GE Test Procedures

Note: These procedures apply to testing parts in normal circumstances, which are
sufficient the majority of the time, but may not be adequate in all situations. Always
check the history of a part being tested to verify any previous problems are specifically
tested for. In special cases additional testing beyond these procedures may need to be
performed.

LightSpeed QX/I (1.X)

Console:

CD-ROM drive:
1. verify the jumpers on the drive
2. make sure applications is down and insert OS disk #1
3. open a unix shell and type: tail -f /usr/adm/SYSLOG
4. open a second unix shell and type: mountCD /mnt, cd /mnt/dist,
sum *
5. time the test and make sure it takes less than 5 minutes to complete
and that no errors show up in the first unix shell
6. after the test is done type: cd /, unmountCD
7. eject the CD

MOD Drive:
1. verify the jumpers on the drive
2. boot the system and insert a disk
3. create a state tape and make sure it doesn’t take unusually long
(over 10 minutes)
4. go to Image Works and label the disk for saving images
5. save an exam and detach the media

Octane computer:
 1. power on the console and make sure the Octane passes the POST
test
2. stop for maintenance and start the diagnostics
3. if the diagnostics pass perform a LFC if there is no software on the
drive
4. with the console booted completely test the hospital network, verify
the devices on the SCSI bus with scsistat, and run test scans of
several hundred images
5. bring the images up in Image Works and verify the window
level/width changes smoothly and that it scrolls through images
normally
6. make sure the computer is power cycled several times during testing

O2 computer:
1. power on the console and make sure the O2 passes its POST test
(only the green light should stay on)
2. perform a LFC on the O2 if there is no software on the drive
3. boot the console completely and run test scans of several hundred
images

RIP board:
1. make sure the board has a new battery installed
2. install the board and power on the console
3. stop applications from coming up
4. open a unix shell and type: rsh sbc, hit enter to get the next prompt
5. if the vxworks prompt comes up, hit the reset button on the RIP
board and it should boot to the ppcbug prompt
6. from the ppcbug prompt type: cnfg, verify the parameters are set
correctly
7. type sd to get to the ppcdiag prompt and type st to start the
Motorola diagnostics
8. exit the prompt by typing: ~.
9. do a pflash by typing: rsh sbc, cd /usr/g/ice/bin, pflash
10.disconnect from the SBC by typing ~. and type st to start applications
11. run 500 passes of Recon Data Path
 12. scan several hundred images
13. power cycle the console (leave off for 5-10 min) and make sure it
boots properly

Mercury board:
1. verify the jumpers on the board
2. power on the console and let it boot completely
3. run 500 passes of Recon Data Path
4. scan several hundred images

DIP board:
1. install the board in the O2 or on the RIP board (if O2-less)
2. boot the system up and run extensive internal DIP diagnostics
3. scan several hundred images and verify the DIP stats stay marginal or
green

VME Power Supply:

1. install the power supply and verify the power connections by the
original or the manual if a different supply is being installed
2. turn on the console and stop for maintenance
3. adjust the voltages on the power supply: +5.00v +/- .04v, +12.4v
+0.0v, -0.1v
4. boot the console, run 5 iterations of recon data path, and some test
scans

Serial Expander Box:

1. install the box and verify jumpers and DIP switches (set to SCSI ID4
with no termination)
2. boot the console and stop applications
3. open a unix shell and type: scsistat
4. scsistat should show the MOD drive as device 1 ID 3, the CDROM
drive as device 1 ID 6, and the serial expander as device 1 ID 4
 5. in the unix shell type: rsh sbc, this verifies the serial connection
between the serial expander and the O2 computer
6. boot applications and test the trackball as it is connected through the
serial expander

Scan Data Drive:

1. verify the jumpers on the drive with the original or the manual
2. install the drive in the cage
3. power on the console and cancel application startup
4. perform a reconfig and regenerate the database
5. after the system boots to applications run 500 passes of Recon Data
Path
6. scan several hundred images

Rhapsode IG board:
1. install the board and let applications boot up normally
2. run 500 passes of Recon Data Path
3. scan several hundred images and verify there are no recon errors

Gantry

X-ray tube:
1. make all of the tube connections and put a lead blanket on the
output of the tube if doing a hanging test
2. run new tube seed shift and automA
3. run HHS scans
4. run heat soak and make sure scanning doesn’t stop due to tube spits
5. make note of any excessive rotor noise
6. if mounting the tube alignments, calibrations, and image analysis can
be performed but may only be required in special cases

HV tanks:
 1. after installing the tank (or doing a hanging test) run automA
2. run HHS scans
3. run Fastcal if the tank is mounted and make sure there are no mylar
window check failures

Collimator assembly:
1. do an initial test by rotating the gantry with the tube at the bottom
and placing the test collimator directly on top of the original
collimator
2. disconnect the original collimator and plug these connections into
the test collimator
3. turn on the gantry and do a hardware reset
4. run a Flash Download and input the correct serial number
5. run the collimator and filtration test on all filter and CAM positions
for 300 seconds, check for unusual noise as the test is running
6. if this test passes the collimator is ready for a full system test
7. mount the collimator on the gantry and do film-less POR (run BOW
and move the tube) if you are starting with known good alignments
8. after BOW is done run the collimator aperture test, ideally this
should pass just above the spec
9. if the aperture test fails the cams will need to be adjusted
10. if the aperture test passes finish the alignments (CBF, ISO, BOW)
11. run hot iso, z-slope cal, DAS gain cal, collimator cal
12. run full cals and auto CT # adjustment on 120kv only
13. do image analysis on the QA and make sure it passes and the images
look good
14. wait 30 minutes after doing image analysis and repeat the series
and make sure the images still look good (especially .625mm)

Collimator Control Board:

1. install the board and make sure to install the metal shield to increase
heat on the board
2. run Flash Download and put in the correct serial number
3. run 300 seconds of the collimation and filtration test on all filter and
CAM positions
 4. run a Fastcal and then do a hardware reset
5. if the board is suspected to have heat related issues, use a blow dryer
to increase the heat of the board and observe if the board resets
with a yellow error LED

Converter boards:
1. install the converter card towards the center of the DAS so that any
issues are noticeable on the QA phantom
2. after the DAS is powered back on, monitor the error log while the
DAS is resetting and look for any POST failures on the test board
3. open DASTools and run 1 iteration of DC Cal Absolute, 3 iterations of
DC noise, 5 iterations of pop noise, 1 iteration of offset drift, and 1
iteration of interconnect; make a note of any failures but don’t
automatically fail the board if any of these tests don’t pass
4. after the board has had a few minutes to warm up, run 1 iteration of
the auxiliary channel converter board temperature test to make sure
the board is registering the temperature correctly
5. run DAS Gain calibration (after at least 20 min)
6. run a FastCal with every KV station selected, verify there are no daily
IQ check failures after FastCal completes (if there are check the error
log for the specific exam and channel failure, if the board was not
warm enough when DAS gain was run it will cause the daily IQ check
failures, run DAS gain and Fastcal again to clear the error after the
board has been in for 20-30 minutes)
7. run Auto CT Number adjustment for every KV station and verify there
are no rings/artifacts in the CT Number images where the board was
installed; if there are hard rings plot the image and look for any
spikes/dips, if nothing is seen in the plot it is probably a calibration
issue, it may take running two Fastcals to eliminate the rings, run
Auto CT Number again and make sure the images are clean
8. if all of the images are clean Image Analysis can also be run but is
optional
9. if there are rings/artifacts plot the image in Scan Analysis and look for
spikes or dips in the plot; record the converter board channels that
are failing; record the same information if DASTools also fails
 10. If all images look good but DASTools fails the board can be
considered acceptable
11. An optional quick test method would be to install the test board, let
it warm up for 5 minutes, run DASTools including interconnect, run
DAS Gain (after 20 min), run full Fastcal (full Fastcal is done when it
has been more than 96 hours from the last Fastcal, restoring the cals
from the state tape may allow this, if this isn’t possible it may require
running two regular Fastcals for the images to look good), run CT #
adjustment on all KV’s but only the apertures that cover the entire
detector (for 16 slice: 16x.625, 16x1.25, for 8 slice: 8x.625, 8x1.25,
for 4 slice: 4x.625, 4x1.25), if all CT # images look good the board can
be considered acceptable

HEMRC:
1. after installing the assembly an initial rotor test can be done
2. if this passes do a Fastcal and some test images at maximum gantry
rotation

Servo Amp:
1. after installing the test servo amp, perform a hardware reset
2. open DASTools and run 10 iterations of pop noise to exercise the
servo amp (pop noise failures are irrelevant)
3. run a Fastcal

Axial Encoder:
1. install the encoder on the axial motor and make sure the gantry is
perfectly level
2. move the tube to the 0° position and place a level on the collimator
to make sure it is perfectly level
3. make sure the three allen screws are loose on the encoder and
rotate it until the c-pulse light comes on
4. tighten down the screws and open DDC to position the gantry to 0°
 5. run 5 pop noise iterations (failures irrelevant) and run scans on the
QA (should also be perfectly level) to make sure the images aren’t
rotated
6. if the images are rotated the encoder can be rotated slightly in either
direction
7. if the QA needs to be rotated CW turn the encoder CCW, if the QA
needs to be rotated CCW turn the encoder CW until it looks good

Slipring Transmitter/Receiver:
1. make note of the current DIP stats
2. after installing the test part run a series of pop noise (failures
irrelevant)
3. run a Fastcal and verify the DIP stats are either unchanged or
improving
4. if machine has a green slipring, verify the LED bar falls within spec
during the fastest rotation

RF shoe:
1. install the RF shoe using the appropriate tool for setting the gap
between the slipring
2. make note of the current DIP stats
3. after installing the test part run a series of pop noise (failures
irrelevant)
4. run a Fastcal and verify the DIP stats are either unchanged or
improving
5. if machine has a green slipring, verify the LED bar falls within spec
during the fastest rotation

KV Control board:
1. remove the original board and measure the resistance of the anode
and cathode adjustment pots (~ 2.50kΩ)
2. set both pots of the test board to the same resistance as the original
and install the board
3. run automA cal, HHS scans, and a Fastcal
Inverter:
1. install the test inverter and run automA cal
2. run HHS scans
3. run a Fastcal and verify the system doesn’t stop scanning due to HV
errors

Table

ETC Board:
1. install the board and run a hardware reset
2. test the functionality of the table elevation, cradle extension, and
gantry tilt
3. perform some scout and helical scans

Cradle Drive:
1. install the drive and test the noise level by driving the cradle in and
out
2. the noise level should be ≤ 80dB and shouldn’t have a noticeable
grinding noise
3. check the condition of the rubber rollers and make sure they are
clean
4. run head and feet first scout scans at maximum length
5. run a helical scan at maximum length and make sure there are no
velocity errors

Longitudinal Encoder:
1. install the encoder and set the C-pulse
2. check the pot voltage
3. perform cradle characterization
4. perform scout and helical scans
Elevation Actuator:
1. bring the table to its maximum height (open the elevation
characterization menu and move the upper magnetic switch up to
bypass limits) until the gas springs become loose and then back the
table down just slightly so there is some tension on one of the gas
springs
2. remove the large bolt holding the end of the actuator to the table
frame, this should slide out fairly easily and if it does not there is too
much tension on the bolt (make sure the gas springs are taking the
load of the table)
3. with the end of the actuator loose, drive the actuator completely
down by using the gantry control panel
4. disconnect the wires from the actuator and loosen the base from the
frame (either remove the 4 allen bolts or remove the pin with the c-
clamp)
5. install the test actuator and secure the base to the table frame
6. connect the wires and drive the actuator up with the gantry control
panel
7. install the actuator bolt to the table upper frame
8. set the upper and lower magnetic interference switches
9. run the table up and down and make sure there isn’t excess noise
(grinding, whining)
10. test the table with at least 450 lbs. of weight

PDU

PDU Control Board:

1. shut down the power at the A1 panel and install the test board
2. run HHS scans and a Fastcal and make sure there are no HVDC bus
errors
LightSpeed Plus/Ultra/16 (4.X)

Console:

CD-ROM drive:
1. verify the jumpers on the drive
2. make sure applications is down and insert OS disk #1
3. open a unix shell and type: tail -f /usr/adm/SYSLOG
4. open a second unix shell and type: mountCD /mnt, cd /mnt/dist,
sum *
5. time the test and make sure it takes less than 5 minutes to complete
and that no errors show up in the first unix shell
6. after the test is done type: cd /, unmountCD
7. eject the CD

MOD Drive:
1. verify the jumpers on the drive
2. boot the system and insert a disk
3. create a state tape and make sure it doesn’t take unusually long
(over 10 minutes)
4. go to Image Works and label the disk for saving images
5. save an exam and detach the media

Octane computer:
1. power on the console and make sure the Octane passes the POST
test
2. stop for maintenance and start the diagnostics
3. if the diagnostics pass perform a LFC if there is no software on the
drive
4. with the console booted completely test the hospital network, verify
the devices on the SCSI bus with scsistat, and run test scans of
several hundred images
 5. bring the images up in Image Works and verify the window
level/width changes smoothly and that it scrolls through images
normally
6. make sure the computer is power cycled several times during testing

RIP board:
1. make sure the board has a new battery installed
2. install the board and power on the console
3. stop applications from coming up
4. open a unix shell and type: cu ice, hit enter to get the next prompt
5. if the vxworks prompt comes up, hit the reset button on the RIP
board and it should boot to the ppcbug prompt
6. from the ppcbug prompt type: cnfg, verify the parameters are set
correctly
7. type sd to get to the ppcdiag prompt and type st to start the
Motorola diagnostics
8. exit the prompt by typing: ~.
9. do a pflash by logging in as root and typing: cd /usr/g/ice/bin, pflash
10.type st to start applications
11. run 500 passes of Recon Data Path
12. scan several hundred images
13. power cycle the console (leave off for 5-10 min) and make sure it
boots properly

DIP board:
1. install the board onto the RIP board
2. boot the system up and run extensive internal DIP diagnostics
3. scan several hundred images and verify the DIP stats stay marginal or
green

PMC SCSI board:

1. install the board onto the RIP board
2. boot the system up and run 500 passes of Recon Data Path
 3. scan several hundred images

VME Power Supply:

1. install the power supply and verify the power connections by the
original or the manual if a different supply is being installed
2. turn on the console and stop for maintenance
3. adjust the voltages on the power supply: +5.00v +/- .04v, +12.4v
+0.0v, -0.1v
4. boot the console, run 5 iterations of recon data path, and some test
scans

Scan Data Drive:

1. verify the jumpers on the drive with the original or the manual
2. install the drive in the cage
3. power on the console and cancel application startup
4. perform a reconfig and regenerate the database
5. after the system boots to applications run 500 passes of Recon Data
Path
6. scan several hundred images

Pegasus IG board:
1. install the board and let applications boot up normally
2. run 500 passes of Recon Data Path
3. scan several hundred images and verify there are no recon errors
4. Pegasus diagnostics can be run if the board fails the initial tests to
narrow down specific issues on the board, shut down applications,
open a unix shell and type: service_browser, go to Diagnostics and
click on the IG Diagnostics, select Full IG Diags and hit Run Diag

Gantry
X-ray tube:
1. make all of the tube connections and put a lead blanket on the
output of the tube if doing a hanging test
2. run new tube seed shift and automA
3. run HHS scans
4. run heat soak and make sure scanning doesn’t stop due to tube spits
5. make note of any excessive rotor noise
6. if mounting the tube alignments, calibrations, and image analysis can
be performed but may only be required in special cases

HV tanks:
1. after installing the tank (or doing a hanging test) run automA
2. run HHS scans
3. run Fastcal if the tank is mounted and make sure there are no mylar
window check failures

Collimator assembly:
1. do an initial test by rotating the gantry with the tube at the bottom
and placing the test collimator directly on top of the original
collimator
2. disconnect the original collimator and plug these connections into
the test collimator
3. turn on the gantry and do a hardware reset
4. run a Flash Download and input the correct serial number
5. run the collimator and filtration test on all filter and CAM positions
for 300 seconds, check for unusual noise as the test is running
6. if this test passes the collimator is ready for a full system test
7. mount the collimator on the gantry and do film-less POR (run BOW
and move the tube) if you are starting with known good alignments
8. after BOW is done run the collimator aperture test, ideally this
should pass just above the spec
9. if the aperture test fails the cams will need to be adjusted
10. if the aperture test passes finish the alignments (CBF, ISO, BOW)
 11. run hot iso, z-slope cal, DAS gain cal, collimator cal
12. run full cals and auto CT # adjustment on 120kv only
13. do image analysis on the QA and make sure it passes and the images
look good
14. wait 30 minutes after doing image analysis and repeat the series
and make sure the images still look good (especially .625mm)

Collimator Control Board:

1. install the board and make sure to install the metal shield to increase
heat on the board
2. run Flash Download and put in the correct serial number
3. run 300 seconds of the collimation and filtration test on all filter and
CAM positions
4. run a Fastcal and then do a hardware reset
5. if the board is suspected to have heat related issues, use a blow dryer
to increase the heat of the board and observe if the board resets
with a yellow error LED

Converter boards:
1. install the converter card towards the center of the DAS so that any
issues are noticeable on the QA phantom
2. after the DAS is powered back on, monitor the error log while the
DAS is resetting and look for any POST failures on the test board
3. open DASTools and run 1 iteration of DC Cal Absolute, 3 iterations of
DC noise, 5 iterations of pop noise, 1 iteration of offset drift, and 1
iteration of interconnect; make a note of any failures but don’t
automatically fail the board if any of these tests don’t pass
4. after the board has had a few minutes to warm up, run 1 iteration of
the auxiliary channel converter board temperature test to make sure
the board is registering the temperature correctly
5. run DAS Gain calibration (after at least 20 min)
6. run a FastCal with every KV station selected, verify there are no daily
IQ check failures after FastCal completes (if there are check the error
log for the specific exam and channel failure, if the board was not
warm enough when DAS gain was run it will cause the daily IQ check
 failures, run DAS gain and Fastcal again to clear the error after the
board has been in for 20-30 minutes)
7. run Auto CT Number adjustment for every KV station and verify there
are no rings/artifacts in the CT Number images where the board was
installed; if there are hard rings plot the image and look for any
spikes/dips, if nothing is seen in the plot it is probably a calibration
issue, it may take running two Fastcals to eliminate the rings, run
Auto CT Number again and make sure the images are clean
8. if all of the images are clean Image Analysis can also be run but is
optional
9. if there are rings/artifacts plot the image in Scan Analysis and look for
spikes or dips in the plot; record the converter board channels that
are failing; record the same information if DASTools also fails
10. If all images look good but DASTools fails the board can be
considered acceptable
11. An optional quick test method would be to install the test board, let
it warm up for 5 minutes, run DASTools including interconnect, run
DAS Gain (after 20 min), run full Fastcal (full Fastcal is done when it
has been more than 96 hours from the last Fastcal, restoring the cals
from the state tape may allow this, if this isn’t possible it may require
running two regular Fastcals for the images to look good), run CT #
adjustment on all KV’s but only the apertures that cover the entire
detector (for 16 slice: 16x.625, 16x1.25, for 8 slice: 8x.625, 8x1.25,
for 4 slice: 4x.625, 4x1.25), if all CT # images look good the board can
be considered acceptable

HEMRC:
1. after installing the assembly an initial rotor test can be done
2. if this passes do a Fastcal and some test images at maximum gantry
rotation

Servo Amp:
1. after installing the test servo amp, perform a hardware reset
2. open DASTools and run 10 iterations of pop noise to exercise the
servo amp (pop noise failures are irrelevant)
 3. run a Fastcal

Axial Encoder:
1. install the encoder and make sure the gantry is perfectly level
2. rotate the gantry until the home flag is near the sensor
3. go to the STC side of the gantry and rotate the gantry until the c-
pulse light comes on
4. go back to the encoder, lift up the wheel without rotating it, spin the
gantry until the home flag is in the middle of the sensor, and let the
encoder down
5. run 5 pop noise iterations (failures irrelevant) and run scans on the
QA (should also be perfectly level) to make sure the images aren’t
rotated
6. verify the encoder isn’t jumping during rotation
7. if the images are rotated the encoder can be rotated slightly in either
direction
8. if the QA needs to be rotated CW turn the encoder CCW, if the QA
needs to be rotated CCW turn the encoder CW until it looks good

Slipring Transmitter/Receiver:
1. make note of the current DIP stats
2. after installing the test part run a series of pop noise (failures
irrelevant)
3. run a Fastcal and verify the DIP stats are either unchanged or
improving

RF shoe:
1. install the RF shoe using the appropriate tool for setting the gap
between the slipring
2. make note of the current DIP stats
3. after installing the test part run a series of pop noise (failures
irrelevant)
4. run a Fastcal and verify the DIP stats are either unchanged or
improving
KV Control board:
1. remove the original board and measure the resistance of the anode
and cathode adjustment pots (~ 2.50kΩ)
2. set both pots of the test board to the same resistance as the original
and install the board
3. run automA cal, HHS scans, and a Fastcal

Inverter:
1. install the test inverter and run automA cal
2. run HHS scans
3. run a Fastcal and verify the system doesn’t stop scanning due to HV
errors

Table

ETC Board:
1. install the board and run a hardware reset
2. test the functionality of the table elevation, cradle extension, and
gantry tilt
3. perform some scout and helical scans

ETC I/F Board:

1. install the board and run a hardware reset
2. run a Flash Download
3. test the functionality of the table elevation, cradle extension, gantry
tilt, and remote tilt
4. perform some scout and helical scans

Cradle Drive:
 1. install the drive and test the noise level by driving the cradle in and
out
2. the noise level should be ≤ 80dB and shouldn’t have a noticeable
grinding noise
3. check the condition of the rubber rollers and make sure they are
clean
4. run head and feet first scout scans at maximum length
5. run a helical scan at maximum length and make sure there are no
velocity errors

Longitudinal Encoder:
1. install the encoder and set the C-pulse
2. check the pot voltage
3. perform cradle characterization
4. perform scout and helical scans

Elevation Actuator:
1. bring the table to its maximum height (open the elevation
characterization menu and move the upper magnetic switch up to
bypass limits) until the gas springs become loose and then back the
table down just slightly so there is some tension on one of the gas
springs
2. remove the large bolt holding the end of the actuator to the table
frame, this should slide out fairly easily and if it does not there is too
much tension on the bolt (make sure the gas springs are taking the
load of the table)
3. with the end of the actuator loose, drive the actuator completely
down by using the gantry control panel
4. disconnect the wires from the actuator and loosen the base from the
frame (either remove the 4 allen bolts or remove the pin with the c-
clamp)
5. install the test actuator and secure the base to the table frame
6. connect the wires and drive the actuator up with the gantry control
panel
7. install the actuator bolt to the table upper frame
 8. set the upper and lower magnetic interference switches
9. run the table up and down and make sure there isn’t excess noise
(grinding, whining)
10. test the table with at least 450 lbs. of weight

PDU

PDU Control Board:

1. shut down the power at the A1 panel and install the test board
2. run HHS scans and a Fastcal and make sure there are no HVDC bus
errors

LightSpeed 5.X, BrightSpeed, RT

Console

IG Node:
1. after installing the test IG node let the console boot completely and
verify the DARC gives the command for the IG node to power on
2. run 20,000 passes of Recon Data Path
3. scan or recon at least 5,000 images and verify there are no RAC
failures
4. if RAC failures occur run RAC diags

HP computer:
1. if there is no software on the computer or the software version
doesn’t match the machine, perform a LFC
2. with software up completely test the hospital network by
sending/receiving images
 3. verify the correct amount of memory and hardware devices are
showing up using the hinv command
4. verify the SCSI devices are showing up by using the scsistat command
5. scan several hundred images
6. power cycle the console a few times to test for stability

DARC/DARC2:
1. if the software on the DARC doesn’t match the system, perform a LFC
on the DARC only
2. after the DARC load is complete and before applications is started,
login as root and type: config_sshd
3. exit root and verify connection through the DARC using the rsh darc
and ssh darc commands
4. test the scan data drives by typing: rsh darc, sudo gre-raid –c
5. uninstall any service packs (login as root, patch_install –u), reboot,
reinstall the service packs (login as root, start_udev, patch_install –c),
and reboot
6. boot applications and run 500 passes of Recon Data Path
7. run several hundred images and monitor the DIP stats

SDDA:
1. shut off the main power before making connections to the test SDDA
2. after installing the test SDDA cancel applications from coming up
3. open a unix shell and type: rsh darc, sudo gre-raid –c
4. boot applications and run 500 passes of recon data path
5. scan several hundred images
6. check the auto voice and remote tilt functions

Intercom Assembly:
1. shut off the main power before making connections to the test
intercom assembly
2. boot up the console and verify the auto voice and remote tilt
functions
MOD Drive:
1. verify the jumpers on the drive
2. boot the system and insert a disk
3. create a state tape and make sure it doesn’t take unusually long
(over 10 minutes)
4. go to Image Works and label the disk for saving images
5. save an exam and detach the media

Gantry

X-ray tube:
1. make all of the tube connections and put a lead blanket on the
output of the tube if doing a hanging test
2. make sure to use yellow transformer oil for systems with a Hercules
or mini-Hercules tube
3. if installing a mini-Hercules tube make sure to properly filter the
glycol before scanning
4. initialize the database under the Generator Tool Jedi menu
5. run filaments cals
6. run HHS scans until all mA’s are within spec
7. run heat soak and make sure scanning doesn’t stop due to tube spits
8. make note of any excessive rotor noise
9. if mounting the tube alignments, calibrations, and image analysis can
be performed but may only be required in special cases

Collimator assembly:
1. do an initial test by rotating the gantry with the tube at the bottom
and placing the test collimator directly on top of the original
collimator
2. disconnect the original collimator and plug these connections into
the test collimator
3. turn on the gantry and do a hardware reset
4. run a Flash Download and input the correct serial number
 5. run the collimator and filtration test on all filter and CAM positions
for 300 seconds, check for unusual noise as the test is running
6. if this test passes the collimator is ready for a full system test
7. mount the collimator on the gantry and do film-less POR (run BOW
and move the tube) if you are starting with known good alignments
8. after BOW is done run the collimator aperture test, ideally this
should pass just above the spec
9. if the aperture test fails the cams will need to be adjusted
10. if the aperture test passes finish the alignments (CBF, ISO, BOW)
11. run hot iso, z-slope cal, DAS gain cal, collimator cal
12. run full cals and auto CT # adjustment on 120kv only
13. do image analysis on the QA and make sure it passes and the images
look good
14. wait 30 minutes after doing image analysis and repeat the series
and make sure the images still look good (especially .625mm)

Collimator Control Board:

1. install the board and make sure to install the metal shield to increase
heat on the board
2. run Flash Download and put in the correct serial number
3. run 300 seconds of the collimation and filtration test on all filter and
CAM positions
4. run a Fastcal and then do a hardware reset
5. if the board is suspected to have heat related issues, use a blow dryer
to increase the heat of the board and observe if the board resets
with a yellow error LED

Converter boards:
1. install the converter card towards the center of the DAS so that any
issues are noticeable on the QA phantom
2. after the DAS is powered back on, monitor the error log while the
DAS is resetting and look for any POST failures on the test board
3. open DASTools and run 1 iteration of DC Cal Absolute, 3 iterations of
DC noise, 5 iterations of pop noise, 1 iteration of offset drift, and 1
 iteration of interconnect; make a note of any failures but don’t
automatically fail the board if any of these tests don’t pass
4. after the board has had a few minutes to warm up, run 1 iteration of
the auxiliary channel converter board temperature test to make sure
the board is registering the temperature correctly
5. run DAS Gain calibration (after at least 20 min)
6. run a FastCal with every KV station selected, verify there are no daily
IQ check failures after FastCal completes (if there are check the error
log for the specific exam and channel failure, if the board was not
warm enough when DAS gain was run it will cause the daily IQ check
failures, run DAS gain and Fastcal again to clear the error after the
board has been in for 20-30 minutes)
7. run Auto CT Number adjustment for every KV station and verify there
are no rings/artifacts in the CT Number images where the board was
installed; if there are hard rings plot the image and look for any
spikes/dips, if nothing is seen in the plot it is probably a calibration
issue, it may take running two Fastcals to eliminate the rings, run
Auto CT Number again and make sure the images are clean
8. if all of the images are clean Image Analysis can also be run but is
optional
9. if there are rings/artifacts plot the image in Scan Analysis and look for
spikes or dips in the plot; record the converter board channels that
are failing; record the same information if DASTools also fails
10. If all images look good but DASTools fails the board can be
considered acceptable
11. An optional quick test method would be to install the test board, let
it warm up for 5 minutes, run DASTools including interconnect, run
DAS Gain (after 20 min), run full Fastcal (full Fastcal is done when it
has been more than 96 hours from the last Fastcal, restoring the cals
from the state tape may allow this, if this isn’t possible it may require
running two regular Fastcals for the images to look good), run CT #
adjustment on all KV’s but only the apertures that cover the entire
detector (for 16 slice: 16x.625, 16x1.25, for 8 slice: 8x.625, 8x1.25,
for 4 slice: 4x.625, 4x1.25), if all CT # images look good the board can
be considered acceptable
Servo Amp:
1. after installing the test servo amp, perform a hardware reset
2. open DASTools and run 10 iterations of pop noise to exercise the
servo amp (pop noise failures are irrelevant)
3. run a Fastcal

Axial Encoder:
1. install the encoder and make sure the gantry is perfectly level
2. rotate the gantry until the home flag is near the sensor and look for
the c-pulse light to illuminate on the encoder cable or TGPU
3. lift up the encoder wheel without rotating it, spin the gantry until the
home flag is in the middle of the sensor, and let the encoder down
4. run 5 pop noise iterations (failures irrelevant) and run scans on the
QA (should also be perfectly level) to make sure the images aren’t
rotated
5. verify the encoder isn’t jumping during rotation
6. if the images are rotated the encoder can be rotated slightly in either
direction
7. if the QA needs to be rotated CW turn the encoder CCW, if the QA
needs to be rotated CCW turn the encoder CW until it looks good

TGPU board:
1. after installing the test board let hardware reset and perform a Flash
Download
2. test all of the table functions and the gantry tilt
3. run some helical and axial test scans

Auxiliary Box:
1. install the test auxiliary box and make sure all connections are secure
(especially the tube HV cable if present)
2. run a Fastcal

Inverter Assembly:
 1. remove the auxiliary box to access the inverter
2. with the test inverter on, initialize the database through the
Generator Tool Jedi menu
3. perform filament cals and HHS scans
4. perform a Fastcal

Jedi tank assembly:

1. when installing the Jedi tank, make sure to use yellow transformer oil
if the system has a Hercules or mini-Hercules tube
2. initialize the database through the Generator Tool Jedi menu
3. perform filament cals and HHS scans
4. perform a Fastcal

ORP board:
1. after installing the test board but before turning on the 120V, open a
unix shell and type: cd /usr/g/fw, touch orpFtp
2. run a Flash Download
3. run some test scans

Slipring Transmitter/Receiver:
1. make note of the current DIP stats
2. after installing the test part run a series of pop noise (failures
irrelevant)
3. run a Fastcal and verify the DIP stats are either unchanged or
improving

RF shoe:
1. install the RF shoe using the appropriate tool for setting the gap
between the slipring
2. make note of the current DIP stats
3. after installing the test part run a series of pop noise (failures
irrelevant)
4. run a Fastcal and verify the DIP stats are either unchanged or
improving
Table

Cradle Drive:
1. install the drive and test the noise level by driving the cradle in and
out
2. the noise level should be ≤ 80dB and shouldn’t have a noticeable
grinding noise
3. check the condition of the rubber rollers and make sure they are
clean
4. run head and feet first scout scans at maximum length
5. run a helical scan at maximum length and make sure there are no
velocity errors

Longitudinal Encoder:
1. install the encoder and perform characterizations (c-pulse
adjustment not required)
2. verify the table elevation and longitudinal function

Elevation Actuator:
1. move the upper magnetic switch up to bypass the limits
2. go to the MTCB board on the table and turn switch S4 to Service
3. using the toggle switch bring the table to its maximum height until
the gas springs become loose and then back the table down just
slightly so there is some tension on one of the gas springs
4. remove the large bolt holding the end of the actuator to the table
frame, this should slide out fairly easily and if it does not there is too
much tension on the bolt (make sure the gas springs are taking the
load of the table)
5. with the end of the actuator loose, drive the actuator completely
down by using the toggle switch on the MTCB board (this may take a
few minutes as the actuator will stop every few seconds)
 6. disconnect the wires from the actuator and remove the motor by
taking out the 4 allen bolts (the motor can remain connected to the
power supply)
7. remove the c-clamp on the pin holding the actuator to the table
frame and slide out the pin
8. the actuator should slide out without having to remove the silver
cover bracket that is mounted over the actuator
9. install the test actuator and secure the base to the table frame
10.connect the wires, install the motor, and drive the actuator up with
the toggle switch
11.install the actuator bolt to the table upper frame
12.set the upper and lower magnetic interference switches
13.run the table up and down and make sure there isn’t excess noise
(grinding, whining)
14. test the table with at least 450 lbs. of weight

MTCB board:
1. run a Flash Download
2. perform table characterizations
3. test all table functions

Extreme Console Components

IG Node:
1. after installing the test IG node let the console boot completely and
verify the DARC gives the command for the IG node to power on
2. run 20,000 passes of Recon Data Path
3. scan or recon at least 2,000 images and verify there are no RAC
failures
4. if RAC failures occur run RAC diags

HP computer:
 1. if there is no software on the computer or the software version
doesn’t match the machine, perform a LFC
2. with software up completely test the hospital network by
sending/receiving images
3. verify the correct amount of memory and hardware devices are
showing up using the hinv command
4. verify the SCSI devices are showing up by using the scsistat command
5. scan several hundred images
6. power cycle the console a few times to test for stability

DARC/DARC2:
1. if the software on the DARC doesn’t match the system, perform a LFC
on the DARC only
2. after the DARC load is complete and before applications is started,
login as root and type: config_sshd
3. exit root and verify connection through the DARC using the rsh darc
and ssh darc commands
4. test the scan data drives by typing: rsh darc, sudo gre-raid –c
5. uninstall any service packs (login as root, patch_install –u), reboot,
reinstall the service packs (login as root, start_udev, patch_install –c),
and reboot
6. boot applications and run 500 passes of Recon Data Path
7. run several hundred images and monitor the DIP stats

SDDA:
1. shut off the main power before making connections to the test SDDA
2. after installing the test SDDA cancel applications from coming up
3. open a unix shell and type: rsh darc, sudo gre-raid –c
4. boot applications and run 500 passes of recon data path
5. scan several hundred images
6. check the auto voice and remote tilt functions

Intercom Assembly:
 1. shut off the main power before making connections to the test
intercom assembly
2. boot up the console and verify the auto voice and remote tilt
functions

ProSpeed

Console

IPU2 board:
1. Remove the original board and compare the part number and
jumper/toggle switch settings with the test board
2. A board with a two million number part number will replace an older
P9* part number but not the other way around. The P9* version can
be installed in a console with the QJBB backplane if you are only
running the P-ON 2 test.
3. Insert the test board and set the toggle switch (eight rowed) to
number three ON and number one OFF located on the CPW board.
This will begin the P-ON 2 test when the console is turned on
4. Turn the console on and allow the test to run through. The screen
will be blank for a couple of minutes before it starts to display the
results. It may take 45 minutes for the test to complete.
5. If the test passes, scan several test images to make sure it recons
properly. If it isn’t possible to scan and the board passes the P-ON 2
test, it is still acceptable to call the board good.

CPW board:
1. Verify the test board is compatible with the floppy drive in the
console by looking in the Renewal Parts manual or by verifying it has
the same part number as the original
 2. Compare the jumper/toggle switch settings on the board with the
original
3. Insert the board and run the P-ON 2 test by setting the eight-rowed
switch block to number one off and number three on
4. After this finishes the console will boot normally. Shut down the
console and set the switches back to normal
5. Boot the console back up and test the floppy drive by initializing a
floppy disk or saving calibrations to disk
6. Scan a few images to verify hard drive function
7. If all these pass the board is good

DAS I/F board:

1. Compare part numbers and jumpers with the original and install the
test board
2. Boot the console and go to the Maintenance menu
3. Insert the boot disk and type $$ to go to the service menu
4. Select Support and then select DAS Data Transfer test
5. Perform this test at the fastest rotation (.8 sec) and allow it to pass
100 times
6. Scan several images to verify data is being transmitted properly
7. If the images are free of artifacts and the data transfer test passed
without error then the board is good

Floppy drive:
1. Ensure the drive being tested is the same color (white or black) as the
original. There are generally two types of drives (Teac and NEC) and
one can’t replace the other due to CPW board differences
2. Install the test floppy drive and boot up the console
3. Insert a boot disk and verify it will go into the service menu. Push the
maintenance button and type $$ to go to service
4. If this works exit these menus and go to Management from the
keyboard
5. Go to dump parameters and then to calibrations
6. Save the calibrations on 3 or 4 disks
7. If this saves without error the drive is good
IPA board:
1. Compare the jumper settings with the original and insert the test
board
2. Turn on the console and scan over 50 images
3. If all the images come out artifact free the board is good

Hard Drive:
1. run the P-ON 2 test
2. perform a LFC loading 6.04 software
3. run 100 passes of DAS Data Transfer at .8 second
4. scan at least 100 images

Display Board:
1. run the P-ON 2 test
2. boot the console and run 100 passes of DAS Data Transfer at .8
second
3. scan at least 100 images

ETC/ETC2 Board:
1. verify the ELNK (ETC) or FELK (ETC2) option is loaded
2. Using a switch, connect an ethernet cable from the laptop to the
switch and then from the switch to the ProSpeed transceiver
3. On the laptop set the internet connection to an IP of 192.168.1.2
and disable the Windows firewall; you may have to disable any
wireless connections as well
4. On the console, go to management, and then communication data
handling to set up the network
5. Edit the Myself (console) IP address to 192.168.1.1
6. Create a new station and give it the following parameters: station 1,
Protocol - Dicom 3.0, Name – EFILM (AE title in E-Film), Base Address
– FF6000, Port No. – 104, CPU No. – 11, IP Address – 192.168.1.2
(laptop address), GW Address – 0.0.0.0
 7. Reset the console and verify the network connection by pinging the
console from the laptop with the IP address of the console
(192.168.1.1)
8. Open E-Film and go to Utility, Process Manager; click on the Settings
button and verify the AE title is set to EFILM and the port number to
104
9. Close the Process Manager window and leave the Study Manager
window up
10.On the console, go management, transmit images, and then manual
transmission
11.Set the target station to 01
12.Set the image ID of the studies that need to be transmitted
13.Turn Manual Transmission to ON and watch the E-Film queue to
make sure the images are being sent

Gantry

ADC board:
1. Turn off the 120V to the gantry and remove the original board
2. Install the new board and verify jumper settings/toggle switch
settings with the original
3. Apply 120V power to the gantry, install DAS cover, and turn on the
service switch for rotation
4. Press the Maintenance button on the plasma screen, insert the boot
disk, and type $$ to enter the service menu
5. Select Automated Linearity and verify all three pass (high, mid, and
low)
6. If all pass, leave the board in the machine for at least 1.5 hours to
allow the board to reach maximum temperature. Run auto linearity
again once it is up to temperature
7. Perform air and phantom calibrations at 120kv only
8. Perform auto CT # adjustment
9. Scan the 25cm water phantom and verify there are no rings in the
images
Xenon CAM, CAM Cont, NCAM, NCAM Cont and Ref Boards:
1. install the test board and allow the DAS to warm up for about 20
minutes
2. perform an air scan and plot the data looking for any spikes or dips
3. run automated linearity and verify it passes consistently
4. run air and phantom calibrations and CT number adjustment
5. check image quality

Hilight CAM Board:

1. install the test CAM board (ideally towards the center) and run mA
linearity checking for spikes or dips in the plot
2. run DG cal, air and phantom cals, and CT number adjustment
3. check image quality on the QA phantom

X-ray tube:
1. Mount the test tube on the gantry
2. Go to the Maintenance menu, insert the boot disk, and type $$
3. Select Support, Generator/Tube, Tube Calibration, Change Parameter
4. Hit enter to scan all techniques listed
5. If the tube fails on any of the techniques with errors ER-441, ER-442,
E535, or E536 then try modifying the tube filament characteristics
6. If all pass, proceed to performing a heat soak on the Maintenance
menu
7. If heat soak passes then the tube is good (assuming the rotor isn’t
too loud)

CTVRC:
1. Make sure the test CTVRC jumpers are set to “ZJ” and there are no
fiber optic jumper cables on the module
2. Install the test CTVRC
3. From the console, enter the service menu
4. Go to Advanced XG Diagnostics
5. Select Advanced Generator test and then Rotor Functional Test
6. Run the Rotor Cycle test once
 7. After the rotor test passes, go back to the main service menu, select
Support, Generator/Tube, Tube Calibration, Change Parameter
8. Hit enter to scan all of the techniques
9. If this passes the CTVRC is good

Aperture:
1. install the aperture and set the software according to the correct
aperture type (7mm or not)
2. perform a quick test by doing an offline, x-ray off scan at every
thickness
3. perform air cals, phantom cals, and auto CT # adjustment
4. make sure there aren’t any strange values during CT # adjustment
5. scan the QA phantom at every thickness and make sure there are no
artifacts
6. verify the means and SD for each thickness

TGP Board:
1. when installing the test board be aware of any jumper or dip switch
settings
2. test all of the functions of the table and gantry, including table
elevation and cradle movement, gantry tilt, speed, and deceleration
3. in some cases it may be necessary to go through the following
adjustments: rotation velocity offset, rotation speed, rotation
deceleration, table height, and cradle absolute position
4. run a tube warmup and some test scans

Servo Amp:
1. install the test servo amp and go through the following adjustments:
rotation velocity offset, rotation speed, and deceleration
2. run DAS Data Transfer at .8 second for 100 passes to exercise the
servo amp
3. on the Hilight machines it may be necessary to adjust VR2 and VR5
1/2 turn CCW if errors occur
Detector:
1. disconnect all of the ribbon cables leading to the CAM boards
2. disconnect the detector heater cable and any other connections
3. lock down the gantry with the detector at the 12 o’clock position
4. unbolt the detector and carefully slide it off the gantry
5. install the test detector in reverse order
6. with all cables connected do an initial air scan plot to find any
obvious spikes or dips
7. let the DAS and detector warm up to temperature and run DAS
linearity
8. perform alignments starting with BOW
9. perform full calibrations and CT number adjustment
10.check image quality on all phantoms

Table

Cradle Potentiometer:
1. remove the cradle and necessary covers to access the cradle pot
2. move the cradle sled to the home position
3. disconnect connector CN3 and loosen the two bottom set screws to
remove the original cradle pot
4. install the test cradle pot and adjust the resistance between pins 2 &
3 of CN3 to 500Ω +/- 100Ω
5. perform the longitudinal adjustment
6. perform long scout and helical scans

Cradle Potentiometer Pulley Cable:

1. Refer to the Component Replacement procedure for details and
diagrams
2. once the cable is replaced adjust the cradle pot by setting the
resistance of pins 2 & 3 on connector CN3 to 500Ω +/- 100Ω
3. perform the longitudinal adjustment
4. make sure the wire isn’t binding when moving in and out
 5. perform long scout and helical scans

Height Potentiometer:
1. to remove the original, move the table height to 350mm +/- 5mm
measured from the center top of the cradle to the bottom of the
table frame
2. remove the cradle and cradle tray panel
3. loosen the two set screws on the pot and disconnect CN2
4. install the test pot and set the resistance of pins 2 & 3 of connector
CN2 to 1000Ω +/- 100Ω
5. the pot can be adjusted by inserting a tweaker through the hole in
the left side cover
6. perform the H0 & HG height adjustments
7. move the table up and down to its maximum positions

HiSpeed CT/i

Console:

CD-ROM drive:
1. verify the jumpers on the drive
2. make sure applications is down and insert OS disk #1
3. open a unix shell and type: tail -f /usr/adm/SYSLOG
4. open a second unix shell and type: mountCD /mnt, cd /mnt/dist,
sum * > /tmp/CDROMtest
5. time the test and make sure it takes less than 5 minutes to complete
and that no errors show up in the first unix shell
6. type the following to verify the checksum: sum /tmp/CDROMtest
7. verify the output is: 30761 10 /tmp/CDROMtest
8. type this to unmount the CD: cd /, unmountCD
9. eject the CD
MOD Drive:
1. verify the jumpers on the drive (will vary depending on model)
2. boot the system and insert a disk
3. create a state tape and make sure it doesn’t take unusually long
(over 10 minutes)
4. go to Image Works and label the disk for saving images
5. save an exam and detach the media

Octane computer:
1. power on the console and make sure the Octane passes the POST
test
2. stop for maintenance and start the diagnostics
3. if the diagnostics pass perform a LFC if there is no software on the
drive
4. with the console booted completely test the hospital network, verify
the devices on the SCSI bus with scsistat, and run test scans of
several hundred images
5. bring the images up in Image Works and verify the window
level/width changes smoothly and that it scrolls through images
normally
6. make sure the computer is power cycled several times during testing

Indigo Computer:
1. power on the console and make sure the Indigo passes the POST test
2. stop for maintenance and start the diagnostics (may take a while,
optional)
3. with the console booted completely test the hospital network, verify
the devices on the SCSI bus with scsistat, verify it has 384MB of RAM,
and run test scans of several hundred images
4. bring the images up in Image Works and verify the window
level/width changes smoothly and that it scrolls through images
normally
5. make sure the computer is power cycled several times during testing
6. verify there is a new NVRAM chip in the computer
SBC Motorola Stealth Board:
1. verify the board has a new NVRAM and battery installed (some also
have a 2nd memory option board)
2. verify the jumpers on the board
3. boot the console verifying there isn’t a yellow error light on the
board and cancel apps from coming up
4. run a reconfig on the OC and SBC
5. run SBC Motorola diags:
a. type cu sbc, if at the MC68040 prompt type x to get to the bug prompt, if
at the sbc login prompt type root and #bigguy and then halt, at the bug
prompt type sd to change to the diag prompt, type st to start the
diagnostics; the diags will fail on two areas on an Indigo or Octane
console: MCECC EXCPTN: ECC Exceptions (Failed), MCECC/EXCPTN Test
Failure Data: MCECC bus error didn’t occur; PIT IRQ: PI/T Port’s IRQ
(Failed), PIT/IRQ Test Failure Data: PI/T PSR Address = FFF45E1B,
Expected = E1, Actual = F0
6. after diags boot the console and run several test scans
7. power cycle the console a few times to test for stability

BIT3 Board:
1. verify the jumpers on the board
2. boot the console completely
3. run several test scans

FEP Board:
1. verify the jumpers on the board
2. boot the console completely
3. run DASTools (failures irrelevant)
4. run test images, especially the Streak Test protocol on the large
phantom

VME Power Supply:

 1. install the power supply and verify the power connections by the
original or the manual if a different supply is being installed
2. turn on the console and stop for maintenance
3. adjust the voltages on the power supply: +5.00v +/- .1v, +12.4v to
+12.5v
4. boot the console, run 5 iterations of recon data path, and some test
scans

Serial Expander Box:

1. install the box and verify jumpers and DIP switches (set to SCSI ID4
with no termination)
2. boot the console and stop applications
3. open a unix shell and type: scsistat
4. scsistat should show the MOD drive as device 1 ID 3, the CDROM
drive as device 1 ID 6, and the serial expander as device 1 ID 4
5. in the unix shell type: rsh sbc, this verifies the serial connection
between the serial expander and the SBC
6. boot applications and test the trackball as it is connected through the
serial expander

Scan Data Drive:

1. verify the jumpers on the drive with the original or CT Notes (manual
can be incorrect)
2. install the drive in the cage
3. power on the console and cancel application startup
4. perform a reconfig on the OC and SBC and regenerate the database
5. after the system boots to applications run several hundred images

SBC hard drive:

1. verify the jumpers on the drive with the original or CT Notes (manual
can be incorrect)
2. install the drive in the cage
3. power on the console and cancel application startup
 4. perform a software load on the SBC only starting with the “loadSBC”
command
5. after the software load set the date and boot up apps
6. scan several hundred images including helical scans

Rhapsode IG board:
1. install the board and let applications boot up normally
2. verify the LED’s on the board are cycling normally
3. scan several hundred images and verify there are no recon errors

Gantry

X-ray tube:
1. make all of the tube connections and put a lead blanket on the
output of the tube if doing a hanging test
2. run new tube seed shift and automA
3. run HHS scans
4. run heat soak and make sure scanning doesn’t stop due to tube spits
5. make note of any excessive rotor noise
6. if mounting the tube alignments, calibrations, and image analysis can
be performed but may only be required in special cases

HV tanks:
1. after installing the tank (or doing a hanging test) run automA
2. run HHS scans
3. run Fastcal if the tank is mounted and make sure there are no mylar
window check failures

HEMRC/CTVRC:
1. after installing the assembly an initial rotor test can be done
 2. if this passes do a Fastcal and some test images at maximum gantry
rotation

Servo Amp:
1. after installing the test servo amp, perform a hardware reset
2. open DASTools and run pop noise to exercise the servo amp (pop
noise failures are irrelevant)
3. run a Fastcal

Collimator:
1. After installing the test collimator, make sure that the reconfig info is
setup for the collimator version (G1-G3, G4, or G5)
2. If not, then perform a reconfig on the OC and SBC and change the
collimator setting under the hardware tab
3. After this, boot the system up and enter the mechanical
characterization menu
4. Click on collimator data and enter the CRC numbers for the aperture
(shown on the sticker of the collimator)
5. Perform a hardware reset
6. Perform the collimation and filtration tests to verify the filter
movement and aperture encoder; physically look at the aperture to
make sure it is where it is supposed to be; if you tell the filter to go to
the closed position it will actually be in the wide open position. This
must be a software bug.
7. Perform the CBF alignment
8. Perform the detector slope test to verify that the aperture is aligned
properly
9. Perform the tube output test as another verification of the aperture
position
10.Perform calibrations (one KV should be fine)
11.Check image quality with the QA on every thickness and verify that
the images are not unusually grainy (due to incorrect aperture
position)
Converter boards:
1. install the test board and reset the smart trend baseline
2. let the board warm up for 15-20 minutes and run DASTools
3. run a Fastcal and check image quality on the QA
4. run the Streak Test protocol on the large phantom

KV Control board:
1. remove the original board and measure the resistance of the anode
and cathode adjustment pots (~ 2.50kΩ)
2. set both pots of the test board to the same resistance as the original
and install the board
3. run automA cal, HHS scans, and a Fastcal

Inverter:
1. install the test inverter and run automA cal
2. run HHS scans
3. run a Fastcal and verify the system doesn’t stop scanning due to HV
errors

Table

ETC Board:
1. install the board and run a hardware reset
2. test the functionality of the table elevation, cradle extension, and
gantry tilt
3. perform some scout and helical scans

Cradle Drive:
1. install the drive and test the noise level by driving the cradle in and
out
2. the noise level should be ≤ 80dB and shouldn’t have a noticeable
grinding noise
 3. check the condition of the rubber rollers and make sure they are
clean
4. run head and feet first scout scans at maximum length
5. run a helical scan at maximum length and make sure there are no
velocity errors

Longitudinal Encoder:
1. install the encoder and set the C-pulse
2. check the pot voltage
3. perform cradle characterization
4. perform scout and helical scans

Elevation Actuator:
1. bring the table to its maximum height (open the elevation
characterization menu and move the upper magnetic switch up to
bypass limits) until the gas springs become loose and then back the
table down just slightly so there is some tension on one of the gas
springs
2. remove the large bolt holding the end of the actuator to the table
frame, this should slide out fairly easily and if it does not there is too
much tension on the bolt (make sure the gas springs are taking the
load of the table)
3. with the end of the actuator loose, drive the actuator completely
down by using the gantry control panel
4. disconnect the wires from the actuator and loosen the base from the
frame (either remove the 4 allen bolts or remove the pin with the c-
clamp)
5. install the test actuator and secure the base to the table frame
6. connect the wires and drive the actuator up with the gantry control
panel
7. install the actuator bolt to the table upper frame
8. set the upper and lower magnetic interference switches
9. run the table up and down and make sure there isn’t excess noise
(grinding, whining)
10. test the table with at least 450 lbs. of weight
PDU

PDU Control Board:

1. shut down the power at the A1 panel and install the test board
2. run HHS scans and a Fastcal and make sure there are no HVDC bus
errors

HiSpeed X/i

Console

DASIFN board:
1. install the test board verifying all jumpers
2. run the DAS data transfer test in sequential mode
3. scan at least 100 images on the large phantom to verify there are no
streaks or unusual artifacts

MOD Drive:
1. verify the jumpers on the test drive and boot up the console
2. cancel application startup and open a shell
3. login as root and type: install.mod
4. exit the shell and start the system
5. if the hinv test fails during start up a reconfig may be required
6. archive some images and create a state tape to test the drive

CDROM Drive:
1. verify the jumpers on the test drive and boot up the console
2. if the hinv test fails during start up a reconfig may be required
 3. there is no specific CDROM test but it can be tested by inserting a GE
service manual CD and verifying it reads the disk or patch software
can be loaded

Raw Data Disk:

1. install the test disk and set jumpers appropriately (according to
correct SCSI ID and termination)
2. after installing the test disk a LFC is required
3. once the LFC is finished scan at least 100 images to verify data is
being saved properly

Serial Port Expander:

1. before replacing the original serial port expander, type scsistat in a
shell and make note of the output
2. install the test serial port expander and boot the console
3. if the hinv test fails during start up a reconfig may be required
4. verify the scsistat output is the same and that the console boot to
applications normally

Hard Disk Drive (O2 computer):

1. after installing the test drive perform a LFC starting with the
partitioning procedure
2. the capacity of the HDD can be 4GB, 9GB, or 18GB depending on the
options loaded
3. after the LFC is done perform test scans

O2 System Module:
1. install the test module with the original CPU, memory, and PCI tray
2. if the O2 doesn’t power on initially push the power switch at the rear
of the console
3. once the O2 is powering up, cancel system startup and run
diagnostics (one section may fail - SCSI Test: Device 4 Failed DMA
Test; Error Code = IP32.08.0c.01.04; w1=00000075 , w2=00000084)
 4. boot the console and run a reconfig if the hinv test fails on startup
5. run some test scans and boot the console several times

O2 Memory:
1. the typical memory amount is 384MB, but may be 512MB on a NX/i
2. make sure to install the memory in pairs starting with slots 1 & 2
3. power on the console and run the O2 diagnostics
4. boot the console, run some test scans, and power cycle the console
several times

O2 PCI Tray:
1. after installing the test PCI tray boot the console and cancel
applications from starting
2. open a shell and type: revokeId
3. this command will bring up the options menu, which will allow the
original options to be loaded
4. verify the system boots normally and do some image recons

DBPCI Board:
1. install the test board and verify any jumper settings
2. boot the system and run a reconfig if the hinv test fails
3. verify the system boots normally and do some image recons

NPRIF Board:
1. install the test board and verify any jumper settings
2. boot the system and run a reconfig if the hinv test fails
3. verify the system boots normally and do some image recons

SCSI Card:
1. install the test board and verify any jumper settings
2. boot the system and run a reconfig if the hinv test fails
 3. verify the system boots normally and do some image recons

BP Controller Card:
1. install the test board and verify any jumper settings
2. boot the system and run a reconfig if the hinv test fails
3. verify the system boots normally and do some image recons

PCI Backplane:
1. install the test board and verify any jumper settings
2. boot the system and run a reconfig if the hinv test fails
3. verify the system boots normally and do some image recons

NPRS Board:
1. install the test board and verify any jumper settings
2. boot the system and run a reconfig if the hinv test fails
3. verify the system boots normally and do at least 100 image recons

NPRM Board:
1. install the test board and verify any jumper settings
2. boot the system and run a reconfig if the hinv test fails
3. verify the system boots normally and do some image recons

Gantry

Jedi Tank:
1. with the test tank in the system clear the filament aging and TNT
data
2. run through the filament aging correction scans:
a. Stationary, 120 kV 30 mA, small focus, 1 mm x 20 times 1 sec scan 1sec ISD
b. Stationary, 140 kV 30 mA, small focus, 1 mm x 20 times 1 sec scan 1sec ISD
c. Stationary, 80 kV 60 mA, small focus, 1 mm x 20 times 1 sec scan 1sec ISD
 d. Stationary, 120 kV 30 mA, large focus, 10 mm x 20 times 1 sec scan 1sec ISD
e. Stationary, 140 kV 30 mA, large focus, 10 mm x 20 times 1 sec scan 1sec ISD
f. Stationary, 80 kV 60 mA, large focus, 10 mm x 20 times 1 sec scan 1sec ISD
3. run the AutoScan sequence for one iteration
4. run Daily Calibration and verify there are no spits

HEMIT Tank:
1. run the AutoScan sequence for one iteration
2. run Daily Calibration and verify there are no HV errors

KV Control Board:
1. before removing the original KV board perform the “Saved RAM data
upload” to save the generator database if possible
2. make sure to install a compatible test board for the generator
version (1.5 or 3.0)
3. with the test board installed perform “Saved RAM data download” to
restore the generator database (can be downloaded from the Jedi
5.47 CD if the original data wasn’t available)
4. make sure the LED’s on the board are cycling normally
5. run through the filament aging correction scans:
a. Stationary, 120 kV 30 mA, small focus, 1 mm x 20 times 1 sec scan 1sec ISD
b. Stationary, 140 kV 30 mA, small focus, 1 mm x 20 times 1 sec scan 1sec ISD
c. Stationary, 80 kV 60 mA, small focus, 1 mm x 20 times 1 sec scan 1sec ISD
d. Stationary, 120 kV 30 mA, large focus, 10 mm x 20 times 1 sec scan 1sec ISD
e. Stationary, 140 kV 30 mA, large focus, 10 mm x 20 times 1 sec scan 1sec ISD
f. Stationary, 80 kV 60 mA, large focus, 10 mm x 20 times 1 sec scan 1sec ISD
6. run the AutoScan sequence for one iteration
7. run Daily Calibration and verify there are no spits or errors

Jedi Generator Assembly:

1. before removing the original Jedi generator perform the “Saved RAM
data upload” to save the generator database if possible
2. with the test assembly installed perform “Saved RAM data
download” to restore the generator database (can be downloaded
from the Jedi 5.47 CD if the original data wasn’t available)
3. run through the filament aging correction scans:
 a. Stationary, 120 kV 30 mA, small focus, 1 mm x 20 times 1 sec scan 1sec ISD
b. Stationary, 140 kV 30 mA, small focus, 1 mm x 20 times 1 sec scan 1sec ISD
c. Stationary, 80 kV 60 mA, small focus, 1 mm x 20 times 1 sec scan 1sec ISD
d. Stationary, 120 kV 30 mA, large focus, 10 mm x 20 times 1 sec scan 1sec ISD
e. Stationary, 140 kV 30 mA, large focus, 10 mm x 20 times 1 sec scan 1sec ISD
f. Stationary, 80 kV 60 mA, large focus, 10 mm x 20 times 1 sec scan 1sec ISD
4. run the AutoScan sequence for one iteration
5. run Daily Calibration and verify there are no spits or errors

X-ray Tube:
1. make all of the tube connections and put a lead blanket on the
output of the tube if doing a hanging test
2. clear the filament aging and TNT data
3. run through the filament aging correction scans:
a. Stationary, 120 kV 30 mA, small focus, 1 mm x 20 times 1 sec scan 1sec ISD
b. Stationary, 140 kV 30 mA, small focus, 1 mm x 20 times 1 sec scan 1sec ISD
c. Stationary, 80 kV 60 mA, small focus, 1 mm x 20 times 1 sec scan 1sec ISD
d. Stationary, 120 kV 30 mA, large focus, 10 mm x 20 times 1 sec scan 1sec ISD
e. Stationary, 140 kV 30 mA, large focus, 10 mm x 20 times 1 sec scan 1sec ISD
f. Stationary, 80 kV 60 mA, large focus, 10 mm x 20 times 1 sec scan 1sec ISD
4. run one sequence of AutoScan if the tube is mounted
5. run heat soak and make sure scanning doesn’t stop due to tube spits
6. make note of any excessive rotor noise
7. if mounting the tube alignments, calibrations, and image quality
checks can be performed but may only be required in special cases

Rotation Board:
1. make sure there is plenty of thermal past on the bottom of the board
when installing it
2. run the AutoScan sequence and Daily Calibration

Inverter MID Power Assembly:

1. remove the Jedi assembly to access the inverter assembly
2. reset the filament aging and TNT data
3. run through the filament aging correction scans:
a. Stationary, 120 kV 30 mA, small focus, 1 mm x 20 times 1 sec scan 1sec ISD
b. Stationary, 140 kV 30 mA, small focus, 1 mm x 20 times 1 sec scan 1sec ISD
 c. Stationary, 80 kV 60 mA, small focus, 1 mm x 20 times 1 sec scan 1sec ISD
d. Stationary, 120 kV 30 mA, large focus, 10 mm x 20 times 1 sec scan 1sec ISD
e. Stationary, 140 kV 30 mA, large focus, 10 mm x 20 times 1 sec scan 1sec ISD
f. Stationary, 80 kV 60 mA, large focus, 10 mm x 20 times 1 sec scan 1sec ISD
4. run the AutoScan sequence for one iteration
5. run Daily Calibration and verify there are no spits or errors

EMC Board 3 Phase:

1. install the board and run one iteration of the AutoScan sequence
2. run Daily Calibration and verify there are no spits or errors

AC/DC 3 Phase Board:

1. install the board and run one iteration of the AutoScan sequence
2. run Daily Calibration and verify there are no spits or errors

Inverter Coils/Capacitor Assembly:

1. this can be replaced without removing the Jedi assembly
2. run one iteration of the AutoScan sequence
3. run Daily Calibration and verify there are no spits or errors

Inverter Gate Board:

1. this board is normally part of the inverter assembly and can be
replaced without removing the Jedi assembly but the capacitor
assembly must be removed
2. after replacing this board there should be four green LED’s on the
board indicating the IGBT’s are working normally
3. run one iteration of the AutoScan sequence
4. run Daily Calibration and verify there are no spits or errors

LV Power Supply 3 Phase Board:

1. install the board and run one iteration of the AutoScan sequence
2. run Daily Calibration and verify there are no errors
Filament Board:
1. install the board and run one iteration of the AutoScan sequence
2. run Daily Calibration and verify there are no errors

CAM Board:
1. verify the correct version is being installed in the DAS
2. install the board in one of the middle slots
3. let the board warm up for 20 minutes
4. run DG-cal, air, and phantom calibrations
5. run CT number adjustment
6. check image quality on the QA phantom

DDP Board:
1. install the board in the left DAS box
2. run Daily Calibration and do a test scan on the QA phantom

CIF Board:
1. install the board in the left DAS box
2. run DG-cal
3. run Daily Calibration and do a test scan on the QA phantom

Detector:
1. remove the original detector carefully and be aware of the heater
strip cable on the rear that is close to the detector adjustment nut
2. after installing the test detector perform an air scan and plot the data
to look for any obvious spikes or dips
3. perform alignments starting with BOW
4. allow the detector to warm up to temperature by checking the
temperature box before doing calibrations
5. perform all Hilight calibrations
6. run air and phantom calibrations and CT number adjustment
 7. run Daily Calibration and verify the home page items are green or
yellow
8. check image quality on the QA and 42cm phantoms

Table

Cradle Potentiometer:
1. remove the cradle to gain access to the cradle pot
2. move the cradle sled to the mechanical out or home position
3. disconnect the cradle pot wire and remove the pot by unscrewing
the two support screws
4. install the test cradle pot
5. turn TGP switch T6 on
6. push the Test 1 button until the display reads 005
7. adjust the cradle pot until the position display reads 70 +/- 50
8. turn T6 off and perform the cradle absolute position adjustment

Cradle Pulley Wire Assembly:

1. refer to the Component Replacement manual or CT Notes for
detailed instructions and pictures; it may also be helpful to look at
the ProSpeed Component Replacement manual for further help
2. once the assembly is mounted verify the cradle pot setting
3. perform the cradle absolute position adjustment

Cradle Encoder:
1. raise the table to its maximum height and remove the cradle
2. disconnect the cradle encoder wire and loosen the set screw to
remove the encoder disk from the shaft
3. remove the 3 screws on the encoder holder to free the encoder
4. install the test encoder and perform longitudinal accuracy and cradle
repeatability tests
Height Potentiometer:
1. position the table so the 2 set screws are accessible
2. remove the pot assembly and its bracket by unscrewing the 2
support nuts
3. disconnect connector CN5 and feed it up through the table
4. install the test height pot in reverse order
5. set TGP switch T6 on and press the Test 1 button until the display
reads 011
6. adjust the pot by turning the shaft (hole in the left side cover) with a
small slotted screw driver until the display reads 120 +/- 55
7. once adjusted tighten the 2 set screws and turn off T6
8. perform the height adjustment in the Functional Check manual