Golden engineering XRS-3 Operator's Manual

OPERATOR'S MANUAL
MARCH 2018
- Golden Engineering
�-Portable X-ray Technology
TABLE OF CONTENTS
PAGE
1.0 INTRODUCTION
2
2.0 WARNINGS
2
DUTY CYCLE
2
STORAGE
2
3.0 PHYSICAL DESCRIPTION
3
HIGH VOLTAGE PULSER/TUBEHEAD
3
BASE
3
BATTERY PACK
3
BATTERY CHARGER
3
3.5 CONTROL MODULE
4
CABLE CONNECTOR DIAGRAM
5
4.0 DESCRIPTION OF OPERATION
6
BLOCK DIAGRAM
6
5.0 OPERATING INSTRUCTIONS
7
OPERATING PRECAUTIONS
8
EXCLUSION ZONE
8
PULSE SETTINGS
8
6.0 NAVIGATING THE MENU
9
7.0 MAINTENANCE
11
DOSE MEASUREMENT
11
TUBE REPLACEMENT
11
8.0 TROUBLE-SHOOTING
11
9.0 INSTRUCTIONS FOR SERVICE
12
REMOVING BOARDS
12
BOARD INSTALLATION
12
HEAD REPLACEMENT
12
BATTERY DISPOSAL
13
10.0 WARRANTY
INSTRUCTIONS TO RETURN FOR SERVICE AND MAINTENANCE
11.0 SPECIFICATIONS
13
14
PHYSICAL DIMENSIONS
14
X-RAY OUTPUT
14
ELECTRICAL & THERMAL CHARACTERISTICS
14
12.0 SPARE PARTS
1
13
14
1.0 INTRODUCTION
The XRS3 produces high levels of radiation and must be operated by quali ed personnel who have read the
WARNINGS and OPERATING INSTRUCTIONS sections of the manual before operating the device.
The XRS3 is a small, lightweight X-ray generator that operates on its own removable battery pack. The XRS3 is a
pulsed X-ray device that produces X-ray pulses of very short duration (25 nanoseconds). It produces a relatively
low dose rate comparable to a 0.25 ma constant potential machine. The energy produced by the XRS3 is up to
270kVp, which makes it possible to radiograph up to one (1) inch (2.54 cm) of steel.
XRS3 standard accessories are two keys, two battery packs, and one battery charger. Remote cable and carrying
case are also common accessories.
2.0 WARNINGS
The XRS3 is a pulsed X-ray generator that emits hazardous ionizing radiation when pulsing. The XRS3 should only
be operated by authorized personnel who are properly trained to safely operate the generator. The XRS3 must
be registered with proper authorities prior to use and should not be used to intentionally expose humans.
Develop and closely follow a safe operating system for using the XRS3. The safe operating system must ensure that
no one is exposed to radiation above the permissible limits which are 2 mR (0.02 mSv) per hour for a member of
the public. The safe operating system must ensure the XRS3 is used within federal and state guidelines.
All operators and users of the XRS3 X-ray machine must wear a personal radiation monitoring device, such as
a TLD (thermoluminescent dosimeter), lm badge, and/or a pocket dosimeter consistent with the appropriate
federal, territorial or provincial standards (note: an electronic dosimeter will not detect the XRS3 radiation pulses).
Due to the short pulse width of the XRS3, survey meters of the Geiger-Mueller and scintillator type do not accurately
detect the radiation emitted from the x-ray source.
Survey meters should be of the ionization type and should be used in the integration mode. Survey meters must not
be used in the rate mode because the XRS3 does not produce constant radiation. The XRS3 produces very high
rates of radiation for very short periods of time resulting in either unrealistically high readings or no readings for
a survey meter in rate mode.
The XRS3 has no explosion proof rating and should not be used in an explosive atmosphere. The Spark Gap
is vented to the air and could be a source of ignition.
DUTY CYCLE WARNING. The XRS3 is a light duty machine that is not made to pulse continuously. The
maximum duty cycle for the XRS3 is 200 pulses every four minutes (3000 pulses per hour). Exceeding the
duty cycle will shorten the life of the tube and head. In temperatures above 90 °F (32.22 °C) or continual
use, rest 30 seconds after every 50 pulses and 4 minutes after every 200 pulses.
STORAGE & USE: Store and use the XRS3 in upright position. Upside down storage or use may cause premature
failure including no output dose.
2
3.0 PHYSICAL DESCRIPTION
HANDLE
CONTROL MODULE
KEY
BATTERY
BEAM ANGLE
LABEL
BASE
COLLIMATOR
HEAD
RADIATION WARNING LABEL
PICATINNY RAIL
Figure 1: XRS3 X-ray Unit
HIGH VOLTAGE PULSER/TUBEHEAD. The main body of the XRS3 is the tube head
which contains the tube cavity, cold cathode type X-ray tube, spark gap, high voltage
capacitor, and transformer. The standard collimator located on the front of the head
limits the X-ray beam to 40 degrees. Special order collimators up to 85 degrees are
available.
TRIPOD MOUNT
RELEASE TAB
BASE. The base of the XRS3 contains an identi cation label and a ¼-20 brass insert
compatible with standard camera tripods. The base also accommodates a quick
release external tripod mount. The identi cation label located on the bottom of the
generator lists the manufacturer’s name and address, model number, serial number,
weight, volt, amp, and production date.
BATTERY PACK. The standard battery pack
is a DeWalt® 20V 2 amp hour Li Ion battery
(DCB203).
BATTERY CHARGER: The standard battery
charger is the DeWalt® DCB107 110V charger
or DCB105 220V charger. (Note DeWalt part
numbers may change). Battery charge time is
less than one hour. See battery charger manual
for additional instructions and warnings.
PICATINNY RAIL: The XRS3 has a 21 mm picatinny rail located on each side of
the housing.
3
TRIPOD MOUNT
Figure 2: Base
3.5 CONTROL MODULE
MODEL
IDENTIFICATION
POWER ON
LIGHT
LCD
X-RAY PULSING
LIGHTS
ENTER /
EMERGENCY
STOP
DELAY SWITCH
KEY
DIRECTIONAL BUTTONS
Figure 3: Control Module
POWER ON LIGHT: Illuminates when battery voltage is applied to control module.
RED X-RAY PULSING LIGHT: Blinks after time delay button or remote cable button is pressed to warn that the
XRS3 is going to pulse. The light stays on continuously while the XRS3 is pulsing. This is a failsafe warning light. If
the light does not work the X-ray unit will not pulse. See settings menu for fail safe override in emergency situations.
LIQUID CRYSTAL DISPLAY (LCD): 80 digit LCD. Home displays number of pulses selected and delay time before
the rst pulse. Home will also indicate if multiple pulse trains have been entered. Arrows allow operator to scroll
through various menu options.
DIRECTIONAL BUTTONS: Used to maneuver through the menu.
DELAY SWITCH: Left and Right arrow buttons pressed simultaneously Initiates the delay mode.
EMERGENCY STOP/ENTER SWITCH: Stops the unit before it begins pulsing or stops the unit in the middle of a pulse
train. Also used as the enter button to select desired option.
4
XRS3 REAR VIEW/CABLE CONNECTOR
CABLE CONNECTOR: Lemo “K” series ve pin connector located on the back of the control module beneath the
battery receives the remote cable or imaging system cable.
1
PIN #
1
2
3
4
5
DESCRIPTION
+5 VOLTS 100 ma MAXIMUM
REMOTE SWITCH
REMOTE SWITCH - NO DELAY
X-RAY ON SIGNAL
COMMON 0 VOLTS
2
5
3
4
REMOTE CABLE CONNECTOR
TEMPERATURE
SENSOR
NEGATIVE -
POSITIVE +
REMOTE CABLE
CONNECTOR
BATTERY
TERMINAL
BLOCK
REMOTE CONNECTOR: LEMO EEG.0K.305.CLN
MATING CABLE PLUG: LEMO FGG.305.CYCC50Z
PIN 2
PIN 5
Remote switch inputs are activated when grounded.
5
4.0 DESCRIPTION OF OPERATION
The block diagram below illustrates how the XRS3 functions. The following sequence of events takes place each
time the XRS3 is red:
1.
2.
3.
4.
5.
6.
7.
User initiates operation of the machine.
The control section sends a signal to the converter section to begin oscillating.
Once oscillating, the converter section changes the 20 volts DC to 22Khz AC.
The transformer charges the High Voltage Capacitor to about 9000 volts.
The spark gap arcs after the High Voltage Capacitor reaches proper voltage.
The pulse detector signals the control block that the unit has pulsed.
As the High Voltage Switch is closed, a high voltage transient of approximately 270,000 volts and
25 nanoseconds in duration is applied across the x-ray tube generating x-rays.
The closing of the High Voltage Switch produces an audible pulsing sound. The XRS3 cannot produce x-rays
without the pulsing sound so it serves as an additional warning the XRS3 is functioning.
This unit generates X-rays through high voltage bombardment of a tungsten target. The XRS3 does not contain
radioactive materials. All the high voltage is contained within the aluminum canister and as long as the canister
is not punctured the operator is not exposed to dangerous voltages.
BLOCK DIAGRAM
X-RAY TUBE
SPARK GAP
HIGH VOLTAGE
CAPACITOR
PULSE DETECTOR
CONVERTER
USER INTERFACE
CONTROLLER
BATTERY
6
5.0 OPERATING INSTRUCTIONS
The following are basic operation instructions to take an X-ray image using the XRS3. Certain applications may
require modi cations to these basic procedures.
7
*XRS3 should be positioned directly in front of the object to be X-rayed and the imager placed directly behind
the object to be X-rayed. Imager should be placed as close to the object as possible. Distance between XRS3 and
imager is usually 24 to 72 inches (30 to 180 cm). During operation XR200 should be stabilized on a at surface,
a tripod, or a custom xture suitable for holding the 11 pound (5 Kg) XRS3.
XRS3
OBJECT
IMAGER
24 to 72 inches (30 to 180 cm)
OPERATING PRECAUTIONS: The operator should always stand at least 10 feet (3m) behind the X-ray unit and clear
all personnel at least 10 feet (3m) behind the unit or at least 100 feet (30m) from the front of the unit before pulsing.
The exclusion zone (below) should be a controlled area free of all personnel while X-ray pulses.
25’ (7.6 m)
10’ (3m)
100’ (30m)
X-ray Beam
10’ (3m)
10’ (3m)
25’ (7.6 m)
Figure 4: Exclusion Zone
SUGGESTED PULSE SETTINGS
The chart below lists approximate pulses necessary to penetrate various materials. Settings vary greatly
depending on imaging system used. Refer to imaging system instructions for more information.
MATERIAL
CARDBOARD / LIGHT WOOD / PLASTIC
LIGHT METAL
STEEL 1/4”
STEEL ½”
STEEL 1”
PULSE SETTING (24” BETWEEN X-RAY & IMAGER)
2-5
10
25
50
99
8
The following is true when using lm or digital systems that generate a positive image. If the radiograph is too
dark, the lm is underexposed. If the radiograph is too light the lm is overexposed. Underexposure can be
corrected by increasing the number of pulses and/or decreasing the distance between the imaging medium and the
XRS3. Overexposure can be corrected by reducing the number of pulses and/or increasing the distance between
the imaging medium and XRS3.
Underexposed
Correct exposures (pulse setting)
Overexposed
Correct exposures (pulse setting)
6.0 NAVIGATING THE MENU
LCD ERROR MESSAGE
Low Battery
9
Battery voltage is too low to pulse the XRS3. Charge the battery.
PWM not running
Could occur at the start of a pulse train or during a pulse train. Power
unit off and back on. If error message continues there is a problem
with electronics.
Slow Pulsing
More than one second between pulses in a pulse train. Either low
battery, problem with transformer, or electronics. Charge battery or
replace oscillator board.
No Feedback
Current not detected. No current ow going to the head. Occurs at
the beginning of pulse train. Check 20 amp fuse on the oscillator
board. If fuse is ok problem could be in head or electronics. Replace
board or send back for repair.
Cycle Reached
Displayed if duty cycle is reached (200 pulses in 4 minutes).
>HOME
PULSES: _ _ _ _
DELAY: _ _ _ _
MENU
PRESETS
HOME
SET PULSE
SET DELAY
TRAINS
>MENU
PRESETS
LIFE PC
RESET PC
SETTINGS
HOME
>SET PULSE
SET DELAY
TRAINS
- MENU
PRESETS
LIFE PC
RESET PC
SETTINGS
HOME
SET PULSE
>SET DELAY
TRAINS
- MENU
HOME
SET PULSE
SET DELAY
>TRAINS
- MENU
HOME
SET PULSE
SET DELAY
TRAINS
- MENU
HOME
SET PULSE
SET DELAY
TRAINS
- MENU
HOME
SET PULSE
SET DELAY
TRAINS
- MENU
PRESETS
LIFE PC
RESET PC
SETTINGS
PRESETS
LIFE PC
RESET PC
SETTINGS
SET PULSE COUNT
_ _ _ PULSES
BACK
SAVE
SET DELAY TIME
_ _ _ SECONDS
BACK
SAVE
SET PULSE TRAINS
_ _ _ PULSE TRAINS:
_ _ _ SECONDS BETWEEN:
BACK
PRESETS
>LIFE PC
RESET PC
SETTINGS
SAVE
LIFETIME PULSE COUNT
_ _ __ _ _ PULSES
PRESETS
LIFE PC
>RESET PC
SETTINGS
#1: _ _ _ _
#2: _ _ _ _
BACK
RESETTABLE COUNTERS
PRESETS
LIFE PC
RESET PC
>SETTINGS
>BACKLIGHT
X-RAY INFO
BACK
>RESET
RESET
SETTINGS
BACKLIGHT
FEEDBACK
ON
SETTINGS
BACKLIGHT
FEEDBACK
INDIVIDUAL PULSE
X-RAY ON / X-RAY OFF
>FEEDBACK
BACK
OFF
BACK
SETTINGS
BACKLIGHT
>E-RAY INFO
BACK
X-RAY INFO
FEEDBACK
SOFTWARE _ _ _
SERIAL # _ _ _
BACK
HEAD # _ _ _
To Enter/Save Presets
1. Enter desired settings (Pulse, Delay Time, Pulse Trains) from main menu as shown above
2. Go to Preset Menu
3. Select Preset #
4. Select SAVE
HOME
> PRESET #1
PRESET #2
PRESET #3
MENU
- PRESETS
PRESET #1
PULSES: _ _ _ _
TRAINS: _ _ _ _
BACK
RECALL
PRESET #1
DELAY: _ _ _ _
BTWN: _ _ _ _
>SAVE
PULSES: _ 50
TRAINS: 05
BACK
RECALL
DELAY: 15
BTWN: 45
>SAVE
To Recall Presets
1. Go to Preset Menu
2. Select Preset #
3. Select Recall
HOME
> PRESET #1
PRESET #2
PRESET #3
MENU
- PRESETS
PRESET #1
PULSES: _ 50
TRAINS: 05
BACK
>RECALL
DELAY: 15
BTWN: 45
SAVE
10
7.0 MAINTENANCE
X-RAY DOSE MEASUREMENT Using a dosimeter, the average X-ray dose for new tube can be established.
 With the dosimeter located 1 foot from the front of the case and in line with the center of the beam angle
label, the reading for 10 pulses should be at least 20 mR to 36 mR.
 The leakage sheet illustrates the X-ray dose and maximum allowable radiation leakage levels for each
X-ray unit. A completed copy of this form accompanies each X-ray.
TUBE REPLACEMENT: If you have a tube replacement kit refer to instructional disk included with the kit. If you do
not have a kit the unit must be sent back to Golden Engineering or an Authorized Distributor for tube replacement.
Tube life is approximately 100,000 pulses. Under normal conditions the tube’s output will decrease slowly with use.
If the tube is broken or the glass cracks the tube output will cease immediately.
8.0 TROUBLESHOOTING
SYMPTOM
No “power on” light
TEST
-Check battery voltage
-Check battery connection
Power on lights, X-ray pulsing light
does not illuminate, X-ray does not
pulse
ACTION
- Replace or charge battery
- Make sure battery is securely
attached and battery clips are not
bent or broken.
- Go to settings menu
failsafe
disable
- To x light replace processor board
X-ray pulses, but no image or black
image.
-Test X-ray output.
-Replace the tube.
Unit stops pulsing in the middle of a
pulse train and LCD displays 00.
-Check the battery voltage.
-Check 15 amp fuse.
-Check feedback line connection.
- Charge battery if necessary.
- Replace the fuse if blown.
- Make sure the screw holding
wire to the oscillator board.
Unit makes loud popping noise while
pulsing.
- Stop immediately and return
for repair.
Oil leaking from unit.
Return for repair.
11
9.0 INSTRUCTIONS FOR SERVICE
INSTRUCTIONS TO REMOVE THE BOARDS AND THE HEAD.
1. Use T10 Torx driver to remove 6 screws holing control module in place.
2. Remove the control module.
3. Remove cable connecting the boards.
4. Control Module Removed
1
2
3
4
Remove keyswitch connector
Remove 3 screws holding processor board to top
Remove processor board.
Disconnect ribbon cable.
Remove the 8 screws that hold the housing together
Remove half the housing.
Remove the head.
Loosen the four screws that hold the feedback wires in place.
12
Remove feedback wires.
Remove the screws that connect the
oscillator board to the head.
Remove the oscillator board.
INSTRUCTIONS FOR BATTERY DISPOSAL Follow all federal, state, and local laws for disposal of lithium-ion
batteries. Batteries may be returned to Golden Engineering.
RETURNING UNIT FOR SERVICE AND MAINTENANCE
 Complete the support form at http://www.goldenengineering.com/home/support and include a copy of
the printed form with the repair. If you do not have internet access prior to sending generator, include a letter
containing a brief description of the problem, contact name, phone number, and return address.
 Remove battery before shipping the unit.
 Accessories are not required.
 Be sure the unit is securely packaged for shipment and wrapped in plastic bag if there is an oil leak.
 Ship to address: Golden Engineering, Inc., 6364 Means Road, Centerville, In 47330 USA
10.0 WARRANTY
Golden Engineering, Inc. warrants XRS3 X-ray unit made and sold by it or its authorized representatives to be
free of defects in materials and workmanship for a period of twelve (12) months from the date of shipment to
the end user. Warranty does not cover maintenance required due to life. To make a claim under this limited
warranty, customer must ship the entire unit (or the component believed to be defective) to Golden Engineering,
post-paid. Golden Engineering assumes no liability for units or components shipped until they are actually in
the custody of Golden Engineering, Inc. Provided Golden Engineering, in its sole discretion, is satis ed that the
failure is not the result of excessive use, abuse, misuse, accident, modi cation or improper disassembly or repair,
Golden Engineering will provide parts and labor required for the repair. Golden Engineering reserves the right
to use reconditioned and remanufactured components that meet original speci cations. The unit or component
will be shipped to customer at customer’s expense. THIS EXPRESS LIMITED WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES AND GUARANTEES, EITHER EXPRESS OR IMPLIED OR CREATED BY OPERATION OF LAW.

XRS3 Manufacturer
European Representative
Golden Engineering, Inc.
Certi cation Experts Europe
6364 Means Road, Box 185
Nieuwstad 100
Centerville, IN 47330 USA
1381 CE Weesp
Phone: 1-765-855-3493
The Netherlands
Fax:
Web:
1-765-855-3492
Serial Number:___________________
13
www.goldenengineering.com
Delivery Date:____________________
11.0 SPECIFICATIONS
PHYSICAL DIMENSIONS INCLUDING BATTERY PACK
LENGTH
14.20 inches (36.07 cm)
WIDTH
4.26 inches (10.82 cm)
HEIGHT
7.44 inches (18.90 cm)
WEIGHT
11.8 pounds (5.4 Kg) with battery
X-RAY OUTPUT
X-ray dose per pulse
2 mR/pulse min,(12 inches in front of unit)
Pulses per battery charge
4000
Pulses per second
15 (Nominal)
Expected tube life (glass tube)
100,000 pulses
X-ray source size
1/8 in. (3mm)
Maximum Photon Energy
270 kVp
X-ray pulse width
25 nanoseconds
ELECTRICAL AND THERMAL CHARACTERISTICS
Battery voltage
18 volts - 20 volts
Battery type
Li Ion
Battery recharge time
One Hour
Current draw
20 amps @ 18/20 volt battery
Current ow
0.25 mA
Temperature range
-10 to 120 degrees F (-23 to 50 degrees C)
Airborne Noise Emissions
80 dB at 10 cm
Maximum duty cycle
200 pulses every 4 minutes (3000 pulses per hour)
Warm-up
None required
12.0 SPARE PARTS AND ACCESSORIES FOR THE XRS3
IITEM
PART NUMBER
Thumbwheel Key
2002000
Flat key
5951020
DeWalt® Battery 20V (2 Amp Hour / 40 Watt Hours) DCB105
1800106
DeWalt® Battery Charger (110V) DCB107
1800152
DeWalt® Battery Charger (220V) DCB105 or DCB115
1800164
Remote Cable
1809022
Tripod Mount
4000352
Handle
4000153
Carrying case (holds X-ray, 2 batteries, charger, cable)
1701656
14