Hochspannungsnetzteil muß immer geerdet sein.
Berühren Sie die Stecker des Netzteiles nur, wenn das Gerät ausgeschaltet ist und die elektrischen
Kapazitäten des Netzteiles und der angeschlossenen Last entladen sind.
Die internen Kapazitäten des Hochspannungsnetzteiles benötigen ca. 5 Minuten, um sich zu entladen.
Erden Sie sich nicht, und arbeiten Sie nicht in feuchter oder nasser Umgebung.
SERVICESICHERHEIT
Notwendige Reparaturen können es erforderlich machen, den Gehäusedeckel während des Betriebes zu
entfernen.
Reparaturen dürfen nur von qualifiziertem, eingewiesenem Personal ausgeführt werden.
“WARNING” im folgenden Text weist auf gefährliche Operationen hin, die zu Verletzungen oder zum Tod
führen können.
“CAUTION” im folgenden Text weist auf Prozeduren hin, die genauestens befolgt werden müssen, um
eventuelle Beschädigungen des Gerätes zu vermeiden.

118091-001 REV. B
PRECAUTIONS IMPORTANTES POUR VOTRE SECURITE
CONSIGNES DE SÉCURITÉ
CETTE ALIMENTATION GÉNÈRE DES TENSIONS QUI SONT DANGEUREUSES ET PEUVENT ÊTRE FATALES.
SOYEZ EXTRÊMENT VIGILANTS LORSQUE VOUS UTILISEZ CET ÉQUIPEMENT.
Les alimentations haute tension doivent toujours être mises à la masse.
Ne touchez pas les connectiques sans que l’équipement soit éteint et que la capacité à la fois de la charge et de
l’alimentation soient déchargées.
Prévoyez 5 minutes pour la décharge de la capacité interne de l’alimentation.
Ne vous mettez pas à la masse, ou ne travaillez pas sous conditions mouillées ou humides.
CONSIGNES DE SÉCURITÉ EN CAS DE REPARATION
La maintenance peut nécessiter l’enlèvement du couvercle lorsque l’alimentation est encore allumée.
Les réparations doivent être effectuées par une personne qualifiée et connaissant les risques électriques.
Dans le manuel, les notes marquées « WARNING » attire l’attention sur les risques lors de la manipulation de ces
équipements, qui peuvent entrainer de possibles blessures voire la mort.
Dans le manuel, les notes marquées « CAUTION » indiquent les procédures qui doivent être suivies afin d’éviter
d’éventuels dommages sur l’équipement.

118091-001 REV. B
IMPORTANTI PRECAUZIONI DI SICUREZZA
SICUREZZA
QUESTO ALIMENTATORE GENERA TENSIONI CHE SONO PERICOLOSE E
POTREBBERO ESSERE MORTALI.
PONI ESTREMA CAUTELA QUANDO OPERI CON QUESO APPARECCHIO.
Gli alimentatori ad alta tensione devono sempre essere collegati ad un impianto di terra.
Non toccare le connessioni a meno che l’apparecchio sia stato spento e la capacità interna
del carico e dell’alimentatore stesso siano scariche.
Attendere cinque minuti per permettere la scarica della capacità interna dell’alimentatore
ad alta tensione.
Non mettere a terra il proprio corpo oppure operare in ambienti bagnati o saturi d’umidità.
SICUREZZA NELLA MANUTENZIONE.
Manutenzione potrebbe essere richiesta, rimuovendo la copertura con apparecchio
acceso.
La manutenzione deve essere svolta da personale qualificato, coscio dei rischi elettrici.
Attenzione alle AVVERTENZE contenute nel manuale, che richiamano all’attenzione ai
rischi quando si opera con tali unità e che potrebbero causare possibili ferite o morte.
Le note di CAUTELA contenute nel manuale, indicano le procedure da seguire per evitare
possibili danni all’apparecchio.

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XRB011 INTRODUCTION
1
XRB011
SERVICE
AND
INSTALLATION
MANUAL
INSTALLATION
2
INTERFACING
3
TROUBLESHOOTING
4
SCHEMATICS (Simplified Diagram)
5

SPELLMAN HIGH VOLTAGE Introduction 1
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CHAPTER 1
XRB011 INTRODUCTION
CONTENTS:
Section
1.1 XRB011 DESCRIPTION............................................................................................................................................... 3
1.2 TECHNICAL SPECIFICATIONS ...........................................................................................................................................3
1.2.1 Generator Hardware Specifications .......................................................................................................................... 3
1.2.2 Generator Control Modes / Application Features ..................................................................................................... 3
1.2.3 Power Supply Requirements ...................................................................................................................................... 3
1.2.4 Environment Requirements........................................................................................................................................ 4
1.2.5 Mechanical................................................................................................................................................................. 5
1.3THEORY OF OPERATION .......................................................................................................................................... 7
1.3.1 Function Overview..................................................................................................................................................... 7
1.3.2 Input Line Power........................................................................................................................................................7
1.3.3 HV Inverter ................................................................................................................................................................ 7
1.3.4 High Voltage Transformer......................................................................................................................................... 7
1.3.5 High Voltage Assembly.............................................................................................................................................. 7
1.3.6 System Control PWB..................................................................................................................................................7
1.3.7 Filament Power.......................................................................................................................................................... 8
1.3.8 High Voltage Interlock...............................................................................................................................................8
1.4SAFETY.........................................................................................................................................................................9
1.4.1 Safety and Warning Symbols...................................................................................................................................... 9

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1.1 XRB011 DESCRIPTION
The XRB011 MONOBLOCKis a complete integrated system consisting of a high voltage power supply
(HVPS), filament supply, X-ray tube and oil encapsulant which provide the required high voltage insulation in
one compact enclosure. The combination of proprietary control system and protection circuitry enables the
supplies to operate under arcing and extreme transient conditions without damage or interruptions. Additional
advantages are the elimination of high voltage cables and extremely low leakage X-ray radiation.
The XRB011 incorporates local and remote programming, monitoring, and fault indicators including safety
interlock. The X-ray source is a sealed unit containing a HVPS and an X-ray tube. The insulating oil provides
electrical insulation for the high voltage sections of the power supply and the X-ray tube in a sealed tank. The
oil also functions as a coolant to carry heat away from the tube. Convection cooling augmented by customer
provided minimum 50cfm external fan is required for the 50W option. A rubber bellows in the tank of the X-ray
source compensates for the expansion of the oil as the oil temperature varies with operating conditions thereby
eliminating the need for bulky overflow tank.
.
1.2 TECHNICAL SPECIFICATIONS
1.2.1 Generator Hardware Specifications
kVp range:
35 to 80 kVp output capability
kVp steps:
Continuous with 12 bits resolution
kVp accuracy:
<=1% (measured after kVp rises to the
peak level)
Ripple (kV):
<= 1% Peak to Peak
Settling time:
< 10ms to within 95% of the
programmed voltage
Reproducibility:
<0.5%
Stability:
<=0.01% per 8 hours after a ½ hour
warm up
Temperature Coefficient:
<=100ppm/ ℃
Time range:
XRB011 is specified as a Continuous
operation.
mA :
250µA maximum for 20W option
700µA maximum for 50W option
mA accuracy:
<2.5% (measured after mA rises to
stable DC level)
mA range
0 to 250 µA for 20W option
0 to 700 µA for 50W option
Reproducibility:
<0.5%
1.2.2 Generator Control Modes / Application Features
Manual Operating Mode –2 Parameters Mode (kV, mA)
System Communication Protocol / Fault & Error Management
See details in the Serial Communication Protocol Specifications
1.2.3 Power Supply Requirements
Single Phase

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Line Voltage
24VDC±1VDC, 2.5A (20W option). 4A (50W option)
The following table defines the power line requirements for the generators.
NOTE: THE FOLLOWING TABLE CONTAINS RECOMMENDED VALUES FOR THE 24V INPUT POWER.
A POOR QUALITY INPUT LINE MAY RESULT IN THE INSTALLER HAVING TO
DERATE THE GENERATOR'S MAXIMUM POWER
Mains
Voltage
Minimum
Recommended
Minimum
Recommended
Ground Wire Size
Apparent
Mains
Resistance
24VDC
J1-1
J1-2
J1-3
#20 AWG (0.52 mm2)
#20 AWG (0.52 mm2)
#20 AWG (0.52 mm2)
0.033 
0.033 
0.033 
24V RETURN
J1-5
J1-6
J1-7
#20 AWG (0.52 mm2)
#20 AWG (0.52 mm2)
#20 AWG (0.52 mm2)
0.033 
0.033 
0.033 
1.2.4 Environment Requirements
Operating Environment
Operating Temperature
0 to 40 C (32 to 104 F).
Relative Humidity
10 to 95%, non-condensing.
Atmospheric pressure range
500 to 1060 hPa (375 to 795 mm Hg).
TRANSPORT AND STORAGE
Ambient temperature range
-20 to 70 C (-4 to 158 F).
Relative humidity
5 to 95%, non-condensing.
Atmospheric pressure range
500 to 1060 hPa (375 to 795 mm Hg).

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1.2.5 Mechanical
20W OPTION

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50W OPTION

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1.3 THEORY OF OPERATION
1.3.1 Function Overview
The XRB011 MONOBLOCK Series is a complete integrated system consisting of a high voltage power
supply (HVPS), filament supply, X-ray tube and oil encapsulant which provide the required high voltage
insulation in one compact enclosure. The combination of proprietary control system and protection circuitry
enables the supplies to operate under arcing and extreme transient conditions without damage or interruptions.
Additional advantages are the elimination of high voltage cables and extremely low leakage X-ray radiation.
The XRB011 MONOBLOCK Series incorporates local and remote programming, monitoring, and fault
indicators including safety interlock. The X-ray source is a sealed unit containing a HVPS and an X-ray tube.
The insulating oil provides electrical insulation for the high voltage sections of the power supply and the X-ray
tube in a sealed tank. The oil also functions as a coolant to carry heat away from the tube. Convection cooling
augmented by customer provided minimum 50cfm external fan is required for the 50W option. A rubber
bellows in the tank of the X-ray source compensates for the expansion of the oil as the oil temperature varies
with operating conditions thereby eliminating the need for bulky overflow tank.
The XRB011 MONOBLOCK is basically a DC to DC power converter. Within the generator, conversions of DC
to DC, then to high frequency AC, then to high voltage DC take place. By reviewing further the sub-
assemblies, a basic understanding of the process can be gained.
1.3.2 Input Line Power
The Input DC voltage provides the voltage for the high voltage inverter and the filament supply.
The line input voltage can vary from 23V up to 25V within the series.
1.3.3 HV Inverter
The inverter is a “Push-Pull” topology. Voltage mode control is used for driving the inverter. Two MOSFET
transistors are used as switches in the HV inverter. These MOSFET provide high frequency switching to
control the primary current flow in the high voltage transformer.
Circuits on the Control board provide the gate control of the switches. The PWM IC generates gate drive
control signals.
1.3.4 High Voltage Transformer
The output of the High Frequency Quasi-resonant Inverter is connected to the primary of the High Voltage
Transformer. The High Voltage Transformer is a step up type. Typical secondary voltage is in the range of
5.7kV depending upon output voltage ratings.
1.3.5 High Voltage Assembly
The High Voltage Assembly circuitry typically consists of two high voltage multipliers to generate ±40kV. The
high voltage section is a bipolar ground-referenced supply. The multiplier is a standard diode-capacitor
multiplier with seven stages of voltage multiplication and the divider is a precision resistance divider string.
Each supply is capable of generating 40 kV.
A high bandwidth resistive/capacitive divider provides voltage feedback for regulation and monitoring. A sense
resistor connected at the low voltage end of the High Voltage Rectifier provides current feedback for regulation
and monitoring.
1.3.6 System Control PWB
Control of the generator utilizes sophisticated analog and digital circuitry resulting in fast and accurate control,
protection and signaling to the user.
This generator is based on advanced PWM control utilizing the specific integrated circuit. Analog signals are
digitized in A/D converter and processed within DSP circuits to provide maximum accuracy and reliability.
All feedback signals are sent to the user interface through digital and D/A circuits where switching is possible
between feedback and program signals. This allows the user to preset the desired output before energizing
high voltage.
All program voltages are typically ramped up to set level by the digital ramp generator.

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A-D and D-A converters and drivers provide system Fault Control and Indication. User interface is processed
on this PWB as well, providing isolated relay coils, opt couplers and open collectors contact.
1.3.7 Filament Power
The filament inverter provides the filament power for the X-ray tube. The filament inverter is a high frequency,
series resonant inverter. The inverter provides ac current to the primary of the filament isolation transformer.
The filament isolation transformer secondary is connected to the filament tube. The filament power is
2.25Vac/1.7Aac.
See Figure 1.2 for a simplified diagram of the X-RAY tube connection and current sensing circuits. The
filament circuitry also provides a variety of control, diagnostic and protection functions.
If any abnormal condition appears, monitoring circuitry will shut down the unit.
Figure 1.2 Simplified schematic of X-RAY tube connection
1.3.8 High Voltage Interlock
The XRB011 is equipped with safety interlocks for user personnel and equipment protection. An open interlock
circuit inhibits operation of the XRB011 MONOBLOCK.
POS HV MULT
NEG HV MULT
GND
+
-kV
+kV
FILAMENT
XFMR
X-RAY TUBE
ARC DETECT
mA Monitor
-
GND
GND
HV XFMR
HV XFMR

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1.4 SAFETY
1.4.1 Safety and Warning Symbols
WARNING: THIS X-RAY UNIT MAY BE DANGEROUS TO OPERATOR UNLESS SAFE EXPOSURE
FACTORS AND OPERATING INSTRUCTIONS ARE OBSERVED.
The following advisory symbols are used on the safety warning labels, and/or on circuit boards.
“CAUTION” symbol used to indicate a potential
hazard to operators, service personnel or to the
equipment.
“CAUTION” symbol used to indicate an X-RAY
RADIATION EXPOSURE, is hazard to operators,
service personnel or to the equipment.
Protective Earth
IEC 60417-5017

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CHAPTER 2
INSTALLATION
CONTENTS:
2.1 INTRODUCTION........................................................................................................................................................11
2.2 UNPACKING ..............................................................................................................................................................11
2.3OVERALL CONNECTIONS................................................................................................................................................12
2.4INPUT POWER VOLTAGE........................................................................................................................................13
2.5CABLE CONNECTION ILLUSTRATION..............................................................................................................................13
2.5.1 MULTI INTERFACE CABLE CONNECTIONS.......................................................................................................13
2.5.1 Pin Layout of the Multi interface .............................................................................................................................14
2.5.2 GROUND CONNECTION ..........................................................................................................................................14
2.5.3 CHASSIS GROUND .........................................................................................................................................................15
2.5.4 X-RAY PORT............................................................................................................................................................15
2.6FINAL CHECKS..........................................................................................................................................................15

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2.1 INTRODUCTION
This Chapter contains instructions for unpacking the XRB011 MONOBLOCK, allowing for initial power-up
and exposures.
2.2 UNPACKING
WARNING: THE XRB011MONOBLOK WEIGHS APPROXIMATELY 20 POUNDS (9.07 KG) IN ITS
SHIPPING CONTAINER.
1. Inspect the package exterior for evidence of damage due to handling in transit. Notify the carrier
and Spellman immediately if damage is evident. Do not destroy or remove any of the packing
material used in a damaged shipment.
2. Remove the cardboard outer pack. See the cautionary note below before removing the pack.
CAUTION: OPEN THE CARDBOARD PACK CAREFULLY. SHARP TOOLS MAY DAMAGE THE
CONTENTS.
3. Set aside the cardboard pack(s).
4. After unpacking, inspect the panel and chassis for visible damage.
5. Keep the shipping containers. In case of shipping damage, place the unit(s) back in its shipping
pack and notify the carrier and the Customer Support Department as shown on the inside cover
page of this manual.
6. Fill out and mail the Warranty Registration card accompanying the unit. Spellman XRB011
MONOBLOCK is covered by warranty.

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2.3 OVERALL CONNECTIONS
NOTE: THIS IS BASIC CONNECTION ILLUSTRATION FOR TESTING. MORE COMPLEX AND
DEDICATED CIRCUITRY IS NEEDED IN ULTIMATE APPLICATION.
All cables should be routed away from the X-Ray port, and dressed and secured neatly in place. Cables
should be cut to the correct length if possible as excess cabling may contribute to EMI/RFI problems. For
those cables that cannot be cut to the correct length, try to minimize the area inside any loops of excess
cable, as these loops are in effect an antenna.
Figure 2-1: XRB011 I/O location
GND
RJ45

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Figure 2-2: Overall connection
2.4 INPUT POWER VOLTAGE
1. Check the input voltage rating on the nameplate of the supply and make certain that this is the
rating of the power source to be connected.
2. Units operate on 24VDC, 2.5A (20W option), 4A (50W option).
3. DO NOT SWITCH ON MAINS POWER AT THIS TIME.
2.5 CABLE CONNECTION ILLUSTRATION
2.5.1 MULTI INTERFACE CABLE CONNECTIONS
Multi Interface connections include digital I/O, serial communication, and interlock. Operator must verify
and connect every signal properly though some of them are optional, before initiating power-up and basic
test.

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The interlock, serial communication and exposure buttons interface shall be made available via a multi
signal cable. Refer to *-* for a schematic of isolation and signal direction.
2.5.1 Pin Layout of the Multi interface
The multi signal interface shall have a female 25 pin D-Sub (J1). Twisted pairs shall be used where
applicable. The pin layout is given in Table 2-3.
PIN
SIGNAL
PARAMETERS
1
+24V
+24Vdc±1Vdc @ 4A
2
+24V
+24Vdc±1Vdc @ 4A
3
+24V
+24Vdc±1Vdc @ 4A
4
NC
No connection
5
+24V RETURN
+24V RETURN
6
+24V RETURN
+24V RETURN
7
+24V RETURN
+24V RETURN
8
Signal Ground
Signal Ground
9
Interlock Input
Input, Active low, Interlock is low safe to enable high
voltage. Connect to +24V Return
10
kV Monitor
Output, 0 to 8V = 0 to rated output voltage. Zout=100Ω
11
µA Monitor
Output, 0 to 10V = 0 to rated output current. Zout=100Ω
12
X-Ray Ready status
Output, Active Low,
Open Collector, 24Vdc @ 10mA max
13
X-Ray ON status
Output, Active Low,
Open Collector, 24Vdc @ 10mA max
14
Filament Standby status
Output, Active Low,
Open Collector, 24Vdc @ 10mA max
15
Over Voltage Fault
Output, Active Low,
Open Collector, 24Vdc @ 10mA max
16
Over Current Fault
Output, Active Low,
Open Collector, 24Vdc @ 10mA max
17
ARC Fault
Output, Active Low,
Open Collector, 24Vdc @ 10mA max
18
Filament Current Limit
Fault
Output, Active Low,
Open Collector, 24Vdc @ 10mA max
19
Signal Ground
Signal Ground
20
Interlock Output
Output, Active Low,
Open Collector, 24Vdc @ 10mA max
21
µA Program
Input, 0 to 10V = 0 to rated output current. Zin=10kΩ
22
kV Program
Input, 0 to 8V = 0 to rated output voltage. Zin=10kΩ
23
X-Ray ON Command
Input, Active low,
Low (short)=X-Ray ON
High (open)=X-Ray OFF
Internal pull up resistor to +15V
24
Signal Ground
Signal Ground
25
Over Temp.
Output, Active Low,
Open Collector, 24Vdc @ 10mA max
Table 2-3 Pin layout of multi signal connector
Refer to chapter 3 for detailed requirements and function descriptions.
2.5.2 GROUND CONNECTION
NOTE: THE INSTALLER SHOULD ENSURE THAT ALL CABLE CONNECTIONS TO THE
GENERATOR ARE SECURE, AND ALL CABLES EXTERNAL TO THE GENERATOR
ARE ADEQUATELY PROTECTED AGAINST ACCIDENTAL DISCONNECTION.

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2.5.3 CHASSIS GROUND
The chassis of the XRB011 MONOBLOCK must be grounded to the local earth ground and also to the
tube housing ground.
2.5.4 X-RAY PORT
ENSURE THAT THE EXIT PORT IS PROPERLY MATED TO COLLIMATOR OR SATISFACTORILY
SHIELDED WITH LEAD PLUG TO LIMIT EXPOSURE TO LEAKAGE RADIATION.
X-ray Safety Procedures must be followed when testing this unit. The XRB011 is capable of producing
Lethal Voltages and X-ray Radiation. Only proceed with operation of the HVPS after
Consulting with the Manufacturer and verification of X-Ray setup for the proper precautions.
Reading this entire document.
NEVER OPERATE THIS UNIT WITH AN OPEN X-RAY EXIT PORT.
It is recommended not to allow leakage radiation exceeding 0.5mR/hr at 5cm from any surface of the
MONOBLOCK.
2.6 FINAL CHECKS
The room interface connections may now be completed. Before power on, user needs to check the items
as below finally.
When finished all wiring, check that all connections are tight and secure.
Check that all cables are dressed neatly outside the cabinet, and secured as necessary.
Check the ground connection again.
THIS EQUIPMENT GENERATES DANGEROUS VOLTAGES THAT MAY BE FATAL.
PROPER GROUNDING OF ALL HIGH VOLTAGE EQUIPMENT IS ESSENTIAL.
WARNING X-RAY RADIATION EXPOSURE IS HAZARDOUS
Failure to follow these procedures may void the warranty.
Check the input voltage rating on the nameplate of the supply and make certain that this is the rating of the available
power source. Spellman MONOBLOCKXRB011 operates on 24VDC±1VDC
WARNING
WARNING