VOTI XR3D-6 Operating instructions

Confidential and Proprietary Notice
©2011 VOTI Inc. Any reproduction, translation or adaptation of this manual, in whole or in part, is prohibited in any form without
the prior written permission of VOTI Inc.
* VOTI reserves the right to amend these specifications without notice.
O
XR3D-6 Scanner
Maintenance & Troubleshooting
EM-XR3D-6-001-EN.D
Prepared by:
VOTI Inc.
7800 Trans-Canada Highway
Pointe Claire, Quebec, H9R 1C6
Canada

XR3D-6 Maintenance & Troubleshooting
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©2011 VOTI Inc.

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TABLE OF CONTENTS
1Introduction.........................................................................................................1-1
1.1 Hardware Overview ..........................................................................................................1-1
1.2 Software Overview............................................................................................................1-2
1.3 Operation Workflow ..........................................................................................................1-3
1.4 Safety Information.............................................................................................................1-3
1.4.1 Responsibility of the Owner ..............................................................................................1-4
1.4.2 Responsibility of Maintenance Personnel.........................................................................1-5
1.5 Glossary............................................................................................................................1-6
2Unpacking and Set Up........................................................................................2-1
2.1 Set 110/240 Power ...........................................................................................................2-1
2.2 Install the Monitor..............................................................................................................2-1
2.3 Level the Scanner.............................................................................................................2-3
2.4 System Verification...........................................................................................................2-3
2.4.1 Power Up..........................................................................................................................2-4
2.4.2 Run a Test Scan...............................................................................................................2-5
2.5 Updating Software ............................................................................................................2-7
3Preventive Maintenance .....................................................................................3-1
3.1 Cleaning............................................................................................................................3-1
3.2 Check for Digital Inputs Outputs using DIOX....................................................................3-2
3.3 Control Box Access - Technician......................................................................................3-4
3.4 Performance Verification Test...........................................................................................3-6
3.4.1 ASTM Test Tool Description.............................................................................................3-6
3.4.2 ASTM Test Tool Placement..............................................................................................3-6
3.4.3 Run a Test Scan...............................................................................................................3-7
3.4.4 Test 1 –Wire Display........................................................................................................3-7
3.4.5 Test 2 –Useful Penetration ..............................................................................................3-8
3.4.6 Test 3 –Resolution...........................................................................................................3-8
3.4.7 Test 4 –Simple Penetration..............................................................................................3-9
3.4.8 Test 5 –Thin Organic Imaging..........................................................................................3-9
3.4.9 Test 6 –IQI Sensitivity......................................................................................................3-9
3.4.10 Test 7 –Organic/Inorganic Differentiation.......................................................................3-10
3.4.11 Test 8 –Organic Differentiation ......................................................................................3-10
3.4.12 Test 9 –Useful Organic Differentiation...........................................................................3-10
3.4.13 Save Test Results...........................................................................................................3-11
3.4.14 Sample ASTM Log Sheet...............................................................................................3-11
3.5 Seasoning the X-ray Generator Tube.............................................................................3-13
3.6 X-ray System Test ..........................................................................................................3-15
3.6.1 Measuring the X-rays......................................................................................................3-17
3.7 Calibration Test Procedure.............................................................................................3-18

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3.7.1 Re-Calibrate the XR3D................................................................................................... 3-21
3.8 Realign the X-ray Source................................................................................................ 3-24
4Software Troubleshooting Procedures..............................................................4-1
4.1 Initialization Error Codes................................................................................................... 4-1
4.2 Run-Time Error Codes...................................................................................................... 4-2
5Hardware Troubleshooting Procedures.............................................................5-1
5.1 Wiring Overview................................................................................................................ 5-1
5.2 AC/DC Power ................................................................................................................... 5-1
5.2.1 Check Keypad Faults........................................................................................................ 5-3
5.2.2 Check for AC Power......................................................................................................... 5-4
5.2.3 Check the UPS................................................................................................................. 5-4
5.2.4 Check the Safety Mat ....................................................................................................... 5-4
5.2.5 Check the Interlock Switches............................................................................................ 5-5
5.3 Emergency Shut Off ......................................................................................................... 5-6
5.3.1 Check the Emergency Switch........................................................................................... 5-6
5.4 Conveyor .......................................................................................................................... 5-7
5.4.1 Adjust the Belt Alignment.................................................................................................. 5-8
5.4.2 Check the Conveyor Motor............................................................................................. 5-10
5.5 Computer........................................................................................................................ 5-10
5.6 X-ray Scan Generation................................................................................................... 5-14
5.6.1 Verify the Photo Sensors................................................................................................ 5-15
5.6.2 Verify Communication between Control Unit and Computer .......................................... 5-16
5.6.3 Partial Scanned Image ................................................................................................... 5-17
5.6.4 15-Pin Connector / Computer and Input/Outputs............................................................ 5-18
5.7 Image Display................................................................................................................. 5-19
5.7.1 Check the Camera.......................................................................................................... 5-19
6Remove and Replace Procedures......................................................................6-1
6.1 Access Items in the Base ................................................................................................. 6-1
6.2 Replace the Computer...................................................................................................... 6-2
6.3 Replace the Detectors...................................................................................................... 6-4
6.4 Replace Interlock Switch .................................................................................................. 6-7
6.5 Remove and Replace the Power Distribution Unit............................................................ 6-7
6.6Remove and Replace UPS............................................................................................... 6-8
6.7 Remove and Replace the Emergency Stop Switch.......................................................... 6-9
6.8 Replace the Conveyor Motor.......................................................................................... 6-10
6.8.1 Replace the Conveyor Belt............................................................................................. 6-12
6.8.2 Replace and Setup the Motor Drive................................................................................ 6-12
6.9 Repair a Molex Connector.............................................................................................. 6-14
6.10 Replace a Photo Sensor................................................................................................. 6-15
6.11 Remove and Replace the X-ray Source ......................................................................... 6-16
6.12 Remove and Replace the Keypad.................................................................................. 6-19

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7XR3D-6 Safety Features......................................................................................7-1

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1 INTRODUCTION
The XR3D-6 is a 3D perspective X-ray imaging scanner designed to provide enhanced and
reliable security screening at critical points-of-entry, and across multiple customer applications.
Based on a single X-ray source, the XR3D-6 scanner provides automatic alerts to operators of
the presence of a range of possible threats, including: explosives, weapons, sharp objects,
narcotics and contraband.
This manual applies to the VOTI XR3D-6 and contains troubleshooting and maintenance
information for VOTI-trained Level 1 and Level 2 technicians.
Level 1 is expected to attempt fix-on-first-contact by way of simple troubleshooting
guidelines or by calling upon the Level 2 Help Desk.
Level 2 requires a VOTI-trained Technician responsible, but is not limited to, onsite
installations or replacements of various hardware components, diagnostic testing, and in
certain cases, Line Replaceable Unit (LRU) repair.
Level 3 requires VOTI personnel responsible for handling the most difficult or advanced
problems denoting expert level troubleshooting and analysis.
The maintenance manual includes instructions to perform software updates, troubleshooting,
and repair procedures for the following hardware components:
oPower sources and 12 VDC circuits
oConveyor assembly
oComputer related issues
oX-ray scan image generation
oImage display
A wiring overview of the XR3D-6 configuration is provided to facilitate verification of power inputs
and outputs.
1.1 Hardware Overview
The XR3D is a self-contained unit with the following major hardware components:
1. TouchScreen Monitor(s) with adjustable articulating arm(s) with BioSans© User Interface

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2. Tunnel and shrouds with protective drapes. The covering also houses the X-ray detectors
and Control Unit and the Computer
3. Operator Key Switch, Keypad, and USB slot
4. Warning Lights
5. Emergency Stop buttons
6. Bi-directional conveyor belt assembly
7. Base on casters and adjustable legs –with locked access panels with interlock switches.
The base houses the UPS, the Power Distribution Unit, and the X-ray source
8. The right base panel contains 110-120V 60Hz (or 210-240V 50Hz) Power connector, 10A (or
5A) Circuit Breaker, Computer On/Off toggle switch, and the optional Floor mat connector
1.2 Software Overview
BioSans© is the main Operator interface for all system communications, generation of 3D
perspective images, and X-ray scanning. Its functionalities focus on the clarity and quality of the
3D perspective images, high level of threat detection and ease of use for the operator. BioSans©
technology includes the following:
Automatic detection system alerts the operator of the presence of potential threats, for
example, prohibited organic material, explosives, high density, or sharp objects. The list of
materials can be customized.
oOrganic –anything with a carbon base –for example, clothing, food, water, paper
oInorganic –anything metallic –for example, cell phone, knife, firearm
oMixed Organic/Inorganic recognition
Image Enhancement uses zoom, pan, flip, and contrast to enhance the scanned image.
Continuous Screening customizable modes, Full, Simple, or Off
Manual Search Required (MSR) to tag items and save the archive files to a specific folder.
The scanned item is directed to an optional search area.
Language Selection provides multilingual operator interface, for example, English, French,
Spanish, Arabic
Remote Monitoring Station (Optional)
Material Classification (Optional) customizable detection material groups
Risk Assessment Module (Optional) defines 5 different levels of security which modify
system settings to provide better image quality and more accurate detection
TIP Management (Optional) provides continuous Operator training and evaluation
Advanced System Settings - BioSans© maintenance applications which are used by a
Technician and can be triggered by an Administrator/Supervisor

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1.3 Operation Workflow
The following flowchart describes how a Technician accesses the XR3D diagnostics software
using the key pad. This is described in Section 3.3 Control Box Access - Technician.
The keypad diagnostics can be used in addition to the DIOX application. The keypad tests
input/output communication with the hardware, whereas the DIOX tests input/output
communication through the computer.
The following flowchart describes how the XR3D is used by an Operator, as described in the
Operator Manual.
Operator Key
Switch ON Log On as Operator Item on Conveyor Belt
Operator on
Pressure Sensitive
Mat (Option)
Click/Release the
Conveyor Control
Forward Arrow
Photosensor
Triggers X-ray
Generation
Red Indicator
lights / Warning
Icons
Photosensor
Triggers End X-ray
Generation
Green Indicator
Lights
Warning Icons Off
Item Exits Tunnel
Image Appears on
Operator Screen
The following flowchart describes how the XR3D is used by a Supervisor, as described in the
Operator manual.
Log On as
Supervisor
Access to
Administration
Modules Manage Operators Manage
Operational
Settings
An XR3D Administrator has access to the exclusive VOTI diagnostic software used for advanced
debugging. Connecting as an Administrator exits the BioSans© user interface and shows the
Windows operating system. The following information flow is described in the Operator manual.
Log On as
Administrator
Access to
Administration
Modules Manage All Users Manage Data Manage Software
Updates
1.4 Safety Information
For a complete list of XR3D safety features, refer to Section 7, XR3D-6 Safety Features.
Training must be provided by a qualified VOTI-certified subject matter expert (SME)
covering scanner operation, maintenance, basic radiation protection, and safety
procedures associated with the XR3D.
The XR3D is a machine that generates X-rays to inspect items for security purposes. This
machine has been designed and constructed to meet or exceed the requirements of the
Radiation Emitting Devices Act (Canada), and the applicable Regulation (Schedule II, Part IV –
Baggage Inspection X-ray Devices) and in accordance with the International Commission on
Radiological Protection (ICRP) methodology, including the As Low As Reasonably Achievable
(ALARA) Principle.

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The XR3D is designed to function so that, at any time X-rays are being produced, the average
exposure is less than than 0.5 milliroentgen per hour or less than 5 μSv/h (Europe - 0.1
milliroentgen per hour or less than 1 µSv/h).
The machine is key-operated, with warning lights to clearly indicate when the power is on and
when X-rays are being produced. There is an optional floor mat upon which the operator stands
equipped with a control switch which stops the conveyor and terminates the production of X-rays
in the event that the operator steps off the mat.
Labels identifying the manufacturer, the model designation, the serial number, and the date and
place of manufacture are located on the left base panel of the machine and on the exterior
surface of the X-ray generator (normally only visible during servicing). These labels must not be
removed by the purchaser or user.
All XR3D’s carry a number of X-ray warning signs, one visible to the operator, and one at each
of the entrance and exit openings. These X-ray warning signs are required under the authority of
the Radiation Emitting Devices Act (REDA) (Schedule II, Part IV, Paragraph 2 (h)), and must not
be removed. If they deteriorate over time, or become damaged while in use, they must be
replaced. Replacement warning signs must comply with Paragraph 4 of the regulation. It is
important to note that although the machine produces X-rays and requires the above warning
signs, when this machine is properly installed and maintained, and operating as designed, the
operators are not required to wear personal dosimeters. When the XR3D is operated according
to design criteria they do not emit detectable radiation higher than the natural limit of permissible
exposure.
In addition to intelligent software that monitors system status, the XR3D ensures the following
safety features are in place before a scan can be conducted:
1. Access panels must be securely in place. This is verified by interlock switches in the access
panels.
2. The Operator Key switch must be turned to the ON position.
3. An Operator must be standing on a safety mat (optional).
4. An item must be detected by the photo sensors in the tunnel.
5. Indicator lights on the top of the XR3D turn Red.
6. Caution symbols display on the operator’s monitor.
The XR3D is safe to operate and it is not necessary for operators to wear personal dosimeters or
special radiation protective clothing. However, the following general safety measures must be
followed when operating the XR3D:
Never reach inside the tunnel past the protective drapes while the system is in operation,
while the conveyor is moving, the X-ray lights are red or the X-ray indicator is showing on
the monitor.
All maintenance must be performed by a VOTI-qualified service technician.
1.4.1 Responsibility of the Owner
Owners of devices installed outside of Canada must comply with the applicable requirements of
their jurisdiction.
The XR3D complies with the requirements of the REDA (Schedule II, Part IV). The owner is
responsible for its safe operation and maintenance. In general, these requirements are
described in Safety Code 29, referenced in Canada Labour Code Part II. Safety Code 29 places

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the ultimate responsibility for the safe operation of the item inspection machine on the owner.
These responsibilities include, but are not limited to:
determining the proper positioning of the machine
ensuring operators and maintenance personnel are VOTI-certified
implementing a maintenance program appropriate to the age and frequency of use of the
device
providing, and ensuring the proper use of, the appropriate equipment during maintenance
operations and safety checks
investigating and taking proper positive corrective action in the event of any radiation
exposure
1.4.2 Responsibility of Maintenance Personnel
Maintenance personnel must complete training in operation, maintenance, repair and x-ray
safety hazards relevant to the x-ray inspection system, and in x-ray safety required by the
authority having jurisdiction in that workplace. They must report in writing any imminent or
foreseen user and/or operator procedure or action that can cause a radiation accident and/or
unsafe event, use a properly functioning and appropriately calibrated ionization-chamber survey
meter to monitor radiation levels during maintenance operations, and respond and investigate
promptly all user and/or operator reports of the x-ray inspection system malfunctions, device and
component failures.
While the primary hazard is the production of X-rays, these devices are also
electronic/mechanical machines. Precautions must be taken at all times, and particularly during
maintenance operations, to guard against electrical and mechanical hazards.

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1.5 Glossary
ALARA As Low As Reasonably Achievable
AOI Area of Interest
ASTM American Society for Testing and
Materials
AWG American Wire Gauge
CE Conformité Européenne (CE Mark)
CFR Cost and Freight
DA Density Alert
DIO Digital Input / Output
FDA Food and Drug Administration
GUI Graphical User Interface
HE High Energy
ICRP International Commission on
Radiological Protection
IED Improvised Explosive Devices
IEE Image Edge Enhancement
kV Kilo voltage
LCD Liquid Crystal Display
LE Low Energy
LRU Line Replaceable Unit
mA Milli-ampere
mR Milli-roentgen
MSR Manual Search Required
µSv/h Micro-Sievert per hour
REDA Radiation Emitting Devices Act (Loi
sur les Dispositifs Émettant des
Radiations)
SME Subject Matter Expert
TSA Transportation Security
Administration
UPS Uninterruptible Power Supply
Zeff Effective Atomic Number

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2 UNPACKING AND SET UP
XR3D-6 is shipped fully assembled with the monitor(s) packaged separately.
Tools:
Screwdriver with Security Chuck
3/32 Allen Key
M4 Allen Key
2.1 Set 110/240 Power
Setting the power requirements for your area needs to be done at installation only. To set the
correct power setting for your area, proceed as follows:
1. Unscrew the front base access panel and lift off the unit.
This allows access to the back of the Power Distribution box.
2. Set the 110/240 toggle to your power requirements.
3. Verify the UPS is started by pressing and holding the UPS button until it beeps.
4. Replace and secure the side panel.
2.2 Install the Monitor
To install the touch screen monitor, proceed as follows:
1. Unscrew 4 security screws (M6 x 25 SS machine screw with a 6 point security head) and
remove the top left blue panel.

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2. Gently extract the Monitor Cable Assembly.
3. Secure the monitor post on the top of the scanner using 2 screws using an M4 Allen key.
4. Replace and secure the top left blue panel ensuring the Monitor Cable Assembly is loose
next to the post.
5. Slide the articulating arm(s) on to the monitor post and secure in place using the set screw
and an allen key.
6. Attach the monitor to the articulating arm and secure to the monitor plate using the four (4)
securing screws.
7. Plug in the monitor cable, which is part of the cable assembly extruding from the top of the
unit, to the monitor ports (Power, USB, VGA).

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When power is supplied, the monitor indicator light illuminates green.
8. Ensure there is nothing in the XR3D tunnel.
9. Level the unit using the instructions in 2.3 Level the Scanner.
2.3 Level the Scanner
The casters enable the XR3D-6 unit to be moved between locations. The stabilizing feet are
lowered using the adjustment wheel. The adjustment wheel can be turned by hand. To stabilize
the unit, proceed as follows:
Tools:
Level
1. Turn the adjustment wheel to lower the foot.
2. Using a level against the base of the XR3D, continue to adjust the feet using the adjustment
wheel until the unit is level.
3. Repeat the adjustment on all four corners ensuring the base is level.
a) Adjustment Wheel
b) Foot
c) Moving Caster
2.4 System Verification
After the XR3D-6 is ready for operation, perform the following steps to confirm the unit functions
as expected.
1. Perform a visual inspection to ensure there are no items in the tunnel which could interfere
with the conveyor belt movement.

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2.4.1 Power Up
1. Plug in the 2.5m power cord that comes with the unit into a grounded 110-120VAC at 60 Hz,
or 220-240VAC at 50 Hz receptacle.
Should an extension cord be required, it should be at least 16-gauge and not exceed 10m
in length.
An Enhanced Grounding Unit kit is available on request.
The unit is ready for a system test.
2. Verify the emergency stop buttons (2) are fully extended.
3. On the left base panel, flip the circuit breaker to ON.
UPS is always on except for initial start up. If the system does not start immediately, the
UPS may not be started. A Supervisor can access and start the UPS.
4. Turn the Key Switch to ON.
Message on Keypad - Please wait, X-ray starting.
Message on Keypad - VOTI BioSans, Enter Password.
5. Enter the 4-digit Operator keypad password.
Do NOT press the Enter button.
Logging in as a Technician allows you to change passwords
for the keypad.
Message on Keypad - System Verification appears on the
keypad screen. System Verification checks all the inputs. If
there is a communication issue with the inputs an X appears
(Contact VOTI).
Message on Keypad - System in Progress. BioSans starting.
Message on Keypad - Check for inputs.
The system performs a self diagnostic to ensure all the inputs
are functioning correctly. For example, Emergency Stop,
Interlocks, there is no power failure, an Operator is standing on
the floor mat (if applicable), Tunnel Interlock (no item in the
tunnel).
Message on Keypad - Press the Power Up button.
6. Press the Power button (button on bottom).
Green lights on XR3D illuminate indicating the scanner is powered on. There are no X-rays
being generated at this time.

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Message on Keypad –System Ready.
Software starts and Operator Login screen appears for the operator to enter a username and
password.
If you press the Power button after the system has started, BioSans shuts down. No data
will be lost as the computer performs a safe shut down. Message on Keypad - BioSans is
turning off.
7. Enter your username and password, click Operator, and click Login.
8. Verify the System Messages area on the Operator screen does not display any warning
messages, for example Status: Locked / Interlock or Key Lock.
9. Also verify if there are any messages on the keypad. If there is any input/output error,
nothing else will happen. The machine will be prevented from starting up (no power) until the
error is fixed. For example:
oSystem is Locked –appears if you removed the security key while the system is running.
Please check the key, verify the Operator Key switch is in the ON position.
oPower Fault –appears if there is no AC power to the machine and the UPS is working.
The message, “Power is off line, system will shutdown in 5 minutes”.
oEmergency Button –appears if the emergency button is depressed.
oInterlock Switch –appears if an access door is open.
oPhoto Sensor 1X –appears if there is something in the tunnel during start up (blocking
the photo sensors).
2.4.2 Run a Test Scan
Run a scan to test the XR3D functionality. An X-ray scan ensures the source has not changed
and the detectors have not moved.
1. Start BIOSansLoginMenu and log in with Operator permission.

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2. Set an item on the conveyor belt at the tunnel entrance.
3. Click and release the forward arrow ( ) on the screen to start the conveyor.
Indicator lights on the scanner turn red during X-ray generation. A warning icon ( )
appears on the monitor.
The resulting scan displays in the Main Viewing Screen and alternate views appear in the
Alternate Scan View area.
4. Check the quality of the image.
5. Repeat the scan in the reverse direction, .
6. Use each feature of the User Interface.
7. Log out and then log in with Administrator privileges.
8. Change the Risk Assessment Level in the Risk Assessment tab.
9. Perform new scans with the different speed, for example, slow conveyor speed is a Severe
risk setting, and a fast conveyor speed is a Low risk setting.

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10. Check the alignment of the image on the Main Viewing Area that it appears in the middle.
If the image is off to the side, contact VOTI Support (Level 2) for them to correct a
configuration issue.
11. Log out by clicking on the Operator icon and selecting Log Off.
The log-in screen appears on the monitor.
2.5 Updating Software
The XR3D-6 is shipped from the factory with software pre-installed. If an update is required, it
will be provided to the System Administrator. To install an update, proceed as follows:
1. Copy the new EXE to a USB key and insert the USB key into a USB slot of the scanner.
2. Copy the EXE to the VOTI root folder, c:\VOTI\and double-click the *.exe to install.
If a custom installation of the update is required, refer to the Readme.TXT file that
accompanies the update for instructions.

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