DUAL VIEW AND SINGLE VIEW 320kV Installation and Maintenance Manual 5 PDF

Astrophysics Inc.
XIS Cargo X
X-ray
ray Imaging System
Service Manual
XIS-1517
1517 320kV
XIS-1818
1818 320kV
XIS-1517
1517DV 320kV
XIS-1818
1818DV 320kV
Document Description
TITLE XIS 320kV Installation and Maintenance Manual
Installation and Maintenance Guide for the Astrophysics X-ray

DESCRIPTION
Imaging Systems.
REVISION M-75-13.16, Rev. A
RELEASE August 2013
Revision History
REV AUTHOR DESCRIPTION CHANGES
A Rob Tobin First Release First Draft
Notice
The information contained in this document is believed to be correct as of the date of

publication. The contents are presented “as is”. Except as required by applicable law, no
warranties of any kind, either express or implied, including, but not limited to, the implied
warranties of merchantability and fitness for a particular purpose, are made in relation to
the accuracy, reliability, or contents of this document. Astrophysics Inc. reserves the
right to make changes to this document and the product specifications contained herein
without notice.
Confidential and Proprietary Notice
This manual contains confidential and proprietary information that is protected by U.S.
and international copyrights and patents. All rights are reserved. No part of this manual
may be copied, photocopied, reproduced, translated, or transcribed in any manner
without written permission from Astrophysics Inc.
M-75-13-15, Rev A Page 2 of 260

Conventions Used In This Manual
Throughout this manual, the Astrophysics X-ray Imaging System (XIS) is referred to as
the XIS.
Operator console button presses are specified in “square” (“[“, “]”) brackets. For example,
pressing the STOP button on the keypad operator console is represented as [STOP STOP]
STOP
“Control” key characters are denoted with square bracket notation, [Ctrl-character].
For example, [Ctrl-x] refers to simultaneously pressing the [Ctrl] key and the [x] key on
the PC keyboard.
“Alt” key characters are denoted with square bracket notation, [Alt-character].
For example, [Alt-x] refers to simultaneously pressing the [Alt] key and the [x] key on the
PC keyboard.
[Alt-Ctrl-del] refers to simultaneously pressing the [Alt] key, the [Ctrl] key, and the [Del]
key.
IMPORTANT
Very important notices are highlighted by the “IMPORTANT” text box. These messages
involve critical safety issues and deserve special attention.
B/W refers to the Black & White (left side) video display monitor
B/W refers to the button B/W on the keypad operator console.
[B/W
B/W]
VERY IMPORTANT OPERATIONAL INFORMATION is highlighted in yellow and

preceded by the word “NOTE
NOTE”
NOTE bolded and in caps.
INFORMATION RELATED TO PERSONAL SAFETY is highlighted in red and preceded

by the word “CAUTION”
CAUTION” or “WARNING
WARNING!
WARNING!” bolded and in caps, and by the following
symbol:
M-75-13-15, Rev A Page 3 of 260

Abbreviations
ACHE Air Cooled Heat Exchanger
Astrophysics Astrophysics, Inc.
CA Cabinet A
CB Cabinet B
CC Cabinet C
CDRH US FDA Center for Devices and Radiological Health
DAS Data Acquisition System
ER Entry Rollers
ER1 Entry Roller (Bed) #1
ER2 Entry Roller (Bed) #2
EX Exit Rollers
EX1 Exit Roller (Bed) #1
EX2 Exit Roller (Bed) #2
FDA United States Food and Drug Administration
LXDA Linear X-ray Detector Assembly
M1 Module #1
M2 Module #2
M3 Module #3
M4 Module #4
M5 Module #5
OSHA United States Dept of Labor, Occupational Safety and Health Administration
NRC United States Nuclear Regulatory Commission
WI Work Instructions
PPE Personal Protective Equipment
XIS X-ray Imaging System
XRG X-ray Generator
XRT X-ray Tube
M-75-13-15, Rev A Page 4 of 260

Table of Contents
SAFETY ............................................................................................................................................ 17
CHAPTER OVERVIEW ............................................................................................................................... 17
Safety Features............................................................................................................................... 17
Safety Precautions .......................................................................................................................... 18
Special Maintenance Information ................................................................................................... 22
U.S. Federal Health and Safety Regulatory Compliance ................................................................... 23
Local Regulatory Compliance .......................................................................................................... 23
Facility Safety ................................................................................................................................. 24
DIFFERENCES BETWEEN DUAL- AND SINGLE-VIEW ............................................................................ 25
LXDA ARRAYS AND PCS .......................................................................................................................... 25
Single-View machines ..................................................................................................................... 25
Dual View machines ....................................................................................................................... 25
SOFTWARE ........................................................................................................................................... 27
[Display] ......................................................................................................................................... 27
[Options] ........................................................................................................................................ 27
[Dual View]..................................................................................................................................... 27
DAS 2.0 SYNCH BOARD CONFIGURATION IN DUAL-VIEW XIS .......................................................................... 27
DUAL-VIEW CONFIGURATION POINTS ......................................................................................................... 29
DUAL-VIEW PC NETWORK TROUBLESHOOTING ............................................................................................ 31
Network ......................................................................................................................................... 31
Keyboard/Mouse Sharing ............................................................................................................... 31
Imaging Software ........................................................................................................................... 31
XIS 320KV DELIVERY AND UNCRATING.............................................................................................. 33
INTRODUCTION ...................................................................................................................................... 33
REQUIRED RESOURCES ............................................................................................................................ 35
Tools .............................................................................................................................................. 35
Recommended Personal Protective Equipment ............................................................................... 37
PRE-ARRIVAL WORK INSTRUCTIONS ........................................................................................................... 37
ON-SITE WORK INSTRUCTIONS ................................................................................................................. 39
Verifying and Examining the Crates ................................................................................................ 39
Uncrating the XIS Machine ............................................................................................................. 42
INSTALLING THE XIS 320KV SINGLE VIEW .......................................................................................... 47
CABLING BETWEEN SECTIONS ................................................................................................................... 49
PANELS ................................................................................................................................................ 50
CONNECTING SECTIONS (MODULES, CABINETS AND ROLLERS) ......................................................................... 53
CONNECTING MODULES AND ROLLER BEDS ................................................................................................. 57
RE-INSTALLING CHAINS............................................................................................................................ 59
CHECK AND FILL THE CHILLER .................................................................................................................... 60
REINSTALLING THE CATHODE .................................................................................................................... 63
SETTING UP THE SUPERVISOR STATION ........................................................................................................ 64
Check the electrical components ..................................................................................................... 65
PEDESTAL CONTROL PANEL ...................................................................................................................... 68
PHOTOELECTRIC CELLS (PECS) .................................................................................................................. 69
PHOTOELECTRIC CELL GAIN ADJUSTMENT.................................................................................................... 70
M-75-13-15, Rev A Page 5 of 260

Sensor Alignment ........................................................................................................................... 71
INSTALLING THE XIS 320KV DUAL VIEW ............................................................................................ 73
MOUNTING THE DOWN-SHOOTER GENERATOR ............................................................................................ 75
REMOVE AND REPLACE LXDA BOARDS FROM DOWN-SHOOTER ....................................................................... 83
Accessing the Bottom LXDA Box...................................................................................................... 86
DUAL-VIEW PC NETWORK TROUBLESHOOTING ............................................................................................ 91
Network: ........................................................................................................................................ 91
Keyboard/Mouse Sharing: .............................................................................................................. 92
Imaging Software: .......................................................................................................................... 92
ADDITIONAL CHILLERS AND POWER SUPPLIES ............................................................................................... 92
OPERATION ..................................................................................................................................... 93
INTRODUCTION ...................................................................................................................................... 93
PROCEDURES FOR EACH OPERATION .......................................................................................................... 94
System Startup ............................................................................................................................... 94
LOGGING INTO THE XIS....................................................................................................................... 95
X-Ray Imaging Procedure................................................................................................................ 99
THE PEDESTAL CONTROL PANEL .............................................................................................................. 102
Stopping The Rollers And X-Ray Generator.................................................................................... 102
Manually Controlling the Rollers ................................................................................................... 103
Pedestal Control Console – Operational Description ...................................................................... 105
MAIN COMPONENT SYSTEMS ......................................................................................................... 115
X-RAY GENERATOR SYSTEM ................................................................................................................... 115
X-Ray Tube ................................................................................................................................... 115
X-RAY GENERATOR POWER SUPPLY: ANODE / CATHODE .............................................................................. 116
The Anode Generator Tank ........................................................................................................... 116
The Cathode Generator Tank ........................................................................................................ 116
X-RAY CONTROLLER BOARD ................................................................................................................... 117
Connector Lay-Out........................................................................................................................ 117
Power Supplies ............................................................................................................................. 118
LXDA FOR XIS-1818-320KV ................................................................................................................. 118
COLLIMATOR ....................................................................................................................................... 119
CHAIN DRIVE SYSTEM & MOTOR ............................................................................................................. 119
VFD (Variable Frequency Drives) ................................................................................................... 120
Roller beds (Electrical) .................................................................................................................. 120
Basic Safety when working with unguarded Chain Drives .............................................................. 122
PC SYSTEM ......................................................................................................................................... 123
Configuration ............................................................................................................................... 124
Monitors ...................................................................................................................................... 124
Keyboard ...................................................................................................................................... 124
Mouse .......................................................................................................................................... 124
UNINTERRUPTIBLE POWER SUPPLY (UPS) ................................................................................................. 124
Overview ...................................................................................................................................... 124
CONTROL PANEL SYSTEM ....................................................................................................................... 126
AOCP ............................................................................................................................................ 126
PCP (Pedestal Control Box) ........................................................................................................... 129
ELECTRICAL WIRING.............................................................................................................................. 130
PHOTOCELLS ....................................................................................................................................... 131
PLC (PROGRAMMABLE LOGIC CONTROLLER) .............................................................................................. 132
M-75-13-15, Rev A Page 6 of 260

STACK LIGHT ....................................................................................................................................... 134
INTERLOCK SWITCHES............................................................................................................................ 134
DIAGNOSTICS................................................................................................................................. 135
SELF-DIAGNOSTICS SYSTEM .................................................................................................................... 135
DCI BOARD ........................................................................................................................................ 135
DAQ BOARD (LABJACK™ BOARD) ........................................................................................................... 137
PHOTOCELLS ....................................................................................................................................... 137
PLC .................................................................................................................................................. 137
VFD .................................................................................................................................................. 138
INTERLOCK SWITCHES............................................................................................................................ 138
LXDA ................................................................................................................................................ 138
DIODE PLOT ........................................................................................................................................ 138
Diode Plot Program – Test Instructions ......................................................................................... 141
DIAGNOSTICS SCREEN ........................................................................................................................... 142
Table of Diagnostic Screen Display Fields ...................................................................................... 143
Error Log – Error Message List ...................................................................................................... 145
BYPASSING THE PLC DURING DIAGNOSTICS ............................................................................................... 147
CABINETS....................................................................................................................................... 149
FRONT CABINETS ................................................................................................................................. 149
Cabinet A...................................................................................................................................... 150
Cabinet B ...................................................................................................................................... 151
Cabinet C ...................................................................................................................................... 152
REPLACEMENT PARTS LISTS ............................................................................................................ 153
CRITICAL PARTS ................................................................................................................................... 153
BASIC PARTS ....................................................................................................................................... 154
SYSTEM-SPECIFIC PARTS ........................................................................................................................ 155
320KV SPECIFIC PARTS ......................................................................................................................... 156
PREVENTIVE MAINTENANCE........................................................................................................... 157
PM CHECKLIST .................................................................................................................................... 157
CLEANING, GAPPING AND GREASING HIGH VOLTAGE CABLES ........................................................................ 162
Cleaning ....................................................................................................................................... 162
Gapping ....................................................................................................................................... 163
Greasing ....................................................................................................................................... 164
Assembly of non spring-loaded cables........................................................................................... 164
Maintenance of High Voltage Cables ............................................................................................ 165
320KV X-RAY GENERATOR SYSTEM ................................................................................................. 167
X-RAY GENERATOR SYSTEM ................................................................................................................... 167
The Anode Generator Tank ........................................................................................................... 168
The Cathode Generator Tank ........................................................................................................ 168
Collimator .................................................................................................................................... 169
X-RAY TUBE REMOVE AND REPLACE ......................................................................................................... 170
Instructions for Removing Radiation Shield Box ............................................................................ 170
Removing the X-ray Tube .............................................................................................................. 173
LAIRD AIR COOLED HEAT EXCHANGER (“CHILLER”) .......................................................................... 175
Replacing the Chiller ..................................................................................................................... 175
M-75-13-15, Rev A Page 7 of 260

Technical Data.............................................................................................................................. 177
CURTAINS ...................................................................................................................................... 179
REMOVE AND REPLACE .......................................................................................................................... 179
Removing Curtains ....................................................................................................................... 179
Replacing Curtains ........................................................................................................................ 181
ROLLERS ........................................................................................................................................ 183
REPLACING ROLLERS INSIDE THE INSPECTION TUNNEL .................................................................................. 183
LXDA (LINEAR X-RAY DETECTOR ASSEMBLY) ................................................................................... 187
ADJUSTING THE LXDA ARRAY ................................................................................................................. 187
Getting Raw Data ......................................................................................................................... 188
Adjusting the Boards with Diode Plot ............................................................................................ 190
LXDA REPLACEMENT INSTRUCTIONS ........................................................................................................ 191
RADIATION SURVEY ....................................................................................................................... 197
REQUIRED RESOURCES .......................................................................................................................... 198
LXDA BOARD INSTALLATION AND GAIN .......................................................................................... 205
PURPOSE AND DESCRIPTION ................................................................................................................... 205
PARTS INCLUDED:................................................................................................................................. 205
REQUIRED MATERIALS AND TOOLS........................................................................................................... 205
PROCEDURE ........................................................................................................................................ 205
LXDA 2.0 Board Installation .......................................................................................................... 205
Setting the LXDA Address in the DIP Switch ................................................................................... 207
Correction Mode Selection: Local vs. Remote ................................................................................ 210
Installing the Hardware and the Hardware Driver ......................................................................... 212
Summary of “Navigating to Driver Folder” .................................................................................... 215
Summary of “Found New Hardware Wizard” for USB-Serial Adapter Cable” ................................. 217
Installing the “Offset Gain Correction 1.0.0” (OGC) Software ........................................................ 219
Summary of “Starting the OGC Installer”: ..................................................................................... 220
Summary of “Navigating to the OGC Application File” .................................................................. 224
Using the “Offset Gain Correction 1.0.0” Software (OGC) .............................................................. 224
Summary of “OGC Window Layout & Functions”........................................................................... 225
Address Test ................................................................................................................................. 228
Setting Offset and Gain Remotely ................................................................................................. 230
Exiting the OGC Software Application ........................................................................................... 233
Troubleshooting: .......................................................................................................................... 233
Summary of “Viewing the COM Port Assignment for the USB-Serial Adapter Cable”...................... 235
Confirming the File Name of Driver Used by System for the USB-Serial Adapter Cable ................... 236
Summary of “Installed “Driver File Details” for the USB-Serial Adapter Cable”: ............................. 238
LXDA 2.0 / 1.0 DIFFERENCES................................................................................................................. 240
High-Energy Side .......................................................................................................................... 240
Summary of Changes to High-Energy Side:.................................................................................... 240
Low-Energy Side ........................................................................................................................... 242
Summary of Changes to Low-Energy Side:..................................................................................... 242
RECOVERING FROM A FAILED HARD DRIVE ..................................................................................... 245
INTRODUCTION: ................................................................................................................................... 245
REQUIRED TOOLS & MATERIALS: ............................................................................................................. 245
M-75-13-15, Rev A Page 8 of 260

PROCEDURE: ....................................................................................................................................... 245
Synergy ........................................................................................................................................ 248
Input Director ............................................................................................................................... 248
TROUBLESHOOTING: ............................................................................................................................. 249
FINGERPRINT READER AND BAR CODE SCANNER ............................................................................ 251
USB CONNECTION ............................................................................................................................... 251
BARCODE READER ................................................................................................................................ 252
FINGERPRINT READER ........................................................................................................................... 256
M-75-13-15, Rev A Page 9 of 260

Table of Figures
Figure 1: Normal DIP Switch Settings ............................................................................28
Figure 2: Normal LED Indications: When configured according to Table 1 ....................29
Figure 3: Abnormal LED Indications: Both configured as Master synch board in Table 1
......................................................................................................................................29
Figure 4: Abnormal LED Indications: Both configured as Slave synch board in Table 1 29
Figure 5: XIS Model 1517DV 320kV ..............................................................................33
Figure 6: XIS Model 1517 SV 320kV .............................................................................33
Figure 7: XIS Model 1818DV 320kV ..............................................................................34
Figure 8: XIS Model 1818SV 320kV ..............................................................................34
Figure 9: Machine Specifications ...................................................................................35
Figure 10: Dimensions for XIS 320kV Models................................................................38
Figure 11: Number of Crates .........................................................................................40
Figure 12: Shipped Items for the 1818 and 1517 Single View........................................40
Figure 13: Shipped Items for the 1818 and 1517 Dual View ..........................................41
Figure 14: TiltWatch and Shockwatch Monitors .............................................................42
Figure 15: Removing a Side Panel from a Crate............................................................43
Figure 16: Forklift Points................................................................................................43
Figure 17: Crate Base Strapping ...................................................................................44
Figure 18: Forklift Holes ................................................................................................45
Figure 19: Modules, Cabinets and Roller Beds ..............................................................47
Figure 20: Descriptions of Modules and Cabinets ..........................................................48
Figure 21: Cabling Between Sections ............................................................................49
Figure 22: Moving Module into Place.............................................................................50
Figure 23: Modules, Cabinets and Roller Beds ..............................................................50
Figure 24: Panel Nomenclature .....................................................................................51
Figure 25: Removed Panels ..........................................................................................51
Figure 26: Mounting Brackets for Panels .......................................................................52
Figure 27: Mounting Bracket for Panels .........................................................................52
Figure 28: Bottom of Panels with Fastening Screws and Keyed Lock ............................53
Figure 29: Screw Hole and Lock Latch ..........................................................................53
Figure 30: Moving Module 2 and Module 3 together ......................................................54
Figure 31: Clamping Modules ........................................................................................54
Figure 32: Fastening Bolts Connecting Modules............................................................55
Figure 33: Lower chain guard removed from the frame .................................................55
Figure 34: Installation of chains .....................................................................................56
Figure 35: Connecting Chain Links ................................................................................56
Figure 36: Rollers on Different Roller Beds Connected by Chains .................................57
Figure 37: Connection between EX (Exit Rollers) and M5 (Exit Tunnel) ........................57
Figure 38: Detail view of the connection between EX (Exit Rollers) and M5 (Exit Tunnel)
......................................................................................................................................58
Figure 39: Replacing Roller Covers on Tunnel and X-Ray Modules ..............................58
Figure 40: Replacing Entry/Exit Roller Covers ...............................................................59
Figure 41: Roller Brackets .............................................................................................59
Figure 42: Installation of edge rollers .............................................................................60
Figure 43: Chiller Housing Fastening Screws ................................................................60
Figure 44: Chiller with Housing Removed ......................................................................61
Figure 45: Shipping Cap for Chiller ................................................................................61
Figure 46: Vented Operating Cap for Chiller ..................................................................61
Figure 47: Oil Level Gauge ............................................................................................62
Figure 48: Temperature Gauge, Inflow and Outflow ......................................................62
M-75-13-15, Rev A Page 10 of 260

Figure 49: Removing the Cathode from the Crate .........................................................63
Figure 50: Approaching the Cabinet with the Cathode ...................................................63
Figure 51: Inserting the Cathode into the Cabinet, Atop the Anode ...............................64
Figure 52: Supervisor Station ........................................................................................64
Figure 53: Procedure for Setting Up Remote Table .......................................................65
Figure 54: Back of Supervisor Station PC......................................................................66
Figure 55: Pedestal Control Panel .................................................................................68
Figure 56: Outlets for External Components ..................................................................68
Figure 57: Photoelectric Cell (PEC) ...............................................................................69
Figure 58: Adjusting the PEC ........................................................................................70
Figure 59: PEC Sensor Alignment .................................................................................71
Figure 60: Dual View Modules and Cabinets .................................................................73
Figure 61: Disassembled XIS 1818DV...........................................................................74
Figure 62: Assembled XIS 1818DV ...............................................................................74
Figure 63: Down-Shooter Funnel and Mounting Bolts....................................................75
Figure 64: Funnel on M4 (Down-shooter) frame ............................................................76
Figure 65: Generator Partially Wrapped ........................................................................76
Figure 66: Down-Shooter Generator with Cutouts for Lifting ..........................................77
Figure 67: Down-Shooter Generator Without Cowling ...................................................77
Figure 68: Generator reference line location (generator is hidden) ................................78
Figure 69: Adjusting the Down-shooter generator position with a crowbar .....................78
Figure 70: Chiller Oil and HV Cable Attachment Points .................................................79
Figure 71: Chiller Oil Hoses Attached to Down-Shooter Generator Bracket ...................79
Figure 72: High Voltage Cables Attached to Down-Shooter Generator ..........................80
Figure 73: Down-Shooter Generator with Hoses and HV Cables Attached ....................80
Figure 74: Down-Shooter Generator and Funnel ...........................................................81
Figure 75: Down-shooter with installed funnel cover ......................................................81
Figure 76: Down-Shooter with 4 cabinet panels installed...............................................82
Figure 77: Down-Shooter Front Panel ...........................................................................82
Figure 78: Down-Shooter Back and side panels ............................................................83
Figure 79: Top panels Installed .....................................................................................83
Figure 80: Side-Shooter and Down-Shooter Side LXDA Boxes .....................................84
Figure 81: Side-Shooter Top LXDA Box ........................................................................84
Figure 82: Side LXDA Boxes for Down-Shooter and Side-Shooter ................................85
Figure 83: Location of Down-Shooter Bottom LXDA Box (beneath roller bed) ...............85
Figure 84: Down-Shooter Side and Bottom LXDA Boxes ..............................................86
Figure 85: Flipping Curtains Up .....................................................................................87
Figure 86: Tying Curtains to Allow Air Flow In Tunnel....................................................87
Figure 87: Removing Roller Covers on Chain Side of Tunnel ........................................87
Figure 88: Lower Roller Covers Removed .....................................................................88
Figure 89: Removing Four Rollers Atop Bottom LXDA Box ...........................................88
Figure 90: Removing Chain Links ..................................................................................89
Figure 91: Removing Brackets and Rollers ....................................................................89
Figure 92: Brackets Holding Rollers in Position .............................................................90
Figure 93: Rollers Removed, Exposing LXDA Box ........................................................90
Figure 94: LXDA Locations with Respect to the LXDA Box Cover and Rollers ..............91
Figure 95: Main AC Circuit Breaker ...............................................................................94
Figure 96: "Auto Man" Key-switch .................................................................................94
Figure 97: Emergency Stop ...........................................................................................95
Figure 98: Advanced Operator Control Panel (AOCP) ...................................................95
Figure 99: “Calibration Required” screen .......................................................................96
Figure 100: “Warning X-rays” screen .............................................................................96
Figure 101: Log In Screen Enabled ...............................................................................97
Figure 102: Entering User Information ...........................................................................97
M-75-13-15, Rev A Page 11 of 260

Figure 103: “System Ready” screen ..............................................................................98
Figure 104: System Ready screen elements .................................................................98
Figure 105: AOCP Console, Pressing [LEFT] ................................................................99
Figure 106: Pedestal Control Panel .............................................................................102
Figure 108: System Startup Flowchart .........................................................................107
Figure 109: X-ray Imaging Flowchart ...........................................................................108
Figure 110: End of Day Key-switch Shutdown Flowchart .............................................109
Figure 111: Complete System Shutdown (for Maintenance) ........................................110
Figure 112: Emergency Situation Flowchart ................................................................111
Figure 113: Quick Reference Guide for System Operation ..........................................112
Figure 114: Power Supply and Earthing ......................................................................115
Figure 115: X-Ray System Block Diagram...................................................................116
Figure 116: Imaging System Block Diagram ................................................................117
Figure 117: Data Flow of Imaging System ...................................................................118
Figure 118: Collimator .................................................................................................119
Figure 119: Inspection Tunnel Motor and VFDs...........................................................119
Figure 120: Conveyor Motor and VFD Locations .........................................................120
Figure 121: Entry Motor Connection ............................................................................120
Figure 122: Exit Roller .................................................................................................121
Figure 123: Motors ......................................................................................................121
Figure 124: Entry, Tunnel and Exit Motors...................................................................122
Figure 125: PC System Diagram .................................................................................123
Figure 126: PC Back Panel .........................................................................................123
Figure 127: UPS ..........................................................................................................125
Figure 128: UPS Remote.............................................................................................125
Figure 129: AOCP .......................................................................................................127
Figure 130: AOCP Functionality ..................................................................................127
Figure 131: Image Review and Archive AOCP Buttons ...............................................128
Figure 133: Pedestal Control Box Buttons and Functions ............................................129
Figure 134: Major Tray Components (Cabinets #1 and #2) .........................................130
Figure 135: Photocell Zones ........................................................................................131
Figure 136: PLC on Cabinet B Tray .............................................................................132
Figure 137: PLC with Extension Module ......................................................................132
Figure 138: Stack Light................................................................................................134
Figure 139: Interlock Switches .....................................................................................134
Figure 140: DCI Board.................................................................................................135
Figure 141: DCI Board in the Windows Device Manager .............................................136
Figure 142: LabJack Module and Expansion Board .....................................................137
Figure 143: 320kV Diode Plot ......................................................................................138
Figure 144: 320kV Diode Plot Off ................................................................................139
Figure 145: 320kV Diode Plot with History...................................................................139
Figure 146: Diagnostics Screen ...................................................................................142
Figure 147: GulmayGeneratorControl.vi Screen ..........................................................147
Figure 148: START Menu Shortcut to Panel.exe .........................................................148
Figure 149: Main Screen .............................................................................................148
Figure 150: Front of XIS-1818 320kV ..........................................................................149
Figure 151: Cabinet A..................................................................................................150
Figure 152: Cabinet B..................................................................................................151
Figure 153: Cabinet C .................................................................................................152
Figure 154: Critical Replacement Parts .......................................................................153
Figure 155: Basic Replacement Parts..........................................................................154
Figure 156: System Specific Replacement Parts .........................................................155
M-75-13-15, Rev A Page 12 of 260

Figure 157: 320kV-Specific Replacement Parts...........................................................156
Figure 158: Preventive Maintenance Checklist ............................................................157
Figure 159: Gulmay Planned Maintenance Report ......................................................158
Figure 160: Cleaning the Cone of the High Voltage Plug .............................................162
Figure 161: Adjusting the HV Cable Flange Gap .........................................................163
Figure 162: Applying Grease to the HV Cable Plug Cone ............................................164
Figure 163: Distance Cable Flange .............................................................................165
Figure 164: 320kV X-Ray Generator Component Diagram ..........................................167
Figure 165: Cathode and Anode (Converter Chassis) Power Supplies ........................168
Figure 166: Collimator .................................................................................................169
Figure 167: X-Ray Tube Radiation Shield....................................................................170
Figure 168: Removing Radiation Shield Box ...............................................................171
Figure 169: Lifting Table and Radiation Shield Box Lid................................................172
Figure 170: Grabbing the Radiation Shield Box Lid by the Handles .............................172
Figure 171: Lifting the Radiation Shield Box Lid onto a Lifting Table ...........................172
Figure 172: X-ray Tube ................................................................................................173
Figure 173: Oil Hoses Inserting into the X-ray Tube ....................................................173
Figure 174: Lair Air Cooled Heat Exchanger ...............................................................175
Figure 175: Entry Tunnel Curtain Sets .........................................................................179
Figure 176: Curtains Flipped onto the Top of the Machine...........................................180
Figure 177: Removing the Metal Curtain Strip .............................................................180
Figure 178: Removing Pair of Curtains ........................................................................180
Figure 179: Installing New Curtains .............................................................................181
Figure 180: Attaching Second Layer of Curtains..........................................................181
Figure 181: Attaching Metal Curtain Strip ....................................................................182
Figure 182: New Curtains Hanging ..............................................................................182
Figure 183: Flipping Curtains Up .................................................................................183
Figure 184: Tying Curtains to Allow Air Flow In Tunnel ................................................183
Figure 185: Removing Roller Covers on Chain Side of Tunnel ....................................184
Figure 186: Lower Roller Covers Removed .................................................................184
Figure 187: Removing Four Rollers Atop the Bottom LXDA Box..................................184
Figure 188: Removing Chain Links ..............................................................................185
Figure 189: Brackets Holding Rollers in Position .........................................................186
Figure 190: Removing Brackets and Rollers ................................................................186
Figure 191: LXDA Access Doors and LXDA Board Adjustment Screws.......................187
Figure 192: Selecting [Explore] ....................................................................................188
Figure 193: Finding [Runtime] .....................................................................................189
Figure 194: Runtime Screen ........................................................................................189
Figure 195: Diode Plot Showing Misalignment.............................................................190
Figure 196: Diode Plot Alignment Results ...................................................................191
Figure 197: Removed LXDA Side Panel ......................................................................192
Figure 198: Removing Screws on LXDA Door .............................................................192
Figure 199: Open LXDA Door, Diode Board Exposed .................................................193
Figure 200: LXDA Board Mounting Screws (left side) and Posts (right side) ................193
Figure 201: Removing Cables .....................................................................................194
Figure 202: Mounting Screws ......................................................................................194
Figure 203: Removing Left side of LXDA Board ..........................................................195
Figure 204: Sliding LXDA Board off Posts ...................................................................195
Figure 205: LXDA Board, Removed ............................................................................196
Figure 206: Radiation Survey Required Resources .....................................................198
Figure 207: High Power Radiation Survey Form ..........................................................203
Figure 208: LXDA Power Connector Differences .........................................................207
Figure 209: LXDA 2.0 Board Numbering on an XIS-6545 ............................................208
Figure 210: DIP Switch Addressing Table for LXDA Component “SW1” ......................209
M-75-13-15, Rev A Page 13 of 260

Figure 211: Address Properly Set on the “Board #1” DIP Switch .................................209
Figure 212: Remote Offset Correction Selected on High Energy Side (“JP5”) .............211
Figure 213: Pin “B1” is Removed on “JP5” and “JP6” During Assembly.......................211
Figure 214: LXDA Interface Board ...............................................................................212
Figure 215: Exiting the XIS Imaging Application to go to the Windows XP Desktop .....213
Figure 216: An Example USB-Serial Adapter Cable and Driver on Mini CD ................213
Figure 217: Navigating to the Driver Folder .................................................................214
Figure 218: USB-Serial Adapter Cable to PC Connection............................................215
Figure 219: “Found New Hardware Wizard” for USB-Serial Adapter Cable .................216
Figure 220: Browse for Folder .....................................................................................217
Figure 221: USB-Serial Adapter Cable to Serial Cable Connection .............................218
Figure 222: Male-to-Female Serial Cable Connection (Male End) to LXDA Interface
Board ..........................................................................................................................219
Figure 223: Starting the OGC Installer .........................................................................220
Figure 224: Step 1 in the OGC Installer .......................................................................221
Figure 227: Navigating to the OGC Application File .....................................................223
Figure 228: OGC Window on Software Start-Up..........................................................225
Figure 229: OGC Window by Sections ........................................................................225
Figure 230: COM Port Selector Dropdown List ............................................................226
Figure 231: Connecting to the Proper COM Port with the COM Selector .....................227
Figure 232: Reset All Boards .......................................................................................227
Figure 233: OGC Window After Being Enabled ...........................................................227
Figure 234: OGC Window During Address Test ..........................................................228
Figure 235: LED Component “D-1” on the LXDA 2.0 Low-Energy Side .......................229
Figure 236: Detailed OGC Window Differences with “Address Test” On and Off .........229
Figure 237: Shortcut to DiodePlot ................................................................................230
Figure 238: Board #5 Selected for Individual Correction ..............................................231
Figure 239: Correcting Board #5 Individually with OGC Software and Diode Plot ........231
Figure 240: All Boards Selected for Correction ............................................................232
Figure 241: Correcting All Boards Simultaneously with OGC Software and Diode Plot 232
Figure 242: O/G Level Selector Controls in Detail .......................................................233
Figure 243: Viewing the COM Port Assignment for the USB-Serial Adapter Cable ......234
Figure 244: Unsuccessful Installation and Assignment of COM Port to USB-Serial
Adapter Cable .............................................................................................................235
Figure 245: Step 1 Confirming File Name of USB-Serial Adapter Cable Driver............236
Figure 248: LXDA 2.0 +5V & -5V Test Points and Mounting Bracket ...........................239
Figure 249: Close-Up of LXDA 2.0 +5V & -5V Test Points...........................................240
Figure 250: LXDA 2.0 High-Energy Side Additions ......................................................241
Figure 251: LXDA 1.0 High-Energy Side Deletions ......................................................242
Figure 252: LXDA 2.0 Low-Energy Side Additions.......................................................243
Figure 253: LXDA 1.0 Low-Energy Side Deletions ......................................................243
Figure 254: Static IP address settings for the Slave PC...............................................246
Figure 255: “AstroDiagnostic” in the Windows Startup folder .......................................247
Figure 256: Folder sharing property settings for the Slave PC’s “Xray Client” folder ....248
Figure 257: Cluster of Outlets ......................................................................................251
Figure 258: USB Hub ..................................................................................................252
Figure 259: XrayClient Error Message .........................................................................252
Figure 260: Barcode Scanner and Base ......................................................................253
Figure 261: Scanner and Base Separate .....................................................................253
Figure 262: Overhead Scan of Object, with Barcode Number ......................................254
M-75-13-15, Rev A Page 14 of 260

Figure 263: Barcode Set to Zero..................................................................................254
Figure 264: “Input Bar Code” Field ..............................................................................254
Figure 265: Bar Code Operational Flow Chart .............................................................255
Figure 266: Fingerprint Reader ....................................................................................256
Figure 267: Administrator/Management Modes ...........................................................256
Figure 268: Administrator Menu screen .......................................................................257
Figure 269: Employee’s Record screen .......................................................................257
Figure 270: Editing or Deleting Employee Records......................................................258
Figure 271: “Add New Employee” screen ....................................................................258
Figure 272: “Register Fingerprint” radio button ............................................................259
Figure 273: Fingerprint prompt ....................................................................................259
Figure 274: Placing Finger on Fingerprint Reader .......................................................260
Figure 275: “Fingerprint Registered” prompt ................................................................260
M-75-13-15, Rev A Page 15 of 260

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M-75-13-15, Rev A Page 16 of 260

Safety
WARNING!
The Astrophysics X-ray Imaging System (XIS) produces and uses ionizing x-ray radiation. X-
rays can be harmful to human health. They cannot be directly detected by any of the human
senses. Please exercise the utmost safety.
Chapter Overview
This chapter provides important safety information on operating the Astrophysics X-ray
Imaging System (XIS). It is intended for all users of the XIS.
Safety Features
The Astrophysics X-ray Imaging System (hereinafter referred to as the XIS) has many
safety features to protect the operator and others including:
• Lead shielded construction to minimize radiation leakage.
• Lead fabric curtains at the inspection tunnel openings to help block scattered
x-rays from escaping the tunnel.
• Interlock switches that stop (power off) the x-ray generator and conveyor belt
when an access panel is opened or removed.
• Steel frame and heavy gauge steel panels that reduce any residual external
x-ray radiation emissions.
• Infrared Photocells inside the inspection tunnels that sense when objects
enter and exit the inspection tunnel. The x-ray generator is activated only for
the minimum amount of time necessary to image items traversing the
inspection tunnel. X-rays are NOT produced when the x-ray machine is idle,
or when the conveyor is stopped, or when the inspection tunnel is empty.
• Emergency Stop switches (at both the entrance and exit of the x-ray tunnel),
that can be pressed to immediately stop (power off) the x-ray generator and
the conveyor belt.
• Green Power-ON LED lamps at each end of the x-ray tunnel and on both the
Pedestal Control Panel (PCP) and the Advanced Operator Control Panel
(AOCP) to indicate when the system is powered on and ready for use.
M-75-13-15, Rev A Page 17 of 260

• Red warning X-ray ON LED lamps at each end of the x--ray tunnel and on
both the Pedestal Control Panel (PCP) and the Advanced Operator Control
Panel (AOCP) to indicate when x-rays
rays are being generated.
• Circuit breakers that disconnect power from the main AC input into the XIS if
the unit becomes overloaded.
• A key-switch
switch that requires that a key
key be inserted and turned to the “ON”
“
position to power up and operate the XIS unit.
• A foot-mat
mat switch that requires the continuous presence of an operator,
manning the controls, while the conveyor and x-ray
x ray generator are being used.
• Password protected access to the application software.
• Prominent labels that warn users to not insert any part of their body when the
x-rays
rays are produced.
Safety Precautions
The Astrophysics X-ray
ray Imaging System (XIS) is designed to be safe and easy to use.
u
However, all major electromechanical devices can be hazardous and should be treated
with care and respect. When operating the XIS, follow the safety precautions below:
• Do NOT operate the unit outdoors. The XIS must be protected from moisture,
precipitation,
ation, and extremes of temperature.
• Connect the unit to a well grounded power outlet. The XIS requires a reliable
protective earth ground to operate.
M-75-13-15, Rev A Page 18 of 260

• Do not operate an x-ray
x ray machine without a good earth (electrical) ground.
• Do NOT operate the unit when

whe the x-ray
ray curtains are torn or missing.
• Clear the x-ray

x ray tunnel of all items before starting the unit.
• Do NOT insert any part of the body into the inspection tunnel while xx-rays are
energized. Avoid all unnecessary radiation exposures.
• If material should become jammed during operation, the machine must be

turned off before an attempt is made to clear the inspection tunnel area.
Either:
o Press
ress the Emergency Stop button, or
o Turn
urn the main AC switch to the OFF position, or
o Turn
urn the key
key-switch to the OFF position BEFORE attempting to clear
the tunnel.
• Although the system utilizes an extremely low xx-ray

ray dose, wait until scanned
items are completely out of the inspection tunnel in order to avoid any
unnecessary radiation exposure.
M-75-13-15, Rev A Page 19 of 260

• Ensure that the conveyor and x-rays are off before reaching into the
inspection tunnel. The X-ray ON warning lights is lit when x-rays are being
produced. The X-ray ON lights are located above the entrances of the
inspection tunnel, on the operator console, and on bottom right of the status
bar on the x-ray imaging screen.
• If required, post appropriate signs around the XIS to warn people that they
are in the vicinity of a device that produces and uses x-ray radiation.
• Check the Power ON and the X-ray ON lights for proper operation before
using the baggage x-ray machine. The Power ON light becomes lit when the
key-switch is turned to the ON position. The X-ray ON light will momentarily
turn on and off when the conveyor belt is just started. (The momentary
operation of the x-rays allows for “x-ray data normalization”). The X-ray ON
light becomes lit again when the x-ray generator is producing x-rays for
imaging. This occurs when objects are carried through the x-ray tunnel by the
conveyor.
• The XIS internally uses high voltages. All cover panels must be closed and
securely fastened before system operation.
• Be careful of sharp objects that can cut the x-ray curtains and conveyor belt.
M-75-13-15, Rev A Page 20 of 260

• If a threatening object is identified, follow the procedures established at your
facility for handling such objects.
• Always perform a comprehensive radiation survey and safety inspection after

an XIS is serviced.
• Turn "OFF" the equipment as soon as an unsafe operating condition or

procedure develops or might develop. Inform your supervisor who will contact
the maintenance technician. The machine is a sophisticated piece of
electronic equipment and must be treated with care. All service adjustments
or repairs must be done only by qualified personnel.
• Do not open the access panels during operation. These panels are designed
with safety switches to prevent exposure to high voltage and radiation.
• The foot mat switch is a design safety component that requires the operator
to stand on it when operating the machine. Do not place heavy objects on the
foot mat switch to defeat it.
• Keep hands, finger, clothing and hair away from conveyor rollers.
• Do not sit on or attempt to ride the conveyor. Never use the machine as a toy.
• Do not stand closer than necessary to the x-ray machine. Do not allow
anyone to loiter within 2 meters of the x-ray chamber or conveyor belt at any
time. Never leave the machine unattended.
• Do not place any objects such as plants, coffee cups, pop cans, bottles etc.
on top of the machine. The liquid, if spilled from these containers, could
create a potential shock hazard which may be fatal.
• Do not obscure or cover the x-ray "ON" warning lights or the x-radiation
warning signs. These items must be clearly visible at all times.
M-75-13-15, Rev A Page 21 of 260

Special Maintenance Information
WARNING!
Always turn off and disconnect power to the XIS BEFORE servicing the x-ray generator or
removing any radiation shielding.
• Do NOT operate the XIS unless all radiation shielding is properly installed
and functioning correctly. Ensure that all access panels are closed before
operating the XIS.
• Perform a comprehensive radiation survey after servicing the XIS.
• Do NOT allow the XIS to operate if external radiation leakage exceeds 0.1
mR/hr (0.001 mSv/hr).
• The XIS is recognized by the U.S. Food and Drug Administration (FDA) as a
cabinet x-ray device.
• In the U.S., the XIS is regulated by U.S. FDA Center for Devices and
Radiological Health. The XIS complies U.S. Statutes including but not limited
to U.S. Code of Federal Regulation (CFR), Title 29, Section 1020.40,
Performance Standards for Cabinet X-ray Device.
• In Canada, the XIS is regulated by Health Canada. The XIS complies with
Canadian statutes including but not limited to Canada Safety Code 29.
• In Canada, Health Canada requires registration of all baggage x-ray

machines.
• United States and Canadian law requires that the XIS should ONLY be
installed, relocated, and serviced by a (factory) trained and certified
technicians. There are no user serviceable parts inside the machine.
• American and Canadian law requires the usage of only factory certified
replacement parts in the XIS.
• For service and support contact:
M-75-13-15, Rev A Page 22 of 260

U.S. Federal Health and Safety Regulatory Compliance
The XIS is classified as a Cabinet X-ray Device. It complies with the following U.S.
Federal Health and Safety Regulations applicable at time of manufacture:
• U.S. Food and Drug Administration, Department of Health and Human

Services, Center for Devices and Radiological Health, Code of Federal
Regulations Title 21 Section 1020.40, Radiological Health Standards for
Cabinet X-Ray Systems;
• U.S. Federal Aviation Administration, Code of Federal Regulations Title 14

Section 108.17, Use of X-ray Systems; and;
• U.S. Federal Aviation Administration, Code of Federal Regulations Title 14.

Section 129.26, Use of X-ray Systems.
Local Regulatory Compliance

• Local radiation safety requirements differ significantly from one jurisdiction to
another.
• Some jurisdictions require the registration of x-ray producing equipment

PRIOR to their usage.
• Many jurisdictions require initial and annual radiation safety surveys.
• Some jurisdictions, including Canada, require certification of baggage x-ray

machine operators.
• In Canada, personal dosimeters are not required for baggage x-ray machine
operators.
• XIS users are responsible for their compliance with all applicable Federal,
state, and local laws. Failure to comply may result in substantial penalties.
M-75-13-15, Rev A Page 23 of 260

Facility Safety
During security screening operations you may identify hazardous contraband, weapons,
explosives, and other threats in the bags, packages, and articles that you are examining
with your XIS. Plan ahead. Have your facility security manager prepare clear and
concise instructions for handling these situations. Be prepared to follow them.
M-75-13-15, Rev A Page 24 of 260

Differences Between Dual- and Single-View
Through there are numerous similarities in technology and use between single and dual-
use XIS machines, there are also significant differences that need to be taken into
account when installing, operating and maintaining these machines.
LXDA Arrays and PCs

Single-View machines
Single View machines have a single LXDA array, controlled by a single PC.
Dual View machines

Two independent LXDA arrays with two corresponding PCs, master & slave, each with a
PCI DAS board for collecting imaging data for the given view’s array.
The main functions of the slave PC are displaying and archiving its own images. The
slave handles no other control or interfacing tasks.
The master PC handles all input and output control signals to/from the system, Inputs
from the system include:
• key switch
• photocells
• interlocks
• all diagnostics signals;
• outputs to the PLC:
o heartbeat
o conveyor L/R
o X-ray on command for both generators
o system shutdown signal
Each PC runs Xray Client software. Only the master PC runs AstroDiagnostics since it
interfaces with the DAQ (LabJack or DCI board).
The two PCs are networked on a Gigabit LAN connection via crossover cable for
passing all control and sensor signals from master to the slave PC.
Each PC has a unique static IP address and Windows PC name.
Each PC has a “DAS synch board” to synchronize the digital clock signals to the LXDAs.
This minimizes cross-talk between the two DAS boards. This cross-talk is a source of
image noise, which is especially visible in high-penetration tests.
M-75-13-15, Rev A Page 25 of 260

Dual View machines have added or changed relays:
• Slave PC power relay added (E-M).
• Fan relay added (high-amp E-M).
• X-ray relay added (E-M, DPDP for the two XRG control boards to use the
same x-ray output signal from the PLC).
• E-stop changed (from E-M to SSR).
Diode plot must be running on both the master and slave in order for imaging
adjustments to be made on the slave.
The master PC assigns all inputs to the PLC. The PLC in turn outputs the control signal
to the x-ray relay for turning both generators on.
The slave PC has no direct command of its own x-ray generator and therefore requires
the diode plot on the master to be running in order to give the technician x-ray control.
NOTE: In the 200kV dual-view system, each PC does control its x-ray generator directly
via RS232 serial port communication. However, the master PC diode plot must still be
used for x-ray on commands due to the software handling of the x-ray signal.
Two screens is the standard setup for all DV systems. Early systems had a three-
screen design with two-screens dedicated to the master view and one to the slave, but
that arrangement has been superseded by the two-screen arrangement. Many three-
screen systems still exist in the field. Also, in certain cases (special order), a four-screen
arrangement is used, with two screens per PC.
Screen selection (via Screen 1 / Screen 2 AOCP buttons) is necessary for the six
primary imaging functions:
• Color
• Organic
• Inorganic
• B/W
• B/W Reverse
• Pseudo Color.
This is much like a single-monitor, single-view system where each view has a single-
monitor. As with all systems XIS, Zone Zoom and Contrast adjustments also still require
screen selection.
NOTE: In some older versions of DV software, the Operator must also use a form of
screen selection for HiPen and Edge Trace, by pointing the cursor on a particular PC’s
monitor screen with the touchpad. In these older versions, these functions were mouse
cursor “focus-dependent.” In even earlier versions, the operator also had to point the
mouse cursor for focus-dependent screen selection when using the Save RGB function.
M-75-13-15, Rev A Page 26 of 260

Software
Dual View machines use Synergy or Input Director multi-PC KVM synchronization
software. This third-party software allows seamless sharing of the AOCP keypad and
mouse pad between screens as if they were a single computer, similar in look to a two-
monitor, single-view system in “Horizontal Stretch” or “Horizontal Span” mode.
Following are the Runtime.ini Dual-View Parameters for Dual View systems.
[Display]
DualDisplay=
;Number of monitors per PC:
; Master Slave
;Two-screen DV =0 =0
;Three-screen DV =2 =0
;Four-screen DV =2 =2
[Options]
Two Screen DV=
;Set for given number of screens in the ;system to let the
software know how to ;display the x-ray status bar. If it’s a
two-screen system then the value is =1. ;If it’s other than a
two-screen system then the value is =0.
[Dual View]
Dual View=1
;0=single-view, 1=master, 2=slave.
Remote Machine=192.168.1.251
;static IP address of the other PC in a dual-view system.
DualView Delay=940
;number of video columns to delay the display of lead view
for a given scan direction to synchronize the scrolling of
both images.
DualView Queue Size=1
;N/A.
Remote Server=Slave
;Windows PC name of the other PC set via ;System
Properties > Computer Name tab. ;Only necessary on the
Master PC.
DAS 2.0 Synch Board Configuration in Dual-View XIS

Dual-view XIS machines use an auxiliary board in both PCs called the “DAS Synch
Board.” The DAS Synch Board facilitates the use of a shared clock signal between the
two DAS boards. The purpose is to eliminate cross-talk between the two 800kHz DAS
clock signals which injects noise in the imaging data.
M-75-13-15, Rev A Page 27 of 260

The cross-talk noise shows up as thin periodic vertical lines, especially in very low
signal/high density regions of scanned objects. The problem is mostly apparent with
steel penetration performance testing.
The apparent penetration of steel step wedges may be significantly reduced by the effect
of cross-talk. Normal scanning is not generally affected by DAS clock cross-talk, so if
synch boards fail in the field, it’s not an immediate requirement to repair unless a
performance test is required. The machine will generally continue to run for normal use.
The relatively small DAS Synch Boards are connected locally to their respective DAS
boards by a 20-pin ribbon cable (inside the PC), and remotely to each other by an 8-pin
mini-DIN cable.
The DAS Synch Boards are mounted on a bracket and occupy a space next to the DAS
boards. This is a space that would normally be used for one of the motherboard PCI
card expansion slots. However, the Synch Boards do actually use the PCI slots, and are
connected only indirectly to the PC via their respective DAS boards.
The two Synch Boards act in a master/slave configuration. The slave shares the clock of
the master DAS board. Thus the clocks are not technically “synched.” Instead, both
Synch Boards share the common clock of the master DAS board, with the slave DAS
board’s clock remaining unused. In this sense, either Synch Board may be the master
or slave, unlike the “master PC” and “slave PC” relationship of the Dual View XIS
machine itself.
The configuration of the dual-DIP switch on each Synch Board determines the
master/slave roles as follows:
DIP Switch 1 2
Board Board
Meaning
enabled role
Master synch board setting ON OFF
Slave synch board setting ON ON
Figure 1: Normal DIP Switch Settings
NOTE: Which Synch Board is configured as Master and which is configured as Slave is
not critical, as long as both boards have DIP Switch 1 set ON (board enabled), and one
board or the other, not both, has DIP Switch 2 set ON to designate it as Slave, so that it
follows/uses the other DAS board’s clock.
M-75-13-15, Rev A Page 28 of 260

When connected and configured correctly, and both PCs are booted, the LED indicators
on each of the synch boards are as follows:
LED Green Amber Red

Flashing at same
Master
ON frequency as DAS clock OFF
synch board
(amber LED on DAS)
Flashing at same
Flashing at same frequency as Master’s
Slave synch frequency as DAS DAS clock (amber LED
OFF
board clock (amber on DAS). Will generally
LED on DAS) be out of synch with its
own PC’s DAS clock.
Figure 2: Normal LED Indications: When configured according to Table 1
When connected, but configured incorrectly and both PCs are booted, the LED
indicators on each of the synch boards are as follows:
LED Green Amber Red

Flashing at same
Both synch
ON frequency as DAS clock ON
boards
(amber LED on DAS)
Figure 3: Abnormal LED Indications: Both configured as Master synch board in Table 1
LED Green Amber Red

Flashing at same
Both synch frequency as DAS
OFF ON
boards clock (amber
LED on DAS)
Figure 4: Abnormal LED Indications: Both configured as Slave synch board in Table 1
Dual-View Configuration Points

1. Windows Startup folder contents:
Primary PC Secondary PC
M-75-13-15, Rev A Page 29 of 260

2. Static IP Addresses
Primary PC Secondary PC
3. Shared folder settings required for the secondary PC “Xray Client” folder:
Secondary PC
M-75-13-15, Rev A Page 30 of 260

Dual-View PC Network Troubleshooting
Network
1. Confirm the cable is a proper cross-over cable, is not damaged, and is connected
securely at each end. The LEDs in the Ethernet connector on each PC should also
be flashing when connected.
2. Confirm the Windows firewall is turned off on both PCs via: Start > Control Panel >
Windows Firewall > General > select “Off” > OK.
3. Confirm the network adapter speed is the same on both PCs. This is set via: Start
> Control Panel > System > Hardware > Device Manager > Network Adapters
> right-click on the network card (usually “…Gigabit Network Connection”) > Link
Speed > Speed and Duplex: > 1.0 Gbps Full Duplex > OK.
4. Confirm the actual IP address of each PC is different. These are typically
192.168.1.250 for the Master PC and 192.168.1.251 for the Slave PC, and set via:
Start > Control Panel > Network Connections > right-click on Local Area
Connection > Properties > General > select Internet Protocol (TCP/IP) >
Properties > General > select “Use the following IP address:” > IP Address: >
OK.
5. Confirm the local area network is now connected via: Start > Control Panel >
Network Connections > Name > Local Area Connection & Status > Connected.
Keyboard/Mouse Sharing
1. Confirm the Master PC’s Windows name is “Master” and the Slave PC’s Windows
name is “Slave.” The multi-PC keyboard/mouse sharing applications use the PC
name when setting the master/slave relationship. This is set via: Start > Control
Panel > System > Computer Name > Change > Computer name: > OK.
Imaging Software
1. Confirm that Xray Client’s runtime.ini file for each PC has the correct settings for
critical dual-view parameters under the header [Dual View] near the bottom of the
file.
a. Master PC:
i. Dual View=1 Sets it as the Master PC
ii. Remote Machine=192.168.1.251 Points to the other PC’s IP address
(Slave)
iii. Remote Server=Slave Parameter exists only on the Master
PC
b. Slave PC:
i. Dual View=2 Sets it as the Slave PC
(Master)
M-75-13-15, Rev A Page 31 of 260

iii.
2. Confirm the slave PC’s Xray Client folder is shared with full privileges. This is set
via:
Slave PC > right-click on the folder C:\Program Files\Xray Client > Properties
> Sharing > select “Share this folder” > select “Share this folder on the
network” & select “Allow network users to change my files” > OK.
M-75-13-15, Rev A Page 32 of 260

XIS 320Kv Delivery and Uncrating
Introduction
Figure 5: XIS Model 1517DV 320kV
Figure 6: XIS Model 1517 SV 320kV
M-75-13-15, Rev A Page 33 of 260

Figure 7: XIS Model 1818DV 320kV
Figure 8: XIS Model 1818SV 320kV
M-75-13-15, Rev A Page 34 of 260

XIS Model 1517 XIS Model 1818
Inspection Length: 150 cm Length: 180 cm

Tunnel Size
Width: 170 cm Width: 180 cm
Mechanical Rotating steel rollers Rotating steel rollers

Transport
System With a variable frequency motor With a variable
controller and high torque 0.5 frequency motor
hp motor controller and high
torque 1.0 hp motor
Roller bed Height 16 inches 16 inches
Roller Motor 1.0 hp 1.0 hp
Roller speed 0.20 m/sec 0.20 m/sec
(40 ft/min) (40 ft/min)
Roller bed Load 2,000 kg 2,000 kg

Capacity
Figure 9: Machine Specifications
The XIS Model 1517 & 1818 are large, heavy duty, high capacity, cargo x-ray machines:
• They have very large inspection tunnels that can accommodate the
inspection of large boxes, crates, and palletized material.
• They use high capacity rollers instead of conveyor belts to transport items
through the inspection tunnel.
• The rollers are low to the ground, 30 cm (12 inches), so they are easy to load.
Required Resources
Tools
• Fluke 123 Travel O-Scope
• Fluke Amp Probe 80i-110s
• Radiation meter
• Jensen Tool Kit JTK-17 WW includes more than 100 tolls in all, as follows:
o Alignment tools (2)
o Feeler gauge
M-75-13-15, Rev A Page 35 of 260

o Hammer, ball peen, 4 oz.
o Handle, driver blades (2): 3-1/8, 4-1/8"
o Hex key set (10), .028-5/32"
o Hex key set (7): Fold up 1.5-6mm
o Hexdriver blades (9): .050, 1/16, 5/64, 3/32, 7/64, 1/8, 9/64, 5/32,
3/16"
o Icepick scribe
o Knife, electrician's
o Mirror, inspection
o Nutdriver blades (9): 3/16, 7/32, 1/4, 9/32, 5/16, 1-1/32, 3/8, 7/16, 1/2"
o Penlight w/batteries
o Pliers (6): diagonal cutter, 4-1/4"; diagonal cutter, 5-1/4"; groove joint,
10"; long nose, 4-3/4"; long nose with cutter, 6-3/4"; retaining ring,
external/internal
o Punch, center, 3/32"
o Punch, Pin (2): 1/16, 1/8"
o Rule, stainless, 6"
o Screwdriver, offset ratchet, Phillips/slotted
o Screwdriver, Phillips #0 x 3", pocket clip
o Screwdriver, Phillips (3): #1 x 3"; #2 x 1-1/4"; #2 x 4"
o Screwdriver, slotted 3/32 x 3", pocket clip
o Screwdriver, slotted (6): 1/8 x 4"; 1/8 x 8"; 3/16 x 3"; 1/4 x 1-1/4"; 1/4 x
4"; 5/16 x 6"
o Screwdriver set, jeweler's, (7 pc.)
o Screwstarter, Phillips/slotted
o Socket set, 1/4" drive, (14 pc.)
o Solder aid, fork and hook
o Soldering iron, 115V*
o Spring tool, pull
o Spring tool, push
M-75-13-15, Rev A Page 36 of 260

o Tweezer, reverse action
o Wire crimper/stripper
o Wire stripper/cutter
o Wrench, adjustable (2): 4"; 8"
o Wrench set, ignition, (8 pc.)
o Tool case with pallets
• Soft Rubber Mallet for aligning generator mount
• Small flashlight for checking funnel mount alignment
o Chain Adjustment tool for installing chains
• Leather Gloves for handling wooden crates
o ½” ratchet for fastening bolts
o Medium Phillips Screw Driver
• 2mm bubble level for leveling frame modules
• “Click” Torque Wrench for tightening mounting bolts
• Power screwdriver
• Volt meter
• Ladder
• Adjustable lift table for the top and front panels of the radiation shield box and
generator.
Recommended Personal Protective Equipment

• Fall harness
• Auto retractable fall harness lanyard
• Eye protection
• Suction Panel lifters
Pre-Arrival Work Instructions

1. Get a copy of the sales order for the unit(s) being installed.
a. Get the following customer contact information:
o The shipping address
M-75-13-15, Rev A Page 37 of 260

o The contact’s name
o The contact’s telephone number
o The contact’s email address
b. Check for any special configuration requirements.

c. Check for any special training requirements.
d. Identify the electrical requirements (110VAC or 220VAC operation).
e. Identify the “footprint” size and width of the unit.
f. Prepare your installation toolkit.
2. Get shipping information:
a. Determine the expected delivery date of the unit(s).
b. Follow up with the shipper to confirm the delivery schedule.
3. Call the customer:
a. Check the background of the customer. Ask if he or she has previous
experience with installing and operating other x-ray imaging systems.
o Does the customer have special or unique training needs?
b. Advise the customer of the site requirements:

o Advise the customer on the physical clearance requirements of the
unit(s). Remind them as well that additional space will be needed in
order to assemble the multiple sections of the machine.
XIS 320kV Model Width Height Length
1517 110.33” [2802mm] 90.50” [2299mm] 351.76”

[8935mm]
1517DV 110.33” [2802mm] 119.75 (3042) 420.91 (10691)
1818 122.25” [3105mm] 94.50” [2400mm] 351.76”

[8935mm]
1818DV 122.25” [3105mm] 123.75 (3143) 420.91 (10691)
Figure 10: Dimensions for XIS 320kV Models
c. Get information about the site:

o Verify that the site is fully prepared for the install.
o Verify that the power requirement of the XIS unit matches the
available AC outlet power.
o Verify that the install site is located inside and protected from weather.
M-75-13-15, Rev A Page 38 of 260

o Verify that the ambient temperature of the install site is within the
operating range of the XIS (5oC to 40oC).
o Verify that the install site is level.
o Verify that there is room for the XIS and that there is adequate
clearance for the operator.
o Verify that two (2) 10,000 lb capacity forklift trucks will be available
onsite at the time of installation.
d. Confirm that there is a clear path from the receiving area to the final install
site.
e. Ask the customer to notify you when the unit(s) arrives.
f. Confirm that the appropriate users will be available for training.
g. Schedule the installation.
h. Get information on where to park (if necessary).
i. Advise the customer that you will be bringing in tools and that you may need
an escort to get past their security staff.
j. Advise the customer that after the system has been installed, it will be
necessary to discard crating, wrapping, and other packaging materials.
4. Book your travel arrangements.
a. Advise the customer of your itinerary.
On-Site Work Instructions

The XIS is a large cargo machine that ships in several crated sections or “modules.” This
necessitates a large area for receiving, storing and assembling the sections into the final,
working machine. It is important to convey this to the customer and insure that there is
space not only to locate and operate the machine, but the extra space needed for
service personnel to work freely, and to accommodate the large number of modules and
cabinets while assembling the machine.
1. Locate the customer’s principal site contact person.

a. The customer’s principal site contact that accepts and “signs-off” on the
completed installations. Get to know this person well.
b. Clearly identify yourself. Bring photo ID.
c. Note the names of everyone you meet.
d. Exchange business cards.
Verifying and Examining the Crates

Once all the crated sections of the unit have been moved to the final installation site:
1. Inventory all crates, comparing the actual delivery to the delivery manifest.
M-75-13-15, Rev A Page 39 of 260

Number Of Crates
Line # MODEL # of Crates
1. XIS 1517 9
2. XIS 1517DV 13
3. XIS 1818 9
4. XIS 1818DV 13
Figure 11: Number of Crates
NOTE: Machines can be shipped with optional extension roller beds. Each of these roller
beds (entry or exit) will require its own crate. So, for example, a machine shipping with
two additional exit and two additional extension roller beds will necessitate four
additional crates.
2. The following items/crates should be present for single-view machines:

1818 & 1517
CRATE
ITEM DESCRIPTION = Rcvd.
#
1 Exit Roller Bed
2 Exit Tunnel Module 5
3 Exit Tunnel Module 4
Side-shooter Module
4
3/Cabinet B
5 Entry Tunnel Module 2
6 Entry Tunnel Module 1
7 Entry Roller Bed
8 Cabinets #A & C
9 Cathode
Figure 12: Shipped Items for the 1818 and 1517 Single View
3. The following items/crates should be present for dual view machines (1517 and
1818).
M-75-13-15, Rev A Page 40 of 260

1818DV & 1517DV
CRATE # ITEM DESCRIPTION = Rcvd.
Exit Roller Bed First (right) 3 rollers are not chain

1
driven.
Exit Tunnel
2
Module-6 X-ray curtain faces out.
Exit Tunnel
3
Module-5
Down-shooter X-
4 Ray Generator
Module-4
Side-shooter X-
5 Ray Generator Widest module
Module 3 Has locking cabinet
Entry Tunnel
6
Module-2
Entry Tunnel
7
Module 1 X-ray curtain faces out.
Entry Roller Bed Last (left) 3 rollers are not chain

8
driven.
9 Cabinets A & C
10 Cabinets D & E
Down-shooter X-
11 ray Generator
Cabinet*
12 Cathode
13 Cathode
Figure 13: Shipped Items for the 1818 and 1517 Dual View
* This refers to the cabinet located atop Module 4, housing the actual down-shooter X-
ray generator, funnel, etc.
4. Inspect all crates for damage that might indicate corresponding damage to the
equipment inside the crates.
5. Inspect all “TiltWatch” and “Shockwatch” monitors (see Figure 14).
6. Photo-document all damage to crates.
M-75-13-15, Rev A Page 41 of 260

Figure 14: TiltWatch and Shockwatch Monitors
Uncrating the XIS Machine

If the unit has still to be moved to its final installation/operation site:
1. Find a clear path from receiving site to the final install site.
2. Verify that the XIS unit can safely pass through all doors and elevators along the
way.
3. Determine whether keeping the unit crated or wrapped will facilitate its safe arrival at
the final install site.
4. Verify that the final location has enough space not only for the assembled machine,
but to accommodate all the individual sections before they are assembled.
IMPORTANT:
IMPORTANT:
• Use special care when handling module “M3/CB;” (single view, M4/CC on the
dual view machines). This particular module is extremely large, heavy and
easy to damage.
• Keep the module upright and do not drop it.
• If M3/CB (or M4/CC) is still crated, use two (2) fork-lift trucks simultaneously
to lift this module, especially while removing from the transport truck. Use a
load supervisor to direct the fork-lift truck drivers and synchronize their
actions.
Each section of the XIS will arrive at the installation site in a crate. The top, sides and
floor of the crate are fastened to each other with drywall screws. When uncrating the
machine, it is important to proceed in the following order:
5. Use a ladder to be able to access and remove the screws from the crate’s lid.
6. Carefully remove the lid from the crate and set it aside.
M-75-13-15, Rev A Page 42 of 260

NOTE: Protect the LED lights and Emergency Stop switches from damage when
removing the top and sides of the crate.
7. Remove the drywall screws from each of the crate’s sides, careful not to allow the
sides to fall.
8. Remove the crate’s end panels.
Figure 15: Removing a Side Panel from a Crate
9. Remove and discard all of the crating material.
Figure 16: Forklift Points
M-75-13-15, Rev A Page 43 of 260

Figure 17: Crate Base Strapping
10. Cut the internal restraining straps holding the equipment to the base of the crate.
11. Discard all straps.
12. Check the packing list. Verify that the correct unit has arrived by model and serial
number.
13. Unwrap the system(s):
a. Cut any remaining restraining straps.
b. Cut the plastic wrapping and bubble wrap at the corners of the XIS frame.
NOTE: Carefully cut away the wrapping. Do NOT cut or scratch the sides of the XIS.
c. Pull plastic wrapping and bubble wrap away from the XIS.
d. Discard the plastic wrapping and bubble wrap.
14. Inspect the XIS unit for any damage.
a. Note any damage and record it on the shipping manifest.
b. Photo-document all shipment damage. Include a sign identifying the date
and serial number of the unit(s) in all photographs.
c. Report any and all damage to the shipper and to Astrophysics.
15. Take inventory.
a. Locate the packing list.
b. Check-off items on the packing list.
c. Note any missing or damaged items on the packing list.
d. Locate the key switch key(s) and panel key(s).
NOTE: The key to the key-switch and panel are very important. Keep track of the keys!
16. Unload the components from the crate using a forklift.

NOTE: You must use a forklift to move each machine piece. Each piece must be lifted a
minimum of 17inches above the ground while being moved. A pallet jack will not work.
17. Use the forklift holes on each machine section when moving the sections to their final
installation location.
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Figure 18: Forklift Holes
M-75-13-15, Rev A Page 45 of 260

M-75-13-15, Rev A Page 46 of 260

Installing the XIS 320kV Single View
Because of the size, weight and number of sections for the unassembled XIS 320kV,
great care must be taken not just in moving and uncrating the sections, but in placing
them in the correct position to be fastened together into the final assembled unit. It is
also important to follow the assembly steps in the order in which they are described in
this section.
This section will deal with the installation of the single view XIS 1818 320kV. These
instructions will apply equally well to the XIS 1517 320kV single view. The following
section will deal with the installation differences between the single view and dual view
XIS 320kV machines.
Figure 19 shows a diagram of the fully assembled XLS-1818 320kV machine. The main
differences between the 1517 1818 models are mostly in terms of size, and the
installation instructions in this section are applicable to both models. The configuration in
Figure 19 shows six roller beds (3 entry, 3 exit), five modules, and three cabinets
(Cabinet B is actually part of Module M3 but for the purposes of this manual is
considered as a separate cabinet).
NOTE: ER1, ER2, EX1 and EX2 are optional roller bed extensions. The standard
configuration includes one entry extension roller bed and one exit extension roller bed.
Figure 19: Modules, Cabinets and Roller Beds
M-75-13-15, Rev A Page 47 of 260

ITEM DESCRIPTION
ER Entry Roller Bed. Abuts tunnel and curtains.
ER1 Entry Roller Bed Extension #1*
ER2 Entry Roller Bed Extension #2*
M1 Module #1. Contains Anode and cathode power supply, entry x-ray curtains.
M2 Module #2.
M3 Module #3. Contains X-ray tube, PC, LabJack.
NOTE: Contents are fragile. Handle with care.
M4 Module #4. Connects to M3 and M5.
M5 Module #5. Connects to M4 and XR.
CA Cabinet A. Contains Anode, cathode power supply, internal circuit breaker,

external circuit breaker, and UPS.
CB Cabinet B. Contains the X-ray generator, funnel, PC, PLC, and DCI.
CC Cabinet C. Contains Air conditioner and oil cooler (AKA “Chiller”).
XR Exit Roller Bed. Connects to M5 and XR1.
XR1 Exit Roller Bed Extension. Connects to XR and XR2.*
XR2 Exit Roller Bed Extension. Connects to XR1.*
Figure 20: Descriptions of Modules and Cabinets
* Optional roller bed extensions. The standard configuration includes 1 entry extension
roller bed, and one exit extension roller bed.
Assembly of the XIS 320kV machine involves the following steps:
1. Place the sections of the XIS 1517/1818 adjacent to each other in the correct order
(see Figure 19 above).
2. Bolt the modules together.
3. Install any components removed from the machine during shipping (e.g. Chiller and
Cathode).
4. Reconnect cabling.
5. Replace all panels.
6. Start and test the machine.
7. Perform a radiation survey.
M-75-13-15, Rev A Page 48 of 260

Cabling Between Sections
The components inside the XIS 320kV are connected via cables and wires that are
routed within each module and cabinet and also between the modules and cabinets.
Most of the wiring and cabling should have been labeled at the factory, in order to
facilitate reconnection and routing in the field during installation. Please see XIS 320kV
wiring diagrams for additional information.
information
Figure 21 shows examples of cabling routing from section to section, via pre-cut holes,
over the top of section frames,, behind cabinets, and around the joints between the
sections.
Figure 21: Cabling Between Sections
Except for the roller beds, none of the sections are wheeled, and thus must be moved
into place with a forklift truck.
M-75-13-15, Rev A Page 49 of 260

Figure 22: Moving Module into Place
Panels
Every panel on the XIS 3 320kV
20kV is unique in terms of size, even if only very slightly, fitting
correctly only to its corresponding module or cabinet. For example, the panel for Cabinet
A will correctly fit only Cabinet A. This exclusivity extends to the front and rear panels of
a module.
odule. For example, the panel for the rear of Module 1 will correctly fit only the rear
of Module 1, not the front of Module 1, nor the rear of Module 2.
In addition, Modules 1 and 5 on the XIS 320kV have both front and rear panels.
However, Modules 2, 3, and 4 have only rear panels, because cabinets A, B, and C are
attached to the front of those modules. Those three cabinets will, in turn, have front
panels, but no rear panels. This is illustrated in Figure 23 below.
Figure 23: Modules, Cabinets and Roller Beds
Because of this exclusive relationship between specific panels and modules/cabinets,

the panels are labeled and referred to by their respective module or cabinet. So following
is a table of panel nomenclature:
M-75-13-15, Rev A Page 50 of 260

Section Panel Nomenclature
Module 1 PM1F (front panel)

PM1R (rear panel)
Module 2 PM2R (rear panel)
Module 5 PM5F (front panel)

PM5R (rear panel)
Cabinet A CA (front panel)
Cabinet B CB (front panel)
Cabinet C CC (front panel)
Figure 24: Panel Nomenclature
Once all the sections, beginning with the entry roller section(s) on the right, and ending
with the exit roller section(s) on the left, are in place and positioned snugly against each
other, remove the panels from the modules and cabinets.
Figure 25: Removed Panels
M-75-13-15, Rev A Page 51 of 260

The panels hang from brackets at the top of each modu
module
le and cabinet, as shown in
Figure 26.
Figure 26: Mounting Brackets for Panels
Figure 27 shows a close-up

close of the mounting bracket.
Figure 27: Mounting Bracket for Panels
The panels are also fastened at the bottom of the machine by screws. The panels for
Module 2 (both back and front panels) also include keyed locks (see Figure 28).
M-75-13-15, Rev A Page 52 of 260

Figure 28:: Bottom of Panels with Fastening Screws and Keye
Keyed Lock
Figure 29 shows one of the screw holes for the bottom of the panel, and the latch for the
panel keyed lock.
Figure 29: Screw Hole and Lock Latch
To remove the panels::
1. Unscrew
nscrew (and unlock,
unlock in the case of the panels on Module 2) the panels at the
bottom of the machine, then lift the panels off the mounting brackets at the top of the
machine.
2. To remove top panels, remove mounting screws under the top panels.
Connecting Sections (Modules, Cabinets and Rollers)

Connecting the various sections (modules, cabinets and roller beds) s) includes leveling,
clamping, bolting and cabling.
cabling Cabling is covered under “Cabling Between Sections
Sections”
earlier in this chapter.
Following are the directions for connecting Module 2 (M2) and Module 3 (M3). The same
steps can be used to connect other modules and cabinets.
1. Move Module 3 (M3)

(M and Module 4 (M4)
4) together so that they abut.
M-75-13-15, Rev A Page 53 of 260

Figure 30:
30: Moving Module 2 and Module 3 together
2. Align M3 and M4 both horizontally and vertically by placing a bubble level across
them and adjusting until
unt they are both evenly leveled (use the leveling casters to
adjust their height).
3. Using a C-clamp,
clamp, clamp M3
M and M4 together.
Figure 31: Clamping Modules
4. Using a ratchet, insert and fasten the bolts joining M3 to M4.
M-75-13-15, Rev A Page 54 of 260

Figure 32: Fastening Bolts Connecting Modules
5. Unbolt the chain guard and place to the side so that the roller chains are exposed
(see Figure 33).
CAUTION:: Be very careful when working in this area as there are many places for
fingers to get caught.
Figure 33:: Lower chain guard removed from the frame
6. Use chains to connect the lead rollers on M3 and M. Figure 34 shows an example of
two abutting roller beds that must be connected by both bolts and chains.
CAUTION: Please be careful when working with the chain and rollers as they are a
finger catching point.
M-75-13-15, Rev A Page 55 of 260

Figure 34: Installation of chains
Figure 35 shows the procedure for inserting a connection link, connection brace and
locking link in order to join a chain.
Figure 35: Connecting Chain Links
Figure 36 shows a chain connecting end rollers from two separate roller beds.
M-75-13-15, Rev A Page 56 of 260

Figure 36:: Rollers on Different Roller Beds Connected by Chains
7. Install and connect

nnect the cable
cabless and wires between the modules, using the labels on
the cabling and, if necessary, wiring diagrams for the XIS 320kV.
Connecting Modules
Module and Roller Beds
Connecting Modules and roller beds differs slightly from connecting Modules and
Cabinets. Following are directions for connecting Module 5 (M5) and the Exit Roller bed
(EX). The same procedure can be applied to connecting Module 1 (M1) to the Entry
roller bed (ER).
1. Move EX over to M5
M (EX is wheeled and can be moved by hand), so that they abut
snugly.
2. Align EX and M5 by placing a bubble level across them and adjusting the EX leveling
casters until EX is level with M5, bolt holes perfectly aligned.
3. Fasten the bolts connecting EX to M5 (see Figure 37 and Figure 38).
Figure 37:: Connection between EX (Exit Rollers) and M5 (Exit

(Ex Tunnel)
M-75-13-15, Rev A Page 57 of 260

Figure 38:: Detail view of the connection between EX (Exit Rollers) and M
M5 (Exit Tunnel)
4. Connect the chains between lead rollers on EX and M5 (see Figure 35and Figure
36).
CAUTION:: Be very careful when working in this area as there are many places for
fingers to get caught.
5. Connect cables between EX and M5.

6. Put the Roller covers back on the Tunnel and X
X-Ray
Ray Modules. (x4).
Figure 39:: Replacing Roller Covers on Tunnel and X-Ray

X Ray Modules
7. Place Entry/Exit Roller covers back on. (x4)
M-75-13-15, Rev A Page 58 of 260

Figure
igure 40: Replacing Entry/Exit Roller Covers
Re-installing Chains
If you experience difficulty when installing the chains on the roller sprockets,
sprockets follow the
instructions below to reinstall chains.
1. Remove all sprocket rollers on EET and SS, and then loosen the roller bracket
Figure 41: Roller Brackets
2. Install the edge roller

rolle with the chains for all modules, and then fasten the bracket.
M-75-13-15, Rev A Page 59 of 260

Figure 42: Installation of edge rollers
3. Install
stall other rollers back to the machine.
Check and Fill the Chiller

1. Remove the four screws holding the Chiller housing in place, and carefully lift the
housing free of the Chiller.
Figure 43: Chiller Housing Fastening Screws
M-75-13-15, Rev A Page 60 of 260

Figure 44: Chiller with Housing Removed
2. Remove & replace the oil chiller tank sealed shipping cap with the vented operating
cap.
Figure 45: Shipping Cap for Chiller
Figure 46: Vented Operating Cap for Chiller
M-75-13-15, Rev A Page 61 of 260

3. Fill the Chiller with Shell Diala Electrical Insulating Oil (Shell Stock Number
9160010433099); the Chiller is shipped empty.
NOTE: The end user should have ten gallons of Shell Diala Electrical Insulating Oil on
hand for operation
peration of the Chiller. This oil cannot be shipped by Astrophysics and must be
supplied by the end user.
4. Check the Oil reservoir level by viewing the oil level gauge. The level should be
approximately ¼ of an inch below full, which is equivalent to approximately
approx 7.5
gallons. This will allow room for expansion as the oil heats up during operation.
Figure 47: Oil Level Gauge
5. Check the Chiller temperature gauge (see Figure 48).

). It should have been preset at
the factory to 55 degrees Fahrenheit.
Figure 48:
48 Temperature Gauge, Inflow and Outflow
M-75-13-15, Rev A Page 62 of 260

Reinstalling the Cathode
The Cathode power supply is shipped in a separate crate. To reinstall the Cathode, it is
necessary to use a forklift to remove the Cathode from the crate and t place it back in
Cabinet A.. The Cathode is very heavy and both the crate and the cabinet are small, so
great care must be taken when using a machine as large as a forklift to move the
Cathode.
Figure 49:: Removing the Cathode from the Crate
Figure 50:
50: Approaching the Cabinet with the Cathode
M-75-13-15, Rev A Page 63 of 260

Figure 51:: Inserting the Cathode into the Cabinet, Atop the Anode
Setting up the Supervisor Station
Figure 52: Supervisor Station
The Supervisor Workstation gives Supervisors and Administrators the ability to moni
monitor multiple x-
ray systems. This allows Supervisors to ensure that the screening is done in the most efficient
and effective means possible. Supervisors have access to all systems and can modify the
permission levels of users, add or remove Operators, as well
well as create or change passwords.
The Supervisor can also adjust the percentage and variation of TIP utilized on the System.
Included in the Supervisor Workstation is a Monitor*, Keyboard, Mouse, Work Table, and
Computer.
M-75-13-15, Rev A Page 64 of 260

STEP STEP PROCEDURE Check off
# each step
Setup PC on desk table
1 Place PC minitower on desk.
2 Place monitor on desk.
3 Place keyboard on desk.
4 Place PC mouse on desk.
Connect power cords
5 Connect PC power cord to power strip.
6 Connect Monitor power cord to power strip.
7 Connect power strip to wall outlet.
Connect Video Monitor Cable to PC
8 Connect DVI-HDMI adapter cable to PC
9 Connect Monitor cable (HDMI-HDMI) to DVI-HDMI Adapter

cable.
Connect USB cables to PC
10 Connect USB key board cable to PC.
11 Connect USB PC mouse to PC.
12 Connect USB security key to PC.
13 Turn on power strip
14 Turn on PC
Figure 53: Procedure for Setting Up Remote Table
Check the electrical components

1. Wire the AC power to the main circuit breaker.
2. Check connections:
a. Check all PC cable connections
b. See checklist in Figure 53.
M-75-13-15, Rev A Page 65 of 260

Figure 54: Back of Supervisor Station PC
3. Check DCI board LED

4. Check PLC / heartbeat LED
a. The Power LED is lit
b. The Run LED is lit
c. The PLC is properly connected
d. The PLC properly switches the PC on
e. The PLC properly switches the XRG on
5. Check Oil Chiller
6. Check AC
7. Check UPS
The following steps briefly describe how to operate the SWS (Supervisor Work Station):
1. Turn on the SWS PC.

a. Press the PC Power ON button.
b. Wait for the “Login Screen.”
2. Login
a. (Left) Click your user group (either “OPERATOR” “SUPERVISOR,”
MAINTENANCE” or “ADMINISTRATOR).
b. Click “SUPERVISOR” (on right side).
c. Enter your password (i.e. PIN).
d. The display screen will display a list of x-ray machines and Suspect Stations
that the SWS can monitor. Click on the one you want to connect to.
e. The display on the SWS will now echo what is displayed to connected
system.
M-75-13-15, Rev A Page 66 of 260

3. Select “CONTROL” or “MONITOR”
In “CONTROL” mode, xx-ray images from the remote x-rayray machine appear on the
supervisor screen as soon as the right edge of an incoming bag is fully visible (on the xx-
ray machine’s screen).
M-75-13-15, Rev A Page 67 of 260

In “MONITOR” mode, the entire screen image of the x-ray machine is periodically sent to
the supervisor’s screen (about every 4 seconds).
4. To shut down the SWS session, press ON/OFF button (while it is on) to shut down
the PC.
a. Wait for the display to go blank.
Pedestal Control Panel

Figure 55 shows the Pedestal Control Panel.
Figure 55: Pedestal Control Panel
Figure 56 shows the outlets for external components, located on the entry end of the XIS
320kV. Note the Pedestal Control Panel outlet in the lower right hand corner (labeled
“Pedestal Console”).
Figure 56: Outlets for External Components
M-75-13-15, Rev A Page 68 of 260

1. Connect Pedestal Control Panel (PCP).
Photoelectric Cells (PECs)

Although the PECs are fixed in place, there is the possibility that they may move out of
alignment during shipping. If, upon installing and operating the XIS 320kV, it is
discovered that one or more PECs have been jarred out of alignment (i.e. the transmitter
is not in alignment with the receiver), it will be necessary to realign them.
Figure 57: Photoelectric Cell (PEC)
Although the PECs actually work in the invisible infrared spectrum, a red visible light has
been included, specifically to facilitate alignment. If an adjustment is necessary, make
that adjustment to the transmitter, not the receiver.
If the red PEC beam is misaligned horizontally:
1. Loosen the two smaller screws holding the transmitter to the bracket (NOT the larger
screws that hold the bracket to the machine frame).
2. Rotate the PEC until the visible red light is striking the center of the receiver.
3. Tighten the screws.
If the transmitter is off vertically, bend the bracket slightly to alter the direction of the
beam until it strikes the center of the receiver. See Figure 58 for a graphic portrayal of
PEC realignment.
M-75-13-15, Rev A Page 69 of 260

Figure 58: Adjusting the PEC
Photoelectric Cell Gain Adjustment

It can sometimes also be necessary or valuable to use gain adjustment to aid in PEC
alignment. It is also sometimes necessary when transparent trays are used to hold items
that are scanned by the XIS. The PECs are to some degree incompatible with these
transparent trays because these trays do not always provide adequate blockage of the
PECs. Blockage is necessary for the PECs to sense that an object is at a specific
location on the machine.
Figure 59 shows the procedure for adjusting gain on PECs.
M-75-13-15, Rev A Page 70 of 260

Figure 59: PEC Sensor Alignment
Sensor Alignment
1. Ensure that the sensitivity knob is set at its maximum (factory default) setting.
2. Pan the sensor left, right, up, and down to center the beam on the sensed object (for
diffuse), reflector (f
(for retro-reflective)) or transmitter (for transmitted beam). Affix the
sensor position when the green LED is ON (not flashing) and the yellow output LED
is ON (light sensed and L.O. output energized). This set up assures a good margin
and that the signal received
received is greater than twice the signal required to energize the
L.O. output.
3. For diffuse and retro
retro-reflective applications:
a. For diffuse applications, remove the object being sensed and observe the
green LED. If the green LED is flashing (at 6 Hz), it indicates
indi that the sensor
is receiving more than half the signal required to energize the L.O. output
when there should be minimal or no received signal. It indicates that the
sensor is getting close to detection of the background. Stability may be
optimized b byy reducing the reflectivity of the background or reducing the
sensitivity. Reducing the sensitivity shortens the sensing range. If sensitivity
is reduced, check that both the green and yellow LEDs are on when the
object is detected (step 2 above). In applications
applications where full range is needed,
i.e., sensitivity cannot be reduced; the green LED may be left flashing.
b. For retro-reflective
reflective and transmitted beam applications, place the object to be
sensed in the beam path and observe the green LED. If the green LED is
flashing (at 6 Hz), it indicates that sensor is receiving more than half the
M-75-13-15, Rev A Page 71 of 260

signal required to energize the L.O. output when there should be minimal or
no received signal. It indicates that the object being detected is letting some
light go through (semi-transparent or too small in size). Adjust sensitivity and
repeat step 2.
The receiver can be set to respond as if it is blocked at a given threshold light level via a
small pot screw for use with semi-transparent and small objects. Put the empty tray in
the beam with the pot at max sensitivity (turn fully CW), then slowly reduce the sensitivity
(turning CCW) until the yellow LED showing the blocked/unblocked state goes out. Also
make sure the green LED is not flashing (6 Hz), which means it is borderline receiving.
Carefully go until just getting the yellow LED off and the green LED solid on, and then
test the machine in normal operation to make sure it’s consistent with triggering x-ray on
normally (not over adjusted or under-adjusted).
M-75-13-15, Rev A Page 72 of 260

Installing the XIS 320kV Dual View
This section will deal only with the installation of the 1517DV and 1818DV dual view
machines, and only with the installation procedures that differ or are in addition to the
procedures and steps described in the previous chapter, Installing the XIS 320kV Single
View on page 47.
Figure 60 shows the layout of the modules, cabinets and rollers of a typical XIS 1818DV
dual view machine. The 1517 model is similar to the 1818 except for size differences,
and these procedures are applicable to the 1517 dual view model.
Note that optional extension rollers are available for use with these units.
Figure 60: Dual View Modules and Cabinets
Figure 61 shows the pre-assembled components of an XIS 1818DV dual view.
M-75-13-15, Rev A Page 73 of 260

Figure 61: Disassembled XIS 1818DV
Figure 62 shows the assembled XIS 1818DV dual view machine, including the down-
shooter x-ray generator cabinet located atop the down-shooter module.
Figure 62: Assembled XIS 1818DV
The modules, cabinets and roller beds on the dual view XIS 320kV models connect as
described in the previous chapter, use the same type of bolts, procedures and cabling
M-75-13-15, Rev A Page 74 of 260

procedures. One of the main differences between the single view and dual view models
is the existence of the second, down-shooter generator.
Mounting the Down-Shooter Generator
WARNING!
The generator is heavy and thus dangerous to handle. This is compounded by being located
atop the large XIS 320kV machine. Please exercise the utmost caution and safety. Use a fall
harness when atop the machine. Use a forklift to move the generator. Take all necessary and
advisable precautions.
1. Raise the funnel onto the M2 frame. Please use forklift to raise it and have 2 or more
people available to place it in the correct location
2. Install the funnel and M2 together.
NOTE: If a separate piece of lead is available, please place the lead on top of the flange
of the funnel, and then bolt them together.
3. Fasten the funnel assembly mounting bolts. Figure 63 shows the funnel assembly
and mounting bolts.
Figure 63: Down-Shooter Funnel and Mounting Bolts
Figure 64 shows the funnel assembly and the location for the extra piece of lead (if
provided).
M-75-13-15, Rev A Page 75 of 260

Figure 64: Funnel on M4 (Down-shooter) frame
4. Install the generator (along with generator bracket, cowling and inner funnel) by
lifting and mounting it onto the top of M4. Please use forklift or other appropriate
machine to lift the Generator (or use crane to lift it with belt/chain through the cutout
of the generator bracket). Then, move it from the forklift to the correct location.
Figure 65 shows the Down-Shooter generator, still partially wrapped and sitting on its
pallet prior to being lifted into place.
Figure 65: Generator Partially Wrapped
Figure 66 shows the Down-Shooter generator having been lifted into place atop M4.
Note the cutouts used to accommodate the forks of a forklift.
M-75-13-15, Rev A Page 76 of 260

Figure 66:: Down-Shooter
Down Shooter Generator with Cutouts for Lifting
5. Remove the generator cowling in order to expose the generator.
Figure 67:
67 Down-Shooter
Shooter Generator Without Cowling
6. Fasten the generator bracket

bracke to the frame with 4 screws. If a reference line is given,
please place the generator along the reference line (Figure 14).
M-75-13-15, Rev A Page 77 of 260

Figure 68: Generator reference line location (generator is hidden)
7. If necessary, adjust the generator, carefully using a crowbar to move it into place.
Figure 69: Adjusting the Down-shooter generator position with a crowbar
8. Attach the hoses from the oil Chiller, and the high voltage cables as shown in Figure
70.
M-75-13-15, Rev A Page 78 of 260

Figure 70:: Chiller Oil and HV Cable Attachment Points
Figure 71:: Chiller Oil Hoses Attached to Down-Shooter

Shooter Generator Bracket
M-75-13-15, Rev A Page 79 of 260

Figure 72: High Voltage Cables Attached to Down-Shooter Generator
Figure 73 shows the generator in place atop M4, with oil hoses and high voltage cables
attached.
Figure 73: Down-Shooter Generator with Hoses and HV Cables Attached
9. Reattach the generator cowling.
M-75-13-15, Rev A Page 80 of 260

Figure 74: Down-Shooter Generator and Funnel
10. Install the funnel cover by sliding it between the generator and the funnel. Fasten it
with 2 nuts.
Figure 75: Down-shooter with installed funnel cover
11. Start the machine and use the diode plot to ensure the Down-shooter generator is at
the proper location.
12. If the diode plot is not giving the results expected, please adjust the Down-shooter
location with a crowbar (see Figure 69). The generator can be adjusted in a different
direction, along the slot on translation and small degrees on rotation.
NOTE: Clear the tunnel when testing the machine.
13. Once the machine is working properly, install the panels of the Down-Shooter
Cabinet to complete the installation:
a. Install 5 walls/panels back to form the Down-shooter cabinet.
b. Install panels around the Down-shooter.
M-75-13-15, Rev A Page 81 of 260

Down with 4 cabinet panels installed
Figure 77: Down-Shooter Front Panel
M-75-13-15, Rev A Page 82 of 260

Figure 78: Down-Shooter Back and side panels
c. Install the 2 top panels for the Down-shooter.

Down
Figure 79: Top panels Installed
Remove and Replace LXDA Boards from Down--Shooter

The procedure for replacing LXDA Boards for the dual view machines is the same as
described for the single view machines on page 191. The Side-Shooter
Shooter on the dual view
is the same as the main LXDA assembly on the single-view
single view machine. The difference
between the two units lies in the Down
Down-Shooter,
Shooter, the LXDA assembly being along the
side and bottom of the machine.
Figure 80 shows the side LXDA boxes for the Side

Side-Shooter
Shooter and Down-Shooter
Down x-ray
generators.
M-75-13-15, Rev A Page 83 of 260

Figure 80: Side-Shooter and Down-Shooter Side LXDA Boxes
Figure 81: Side-Shooter Top LXDA Box
M-75-13-15, Rev A Page 84 of 260

Figure 82:: Side LXDA Boxes for Down-Shooter
Down and Side--Shooter
The bottom LXDA Box for the Down-Shooter

Down Shooter Generator is located on the bottom of the
machine, beneath
eneath the roller bed in M4. Figure 83 shows the position in the tunnel
beneath which the bottom LXDA box is situated.
Figure 83: Location of Down-Shooter

Down Shooter Bottom LXDA Box (beneath roller bed)
Figure 84 shows the relationship between the bottom LXDA box, and the side LXDA box.
M-75-13-15, Rev A Page 85 of 260

Down Shooter Side and Bottom LXDA Boxes
Accessing the Bottom LXDA Box

To access the bottom LXDA box, it is necessary to remove the rollers sitting above the
box. To do so, follow these steps:
WARNING!
Before beginning any examination, repair or replacement of an LXDA board, make
m sure the
machine is turned OFF. DO NOT turn on any X-rays
X rays when a person is working inside the
machine.
1. Flip up the outside curtains (to sit on top of the frame) and tie the inside curtains
together to create air flow thru the inside of the machine.
M-75-13-15, Rev A Page 86 of 260

Figure 85: Flipping Curtains Up
Figure 86:
86 Tying Curtains
ns to Allow Air Flow In Tunnel
2. Remove the internal lower panel of the down shooter module. Make sure the
removed panel is on the chain side.
Figure 87:: Removing Roller Covers on Chain Side of Tunnel
M-75-13-15, Rev A Page 87 of 260

Figure 88: Lower Roller Covers Removed
3. Remove the chains of the 4 rollers that are directly atop the LXDA box. It is possible
to access the box by removing only two of the rollers, but the option of removing all
four eases access to the box.
Figure 89:: Removing Four Rollers Atop Bottom LXDA Box
Figure 35 shows the procedure for removing a connection link, connection brace and
locking link in order to undo and then remove a chain from the sprocket of a roller.
M-75-13-15, Rev A Page 88 of 260

Figure 90: Removing Chain Links
4. On the non-chain
chain side of the rollers, undo the two screws on the brackets that hold
the rollers in position. Remove the brackets, then lift the non-chain
chain end of the roller
and slip the chain end of the roller out.
out
Figure 91: Removing Brackets and Rollers
M-75-13-15, Rev A Page 89 of 260

Figure 92: Brackets Holding Rollers in Position
5. Remove all four rollers atop the Down-Shooter bottom LXDA box.
6. Remove the black tape from the center of the LXDA.
7. Remove the covers of LXDA box, exposing the damaged LXDA board.
Figure 93: Rollers Removed, Exposing LXDA Box
Figure 94 shows the LXDA board locations with respect with the covers.
M-75-13-15, Rev A Page 90 of 260

Figure 94: LXDA Locations with Respect to the LXDA Box Cover and Rollers
8. Following the procedure described in LXDA Replacement Instructions on page 191,

replace the LXDA and temporarily replace the covers.
9. Perform the appropriate collimation if needed.
WARNING!
This collimation process must be done by trained technicians. Make sure to follow appropriate
safety process while performing the collimation.
10. Once the machine is ready, replace black tape onto the LXDA box.
11. Replace the rollers by reversing the aforementioned directions.
Dual-View PC Network Troubleshooting

Network:
1. Confirm the cable is a proper cross-over cable, is not damaged, and is connected
securely at each end. The LEDs in the Ethernet connector on each PC should also
be flashing when connected.
2. Confirm the Windows firewall is turned off on both PCs via: Start > Control Panel >
Windows Firewall > General > select “Off” > OK.
3. Confirm the network adapter speed is the same on both PCs. This is set via: Start
> Control Panel > System > Hardware > Device Manager > Network Adapters
> right-click on the network card (usually “…Gigabit Network Connection”) > Link
Speed > Speed and Duplex: > 1.0 Gbps Full Duplex > OK.
4. Confirm the actual IP address of each PC is different. These are typically
192.168.1.250 for the Master PC and 192.168.1.251 for the Slave PC, and set via:
Start > Control Panel > Network Connections > right-click on Local Area
Connection > Properties > General > select Internet Protocol (TCP/IP) >
Properties > General > select “Use the following IP address:” > IP Address: >
OK.
5. Confirm the local area network is now connected via: Start > Control Panel >
Network Connections > Name > Local Area Connection & Status > Connected.
M-75-13-15, Rev A Page 91 of 260

Keyboard/Mouse Sharing:
1. Confirm the Master PC’s Windows name is “Master” and the Slave PC’s Windows
name is “Slave.” The multi-PC keyboard/mouse sharing applications use the PC
name when setting the master/slave relationship. This is set via: Start > Control
Panel > System > Computer Name > Change > Computer name: > OK.
Imaging Software:
1. Confirm that Xray Client’s runtime.ini file for each PC has the correct settings for
critical dual-view parameters under the header [Dual View] near the bottom of the
file.
a. Master PC:
i. Dual View=1 Sets it as the Master PC
(Slave)
iii. Remote Server=Slave Parameter exists only on the Master
PC
b. Slave PC:
i. Dual View=2 Sets it as the Slave PC
(Master)
2. Confirm the slave PC’s Xray Client folder is shared with full privileges. This is set
via:
Slave PC > right-click on the folder C:\Program Files\Xray Client > Properties
> Sharing > select “Share this folder” > select “Share this folder on the
network” & select “Allow network users to change my files” > OK.
Additional Chillers and Power Supplies

In addition to the second generator, the XIS 320kV dual view features dual chillers,
cathodes, and LXDA boxes. Use the procedures described in the previous section for
installing and servicing the chillers, cathodes and LXDA boards.
M-75-13-15, Rev A Page 92 of 260

Operation
This chapter describes the operation of the XIS-1517DV-320KV (Single View), XIS-1517
DV-320KV (Dual View), XIS-1818 320KV (Single View), and XIS-1818 DV-320KV (Dual
View) x-ray machines. In this chapter the XIS-1517 320KV and XIS-1517DV 320KV x-
ray machines are referred to as the “1517s”. The XIS-1818 320KV and the XIS-1818
DV-320KV are referred to as the “1818s”. All of these systems are collectively referred to
as the “XIS320KV” systems. This chapter is intended for all operators of these systems.
Introduction
The XIS320KV systems are large capacity, high performance “cargo” x-ray imaging
system. The “1517s” and “1818s” are capable of imaging items weighing up to 1,000 and
2,000 kg, respectively. All of these models use “320KV” x-ray generators that are
capable of imaging items through as much as 80 mm of steel. The Single view systems,
the XIS-1517 320KV and the XIS-1818 320KV produce a single side (shooter) view of
the item being inspected. The “Dual View” systems, the XIS-1517DV 320KV and the
XIS-1818DV 320KV systems, produce x-ray images with two different perspectives, or
“views”: a side-ward projection and a down-ward imaging projection. The two separate
perspectives complement each other by providing more visual information on items
being inspected. Potential threats that may be obscured by “clutter” in one view are often
readily apparent in the other view. The two views also collectively provide more “spatial”
information for locating hidden objects.
The XIS320KV systems use high capacity rollers to carry items through the inspection
tunnel. There all have at least three sets of rollers: (1) an entry roller set, (2) a tunnel
roller set, and (3) an exit rollers set. The entry roller set is located on the right end of the
machine and extends to the tunnel entrance. The tunnel rollers are located inside the
inspection tunnel. The exit rollers set extends outward from the tunnel exit. Additional
“queuing” rollers can be attached to entry and exit roller sets. Each roller set has its own
motor and operates independent of the other sets. This allows x-ray imaging of items on
the tunnel rollers while the entry roller and exit rollers remain stationary for loading and
unloading of cargo pallets. This allows efficient queuing of items for inspection.
The XIS-DV-320 has four phases of operation:
1. System Startup
2. Login
3. X-ray Imaging
4. System Shutdown
The operation of the XIS320KV systems is very similar to that of a regular X-ray Imaging
Systems (“XIS”). The System Startup, Login procedures, and imaging control buttons
are essentially the same as in a regular XIS system. The actual process of x-ray
imaging is different because the XIS-DV-320 uses rollers to carry items through the
inspection and has two views with two larger, more powerful x-ray generators.
M-75-13-15, Rev A Page 93 of 260

Procedures for Each Operation
System Startup
1. Insert the key into the AOCP key-switch
key
NOTE: Ensure that the main AC circuit breaker is set to the ON position.
Figure 95: Main AC Circuit Breaker
2. Turn the “AUTO MAN” key-switch

key to “AUTO.”
Figure 96: "Auto Man" Key-switch
3. “Clear” all Emergency Stop Switches by turning the E-stops

stops counterclockwise, which
releases them.
M-75-13-15, Rev A Page 94 of 260

Figure 97: Emergency Stop
LOGGING INTO THE XIS

Figure 98 shows the Advanced Operator Control Panel (AOCP).
Figure 98:
98: Advanced Operator Control Panel (AOCP)
M-75-13-15, Rev A Page 95 of 260

In order to log in, follow these steps:
1. Switch the keyswitch to the “ON” position. After a brief warm-up, the following
message will appear. Click “Continue.”
Figure 99: “Calibration Required” screen
2. When the following message appears, click “OK.”
Figure 100: “Warning X-rays” screen
M-75-13-15, Rev A Page 96 of 260

Once the XIS completes calibration, including turning the X-rays and conveyors on and
off, the Log In screen is now available.
3. Click on [Screener].
4. Click on [Scan Mode].
Figure 101: Log In Screen Enabled
5. Click on the drop-down list button, and select your username.

6. Type in your password, using the control panel keyboard or clicking on the screen
keypad.
Figure 102: Entering User Information
After a brief pause, the “System Ready” screen will appear. You are now logged in.
M-75-13-15, Rev A Page 97 of 260

Figure 103: “System Ready” screen
The System Ready screen consists of the elements shown in Figure 104.
Figure 104: System Ready screen elements
M-75-13-15, Rev A Page 98 of 260

X-Ray Imaging Procedure
1. Turn the Pedestal Key-Switch to “AUTO”
2. Load cargo pallet on to the entry rollers.
WARNING!
• If the rollers are moving, press [STOP]. Wait for the rollers to stop before
loading items onto it.
• Do not load items onto moving rollers.
• Do not overload the rollers. Observe the maximum weight limits:
o XIS-1517 & XIS-1517DV 1,000 kg maximum weight limit
o XIS-1818 & XIS-1818DV 2,000 kg maximum weight limit
• Inspect the pallet. Items loaded directly on the rollers must be at least 0.8 m
long. Shorter items may fall between the rollers.
3. Press the [LEFT] button on the AOCP.
Figure 105: AOCP Console, Pressing [LEFT]
M-75-13-15, Rev A Page 99 of 260

NOTE: Pressing [LEFT] starts the Entry roller conveyor (moving from the right to left
direction).
• The rollers roll only in the forward direction (while under program control).
• The rollers operate at only two speeds: 0 (stopped) or 0.2 m/sec.
• A pallet entering the tunnel starts the “SCAN CYCLE”.
• The scan cycle directs pallets through the inspection tunnel where they are x-
ray imaged.
• The Scan Cycle should not be interrupted.
• The scan cycle:
o Starts a “continuous” alarm for 8 seconds to warn anyone who is

standing on the rollers to get off.
o Turns on a yellow warning light (on the “stack” light pole) that warns
nearby persons that the x-ray generator is about to be turned on.
o Turns on a safety light inside the inspection tunnel so that anyone

inside the tunnel can safely evacuate. (the light actually turns ON
when switched to MAN on the PCP, and goes OFF when in AUTO on
the PCP)
o After 8 seconds the rollers start.
o The inside safety light is turned off.
o The x-ray generator is turned on and allowed to “ramp-up”.
o The red light on the stack light pole is turned on to warn nearby
persons that the x-ray generator is now turned on (and emitting x-
rays).
o A chirping alarm is activated to warn nearby persons that the x-ray

generator is on and emitting x-rays.
o The rollers motor turns on to move the next pallet through the
inspection tunnel.
o The red x-ray on light and the chirping alarm continues until the x-ray
generator is turned OFF.
o The roller motor (and rollers) stops after the pallet has exited the
tunnel.
o The lights inside the tunnels illuminate the “Emergency Stop Strip”
(ESS) switches.
o The exterior yellow “light pole” warns users to stay clear of the x-ray
machine and rollers.
M-75-13-15, Rev A Page 100 of 260

• After ten seconds the rollers start.
o Both the entry rollers and tunnel rollers are activated.
o The cargo pallet is then carried in to the inspection tunnel.
o The lights inside the tunnel are turned off.
o The x-ray generator is turned on and x-ray images are produced

automatically.
o During the Scan Cycle, the [RIGHT] button is inoperative. (NOTE: For
Dual View machines, the [RIGHT] button is used only for Archive and
Review, not at all during imaging, since the Dual View machines are
unidirectional.)
o Once the pallet has entered the tunnel, pressing the [STOP] button
does not stop the Scan Cycle until the pallet has been fully imaged.
o The x-ray image can be examined by pressing any of the x-ray image
adjustment buttons.
o All x-ray images are automatically archived, (if this feature is enabled
on the Management Mode screen).
• The next cargo pallet for inspection can be queued up by placing it on the idle
(stopped) entry roller.
• When imaging process has been completed the XIS will automatically move
the first pallet to the exit end of the XIS.
• In an emergency, the x-ray generator and rollers can be stopped by pressing

any of the emergency stop buttons on the machine, or on the AOCP.
4. Remove the cargo pallet from the exit end of the XIS
5. If another cargo pallet has not already been queued; place it on the entry rollers now.
• If there are no other cargo items to be “scanned”, press [STOP].
6. Repeat Steps #3 through #5.
M-75-13-15, Rev A Page 101 of 260

The Pedestal Control Panel
The Pedestal Control Panel (PCP)

( ) is an auxiliary console that bypasses the
t main AOCP
(Advance Operator Control Panel) console. The PCP allows the user to directly turn on
and off the rollers and x-ray
x generator.
• The primary purpose of the PCP is to clear items that are stuck or jammed in
the inspection tunnel.
• The PCP can also

also be used by maintenance personnel to check for system
faults and verify the operation of the x-ray
x generator.
The PCP operates as a separate standalone control. The XIS operates either under
control of the AOCP or the PCP, but not both together. The PCP is enabled by turning
the PCP’s’s “AUTO MAN” key
key-switch
switch clockwise to the “MAN” (Manual) position.
• When the PCP is enabled, the AOCP is disabled and vice-versa.

vice
• When the AOCP is disabled, all button presses on the AOCP are ignored.
• If the XIS-DV
DV-320 is imaging when the AUTO-MAN
MAN switch is turned, the XIS-
DV-320 continues to complete its current imaging cycle before surrendering
control to the PCP.
The AOCP can be re-selected

selected and re-enabled
re enabled by turning the “AUTO-MAN”
“AUTO key-switch
counter-clockwise
clockwise to the “AUTO” position.
• When the AOCP is enabled, the PCP is disabled.
• When the PCP is disabled, all button presses on the PCP are ignored.
Stopping The Rollers And X

X-Ray Generator
Pressing the [STOP] button will stop the xx-ray generator and rollers
s, but NOT
immediately.
M-75-13-15, Rev A Page 102 of 260

• If XIS-DV-320 is imaging, the XIS-DV-320 will first complete its current
imaging cycle.
• When the current pallet in the tunnel has finished imaging, the XIS-DV-320
will move the pallet to end of the exit rollers and then stop the rollers.
• The XIS-DV-320 may delay as much as 60 seconds before finally stopping

the rollers and x-ray generators.
WARNING!
If you need to IMMEDIATELY stop the rollers:
• Press the [EMERGENCY STOP] button. OR:
• Turn the pedestal key-switch to MAN (Manual Mode), THEN:
• Resolve the emergency situation.
• Do not load items onto moving rollers.
Manually Controlling the Rollers

If you need to manually operate the rollers to clear the tunnel, switch to the manual
control of the rollers as described in the section below.
The [EMERGENCY STOP] button is reset by turning the switch counter clock-wise 90
degrees. After the emergency stop (and after the emergency itself has been resolved),
wait at least 60 seconds before resetting the emergency stop button. This allows the
motor controller sufficient time to properly re-start.
The rollers and x-ray generator normally operate under program control. However,
sometimes it is necessary to manually control both. For example, clearing a jammed
heavy pallet inside the inspection tunnel typically requires manual control of the rollers.
Checking the x-ray generator during maintenance often requires manual operation of the
x-ray generator. In these cases, it is necessary to switch to PCP operation.
To switch from AOCP to PCP operation, follow the steps below:
1. Turn the PCP “AUTO MAN” key-switch to “MAN”

• If XIS-DV-320 is imaging, the XIS-DV-320 will first complete its current
imaging cycle.
• When the current pallet in the tunnel has finished imaging, the XIS-DV-320
will move the pallet to end of the exit rollers and then stop the rollers.
M-75-13-15, Rev A Page 103 of 260

• The XIS-DVDV-320
320 may delay as much as 60 seconds before finally stopping
the rollers and x-ray
x generators.
2. Press the [FORWARD] or [REVERSE] buttons to run the rollers.

• The [FORWARD] and [REVERSE] buttons are toggle switches. Pressing
them once starts the roller moving. Pressing the button again stops the rollers.
• Pressing the [FORWARD] button will move items left (i.e. going from right to
left) to the exit rollers.
• Pressingng the [REVERSE] button will move items right (i.e. going from left to
right) to the entry rollers.
• Ensure that items do not abruptly fall off the end of the rollers.
3. Turn the PCP “AUTO MAN” key-switch to AUTO. This will return the AOCP to normal
AOCP based
ased operation.
M-75-13-15, Rev A Page 104 of 260

Pedestal Control Console – Operational Description
# LABEL Description COMMENTS
Red Emergency Stop Red light ON: Emergency stop has been activated.
Emergency
1. switch status light
Stop
Red light OFF : Conditions are normal
Green Automatic Green light ON: The XIS has a “heartbeat” and is ready
Start status light to test.
AUTO
2.
START
Green light OFF: AOCP console is disabled. Manual
control console is enabled.
Yellow Fault light Yellow light ON: a system fault has been detected.
Check diagnostic screen.
3. FAULT
Yellow light OFF: Conditions are normal.
Roller Forward This button is a momentary contact control switch.

4. FORWARD (LEFT) light. This is a
toggle button. Press once to start rollers in forward direction.
Automatic / Manual Key-switch turned to AUTO position: the AOCP is

mode select key- enabled. This is turned ON before start-up.
5. AUTO MAN switch
Key-switched turned to MAN position: Pedestal Control
Panel (PCP) is enabled.
Automatic select This is a “toggle control switch”.

button
Press once to enable AOCP and disable PCP.
6. AUTO
Press again to override AOCP console and enable
manual control. This continues to work after you press
LEFT, RIGHT direction on the AOCP and the Cycle
Timer is still ON.
Roller Reverse This is a “toggle control switch”.

7. REVERSE (RIGHT) button. This
is a toggle button. Press once to start rollers in reverse direction.
Warning light test This is a momentary contact control switch.

WARNING button
8. TEST Press to test warning lights.
SIGNAL
Warning lights stay lit while button is pressed.
This tests the stack This button is a momentary contact control switch.
light.
TEST X-
9. Press to test the stack light.
RAY
The stack light stays on while button is pressed.
M-75-13-15, Rev A Page 105 of 260

WARNING!
Check the inspection tunnel before operating the rollers or x-ray generator. Ensure that
the tunnel is clear of personnel before pressing x-ray test button.
Check the roller bed and inspection tunnel before manually starting the rollers. Ensure
that no one is sitting, standing, or riding on the rollers before pressing the [FORWARD]
or [REVERSE] button.
Following is a flowchart for system startup.
NOTE: The XIS needs to be in “AUTO” mode before start-up on the PCP.
M-75-13-15, Rev A Page 106 of 260

START
Turn MAIN WALL

Circuit Breaker to
Login
ON
Wait for “System

Ready” Screen to
Turn XIS MAIN Appear
Circuit Breaker to
ON
END
Turn XIS SUB-

MAIN Breaker to
ON
Turn AOCP Key-

switch to ON
Turn PCP switch

to AUTO
Warm up the
generator
according to the
on-screen dialogs
Wait for “Please

Login” Screen to
Appear
Figure 108: System Startup Flowchart
Following is a flowchart for X-ray imaging.
M-75-13-15, Rev A Page 107 of 260

Figure 109: X-ray Imaging Flowchart
Following is a flowchart for system shutdown.
M-75-13-15, Rev A Page 108 of 260

Figure 110: End of Day Key-switch Shutdown Flowchart
M-75-13-15, Rev A Page 109 of 260

Figure 111: Complete System Shutdown (for Maintenance)
M-75-13-15, Rev A Page 110 of 260

Figure 112: Emergency Situation Flowchart
Following is a quick reference guide for system operation.
M-75-13-15, Rev A Page 111 of 260

When Do’s and Don’ts
When starting the Ensure that the main wall AC breaker is turned to ON.
system
Ensure that the XIS main circuit breaker is turned to ON.
Ensure that the XIS sub-main circuit breaker is turned to ON.
Ensure that all [EMERGENCY STOP] buttons are reset and

cleared.
Ensure that the “AUTO-MAN” key-switch (on the PCP) is

turned to “AUTO."
Starting the XIS Turn the AOCP key-switch to ON.
Wait for the “Please Login” screen.
Click on [Screener]
Click on [Scan Mode]
Click on the Username drop down list button and select your
username.
Enter your password using the AOCP or screen keypad.
Wait for the “System Ready” Screen.
When loading items Do not load items onto moving rollers.

onto the rollers
Press the [STOP] button on the AOCP.
If the XIS is imaging, wait for imaging cycle to finish (1 min

max)
Place small items on pallets. Otherwise, they may fall between

the rollers.
Figure 113: Quick Reference Guide for System Operation
M-75-13-15, Rev A Page 112 of 260

To Start Imaging Load pallet on entry rollers.
Ensure that no one is inside the inspection tunnel or standing

on the rollers.
Ensure that the PCP AUTO-MAN key-switch is turned to AUTO
Start the rollers:
Press [LEFT] OR [RIGHT] on the AOCP – the XIS 320kV is

bidirectional, allowing loading at either end, and movement in either
direction.
OR
Press [AUTO-START] on the PCP
Wait for x-ray image to appear on the screen.
Examine the image Refer to XIS User’s Guide for information on using the DV
imaging adjustment controls.
During routine use Do not use the [EMERGENCY STOP] button to casually stop
the XIS.
Ensure that items exiting the tunnel do not drop on the floor at
the end of the exit rollers.
The [RIGHT] button is NON-FUNCTIONAL.
The [STOP] button does not immediately stop the rollers if the
XIS is still in a “Scan Cycle”. The rollers will keep moving until
the current x-ray imaging “Scan Cycle” is complete (i.e. when
the current pallet is fully imaged).
Pallets on the exit rollers must be removed before new pallets

will be moved onto it. The XIS will stop imaging new pallets if
the previous pallets are not cleared from the exit rollers.
M-75-13-15, Rev A Page 113 of 260

To Logout Wait for the XIS to complete imaging of the current pallet.
Press [LOG OUT]
Do not leave the XIS powered on, logged in and unattended.
To Logout and to stop Wait for the XIS to complete imaging of the current pallet.
at the end of the day.
Ensure that the PCP key-switch is turned to AUTO.
Press the AOCP’s [LOG OUT] button.
Turn the AOCP key-switch to OFF.
M-75-13-15, Rev A Page 114 of 260

Main Component Systems
X-Ray
Ray Generator System
X-Ray Tube
The generator is designed to power a unipolar sealed X-ray
X ray tube up to 320kV at 3.2 kW -
4.5 kW, depending on model, with controlled dual filament supplies isolated to the EHT
potential.
The generator consists of two major elements, the Extra High Tension
ension tank and the
converter chassis.
The EHT Tank contains all the high voltage circuitry required
required to produce EHT output
together with dual filament isolation transformers. The high voltage isolation is obtained
by means of resin encapsulation and transformer oil immersion. (see( Figure 114).
The converter chassis unit fits directly onto the EHT Anode tank. It contains all the
electronic circuitry to produce the controlled 32
320kV at 3.2 kW - 4.5 kW drive for the EHT
supply together with the drives for dual filame
filament
nt transformers. The converter chassis is
secured to the top of the Anode tank.
Figure 114: Power Supply and Earthing
M-75-13-15, Rev A Page 115 of 260

Figure 115: X-Ray System Block Diagram
X-Ray Generator Power Supply: Anode / C

Cathode
athode
The Anode Generator Tank
Primary power connection to the EHT transformer is made by flying leads terminated in
the 6mm ring terminals. These are screwed on to terminals T1 and T2 on the converter
chassis and anode chassis.
The filament connection is made by flying 12 way crimp connector to the Dual
Filament/Feedback PCB. (see Figure 115)
The EHT transformer drives a cascaded 10 stage multiplier and is connected through a
surge resistor to the output receptacle common terminal. All three output connections
(1.) Main Power, (2)
2) Auxiliary Power (3) Communication Interface are connected to the
output of the converter.
Two filament drives are connected to the primaries of two isolation transformers. The
outputs are rectified and smoothed on the Filament Output PCB assembly and
connected
nnected to L (Broad) and S (Fine).
The Cathode Generator Tank

Primary power connection to the Cathode tank connects to the positive input (+) of the
X-Ray
Ray tube. The negative output from the X-Ray
X Ray tube connects to Anode (see Figure
115).
M-75-13-15, Rev A Page 116 of 260

are common.
Figure 116: Imaging System Block Diagram
X-Ray Controller Board

Connector Lay-Out
PL1 is a 10 way ribbon connector which interfaces to the Control PCB. It contains ±18V
DC supplies and the control signals for the kV loop.
PL2 is a 12 way crimp connector which routes into the chassis loom wiring. It contains
the auxiliary power wiring for +30V and the AC power supplies for the ±18V rectifier
circuits. It also contains the sense wires to detect the inverter output.
PL3 is a 15 wayy crimp connector which sends drive signals to the IGBT Drive and
Sensing PCB. A freeze signal is returned through this connector in the event of a tube
arc.
M-75-13-15, Rev A Page 117 of 260

Power Supplies
Through PL2, unregulated plus and minus 18 DC supplies and fed from the IGBT
Controller PCB. These are regulated by IC14 and IC15. IC14 is adjustable and is set by
RV1 for an output at TP8 of 12.0 VDC. This is the positive supply to all the ICs as well
as being the reference for the trip signals. It can also be used as a referenced for the
interface demand signals. IC15 regulates the incoming supply to -12V +/- 0.6V and can
checked at TP6.
LXDA for XIS-1818-320kV

The imaging system uses an array of 19 dual-energy LXDA (linear x-ray detector
assembly) boards for the detection of x-ray energy and the generation of imaging data
signals. Each board has 64 pairs of high-energy and low-energy photodiodes, 128
channels in total. The photodiodes operate in the visible spectrum, so a luminescent
scintillator crystal is used to convert x-ray photons into visible light photons. When
excited by ionizing radiation, visible light is generated by the scintillator, absorbed by the
photodiodes, and then converted into a low-voltage electrical signal through the photo-
electric effect. These signals are amplified locally on the LXDA to produce a usable data
signal transmittable back to the PC.
Figure 117: Data Flow of Imaging System
M-75-13-15, Rev A Page 118 of 260

Collimator
Figure 118: Collimator
A collimator is a device that narrows a beam of particles or waves. To "narrow" can

mean either to cause the directions of motion to become more aligned in a specific area
to be scanned by an X-Ray
X beam from the X-Ray generator.
A collimator is a device that filters a stream of rays so that only those traveling parallel
to a specified direction are allowed through. Collimators are used in neutron, X-ray,
X and
gamma-rayray optics because it is not yet possible to focus radiation with such short
wavelengths into an image through
through the use of lenses as is routine with electromagnetic
radiation at optical or near-optical
near optical wavelengths. Collimators are also used with radiation
detectors in nuclear power stations for monitoring sources of radioactivity.
The XIS-1818-320kV collimator is located between module 2 (AC/DC Power) and

module 4 on the main system.
Chain Drive System & Motor
Figure 119: Inspection Tunnel Motor and VFDs
M-75-13-15, Rev A Page 119 of 260

VFD (Variable Frequency Drives)
Programmable VFDs (variable frequency drives) or “motor inverters” equip each of the
five conveyor sections in the system, and each VFD is physically collocated with its
respective motor. Input power is 240VAC 50/60 Hz single-phase,
single and output power to
the motor is three-phase
phase but regulated in both voltage
voltage and frequency to control ramping
up, running, and braking of the motor according to the programming of the VFD. All five
drives are programmed the same and are interchangeable. 24VDC logical inputs come
from the PLC for motor left and right commands.
commands
General locations of the motors and VFDs are as follows (see Figure 6):
• Inspection tunnel (Motor 3)
• Each of the four roller extension beds (Motors

Motors 1, 2, 4, & 5
5).
Figure 120: Conveyor Motor and VFD Locations
Roller beds (Electrical)
Figure 121: Entry Motor Connection
M-75-13-15, Rev A Page 120 of 260

Figure 122: Exit Roller
Figure 123: Motors
M-75-13-15, Rev A Page 121 of 260

Figure 124: Entry, Tunnel and Exit Motors
Basic Safety when working with unguarded Chain Drives
WARNING!
Do not place hands on both guard rails where PECs 1 through 5 are located.
M-75-13-15, Rev A Page 122 of 260

PC system
Figure 125: PC System Diagram
Figure 126: PC Back Panel
M-75-13-15, Rev A Page 123 of 260

Configuration
• The Dell Optiplex 790 has an Intel iCore 5 microprocessor, 2400CPU @ 3.10
GHz.
• The installed memory (RAM) is 4.0 GB.
• The PC System runs XP Windows OS which is a 32-bit operating system.
• Mother board can connect up to four monitors / displays.
Monitors
• The HP LA2405x 24” LED backlit monitor features screen performance with
widescreen design with 16:10 display ratio.
• The monitor has a built in USB slot with the screen coated with anti-glare
• Resolution: Full HD 1920 x 1200 at 60Hz.
• Color Support: 16,000,000 colors
• Response Time: 5ms
• Pixel pitch: 0.27mm
Keyboard
Any keyboard can be hooked up to any USB port on the Dell 790 Optiplex PC.
Mouse
Any mouse can be hooked up to any USB port on the Dell 790 Optiplex PC.
Uninterruptible Power Supply (UPS)

Overview
This OPTI UPS-800C is a line interactive, simulated sine wave uninterruptible power
system designed to prevent spikes, surges, sags, transients, and blackouts from
reaching your sensitive equipment like computers and computerized equipment. When
AC power is present, the UPS filters and conditions the power continuously. When AC
power fails, the unit employs its internal battery to supply back-up power without any
interruption,
M-75-13-15, Rev A Page 124 of 260

Figure 127: UPS
The UPS is equipped with a remote ON/OFF push button, as shown in Figure 128.
Figure 128: UPS Remote
The UPS also has an audible alarm to notify users of problems. The following table
describes the alarm states.
M-75-13-15, Rev A Page 125 of 260

AUDIBLE ALARM CONDITION RECOMMENDED
ACTION
Beeps every 2 seconds The OPTI UPS-800C Back-Up mode Restore power to XIS
is working under “Battery” mode and
will have an audible alarm sound-off.
This alarm beeps every 2 seconds until
System power is turned on and the
UPS returns to “AC” mode.
Beeps every ½ second LOW BATTERY: In the “Battery” Restore power to XIS
mode, the alarm will begin to beep
more rapidly when the battery energy
becomes low. This means the UPS will
shutdown from battery exhaustion, until
the unit can return to “AC” mode and
charge the batteries again.
Continuous buzzer OVERLOAD: When the UPS is Call customer support for
working under overload condition, (the service
connected equipment exceeds the
maximum rated capacity), the UPS will
continue to alarm to warn. In order to
protect the unit and the connected
equipment, the UPS may automatically
turn off. Please disconnect any
electronic devices to shut-off the alarm
overload.
Control Panel System

AOCP
Figure 129 shows the XIS Operator Control Panel (AOCP).
NOTE: The CBT (Computer Based Training) button is disabled.
M-75-13-15, Rev A Page 126 of 260

Figure 129: AOCP
Figure 130: AOCP Functionality
M-75-13-15, Rev A Page 127 of 260

Figure 131
131: Image Review and Archive AOCP Buttons
M-75-13-15, Rev A Page 128 of 260

PCP (Pedestal Control Box)
Figure 133:: Pedestal Control Box Buttons and Functions
M-75-13-15, Rev A Page 129 of 260

Electrical Wiring
Figure 134 shows the components situated on the three “trays” in Cabinets 1 and 2.
Figure 134:: Major Tray Components (Cabinets #1 and #2)
M-75-13-15, Rev A Page 130 of 260

Photocells
The system uses photo-sensitive cells or “PECs” (photo-electric cells) for monitoring the
position and movement of parcels throughout the various conveyor zones during the
scan cycle. Each complete sensor is composed of a pair of PECs, a light transmitter on
one side of the conveyor and a light receiver on the opposite side of the conveyor. They
operate in the infrared band, but the transmitter also has a visible red beam to aid the
technician in beam path alignment.
When the receiver is successfully receiving the infrared light from the transmitter, it
outputs a signal which is interpreted by the system’s software as “unblocked,” or no
parcel present at that location. When a parcel blocks the beam path and the receiver is
no longer sensing the transmitter’s light, it outputs a signal which is interpreted by the
system’s software as “blocked.” This in turn triggers action from the system on how to
handle the parcel at that location given the location of other parcels in their respective
scan cycles.
There are a total of 14 PEC zones throughout the system (See Figure 135 below). Each
zone represents at least one pair of photocells (transmitter and receiver on opposing
sides of the conveyor), but may actually be multiple pairs arranged vertically and
operating together as a group such that they are one logical or “effective” beam, or
“stacked PECs.” In the latter case, if any single pair of PECs in a group is blocked, then
it registers as a blockage at that PEC zone. The PEC zones represented in the roller
extension beds are one pair each (PECs 1-5 & PECs 10-14). The PEC zones shown in
the tunnel modules are groups of three pairs operating as one logical beam (PECs 6-9).
This is to improve detection of oddly-shaped parcels and minimize imaging
discontinuities.
Figure 135: Photocell Zones
PEC receiver signals are directly connected to PLC inputs by individual zone, and
secondarily connected to the DCI board for monitoring by the imaging software (PC). All
PECs are powered by the 24VDC power supply. The PEC receiver gains are field-
adjustable for sensitivity via small potentiometers on the cell housings. These should
generally be left at factory settings, although certain unusual types of semi-transparent
containers may require PEC receivers to be adjusted for proper triggering performance.
Green and amber LEDs on the receiver PECs indicate the state of transmitter beam
reception as follows:
M-75-13-15, Rev A Page 131 of 260

LED Color LED Status Meaning
Green Off Power is off
On Power is on
Flashing Receiver marginally

blocked (sends blocked
signal)
Amber Off Receiver blocked
On Receiver unblocked
PLC (Programmable Logic Controller)

The PLC sits on the Cabinet 2 tray, as shown in Figure 136.
Figure 136: PLC on Cabinet B Tray
Figure 137: PLC with Extension Module
M-75-13-15, Rev A Page 132 of 260

The PLC (Programmable Logic Controller) is a critical central control device, and also a
good diagnostics tool for field technicians because of its state LEDs representing each
individual input and output. The unit handles all the on/off commands to main system
components such as the x-ray generator, the conveyor motors, the visible and audible
warning indicators on the frame and the operator control stand, etc.
Based on input signals from the PC (via the DCI board) and an array of system sensors,
output signals are generated according to the PLC’s internal programming. These
signals are transmitted via output terminals from a series of relays within the PLC to
each connected device. Some outputs go to intermediate relays which then signal
respective devices. The PLC in the XIS-1818SV 320kV has an added extension module
to handle all the required inputs and outputs. It is located in tunnel module 3.
An overview of the signals carried by the PLC is as follows:
• Inputs:
o AOCP key switch
o Heartbeat from imaging software
o Interlocks
o Photocells
o Chiller fault (temperature and flow interlocks)
o X-ray on request
o X-ray on and x-ray ready (ramp-up complete & ready to scan)

feedback signals
o Operator Control Stand control inputs (6)
o System conveyor forward and reverse
o Normal stop and emergency stop signals
• Outputs:
o X-ray on command
o Motor commands (10 total, 5 motors each with left and right directions)
o Stack light commands (entry and exit x-ray warning amber LEDs and
buzzers)
o Operator Control Stand indicator LEDs (3)
o PC power
M-75-13-15, Rev A Page 133 of 260

Stack Light
Figure 138: Stack Light
Interlock Switches
The system is equipped with safety interlock switches which protect each access panel
on the tunnel modules. When a panel opens its respective interlock switch opens, a
signal is sent both to the PLC and the PC (via the DCI board) to bring the system to a
safe state. System safe state includes de-energizing of the x-ray generator and stopping
of all conveyor motors.
Each tunnel module has one interlock switch on either side of the frame for a total of two
interlocks per module (see Figure 7). The two interlocks are connected in series per
module and generate a single signal to the system. If either switch opens, the specific
tunnel module is identified in Diagnostics as having an open interlock but not which one
specifically. The technician can then narrow down electrically where an actual open
switch or a possible bad connection is located.
Figure 139: Interlock Switches
M-75-13-15, Rev A Page 134 of 260

Diagnostics
Self-Diagnostics System
The 1818-320kV x-ray machine has an integrated real-time Self-Diagnostic System. The
Self-Diagnostic System (SDS) is a combination of special software and hardware that
continuously monitors the operation of key system components. The SDS warns the
user when components are about to fail or are failing. The SDS is a critical tool trouble-
shooting the x-ray machine. The SDS has two (2) main hardware sub-assemblies:
• DCI Board
• (LabJack™) DAQ Board
DCI Board
The DCI (Diagnostics & Control Interface) board is the primary interface between the PC
and the system for input/output control signals and diagnostics input signals (see Figure
140 below). It is located in tunnel module 3 and is powered by the 12VDC power supply.
Figure 140: DCI Board
The DCI board’s primary connection to the PC is via USB, with secondary through-
connections between the PC and the USB keypad and touchpad on the AOCP. The
board uses a main control chip which communicates to the PC via a USB bridge chip,
which is also mounted on the board. The driver for the USB bridge chip is what must be
M-75-13-15, Rev A Page 135 of 260

installed on the PC for the DCI board hardware to communicate properly. In the
Windows Device Manager, a correctly installed and connected DCI board will show as
“USBXpress Device” under “Universal Serial Bus controllers” (see Figure 141 below).
Figure 141: DCI Board in the Windows Device Manager
An overview of the signals carried by the DCI board is as follows:
• Primary DCI board USB connection to/from the PC (JP1).
• AOCP keypad and touchpad USB through-connections to/from the PC (JP2-

keypad & JP3-touchpad).
• AOCP connection (JP4).
• Connection to the input terminals of the PLC for sending command signals
(TB1, TB4, & TB5).
• 24VDC power supply diagnostic connection (TB5).
M-75-13-15, Rev A Page 136 of 260

• Foot mat connection (TB5).
• +/-5VDC power supply diagnostic connections (TB1).
DAQ Board (LabJack™ Board)

The machine uses an off-the-shelf DAQ (data acquisition) module by the LabJack
Corporation for measurement of some of the signals displayed to the operator in System
Diagnostics. The DCI board collects the majority of the diagnostics signals, but does not
have enough inputs for the whole machine, so the LabJack is used as an auxiliary DAQ.
It is connected to and powered by the PC via USB with a respective hardware driver that
must be installed, and consists of two components including a main module and an
expansion board (see Figure 142 below). It is located in tunnel module 3.
Figure 142: LabJack Module and Expansion Board
An overview of the signals measured by the LabJack assembly is as follows:
• Feedback from output relays of the PLC for monitoring system control signals
(main module and expansion board).
• Feedback from the interlock switches grouped by module, one feedback per
module 1-5 (expansion board).
• Feedback from the e-stop relay (expansion board).
• Feedback from the x-ray generator controller for x-ray warm up and x-ray
signals (expansion board).
Photocells
See the section on photocells on page 131.
PLC
See PLC (Programmable Logic Controller) on page 132.
M-75-13-15, Rev A Page 137 of 260

VFD
See VFD (Variable Frequency Drives) on page 120.
Interlock Switches
See section on Interlock Switches on page 134.
LXDA
See LXDA for XIS-1818-320kV on page 118.
Diode Plot
The Diode Plot Program (DPP) is a standalone utility program that monitors the real-time
output from the Linear X-ray Detector Assembly (LXDA). LXDA output is crucial in the
creating x-ray images that are displayed on the screen. X-rays from the x-ray generator
are first projected through the inspection tunnel and then through to the LXDA. X-ray
images are created when items entering the inspection tunnel attenuate (i.e. lowers) the
x-ray signal.
Following are examples of Diode Plot readouts, including with Diode Plot On and Off,
and with “History,” meaning it shows previous Diode Plot results on the graph.
Figure 143: 320kV Diode Plot
M-75-13-15, Rev A Page 138 of 260

Figure 144: 320kV Diode Plot Off
Figure 145: 320kV Diode Plot with History
Instead of displaying x-ray images, the Diode Plot Program (DPP) displays a graph of
blue and red dots. The red dots represent output from the “high-energy” (i.e. high
frequency spectra output) x-ray detectors and the blue dots represents the output from
M-75-13-15, Rev A Page 139 of 260

the “low-energy” detector x-ray detectors. The Y-AXIS of the graph represents signal
strength. The detectors are mounted on circuit boards. Each board has 64 diode sets.
Each set consists of a “stacked” high energy and low energy diode set. The high energy
diode is physically on top of the low energy diode. On the graph, each diode set
displayed as a set of one red and one blue dot. The high energy, red dot, is shown next
to (i.e. higher than) its corresponding low energy diode, blue dot.
The XIS1818, for example, has 20 boards with 64 high/low energy diode sets (20 x
128=2560 total diodes). The DPP is a powerful diagnostic tool. With it you can inspect
and rapidly verify that:
• The x-ray generator is properly working.
• If the x-ray generator is properly working, that indicates that the x-ray
machine is properly powered, the DC power supplies are working, the PLC is
working properly, the x-ray controller is working properly, the x-ray tube is
powered and working, and that the x-ray generator is powered and ON.
• It also indirectly indicates that the x-ray tube oil cooler is powered and
properly working.
• It also indirectly indicates that all Emergency Stop switches are “clear” and
that all safety inter-lock switches are closed (i.e. all panels are closed and
fastened).
• All 20 LXDA boards are working.
• If they are all working, that indicates that all necessary +5, -5, & +12VDC
power supplies are properly working, connected and powered up.
• This also indirectly indicates that the computer is properly working and that
the DAS (Data Acquisition System) is properly powered, connected, and
working.
• All 20 LXDA boards are properly aligned.
• If they are aligned, vertical lines on the screen will appear as a contiguous,
straight vertical line.
• All LXDA boards are not blocked and do not overlap.
• That all 20 LXDA boards are generating proper output.
• If they are generating proper output, they DPP will display a characteristic
graph that shows a “saddle” (low point) in the middle.
M-75-13-15, Rev A Page 140 of 260

Diode Plot Program – Test Instructions
Steps Expected results PASS?
1. Start Diode Plot Program The DPP starts up.

(DPP)
2. Verify that the DPP The DPP Screen shows the proper format
started correctly. with 20 vertical columns.
Inspect the Diode Plot The DPG display a characteristic blue-red

Graph (DPG) with X-rays dot spread (not perfectly linear) at 0.
OFF
Turn the X-rays ON. The DPG rises up in steps and stays up.
(i.e. it does not rise up and drop down

immediately.)
Inspect the DPG. The DPG displays a characteristic blue-red

dot spread.
The red dots are typically above the blue

dots.
The dots do NOT show signal saturation.
(they do not cluster at the top)
M-75-13-15, Rev A Page 141 of 260

Diagnostics Screen
The Diagnostics Screen is a diagnostics tool available on your PC monitor, via the
AOCP.
Figure 146: Diagnostics Screen
To access this screen:
• Press the [DIAG] button to activate and display the Real-Time Diagnostic
Screen.
• Press the [DIAG] button again to return to the regular x-ray imaging screen.
M-75-13-15, Rev A Page 142 of 260

Table of Diagnostic Screen Display Fields
Real-Time Diagnostic Field Comments
X-ray Tube kV Setting Displays X-ray tube kV setting (anode potential)
kV & mA OK Indicator Displays kV & mA feedback OK indicator
X-ray Tube kV Output (digital Displays x-ray tube kV (feedback output)

display)
X-ray ON/OFF Indicator Displays x-ray ON status.
Green indicates that x-ray generator is powered and producing

x-rays.
X-ray Tube kV Output (analog Displays x-ray tube cathode mA (feedback) output
meter display)
X-ray Tube mA Setting Displays X-ray tube cathode mA setting in milliamperes
Error Message Log Displays Error Message Log
C & F Toggle Centigrade / Fahrenheit indicator
C = Centigrade temperature display
F = Fahrenheit temperature display
Temperature (digital display) Displays internal frame temperature with digital display
Temperature (analog meter display) Displays internal frame temperature with analog (meter) display
C / F (Centigrade / Fahrenheit Displays Centigrade / Fahrenheit indicator.

indicator)
“C” indicates centigrade.
“F” indicates Fahrenheit.
+24VDC Power Supply Status Displays +12VDC power supply #1 output status
Green = Good
Yellow = Warning
Red = Fault
M-75-13-15, Rev A Page 143 of 260

Real-Time Diagnostic Field Comments
+5VDC Power Supply #1 Status Displays +5VDC power supply #1 output status
Green = Good
Yellow = Warning
Red = Fault
-5VDC Power Supply #1 Status Displays -5VDC power supply #1 output status
Green = Good
Yellow = Warning
Red = Fault
+5VDC Power Supply #1 Output Displays +5VDC power supply #1 output voltage.
Voltage
Output should be within +/- 10% of +5V.
-5VDC Power Supply #1 Output Displays -5VDC power supply #1 output voltage.
Voltage
24VDC Power Supply #1 Output Displays 24VDC power supply #1 output voltage.
Voltage
Username Entry Username login entry field for access to diagnostic report and
sub-graph menu
Password Entry Password entry field for access to diagnostic report and graph
sub-menu
Display Report Sub-Menu (button) Display Report Sub-menu (after successful display)
Display Graph Sub-Menu (button) Display Graph Sub-menu (after successful display)
Conveyor Right Direction Green = Conveyor motor is on and moving right (i.e. from left to
right)
Conveyor Left Direction Green = Conveyor motor is energized and moving left (i.e. from
right to left)
PEC Photocell Detect Displays all photocell (photo-sensor) status.

Green = Exit photo-cell is “triggered”, indicating bag is exiting
inspection tunnel.
Key-switch ON/OFF Status Displays AOCP (Operator Console) key-switch status Green =
key-switch is ON position.
M-75-13-15, Rev A Page 144 of 260

Error Log – Error Message List
The list below itemizes the various types of error messages that may be displayed in the
Diagnostic Screen’s ERROR LOG. For a full list of x-ray generator error codes, refer to
the Gulmay CP 12 Bit RS232 PCB Version 5.0 Technical Manual.
ERROR LOG MESSAGE COMMENTS & DISCUSSION
1 X-RAY Generator's/Controller's malfunction. DESCRIPTION

(KV/mA is under min or over max)
X-ray generator has malfunctioned and NO x-rays are
being produced.
XIS may show a “scrolling” black screen.
RECOMMENDATION
Contact Customer Support for assistance.
Report error message.
Request assistance.
2 System 12VDC Power Supply's malfunction. DESCRIPTION
The 12VDC power supply has failed.

The key-switch, warning lights, and DAS board will fail to
operate.
The XIS will not display proper x-ray images.
RECOMMENDATION
Request assistance.
3 +5VDC PS1's malfunction. DESCRIPTION
The +5VDC power supply (first set) has failed.

The x-ray detector assembly will fail to operate.
The XIS will not display proper x-ray images
RECOMMENDATION
Request assistance.
M-75-13-15, Rev A Page 145 of 260

ERROR LOG MESSAGE COMMENTS & DISCUSSION
4 -5VDC PS1's malfunction. DESCRIPTION
The -5VDC power supply (first set) has failed.
The XIS will not display x-proper ray images
RECOMMENDATION
Request assistance.
5 +5VDC PS2's malfunction. DESCRIPTION
The -5VDC power supply (second set) has failed.
The XIS will not display x-proper ray images
RECOMMENDATION
Request assistance.
6 -5VDC PS2's malfunction. DESCRIPTION
The -5VDC power supply is not operational.
The XIS will not display x-ray images
RECOMMENDATION
Request assistance.
7 No System malfunction has been detected. DESCRIPTION
The XIS is operating normally.
RECOMMENDATION
Continue using XIS.
M-75-13-15, Rev A Page 146 of 260

Bypassing the PLC During Diagnostics
The proprietary Astrophysics diagnostic software access the X-ray generator via the
PLC, sending startup, stop and diagnostic signals to and from the generator through the
PLC. If, however, the problem with the unit is with the PLC itself, the maintenance
engineer will not be able to receive signals from the generator. In this case it is possible
to bypass the PLC when accessing the generator, with the use or third party software
loaded onto every XIS 320kV machine.
This third party diagnostics software is called Gulmay Panel.exe. If you are running
Gulmay Generator Control software, you must exit the program before starting
Panel.exe.
1. Click on the GulmayGeneratorControl.vi shortcut.
Figure 147: GulmayGeneratorControl.vi Screen
2. Click [Exit].
3. Open the Windows START menu.
M-75-13-15, Rev A Page 147 of 260

Figure 148: START Menu Shortcut to Panel.exe
4. Select “Shortcut to Panel.exe” which brings up the Panel.exe main screen.
Figure 149: Main Screen
If you get a full kV and mA reading on the Panel.exe main screen but were unable to get
any readings from the Astrophysics diagnostics screen, this is a clear indication that the
problem lies with the PLC itself.
it
M-75-13-15, Rev A Page 148 of 260

Cabinets
Front Cabinets
NOTE: For information and illustrations for dual view machines, see Installing the XIS
320kV Dual View on page 73.
Figure 150 shows the three front cabinets on the XIS 1818 320kV single view machine,
and the major components in each of those cabinets.
Figure 150: Front of XIS-1818 320kV
M-75-13-15, Rev A Page 149 of 260

Cabinet A
Figure 151 shows Cabinet A and the major components therein. The shelf upon which
the UPS rests, and the back panel on which the Internal Circuit Breaker is mounted, are
both known as “trays.”
Figure 151: Cabinet A
M-75-13-15, Rev A Page 150 of 260

Cabinet B
Figure 152 shows Cabinet B and its major components. The top shelf of the cabinet,
which holds the PLC and PC among other components, is known as a “tray.”
Figure 152: Cabinet B
M-75-13-15, Rev A Page 151 of 260

Cabinet C
Figure 153 shows Cabinet C and its major components.
Figure 153: Cabinet C
M-75-13-15, Rev A Page 152 of 260

Replacement Parts Lists
Critical Parts
Figure 154 is a list of the most critical and most often replaced parts in the XIS 320kV
320
systems (1818 and 1517).
Figure 154: Critical Replacement Parts
M-75-13-15, Rev A Page 153 of 260

Basic Parts
Figure 155 is a list of basic replacement parts, parts that are used in several XIS
systems.
Figure 155: Basic Replacement Parts
M-75-13-15, Rev A Page 154 of 260

System-Specific Parts
Figure 156 is a list of replacement parts unique to the 1818 and 1517 systems
(regardless of whether they are using the 320kV
320 generator).
Figure 156: System Specific Replacement Parts
M-75-13-15, Rev A Page 155 of 260

320kV Specific Parts
Figure 157 is a list of parts specific to 320
320kV systems. This consists of the 320
320kV
generatorr system and subcomponents.
Figure 157: 320kV-Specific Replacement Parts
M-75-13-15, Rev A Page 156 of 260

Preventive Maintenance
PM Checklist
Figure 158: Preventive Maintenance Checklist
M-75-13-15, Rev A Page 157 of 260

Figure 159
159: Gulmay Planned Maintenance Report
M-75-13-15, Rev A Page 158 of 260

INSPECTION
INSPECTION EXPECTED RESULTS
INTERVAL
Inspect curtains All curtain strips are intact Weekly
Inspect warning lights

All warning lights and alarms work. Weekly
and alarms with PCP
Inspect rollers All rollers nominal Weekly
Inspect emergency
All emergency stop switches nominal Weekly
stop switches
The photocells are properly wired and

securely fastened down.
Inspect the photocells The photocells are aligned. Annually
The receiver indicates a clear signal

from the transmitter.
Inspect all panels All panels are closed. Weekly
All chains drive assemblies are

Lubricate chains Monthly
lubricated.
Clean air conditioner

Air conditioner filter clear Monthly
filter
Replace dielectric oil Dielectric oil replaced. Semi-Annually
Perform radiation Max. external radiation emissions meets

Semi-Annually
survey all applicable standards.
Perform full system

All systems are nominal Semi-Annually
check
M-75-13-15, Rev A Page 159 of 260

INSPECTION
INTERVAL
Check PC/PEC
operation.
PECs operate normally. Weekly
The interlock switches are tightly fastened down.

Inspect the interlocks
switches. The interlocks switches are properly wired up.
Annually
The interlock close properly when the panels
are mounted.
All buttons are securely in place.
All buttons operate as required.

Inspect the Advanced
Operator Control Panel All buttons are properly labeled and mounted in
proper order. Annually
The USB cable is mechanically intact.
The USB connector is good shape.
The Power LED is lit.
The Run LED is lit.

Inspect the PLC
The PLC is properly connected. Annually
The PLC properly switches the PC on.
The PLC properly switches the XRG on.
The PC Keyboard is present.

Inspect the PC keyboard
The PC keyboard is properly connected. Annually
The PC keyboard operates properly.
The PC mouse is present.

Inspect the PC mouse
The PC mouse is properly connected. Annually
The PC mouse operates properly.
Inspect the PC power

The PC power cord is the correct 14 AWG cable.
cord
Annually
The PC power cable plug is good order.
M-75-13-15, Rev A Page 160 of 260

INSPECTION
INTERVAL
Inspect the PC
Check the power cord
connection.
Check the PC keyboard
cable connection.
Check the PC mouse
cable connection.
Check the USB Security
Key connection. The PC is present.
Check the Ethernet The PC is securely fastened down
Loopback connection. All cables are properly connected and
Check the DAS board secured. Annually
data (40 conductor The PC Power Supplies is operational.
ribbon cable) connection. All cables are properly
Check the DAS board connected.
HE Coax cable
connection.
Check the DAS board LE
Coax cable connection.
Check the DAS
board power
cable
connection.
The ELC is present.

Inspect Ethernet The ELC is properly connected. Annually
Loopback Connector
The ELC operates properly.
(ELC)
Inspect the imaging with
F792-88 Step Wedge
XIS F792-88 image ok Semi-
Annually
Semi-
Inspect the diode plot
graph
The DPG shows no diode signal saturation. Annually
Inspect conveyor The conveyor operates smoothly in both Annually

operation directions.
The XRG should show no signs of oil Semi-
Inspect the x-ray
generator (XRG)
leakage Annually
The XRG show no sign of internal arcing.
Inspect the x-ray
controller
Check the KV controller
fuse. KV Controller Fuse is OK
Semi-
Check the mA controller mA Controller Fuse is OK
fuse 5VDC P/S is within +/- 5%
Annually
Measure the 5VDC 65VDC P/S is within +/- 5%
power input
Measure the 65 VDC
power input
M-75-13-15, Rev A Page 161 of 260

Cleaning, Gapping and Greasing High
H Voltage Cables
Cleaning
Use a cleaning tool to clean the socket before every installation.
NOTE: Clean the cable flange before it is attached to the

the connector. To support the
cleaning, apply a small amount of alcohol.
Figure 160:
160: Cleaning the Cone of the High Voltage Plug
NOTE: Always clean

lean the high-voltage
high voltage plug before connecting to the socket.
M-75-13-15, Rev A Page 162 of 260

Gapping
• Position the clean and dry connector with small pressure in the socket.
• Adjust the cable flange so that the required gap is achieved.
• Make sure that the contact head is fully inducted while checking the gap
width.
• Check whether the bores of the cable flange are in line with the intake bores.
• Tighten the setscrews of the cable flange to avoid unwanted turning of the
same.
Figure 161: Adjusting the HV Cable Flange Gap
M-75-13-15, Rev A Page 163 of 260

Greasing
• Apply silicone grease quantity according to the table
• Spread the grease equally on the cone surface until a thin layer completely
covers the surface.
Figure 162: Applying Grease to the HV Cable Plug Cone
Assembly of non spring-loaded cables

1. Loosen the four screws at the protecting cap and remove them.
2. Remove the protective casing from the cable cone.
3. Fully insert the cleaned and silicone greased high-voltage plug into the high-voltage
connector of the X-ray tube, respectively the high-voltage generator.
4. Make sure not to touch the high-voltage connector when inserting the connection
contacts.
M-75-13-15, Rev A Page 164 of 260

5. Also make sure that the plug is fully inserted into the high-voltage connector and that
the cable head is laid to the electrical contacts via the opening.
6. Measure the distance between the cable flange and the tube flange / the high
voltage generator flange and adjust it if necessary.
Figure 163: Distance Cable Flange
7. If the distance is not X mm, loosen the locking screws at the cable flange and rotate
the flange until the distance of X mm is reached.
8. One turn of the flange corresponds to a distance variation of 1.5 mm.
9. Insert the screws and retighten them until the cable flange is firmly secured.
10. Wait for approx. 10 min.
11. Undo the cable flange screws.
12. The cable cone must return to the set distance X.
13. Do not remove the cable flange during examination.
14. Check the distance between the cable flange and the counter flange.
If the distance is not X mm, readjust correspondingly by rotating the cable flange.
15. Let the machine run program 102 for approximately 2 hours at initial installation.
Recheck the distance after 24 hours.
16. Repeat as described above.
17. Retighten the cable flange and fix the high-voltage cable using setscrews.
Maintenance of High Voltage Cables

• According to utilization, maintenance is recommended every 3 – 6 months for
non spring-loaded cables and 6 – 12 months for spring-loaded cables.
• Follow the above mentioned procedural steps and check the process to finish
maintenance.
Please contact Comet if maintenance intervals must be adjusted to customer needs.
M-75-13-15, Rev A Page 165 of 260

M-75-13-15, Rev A Page 166 of 260

320kV X-Ray Generator System
X-Ray Generator System
NOTE: For information and illustrations for dual view machines, see Installing the XIS
320kV Dual View on page 73.
The Generator System extends across all three cabinets and includes the Cathode and
Anode power supplies, X-ray tube, and the Air Cooled Heat Exchanger used to cool the
Generator’s oil.
Figure 164: 320kV X-Ray Generator Component Diagram
The generator is designed to power a Unipolar sealed X-ray tube up to 320kV at 3.2 kW
- 4.5 kW, depending on model, with controlled dual filament supplies isolated to the EHT
potential.
The generator consists of two major elements, the Extra High Tension tank and the
converter chassis.
The EHT Tank contains all the high voltage circuitry required to produce EHT output
together with dual filament isolation transformers. The high voltage isolation is obtained
by means of resin encapsulation and transformer oil immersion.
The converter chassis unit fits directly onto the EHT Anode tank. It contains all the
electronic circuitry to produce the controlled 320kV at 3.2 kW - 4.5 kW drive for the EHT
M-75-13-15, Rev A Page 167 of 260

supply together with the drives for dual filament transformers. The converter chassis is
secured to the top of the Anode tank.
Figure 165: Cathode and Anode (Converter Chassis) Power Supplies
The Anode Generator Tank

The tube is powered by two large power supplies: a Cathode Power Supply, and an
Anode power supply. Primary power connection to the EHT transformer is made by
flying leads terminated in the 6mm ring terminals. These are screwed onto terminals T1
and T2 on the converter chassis and anode chassis.
The filament connection is made by flying 12 way crimp connector to the Dual
Filament/Feedback PCB.
(1.) Main Power (2.) Auxiliary Power (3.) Communication Interface are connected to the
output of the converter.
Two filament drives are connected to the primaries of two isolation transformers. The
outputs are rectified and smoothed on the Filament Output PCB assembly and
connected to L (Broad) and S (Fine).
The Cathode Generator Tank

Primary power connection to the Cathode tank connects to the positive input (+) of the
X-Ray tube. The negative output from the X-Ray tube connects to Anode (see FIG. 2)
are common.
M-75-13-15, Rev A Page 168 of 260

Collimator
Figure 166 shows the collimator from an XIS 1818 320kV machine.
Figure 166: Collimator
A collimator is a device that narrows a beam of particles or waves. It is used whenever

the wavelengths and distance are too small to use lenses to focus radiation. In the case
of XIS machines, “narrows” mean
means to cause the beams s to become more aligned in a
specific area to be scanned by an XX-Ray beam from the X-Ray
Ray generator.
The XIS-1818-320kV collimator is located between module 2 (AC/DC Power) and

module 4 on the main system.
M-75-13-15, Rev A Page 169 of 260

X-ray Tube Remove and Replace
In order to replace, repair or maintain the 320kV X-ray Generator, it is necessary to first
remove the X-ray Tube Radiation Shield Box.
Figure 167: X-Ray Tube Radiation Shield
Instructions for Removing Radiation Shield Box
WARNING!
Always turn off and disconnect power to the XIS BEFORE servicing the x-ray generator or
removing any radiation shielding.
M-75-13-15, Rev A Page 170 of 260

The lid and front panel of the Radiation Shield Box are heavily impregnated with lead.
Because of this they are very heavy, far too heavy for one person to handle alone. Thus,
two people are needed.
Even with two people, the lid and front panel are too heavy to easily handle and, if
dropped, can cause injury and damage. Thus it is important to have a hydraulic lift stand
or “lifting table” as shown in Figure 168.
Figure 168: Removing Radiation Shield Box
Note in Figure 168 that there is a lead apron on the front of the Radiation Shield Box that
is bolted to the top of the box and draped/bent over the front, to add extra protection
against radiation leakage.
1. Turn off x-ray machine.

2. Turn Main Circuit Breaker to OFF position.
3. Press Emergency Stop Switch for added safety.
4. Disconnect power.
5. Remove 9 fastening bolts on the front and sides of the lid.
6. Remove the lead apron.
7. Raise the lifting table to the height of the Radiation Shield Box lid.
M-75-13-15, Rev A Page 171 of 260

Figure 169:
169: Lifting Table and Radiation Shield Box Lid
8. Very carefully, with at least two people, grab the handles on the sides of the lid and
lift it onto the lifting table, being careful to lift with the legs, not the back, and to keep
a firm grip on the lid handles in order to avoid dropping the heavy lid.
Figure 170:: Grabbing the Radiation Shield Box Lid by the Han
Handles
9. Lift the lid onto the lifting table, and clear of the Radiation Shield Box.
Figure 171:: Lifting the Radiation Shield Box Lid onto a Lifting Table
M-75-13-15, Rev A Page 172 of 260

Removing the X-ray Tube
Once the lid has been removed, the X-ray tube will be exposed, inside its oil-filled tank at
the bottom of the Radiation Shield Box. Figure 172 shows the tube and the two thick
High Voltage cables attached to the tube, connected on the other end to the Cathode
power supply. Not also that the tube is bolted at either end to metal brackets that hold
the tube in place.
Figure 172: X-ray Tube
10. With the system powered down and disconnected from the power source, remove
the High Voltage cables from the X-ray tube.
Figure 173 shows the hoses carrying the cooling oil from the heat exchanger to the X-
ray tube tank and back again. These are quick-connect hoses and when you remove
them there should be very little dripping of oil as the outlet on the tank should
instantaneously self-seal when the hoses are removed.
Figure 173: Oil Hoses Inserting into the X-ray Tube
M-75-13-15, Rev A Page 173 of 260

1. Remove the oil hoses from the X-ray Tube.
2. Remove the bolts holding the tube to the two brackets, careful not to let the tube fall.
3. Carefully lift the tube out of the Radiation Shield box.
4. To install the new tube, reverse these directions.
M-75-13-15, Rev A Page 174 of 260

Laird Air Cooled Heat Exchanger (“Chiller”)
Figure 174: Lair Air Cooled Heat Exchanger
Replacing the Chiller

Reference Manual is “Gulmay Manual 12AR258N.PDF”:
1. Turn off x-rays and allow the system to cool down for 5 minutes.
2. Remove power from the x-ray system and chiller.
3. Drain oil from existing oil chiller into suitable containers… two clean 5 gallon plastic
buckets will do. Seal the buckets and store for future use.
4. Remove oil lines from existing chiller be means of threaded 1/2" NPT fittings at
chiller.
5. Disconnect all electrical lines supplying existing chiller from the control/power
system.
6. Install the oil lines removed in item 4 onto the new chiller. It is best to use some type
of sealant on the threads such as Teflon tape or paste. (see page 4 of Reference
Manual)
a. The return line FROM the tube goes to the port marked “OIL RETURN” on the
chiller.
b. The supply line going TO the tube should be connected to the port mark “OIL
OUTLET”.
M-75-13-15, Rev A Page 175 of 260

NOTE: Reversing these connections voids any warranty on the tube and the chiller.
7. Connect the supplied Control Voltage cable to the system safety circuits observing
the pin-outs listed below. (Page 4 of Reference Manual) Circuit is the same as
existing chiller:
a. Pin A is temperature
b. Pin B is temperature Common
c. Pin C is Flow (14 liters/minute)
d. Pin D is Flow Common (this may be tied to Pin B depending on installation.)
8. Connect the supplied Power Cable to system power 208-240/50-60Hz/Single Phase.
Power requirements are very similar to the existing Chiller (see page 4 of Reference
Manual):
a. Pin A is Line 1
b. Pin B is Ground
c. Pin C is Line 2
9. Remove the “Hydraulic Oil Fill” cap located on the top of the new chiller. Insert a
medium to large funnel or other device to minimize the oil spillage. (See page 3 of
Reference Manual)
10. Find the one of the two, 5 gallon buckets of NEW Shell Diala insulating oil shipped in
the crate with the new chiller and pour all of the contents of that one bucket into the
reservoir on the new chiller.
11. Find the remaining 5 gallon bucket of oil and pour into the reservoir while watching
the oil level indicator on the side of the tank. Stop pouring when the oil in the
reservoir reaches the top of the site-glass.
12. Turn on the power to the chiller for 2-3 minutes. Look for leaks and correct as
required.
13. Top off reservoir with remainder of new oil. Unused oil may be kept for emergencies
in the resealed bucket. If additional oil is required, use the oil drained from the first
chiller. It too may be safely stored if sealed from environmental exposure.
14. Use the aforementioned Gulmay Manual 12AR258N.PDF instruction book (Page 5 of
Reference Manual) book to set the temperature set point. This will determine when
the compressor turns off and on. It is recommended to set this number at room
temperature.
15. Routinely inspect for leaks, bulges and abrasions since any of these can cause
leaks.
M-75-13-15, Rev A Page 176 of 260

Technical Data
M-75-13-15, Rev A Page 177 of 260

M-75-13-15, Rev A Page 178 of 260

Curtains
The XIS 320kV single view and dual view machines have several sets of lead-
impregnated curtains which help prevent scattered radiation from escaping the
inspection tunnel. The entry and exit tunnels each have two sets of double curtains (one
pair of curtains
ns on the front of the entry and exit modules,, and one pair of curtains on the
back of the entry and exit modules).
Thus each pair of curtains consists

consist of two curtains layered atop each other to double the
amount of protection they provide against the escape
escape of scattered radiation.
Figure 175: Entry Tunnel Curtain Sets
Remove and Replace

Removing Curtains
The curtains are heavy. To relieve the weight of the curtains while removing and
replacing them, carefully flip them up onto the top of the machine as shown in Figure
176.. Note the metal strip held in place by several small posts, holding the curtains to the
frame of the machine.
M-75-13-15, Rev A Page 179 of 260

Figure 176:: Curtains Flipped onto the Top of the Machine
1. Unscrew the nuts from the posts.

posts
2. Remove the metal strip.
Figure 177: Removing the Metal Curtain Strip
3. Remove first the outer and then the inner curtain from the posts.
Figure 178: Removing Pair of Curtains
M-75-13-15, Rev A Page 180 of 260

Replacing Curtains
1. Place curtains atop of the machine,, the top of the curtains hanging over the
entrance.
2. Slip the holes located at the top of the curtains onto the posts, beginning with the first
layer of curtains.
Figure 179: Installing New Curtains
3. Add the second layer of curtains atop the first layer, placing the holes located at the
top of the curtains onto the posts.
Figure 180:: Attaching Second Layer of Curtains
4. Attach the metal curtain strip.
M-75-13-15, Rev A Page 181 of 260

Figure 181: Attaching Metal Curtain Strip
5. Carefully allow the curtains to hang down, not allowing the heavy curtains to fall too
hard, as this may cause them to be damaged.
Figure 182: New Curtains Hanging
M-75-13-15, Rev A Page 182 of 260

Rollers
Most of the rollers (except for the first three rollers on the entry roller bed and the last
three on the exit roller bed) have a chain end, and a non-chain
non chain end. The chain end of the
roller contains two sprockets. Chains are wrapped from the sprocket of o one roller to the
sprocket of the next roller, allowing one motor to turn several rollers simultaneously.
Rollers are located on roller beds outside the inspection tunnel, and inside the inspection
tunnel. Slightly different remove-and-replace
remove procedures are needed, depending on
where the rollers are located.
Replacing Rollers Inside the Inspection Tunnel

1. Flip up the outside pair of curtains so that they sit atop
top the frame of the machine. Tie
the inside set of curtains together to create air flow thru the inside of the machine.
Figure 183: Flipping Curtains Up
Figure 184:
184: Tying Curtains to Allow Air Flow In Tunnel
2. Remove the internal lower panel of the down shooter module. Make sure the
removed panel is
s on the chain side.
M-75-13-15, Rev A Page 183 of 260

Figure 185:: Removing Roller Covers on Chain Side of Tunnel
Figure 186: Lower Roller Covers Removed
3. Remove the chains of the 4 rollers that are directly atop the LXDA box.
Figure 187:: Removing Four Rollers Atop the Bottom LXDA Box
M-75-13-15, Rev A Page 184 of 260

Figure 35 shows the procedure for removing a connection link, connection brace and
locking link in order to undo and then remove a chain from the sprocket of a roller.
Figure 188: Removing Chain Links
4. On the non-chain
chain side of the rollers, undo the two screws on the brackets that hold
the rollers in position. Remove the brackets, then lift the non
non-chain
chain end of the roller
and slip the chain end of the roller out.
M-75-13-15, Rev A Page 185 of 260

Figure 189: Brackets Holding Rollers in Position
Figure 190: Removing Brackets and Rollers
5. Remove the damaged roller.

6. To install the new roller, simply reverse these directions.
M-75-13-15, Rev A Page 186 of 260

LXDA (Linear X-Ray
X Ray Detector Assembly
Assembly)
NOTE: For information and illustrations for dual view machines, see “Installing the
XIS 320kV Dual View” on page 73.
The imaging system uses an array of nineteen (19) dual-energy

dual energy LXDA (Linear X X-Ray
Detector Assembly) boards for the detection of xx-ray
ray energy and the generation of
imaging data signals. Each board has sixty-four (64) pairs of high--energy and low-
energy photodiodes, 128 channels in total. The photodiodes operate in the visible
spectrum, so a luminescent scintillator crystal is used to convert x-ray
x ray photons into
visible light photons. When excited
excited by ionizing radiation, visible light is generated by the
scintillator, absorbed by the photodiodes, and then converted into a low low-voltage
electrical signal through the photo-electric
photo electric effect. These signals are amplified locally on
the LXDA to produce a usable data signal transmittable back to the PC.
A DAS (data acquisition system) board inside the PC is the control and data collection
device for the LXDA array. An outbound digital clock signal is sent to the LXDA array,
and each LXDA board responds back to the DAS board in sequence with its respective
analog data signal. The analog signals are converted to digital signals back at the DAS
board for transmission to the CPU and use by the imaging software. The LXDAs are
connected in series for receivi
receiving and re-transmitting
transmitting the digital clock from the DAS to the
next board. This ordered sequence provides for the multiplexing of the returned data
signals on a single channel back to the DAS board, which is connected in parallel to
each board. The data reporting
rep is a domino-effect
effect requiring no addressing of individual
boards. A DIP switch on each LXDA allows addressing for use by separate software
used for calibration purposes and not related to basic imaging functions.
Adjusting the LXDA Array
Figure 191:: LXDA Access Doors and LXDA Board Adjustment Screws
M-75-13-15, Rev A Page 187 of 260

Figure 191 shows the side LXDA box on the 1818 320kV X X-ray
ray machine, including the
access doors (one door per two boards) and the adjustment screws (one per board, on
either side of the box) that move the boards side to side.
If the Diode Plot program indicates that there are alignment problems interfering with
efficient scanning, it is necessary
necess to shift each board to one side or the other until it is
aligned and showing correctly on the Diode Plot program.
Getting Raw Data

To perform the LXDA board alignment, the first step is to isolate the misaligned board.
To do this it is necessary to get raw data and thus a “true” picture of the alignment of the
individual boards.
1. Exit X-ray
ray Client program.
2. Right mouse click on My Computer.
3. Select [Explore].
Figure 192: Selecting [Explore]
4. Expand Local Disk (C:)

5. Expand Program Files folder.
6. Open X-ray
ray Client folder.
M-75-13-15, Rev A Page 188 of 260

Figure 193: Finding [Runtime]
7. Scroll until you find Runtime file. Open the Runtime file.
8. Check the following two lines:
a. Diode Expansion (located under [Data Input] heading)
headin
b. Diode Compression (located
located under [Data Input] heading directly under
“Diode Expansion”)
Expansion”
9. Change both settings to zero.
Figure 194: Runtime Screen
M-75-13-15, Rev A Page 189 of 260

10. Press Ctrl + S to save file
Adjusting the Boards with Diode Plot

1. From within the X--Ray Client program do the following:
a. Click on Menu
b. Select Diode Plot
c. Select X-Ray
Ray ON
d. Select Both Energy
Figure 195: Diode Plot Showing Misalignment
NOTE: Each column represents an LXDA board.
Itt should now be possible to isolate the misaligned diode board by regarding the raw
data displayed in Diode Plot. Once it has been determined which board needs
adjustment, perform the following steps:
2. Turn the adjustment screw for the corresponding LXDA board. Observe that the
pattern of red and blue “dots” moves upward.
3. Continue to turn the adjustment screw until the “dots” just begin to move down and
then bring them back to their maximum position.
M-75-13-15, Rev A Page 190 of 260

Figure 196: Diode Plot Alignment Results
4. Once the optimum readout for the previously misaligned board is achieved, close the
access door and replace the panel.
5. Exit the Diode Plot Screen.
LXDA Replacement Instructions

The following instructions are for replacing an LXDA board from the side LXDA box. The
instructions
ons apply to the top box as well, the only difference being that the top panel
would be removed instead of the side panel.
1. Make sure the machine is turned OFF. DO NOT turn on any X--rays when a person is
working inside the machine.
2. Remove the panel covering the side LXDA box.
M-75-13-15, Rev A Page 191 of 260

Figure 197: Removed LXDA Side Panel
3. Remove the two screws that secure the LXDA door behind which the problem LXDA
board sits.
Figure 198: Removing Screws on LXDA Door
4. Open the LXDA door, exposing the problem LXDA board.
M-75-13-15, Rev A Page 192 of 260

Figure 199:
199: Open LXDA Door, Diode Board Exposed
5. Figure 200 shows the LXDA board along with the two mounting bolts on the left side
of the board and the two mounting posts on the left side.
Figure 200:: LXDA Board Mounting Screws

Sc (left side) and Posts (right side)
6. Remove the cable connectors from the LXDA board.
M-75-13-15, Rev A Page 193 of 260

Figure 201: Removing Cables
7. Remove the two mounting screws shown in Figure 202,, being careful not to let them
drop.
Figure 202: Mounting Screws
8. Once the mounting screws are removed, slide the left side of the LXDA board off.
M-75-13-15, Rev A Page 194 of 260

Figure 203: Removing Left side of LXDA Board
9. With the left side of the board free, slide the right side of the board off the two
mounting posts on the right side.
Figure 204: Sliding LXDA Board off Posts
10. The LXDA board is now free.
M-75-13-15, Rev A Page 195 of 260

Figure 205: LXDA Board, Removed
11. To install a new board, reverse these directions.

12. When installing the new board, adjust the jumpers and DIP Switches on the new
board to match those of the board you are replacing.
13. After
fter replacing the problem board, perform
p the appropriate collimation if needed.
NOTE: This process must be done by trained technicians. Make sure to follow
appropriate safety process while performing the collimation.
14. Use Diode Plot to confirm that the new

new board is performing correctly.
M-75-13-15, Rev A Page 196 of 260

Radiation Survey
Following are directions for conducting a radiation survey on XIS X
X-ray machines.
M-75-13-15, Rev A Page 197 of 260

Required Resources
Qty Item Comments

1 Fluke™ Model Victoreen 451P Must have current (unexpired) calibration.
Pressurized Ion Chamber Radiation
meter or other appropriate calibrated
radiation measurement meter.
1 Astrophysics Quality Assurance – Verify that it is the most current revision.

Radiation Survey Form.
2 Radiation Scatter-Block Either a 9” x 12” soft pine block (as described

in ASTM F792-01 Section 1) or a wrapped
ream of commercial paper (500 sheets), 20 lb
basis. For Canadian bound x-ray systems,
use a rectangular 4x4 (3.5” x 3.5” x “width of
conveyor belt) pine wood “log” block.
Figure 206: Radiation Survey Required Resources
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Figure 207: High Power Radiation Survey Form
M-75-13-15, Rev A Page 203 of 260

M-75-13-15, Rev A Page 204 of 260

LXDA Board Installation and Gain
Purpose and Description
The OGC software is used in conjunction with a standard diode plot, however it offers
two important capabilities. In addition to remote correction, it allows much finer control
than local corrections made at the board itself. Offset and gain level now each have a
discrete range from 0 to 254.
Parts Included:
• LXDA 2.0 Board
• LXDA Interface Board 2.0.
• USB-Serial (DB9) Adapter Cable and its Hardware Driver on a provided

media (typically CD).(Generic component, may be obtained locally if required.)
• Male-to-Female Serial Cable (DB9). (Generic component, may be obtained

locally if required.)
• OGC Software REV 1.0.0 on a provided media (typically CD).
Required Materials and Tools

• USB flash drive to copy the hardware driver for the USB-Serial Adapter Cable
and the OGC software to the XIS’ embedded PC.
• Access to an additional PC with the drive types required to copy all files from
the provided media to the USB flash drive above. For example, a PC with an
optical drive (if on CD) and a USB port.
• USB keyboard and mouse for convenience.
• Tools required for LXDA assembly mounting and adjusting.
Procedure
LXDA 2.0 Board Installation
One of the primary design features to be aware of with the introduction of LXDA 2.0
boards is that they are part of a complete system, with two-way communication to and
from the PC. For the purpose of remote offset and gain correction, a communication
protocol must be carried through the LXDAs as a connected, "daisy chain" of boards. If
communication is broken at any point in the chain, all LXDA 2.0 boards beyond the
break will not be accessible to the OGC software, and can only be corrected locally.
For example, if there is an LXDA 1.0 board in the system, remote correction will be
unavailable to that board, as well as to any LXDA 2.0 boards beyond that point.
However, all 2.0 boards before that point will be accessible. For this reason, if there is a
mixture of LXDA 1.0 and 2.0 boards in an XIS (for example if field replacements are
M-75-13-15, Rev A Page 205 of 260

made), it is ideal to have all 2.0 boards at the beginning of the chain, and all 1.0 boards
at the end. The chain begins at the LXDA board which has the LXDA Interface Board
mounted to it, is “board #1.” This arrangement allows remote correction capability to all
2.0 boards in the system.
Some additional requirements for remote OGC capability are the inclusion of a new
LXDA Interface Board 2.0 (2 in "Parts Included" section above), and its associated cable
connections to the PC (3 and 4 in "Parts Included" section above). This hardware
completes the communication link for the OGC software to the LXDAs. The interface
board has a new serial connector, and is a direct replacement for earlier LXDA Interface
Board 1.0s. The cables combine to provide a USB connection at the PC, and a serial
connection at the LXDA Interface Board. These components must all be included when
upgrading earlier-production XIS machines.
1. While making sure that all standard safety precautions are complied with, open the
XIS cabinet, and open the lead LXDA box cover to gain access to the LXDA boards.
2. If a board is being replaced, remove the existing LXDA assembly. Do this by first
disconnecting all electrical input and output connectors as follows (seven total), and
then remove the board assembly from the XIS.
3. On the high-energy side disconnect:
a. Power connector (“J6” on LXDA 1.0 or “J11” on LXDA 2.0).
b. 10-pin control input “J8”
c. 10-pin control output “J9”
d. Analog output “JP4”
4. On the low-energy side disconnect:
a. 10-pin control input “J5”
b. 10-pin control output “J4”
c. Analog output “JP1”
5. Before installation of the LXDA 2.0 board assembly, inspect it for security to its
mounting bracket, and the security of the daughter board. A complete assembly will
have the steel mounting bracket and the photo diode daughter board in place.
Ensure that they are clean and free from any foreign objects between components.
6. Mount the assembly on the XIS, and connect all electrical inputs and outputs.
NOTE: For the power connectors, a change in design is currently being implemented.
As the transition is made to LXDA 2.0 boards, new 6-circuit wire harnesses are replacing
the older 3-circuit design. As mentioned previously, LXDA 2.0 boards are fully back-
compatible, but please see the caution note below.
NOTE: The power header “J11” on the LXDA 2.0 board is a new 6-circuit connector. It
replaces the 3-circuit header “J6” on the LXDA 1.0 board. The 3-circuit connectors on
the older wire harnesses are fully compatible with the 6-circuit header connectors on the
LXDA 2.0 boards, but beware of orientation and fit. The 3-circuit wire harness must be
coupled to the 3 circuits on the 6-circuit header that are closest to the edge of the board.
They are keyed to fit only one way, but can be fit incorrectly if forced together. The
correct connection is very easy to make and will clip in place. All future production
machines will have 6-cicuit power wire harnesses. However, in the field there will be
many 3-circuit wire harnesses.
M-75-13-15, Rev A Page 206 of 260

Figure 208: LXDA Power Connector Differences
Setting the LXDA Address in the DIP Switch

Once an LXDA 2.0 board is installed in its position on an XIS, the board must be
assigned its proper address using the DIP (“dual in-line package”) switch “SW1” located
on the low-energy side. This address is used by the OGC software to identify and
communicate with each specific board. Individual switches on the DIP component act
much like a typical jumper.
The board addresses are simply their position in the chain beginning with board #1 (the
board that the LXDA interface board is mounted to), and ending with the last board in the
chain. The total number of boards varies by model of XIS, and currently would be no
more than 18 boards. See an example of board numbers on the open LXDA box of an
XIS-6545 in Figure 209 below.
M-75-13-15, Rev A Page 207 of 260

Figure 209: LXDA 2.0 Board Numbering on an XIS-6545
NOTE: The board numbering on an XIS begins from the board to which the LXDA
interface board is mounted.
The board number must first be converted to “binary” to be able to set it in the DIP
switch. The conversion is given in the figure below. To find the correct DIP switch
setting, look up the board number in the first column of the table, and then find the
corresponding binary board address to the right of it.
Notice that the switch numbers in the table go from right to left, the same as printed on
the LXDA 2.0 board. The switch settings simply need to match the table. On the DIP
switch itself, up is “On” and down is “Off,” as marked. They are very small switches
which should be carefully set with a pointed device or fingernail.
NOTE: It is important to use the switch numbers printed on the LXDA 2.0 board labeled
“Address,” and to ignore the numbers printed on the DIP switch component itself. They
are numbered in opposite sequence. Also, all switches are not used. The switch to the
left of “Switch 4” is to remain in the “Off” position.
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Figure 210: DIP Switch Addressing Table for LXDA Component “SW1”
Example: Board #1 in the table in the figure above has a DIP switch configuration “Off –
Of f – Off – Off – On.” Compare that to the picture in the figure below. This shows an
actual board #1 DIP switch configured to match the table.
Figure 211: Address Properly Set on the “Board #1” DIP Switch
M-75-13-15, Rev A Page 209 of 260

Correction Mode Selection: Local vs. Remote
It is not possible to do both local and remote corrections at the same time. One mode or
the other must be selected. There are two new jumper components found on the LXDA
2.0 boards, “JP5” on the high-energy side and “JP6” on the low-energy side. Mode
selection is made using these jumpers. Offset and gain each have their own pins, and
are independent of each other.
Components “JP5” and “JP6” each have pin columns “A” and “B,” and pin rows “1,” “2,”
and “3.” Column “A” corresponds to offset, and column “B” corresponds to gain. A
jumper across rows “1” and “2” would correspond to local, and a jumper across rows “2”
and “3” would correspond to remote. See the summary below.
For “JP5” and “JP6”:
A = Offset
B = Gain
Jumper Across 1 & 2 = Local
Jumper Across 2 & 3 = Remote
For quick-reference, these settings are also printed on the center of the board itself,
immediately above the part number.
NOTE: Although the capability exists for both remote offset and gain correction, in
general only remote offset corrections will be made. Gain will generally be set locally at
production with the jumpers “J10” (high-energy) and “J1” (low-energy), and will no longer
need to be corrected. Certain special applications may require the use of fine-tuned,
OGC remote gain correction.
Example: On the high-energy side, to select remote correction mode for offset, do the
following. On component “JP5” (high-energy), in column “A” (offset), place a jumper
across rows “2” and “3” (remote). See the figure below, which shows “JP5” set up in this
configuration.
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Figure 212: Remote Offset Correction Selected on High Energy Side (“JP5”)
NOTE: On early-production LXDA 2.0 boards, for both “JP5” and “JP6,” pin “B1” is to be
cut off during assembly. No jumper connection across pins “B1” and “B2” is necessary
to make local gain corrections. The board defaults to local, and only a jumper is needed
across “B2” and “B3” to select the remote mode for gain. A different component design
will be used in the future. See the figure below.
Figure 213: Pin “B1” is Removed on “JP5” and “JP6” During Assembly
When corrections are to be made locally, LXDA 2.0 boards are identical to 1.0 boards
except for some component name changes. For offset, the high-energy side square
M-75-13-15, Rev A Page 211 of 260

trimming potentiometer is renamed “R-POT2” instead of “R759.” For the low-energy
side it is renamed “R-POT1” (low-energy) instead of “R27.” For gain the jumpers have
the same names, “J10” on the high-energy side and “J1” on the low-energy side.
Installing the Hardware and the Hardware Driver

The additional hardware components required to make the OGC software capable of
communicating with the LXDA 2.0 boards are the following (see part numbers in the
“Parts Included” section above).
A. LXDA Interface Board 2.0
B. USB-Serial (DB9) Adapter Cable and its Hardware Driver
C. Male-to-Female Serial Cable (DB9)
Newly manufactured XIS units will have an LXDA Interface Board 2.0 installed as
standard, replacing the previous-generation interface boards. All others must be
upgraded for OGC capability. The new interface boards are designed to carry a serial
COM link from the PC, and are mounted to the #1 LXDA board as normal.
Figure 214: LXDA Interface Board
The USB-Serial Adapter Cable and the Male-to-Female Serial Cable are both generic
parts. They may be obtained locally if required.
The required driver for the USB-Serial Adapter Cable must be copied into the proper
folder before hardware installation can begin. To install the required hardware driver,
follow the steps below.
1. The technician must be at the Windows XP desktop to install the driver and complete
the “Found New Hardware Wizard.” If currently in the XIS Imaging application, first
logout by pressing the AOCP “Logout” key, and then press the AOCP “Enter” key (or
the keyboard “Esc” key) to exit to the desktop. If pressing the “Enter” key at the login
screen does not exit the application, be sure to point and click inside the password
box first to activate the window, and then press the AOCP “Enter” key (or the
keyboard “Esc” key). See the figure below.
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Figure 215: Exiting the XIS Imaging Application to go to the Windows XP Desktop
2. Copy the provided USB-Serial Adapter Cable driver file to the correct driver folder.
The full path is as follows:
“C:\Program Files\Astrophysics Drivers\USB-SERIAL ADAPTER\WINDOWS”
The driver file that comes with the USB-Serial Adapter Cable will typically be on a CD.
However, the XIS’ embedded PC does not have an optical drive to directly copy the file
from if this is the case. Therefore, the file will probably first need to be copied from the
media that it was supplied on to a USB flash drive for transfer to the XIS’ PC.
Both Astrophysics-supplied and locally obtained USB-Serial Adapter Cables will vary in
appearance and driver media. One example package is given in the figure below.
Figure 216: An Example USB-Serial Adapter Cable and Driver on Mini CD
M-75-13-15, Rev A Page 213 of 260

If there is any problem locating the required driver folder in the XIS’ PC, follow the steps
in Figure 8 and the summary below.
Figure 217: Navigating to the Driver Folder
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Summary of “Navigating to Driver Folder”
Fig. 8 / Step 1: Click the Windows XP “Start” button (1-A), and then click the “My
Computer” menu item (1-B).
Fig. 8 / Step 2: Double-click the “Local Disk (C:)” drive.
Fig. 8 / Step 3: Notice the path beginning to build in the “Address” text box (outlined with
a thin ellipse) through the remaining steps. Double-click the “Program Files” folder to
open it.
Fig. 8 / Step 4: Double-click the “Astrophysics Drivers” folder to open it.
Fig. 8 / Step 5: Double-click the “USB-SERIAL ADAPTER” folder to open it.
Fig. 8 / Step 6: Next, either drag-and-drop, or copy-and-paste the supplied driver from
the USB flash drive, directly into the “WINDOWS” folder. If desired, confirm that the
driver file copied successfully by clicking on the “WINDOWS” folder to open it and view
its contents.
1. Connect the USB end of the USB-Serial Adapter Cable to an open USB port on the
PC. See the figure below. If there are no open ports available on the back of the
PC, there may be additional ports on the front.
Figure 218: USB-Serial Adapter Cable to PC Connection
When the USB-Serial Adapter Cable is connected to a USB port, Windows XP will either
automatically start its “Found New Hardware Wizard,” or do nothing. If nothing happens,
it is possible that a driver for this type of adapter has already been installed on that port,
which is OK. Otherwise it could be a bad USB port or a bad adapter.
NOTE: Each USB port is independent, and will recognize the USB-Serial Adapter Cable
as new hardware only if it was not previously installed on that USB port.
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When the wizard starts, follow the steps in Figure 10 and the summary below.
Figure 219: “Found New Hardware Wizard” for USB-Serial Adapter Cable
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Summary of “Found New Hardware Wizard” for USB-Serial Adapter Cable”
Fig. 10 / Step 1: The driver will be located manually. Check the “No, not this time” radio
button (1-A), and then click the “Next” button (1-B).
Fig. 10 / Step 2: The driver will be installed from where it was copied to in Step 4B
above. Check the “Install from a list or specific location (Advanced)” radio button (2-A),
and then click the “Next” button (2-B). The “Found New Hardware Wizard” may find and
use the correct driver automatically if allowed to, but the best way to be certain is to
locate it specifically using this option.
Fig. 10 / Step 3: Check the “Search for the best driver in these locations.” radio button
(3-A), uncheck the “Search removable media” check box (3-B), and check the “Include
this location in the search:” check box (3-C). Next, click the “Browse” button (3-D), and
navigate to the driver location that it was copied to in Step 4B above (“C:\Program
Files\Astrophysics Drivers\USB-SERIAL ADAPTER\WINDOWS”). Do this using the
“Browse For Folder” window which pops up. Starting from the “My Computer” location,
follow the same basic procedure that was followed above. Clicking the “+” symbol to the
left of an icon will expand the contents of that location for quick viewing and selection.
See immediately below.
Figure 220: Browse for Folder
When successful, the path will now show in the text box to the left of the “Browse”
button, ending with the “…\WINDOWS” folder (highlighted in blue in Figure 10 / Step 3).
Click the “Next” button (3-E).
Fig. 10 / Step 4: The wizard will now begin to install the driver. A dialog will immediately
pop up saying that the software “has not passed Windows Logo testing,” which is OK.
Click the "Continue Anyway" button.
NOTE: The “Prolific USB-to-Serial Bridge” hardware name that is referred to in the
dialog is a brand name. Brands will vary, but look for some reference to a USB-to-Serial
device.
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Fig. 10 / Step 5: If the driver installed successfully, the “Completing…” window will pop
up. Again, the same hardware brand name will be referenced. Click the “Finish” button
to close the wizard.
The USB-Serial Adapter Cable will now be recognized and assigned a COM port
number, “COM7” for example (which will be used as the example later in the OGC
software instructions). To install the rest of the required hardware, follow the steps
below.
1. The Male-to-Female Serial Cable is necessary because both the USB-Serial Adapter
Cable and the LXDA Interface Board 2.0 have male connectors. Plug the serial end
of the USB-Serial Adapter Cable into the female end of the Male-to-Female Serial
Cable. See the figure below.
Figure 221: USB-Serial Adapter Cable to Serial Cable Connection
2. Plug the male end of the Male-to-Female Serial Cable into the LXDA Interface Board
2.0 serial connector “J6,” which is mounted to LXDA 2.0 board #1. See the figure
below.
NOTE: If required, remove the LXDA Interface Board 1.0, and replace it with an LXDA
Interface Board 2.0 which has the serial connector.
M-75-13-15, Rev A Page 218 of 260

Figure 222: Male-to-Female Serial Cable Connection (Male End) to LXDA Interface Board
Installing the “Offset Gain Correction 1.0.0” (OGC) Software

If the OGC software has not yet been installed on the XIS, the procedure in this section
must be completed. To install the OGC software, the folder “OGC_1_0_0” will first need
to be copied to a USB flash drive from the provided media as discussed in the “Parts
Included” section above.
1. Connect and open the USB flash drive containing the OGC software. The
“setup.exe” installer file is found in the following location:
“…\OGC_1_0_0\OGC_1_0_0 Installer\setup.exe”
IMPORTANT NOTE: It is strongly recommended that the technician exit all programs
before running the installer, including virus-scanning utilities.
Double-click the “setup.exe” file to start the OGC installer. If there is any problem
locating the “setup.exe” file, follow the steps in Figure 13 and the summary below.
M-75-13-15, Rev A Page 219 of 260

Figure 223: Starting the OGC Installer
Summary of “Starting the OGC Installer”:

Fig. 13 / Step 1: Open the USB flash drive and double-click the “OGC_1_0_0” folder to
open it.
Fig. 13 / Step 2: Double-click the “OGC_1_0_0 Installer” folder to open it.
Fig. 13 / Step 3: Double-click the “setup.exe” file to start the OGC installer.
1. Once the installer has finished initialization (the window with the green status bar
closes), the “Destination Directory” window will open. Accept the default directories
for both “OGC_1_0_0” and the “National Instruments products” by clicking the “Next”
button. In the “License Agreement” window, select the “I accept the License
Agreements(s).” radio button, and then click the “Next” button. See the figure below.
M-75-13-15, Rev A Page 220 of 260

Figure 224: Step 1 in the OGC Installer
M-75-13-15, Rev A Page 221 of 260

2. Complete the process as prompted by the installer, and then restart the PC to
complete the installation.
3. After restarting the PC, return to the Windows XP desktop as described in Step 4A
above. Create an OGC application desktop shortcut for easier technician access.
To do this, navigate to and open the “OGC_1_0_0” folder in the following location:
“C:\Program Files\OGC_1_0_0”
4. Drag-and-drop a copy of the “OGC_1_0_0” application file to the desktop to create a

shortcut. The application file appears as shown immediately below.
The desktop shortcut will then appear.
If there is any problem locating the “OGC_1_0_0” application file, follow the steps in the
figure and summary below.
M-75-13-15, Rev A Page 222 of 260

Figure 227: Navigating to the OGC Application File
M-75-13-15, Rev A Page 223 of 260

Summary of “Navigating to the OGC Application File”
Fig. 15 / Step 1: Click the Windows XP “Start” button (1-A), and then click the “My
Computer” menu item (1-B).
Fig. 15 / Step 2: Double-click the “Local Disk (C:)” drive.
Fig.15 / Step 3: Double-click the “Program Files” folder to open it.
Fig. 15 / Step 4: Double-click the “OGC_1_0_0” folder to open it.
Fig. 15 / Step 5: Locate and then drag-and-drop a copy of the application file to the
desktop to create a shortcut. If needed, resize the “OGC_1_0_0” folder window using
the “Restore Down” button in the upper right corner. This will allow viewing of the folder
and the desktop at the same time. See immediately below.
Using the “Offset Gain Correction 1.0.0” Software (OGC)

1. Software Start Up: Start the “Offset Gain Correction 1.0.0” software using the
desktop shortcut shown immediately below.
NOTE: If a diode plot has already been started, it will likely cover up the shortcut for the
OGC software on the desktop. The OGC can also be started from the Windows XP
“Start” > “All Programs” menu. Typically, start the OGC software and get it set up before
starting a diode plot.
2. Once the software starts, the OGC window opens as shown in the figure below.
M-75-13-15, Rev A Page 224 of 260

Figure 228: OGC Window on Software Start-Up
To become familiar with the layout and function of the controls and indicators in the OGC
window, see the highlighted sections in Figure 17 and the summary below. Details
follow in the procedure instructions.
Figure 229: OGC Window by Sections
Summary of “OGC Window Layout & Functions”

COM Port Selector: On software startup, this is the active section of the window. It is
where the correct COM port is selected, and communications are established with the
LXDA 2.0 board chain.
Board Selector: This section has a slider control and board indicator lights to allow a
specific board to be singled out for corrections. Board indicator lights are feedback for
the technician, and flash whenever a board is acknowledging the receipt of a command.
Offset/Gain (O/G) Selector: This control is a toggle to select either offset or gain
correction. It determines what correction the “level selectors” are enabled to make.
Level Selectors: The level selectors are divided by energy. The top selector is high-
energy (“HE”), and has a red graphical level indicator, corresponding to the red high-
energy points on a diode plot. The bottom selector is low-energy (“LE”), and has a blue
graphical level indicator, corresponding to the blue low-energy points on a diode plot.
Each energy has two basic controls, a slider on the right for “coarse,” or large
M-75-13-15, Rev A Page 225 of 260

corrections (matched against a scale from 0 to 254), and up & down arrows on the left
for “fine,” or small corrections. Between the two is a text box which digitally shows the
precise level selected. A technician may typically start with a coarse adjustment. This is
done by either dragging the slider, or clicking in the slider track, to quickly approach
where the level needs to be on a diode plot. Then, a final adjustment is made either
using the up and down arrows, or by directly typing a level into the text box. The up &
down arrows are probably the most convenient method.
Options & Exit:
• “Address Test” button: This button is used to test communication with each
board, and is used as a verification of proper addressing, and that each
board is responding to commands.
• “Reset All Boards” button: A function to reset all boards to a nominal mid-
range value. It is used typically by production as a starting point for setting
levels on a new installation of LXDA 2.0 boards.
• “Single Board” / “All Boards” selector: A toggle control for either individual
board correction, or for all boards to be corrected simultaneously to the same
level.
• “Exit” button: To exit the software, and is always enabled.
Establish a Communication Connection
Communication with the LXDA boards must now be established. Until it is, all correction
controls will be inactive. To establish a communication connection, select the COM port
that was assigned to the “Prolific USB-to-Serial Bridge” during the hardware driver
installation. Locate it in the “Selected Com Port” dropdown list. Expand the list using
the arrow on the right side of the I/O text box. See the figure below.
Figure 230: COM Port Selector Dropdown List
NOTE: There are two simple ways to find the correct port if it is not immediately known.
First, it will usually be the other COM port in the list that is not COM1. COM1 is normally
assigned for other purposes like the cabinet interlock and PEC switches. LPT1 is
assigned to the PLC. Second, simply try each port in the list until the correct port is
found. The correct one will be detected by the OGC software automatically.
When the COM port is detected, the message box for “Com Port Status” will switch from
“No Connection” to “Detected COM7” (for example), and the round indicator light
M-75-13-15, Rev A Page 226 of 260

immediately to the left of the message box will flash green. Very shortly after, the
rectangular indicator below “Control Console” will turn green, and the “Enable” button will
become active. See Figure 19 below for an example of "before and after" a connection
is established.
NOTE: If a communication connection cannot be established with the LXDA boards,

please see “Condition 1” in the “Troubleshooting” section below.
Figure 231: Connecting to the Proper COM Port with the COM Selector
1. Click on the “Enable” button. The button will switch from “Enable” to “Enabled,” it will
become non-active, and a dialog box will pop up with the question, “Reset All
Boards?” Under normal service circumstances, this will not be necessary. Resetting
all boards is primarily used for initial production corrections. Unless otherwise
required, click on “Cancel,” as shown in the dialog immediately below.
Figure 232: Reset All Boards
All of the correction controls on the right-hand-side will now be enabled and ready for
use, and the OGC window will look as shown in the figure below.
Figure 233: OGC Window After Being Enabled
M-75-13-15, Rev A Page 227 of 260

Address Test
Once communication is established with the LXDA boards and the correction controls
are enabled, it is a good idea to begin with an address test using the “Address Test”
button. This function tests communication with each of the LXDA 2.0 boards. It is an
on-off toggle type control. When the button is clicked on, the board indicators in the
OGC window will flash green in continuous sequence from board #1, to the last board in
the system. In the example of an XIS-6545, it would flash only from 1 to 10 out of the 18
board indicators. If one board is not responding, but all other boards are, it is probably
because it has been addressed incorrectly.
NOTE: Again, any LXDA 1.0 boards in the chain will not respond. Also, any LXDA 2.0
boards in the chain which are located anywhere after an LXDA 1.0 board will not
respond. LXDA 1.0 boards will stop communication to all boards after their position.
The figure below shows how the OGC window appears when an address test is being
conducted. The Address Test button indicator light will be on, the board indicators will
flash from left to right, and all other controls will be disabled except "Exit" and "Test
Speed" (which is not visible except during an address test).
Figure 234: OGC Window During Address Test
Whenever an address test is being conducted, a new LED component “D-1” on the
LXDA 2.0 boards (low-energy side) will also flash in sequence, together with the
indicators in the OGC window. See the figure below. Both are feedback indicators, and
acknowledge control commands that are received by the LXDA 2.0 board from the OGC
software.
M-75-13-15, Rev A Page 228 of 260

Figure 235: LED Component “D-1” on the LXDA 2.0 Low-Energy Side
The figure below shows some of the detailed differences in the OGC window controls
with the “Address Test” on and off. “Test Speed” is how quickly the test runs through
and flashes each board indicator, which ranges from 1 to 10. The default speed is 1 and
is the fastest setting. If it is difficult to track the flashes of the board indicator lights, use
the test speed arrows to adjust it to a slower speed (toward 10). See the left side of
Figure 23.
Figure 236: Detailed OGC Window Differences with “Address Test” On and Off
By first checking individual communication with an address test, it will be known to the
technician what boards are available for remote correction, and to troubleshoot if
required.
M-75-13-15, Rev A Page 229 of 260

Setting Offset and Gain Remotely
While making sure that all standard safety precautions are complied with, pull out the
interlocks to the service-closed position. If this is not done first, the DiodePlot
application will give an “Interlock Open – Please Clear to Continue” message until the
interlocks are pulled out.
1. Start the “DiodePlot” application using the desktop shortcut shown immediately
below.
Figure 237: Shortcut to DiodePlot
After starting the diode plot application, it will be fixed above the OGC window, and the
OGC control functions will be available for use. Confirm that the O/G Selector is in the
“Offset” (up) position. Now, offset can be easily corrected for either a single board, or for
all boards simultaneously.
By first selecting the “Single Board” option, and then the specific board number desired
using the “Board Selector” control, that board may now be corrected for offset
individually. See the figures below. The example in this case is board #5.
NOTE: When selecting the board number using the “Board Selector” control, either the
slider itself can be dragged to the board number desired, or the technician may click in
the dark gray area of the “Slider Track” to move the control. See the figure below.
M-75-13-15, Rev A Page 230 of 260

Figure 238: Board #5 Selected for Individual Correction
Figure 239: Correcting Board #5 Individually with OGC Software and Diode Plot
Alternatively, by first selecting the “All Boards” option, all boards may now be corrected
for offset simultaneously. See the figures below.
NOTE: When the “All Boards” option is selected, the “Board Selector” control is
disabled. See the figure below.
M-75-13-15, Rev A Page 231 of 260

Figure 240: All Boards Selected for Correction
Figure 241: Correcting All Boards Simultaneously with OGC Software and Diode Plot
The figure below shows additional control details for offset and gain (O/G) level
selection. There are both coarse and fine correction controls. In general, begin by
dragging the “Slider Control” to make any large (or coarse) corrections required, and
then make the final small (or fine) corrections by using the “Up & Down Arrows.” This is
also described above in the “Summary of ‘Figure _. OGC Window Layout & Functions’,”
under the section “iv. Level Selectors:.”
M-75-13-15, Rev A Page 232 of 260

Two types of level indicators are available. The first are coarse “Graphical Level
Indicators” in the form of horizontal bars. These are associated with the coarse slider
controls. The second are fine “Digital Level Indicators,” which are associated with the
fine-tuning up & down arrow controls.
NOTE: Alternative methods of making coarse and fine corrections are the following.
For coarse corrections, the technician may click in the “Slider Track” to move the control
instead of dragging it. This is the same way that the “Board Selector” control functions
as described above. For fine corrections, the technician may select and then type a
value in the “Digital Level Indicator” instead of using the up & down arrows.
Figure 242: O/G Level Selector Controls in Detail
Exiting the OGC Software Application

When all desired corrections have been made to the LXDA boards, the OGC software
application may be closed using the “Exit” button in the bottom right corner of the OGC
window. The DiodePlot application may also be closed at any time.
Troubleshooting:
This section describes troubleshooting solutions for LXDA 2.0 installation, testing, and
correction.
Condition 1. A communication connection cannot be established with the LXDA 2.0

boards in Step 6B above.
1. Confirm that a COM port has successfully been assigned to the USB-Serial Adapter
Cable. The connection can be viewed via the hardware “Device Manger” under its
“Ports (COM & LPT)” section. To navigate there quickly, see the figure and
summary below.
M-75-13-15, Rev A Page 233 of 260

The connection name will have a “USB-to-Serial” reference of some sort, and a COM
port number. The specific name will vary by manufacturer, and the actual port
assignment. The example in this case is “Prolific USB-to-Serial Bridge (COM7).
Figure 243: Viewing the COM Port Assignment for the USB-Serial Adapter Cable
M-75-13-15, Rev A Page 234 of 260

Summary of “Viewing the COM Port Assignment for the USB-Serial Adapter
Cable”
Fig. 29 / Step 1: Click the Windows XP “Start” button (1-A), and then click the “Control
Panel” menu item (1-B).
Fig. 29 / Step 2: Double-click the “System” icon to open the “System Properties”
window.
Fig. 29 / Step 3: Click the “Hardware” tab.
Fig. 29 / Step 4: Click the “Device Manager” button to open its window.
Fig. 29 / Step 5: Click the “+” symbol to the left of the “Ports (COM & LPT)” icon, or
double-click the icon itself, to expand and view all available connections.
Fig. 29 / Step 6: The connection name will have a “USB-to-Serial” reference of some
sort, and a COM port number. The specific name will vary by manufacturer, and the
actual port assignment. The example in this case is “Prolific USB-to-Serial Bridge
(COM7).”
If the USB-Serial Adapter Cable was not successfully installed and assigned a COM port
while going through the “Found New Hardware Wizard” process, the name and icon for
the adapter will not appear as shown in Figure 29 / Step 6 above. Instead, an
exclamation mark will show up on top of the USB-Serial icon, and a generic “USB-Serial
Controller” name will be given. An example of this is shown in the figure below.
Figure 244: Unsuccessful Installation and Assignment of COM Port to USB-Serial

Adapter Cable
If the installation was not successful, there are several possible causes. Either, the
original driver was not correct, the driver was not successfully copied to the required
M-75-13-15, Rev A Page 235 of 260

location, the “Found New Hardware Wizard” process was not completed properly, or the
USB port that was used is faulty.
First, confirm that the driver is the one that was supplied with the USB-Serial Adapter
Cable. Next, confirm that the driver was copied to the correct location in Step 4B above.
Finally, try another available USB port for the adapter in case the original one used is
faulty, and then go back through the “Found New Hardware Wizard” in Step 4C above.
Once successfully installing the hardware driver for the USB-Serial Adapter Cable,
further confirm that the file used by the system for the adapter is correct by viewing the
“Driver File Details.” See the figure and summary below.
Confirming the File Name of Driver Used by System for the USB-Serial
Adapter Cable
Figure 245: Step 1 Confirming File Name of USB-Serial Adapter Cable Driver
M-75-13-15, Rev A Page 236 of 260

M-75-13-15, Rev A Page 237 of 260

Summary of “Installed “Driver File Details” for the USB-Serial Adapter
Cable”:
Fig. 31 / Step 1: From Figure 29 / Step 6 above, first double-click on either the
connection’s icon or its name to view its properties. The specific name will vary by
manufacturer, and the actual port assignment. The example in this case is “Prolific
USB-to-Serial Bridge (COM7).” Then, click on the “Driver” tab.
Fig. 31 / Step 2: Click on the “Driver Details…” button to open the “Driver File Details”
window.
Fig. 31 / Step 3: In one of the displayed lines, the original driver file name should show
up at the end of the following path: “C:\WINDOWS\system32\DRIVERS\...” The
example in this case is “ser2pl.sys.” It is OK if it does not show a green “digitally signed”
checkmark icon to the left of the driver file’s path.
Condition 2. An LXDA 2.0 board is not responding during an address test, or to the
correction controls, but all other boards are responding.
If a single LXDA 2.0 board does not respond to OGC commands, whether during an
address test or during actual corrections if an address test was not done first, the most
likely cause is a problem with addressing. While making sure that all standard safety
precautions are complied with, open the LXDA box and check the DIP switch (“SW1”) for
the correct board address. If the address is correct, then the DIP switch itself may be at
fault. Each DIP switch is like an individual jumper, except that they are switched to an
“on” position instead of placing a jumper block between pins. Troubleshoot all the
individual switches in the DIP component with a continuity check to see if a switch that is
supposed to be “on” is open, or a switch that is supposed to be “off” is shorted. It is
important in the checks to include the unused sixth switch on the left side of the row.
Condition 3. One energy level (high or low) is not responding beyond a given board
number during an address test, or to the correction controls, but the other energy level is
responding on all boards.
This situation will occur when a communication link is broken on one energy side at a
given point in the LXDA chain. While making sure that all standard safety precautions
are complied with, open the LXDA box and check the connection of the 10-pin ribbon
cable between the last responding board and the first non-responding board in the chain.
This needs to be done only on the side of the board (energy level) that is non-
responsive. If the 10-pin ribbon cable connections appear good, try a different cable. If
the cable is good, there may be a problem with a connector on either of these two
boards. Otherwise, some other board-related problem on the non-responsive board may
exist. To confirm, remove and replace it with a different LXDA board.
Condition 4. No LXDA boards are responding for either energy level beyond a given
board number during an address test, or to the correction controls.
This situation will occur when the communication link is stopped for both energy levels at
a given point in the LXDA chain. There are several possible causes for this. If all LXDA
boards beyond the point of lost communication are otherwise functional, there may be
one or more LXDA 1.0 boards in the system, beginning at that point. If there is a mixture
of boards in the XIS, then all 1.0 boards should be at the end of the chain for best use of
the LXDA 2.0 and OGC software’s capabilities.
M-75-13-15, Rev A Page 238 of 260

If not only communication is lost on all boards beyond a given board number, but
functionality is also lost as seen on a diode plot, then there is a problem with the first
malfunctioning LXDA in the chain. While making sure that all standard safety
precautions are complied with, open the LXDA box. First, check the power connection
to the failed board. Next, carefully check the board’s +5 and -5 voltages using the test
points available on the high-energy side near the power connector. These points are at
“F2” (+5) and “F4” (-5). See the figures below. There are two contact points available at
each location “F2” and “F4.” If the board has failed completely, then the 10-pin
communication line for both energy levels will be stopped, and all boards beyond that
point will not function on the diode plot.
CAUTION: To avoid damage, do not short the voltage test probe on the LXDA 2.0
board mounting bracket when testing the voltages at the “F2” and “F4” contact points.
Figure 248: LXDA 2.0 +5V & -5V Test Points and Mounting Bracket
M-75-13-15, Rev A Page 239 of 260

Figure 249: Close-Up of LXDA 2.0 +5V & -5V Test Points
If the board needs to be replaced for any reason, and a spare is not immediately
available, then swap the failed board with the last board in the chain to minimize the
impact on imaging until it can be replaced.
LXDA 2.0 / 1.0 Differences

This section is provided as a quick familiarization guide for production technicians and
field service technicians on the differences between LXDA 1.0 and 2.0 boards. It
highlights the most important component changes made to LXDA 2.0 boards relative to
LXDA 1.0 boards, and is organized by high-energy and low-energy sides.
High-Energy Side
The high-energy side of the LXDA 2.0 board, which is easily identified by the white
power connector “J11” and the name “Astrophysics Inc.” printed near the edge of the
board, is shown in Figure 250 below. The important component additions are
highlighted. For reference, the high-energy side of the LXDA 1.0 board is also shown in
Figure 251. The important component deletions are highlighted. A summary of all
important changes is as follows.
Summary of Changes to High-Energy Side:

New on the LXDA 2.0:
M-75-13-15, Rev A Page 240 of 260

1. JP5: Jumpers for selection of remote vs. local offset and gain trimming
2. F1: +5V resettable fuse (not visible with mounting bracket on)
3. F3: -5V resettable fuse (not visible with mounting bracket on)
4. J11: 6-circuit power connector
a. Deleted on the LXDA 2.0
5. JP3: 8-pin JTAG to load firmware
6. J6: 3-circuit power connector
a. Renamed on the LXDA 2.0
7. R-POT2: R759 on LXDA 1.0 (square trimming potentiometer)
Figure 250: LXDA 2.0 High-Energy Side Additions
M-75-13-15, Rev A Page 241 of 260

Figure 251: LXDA 1.0 High-Energy Side Deletions
Low-Energy Side
The low-energy side of the LXDA 2.0 board, which is easily identified by the six-switch
DIP “SW1,” is shown in Figure 252 below. The important component additions are
highlighted. For reference, the low-energy side of the LXDA 1.0 board is also shown in
Figure 253. The important component deletions are highlighted. A summary of all
important changes is as follows.
Summary of Changes to Low-Energy Side:

New on the LXDA 2.0:
1. J12: 6-pin JTAG to load firmware

2. JP6: Jumpers for selection of remote vs. local offset and gain trimming
3. D-1: LED for LXDA communications feedback indication
4. SW1: DIP (dual in-line package) switch for setting LXDA address
a. Deleted on the LXDA 2.0
5. JP2: 8-pin JTAG to load firmware
a. Renamed on the LXDA 2.0
6. R-POT1: R27 on LXDA 1.0 (square trimming potentiometer)
M-75-13-15, Rev A Page 242 of 260

Figure 252: LXDA 2.0 Low-Energy Side Additions
Figure 253: LXDA 1.0 Low-Energy Side Deletions
M-75-13-15, Rev A Page 243 of 260

M-75-13-15, Rev A Page 244 of 260

Recovering from a Failed Hard Drive
This procedure is written specifically for a dual view XIS 320kV machine.
Introduction:
One benefit of a dual-view system is the recovery options available with the master/slave
PC redundancy. Having dual-PCs is a particular advantage in the event of an operating
system or hard drive failure because a disk image (clone) of the operational PC may be
used to get the other PC functional again. The procedure below describes the steps and
configuration settings necessary to complete the task. If a hard drive has failed
completely and a new one is not immediately available, then the dual-PC design also
has the advantage of allowing temporary operation of the machine in single-view mode.
In this case it’s required to have the master be the running PC, so if the master PC fails
then the slave must be configured as the master. This procedure will also give the
necessary steps for that if used in the reverse direction as the example given (i.e. slave-
to-master instead of master-to-slave).
Required Tools & Materials:

• Bootable USB drive with a disk imaging (cloning) utility
• USB keyboard
• USB mouse
• 2 x USB extension cables
• USB hub
• #2 Phillips screwdriver
• Keys for frame panel locks (if applicable)
• Replacement HDD (if applicable, usually failed operating system or other

software and not necessary to replace the hard drive)
• New or reset USB security key possibly required
Procedure:
Ideally disk images have already been saved on an external drive for a master PC and
slave PC of the same model dual-view unit with the same model PC. In this case
recovery is a simple re-imaging of the failed disk, and then restoring the original
“C:\Program Files\Xray Client\runtime.ini” configuration file. If not available, then the
following are the configuration steps necessary when imaging one hard drive to the
other.
The example given is for a master PC hard drive being imaged to a slave PC:
1. Many times it’s possible to access files on the corrupt hard drive by booting from an
external drive, then copying the original “C:\Program Files\Xray Client\runtime.ini”
M-75-13-15, Rev A Page 245 of 260

configuration file. If not, then please contact service@astrophysicsinc.com with the
machine serial number to request a copy.
2. Create a master PC disk image and clone it to the slave PC. Some additional
guidelines are given in the document “Creating a Disk Image”.
3. Boot the slave PC on its local hard drive, and immediately close “shutdown.exe” to
prevent the PC from shutting down due to the lack of a network connection and
therefore no key switch “on” signal. Note that the slave PC will not be accessible
from the master PC when the network connection is unavailable. It will only be
accessible by keyboard and mouse via direct USB connection.
4. Change the PC name to “Slave”. The multi-PC KVM application uses the machine
name when setting the master/slave relationship. Path: “Start” > “Control Panel” >
“System” > “Computer Name” > “Change”.
5. Change the last octet of the static IP address from “.250” to “.251”. Note that any
valid IP address will work, but the typical setup for master and slave is
“192.168.1.250” and “192.168.1.251” respectively, both with a subnet mask of
“255.255.255.0”. Path: “Start” > “Control Panel” > “Network Connections” >
right-click “Local Area Connection” > “Properties” > select “Internet Protocol
(TCP/IP)” > “Properties” > “IP address”. Please see Figure 1 below.
Figure 254: Static IP address settings for the Slave PC
6. Delete the shortcut to Diagnostics from the Startup folder. Diagnostics runs on the
master PC only. Path: “Start” > “All Programs” > “Startup” > right-click
“AstroDiagnostic” > “Delete”. Please see Figure 2 below.
M-75-13-15, Rev A Page 246 of 260

Figure 255: “AstroDiagnostic” in the Windows Startup folder
7. Copy the original slave PC runtime.ini file to the Xray Client folder.
8.
9. Enable sharing of the Xray Client folder. Note that this is not necessary on the
master PC. Path: right-click “Xray Client” folder > “Properties” > “Sharing” > “If
you understand the security risks but want to share files without running the wizard,
click here.” > “Just enable file sharing” > “OK” > select both “Share this folder on
the network” and “Allow network users to change my files”. Please see Figure 3
below.
M-75-13-15, Rev A Page 247 of 260

Figure 256: Folder sharing property settings for the Slave PC’s “Xray Client” folder
10. Create a shortcut to the slave PC’s Xray Client folder on the master PC’s desktop to
simplify maintenance access to the slave’s folder. Path: “Start” > “My Network
Places” > right-click “Xray Client on Slave” > “Send To” > “Desktop (create
shortcut)”.
11. Configure the multi-PC KVM application being used, such as “Synergy” or “Input
Director”. Early units used Synergy, later units used Input Director, and the latest
units as of 25OCT2012 are using Synergy again.
Synergy
If it is possible to access files on the corrupt slave PC hard drive from a bootable external
drive, then copy the original “C:\Program Files\Synergy\synergy.sgc” configuration file
and place in the same folder on the slave PC. If not, then please contact
service@astrophysicsinc.com with the machine serial number to request a copy.
Input Director
Double click the “ID” icon on the Windows taskbar to bring up the interface > under
“Slave Configuration” > select “Allow any computer to take control”, and under
“Global Preferences” > select:
• “Input Director is enabled as a Slave”
• “Background slave active for all users and at logon”
• “Run Input Director on Startup”
M-75-13-15, Rev A Page 248 of 260

• “For All Users”
1. Shutdown the slave PC via Windows, then shutdown the complete system with the
key switch, and finally do a normal system restart.
2. The slave PC theoretically should not need a new USB security key since the Xray
Client software REV and the PC hardware is not changing. However, sometimes a
new hard drive requires a new or reset USB security key.
Troubleshooting:
1. If there is no network connection between the PCs after start up, then check that the
network speed is set to “Auto Negotiation” on both PCs, and restart both PCs. If this
doesn’t repair the connection, then force the speed “1.0 Gbps Full Duplex” on both
PCs, and restart both PCs. Path: “Start” > “Control Panel” > “System” >
“Hardware” > “Device Manager” > expand “Network adapters” > right-click on the
network adapter card, will be the only one and something similar to “Intel® 82567LM-
3 Gigabit Network Connection” > “Properties” > “Link Speed” tab > “Speed and
Duplex:” drop down list > “Auto Negotiation” or “1.0 Gbps Full Duplex” respectively.
M-75-13-15, Rev A Page 249 of 260

M-75-13-15, Rev A Page 250 of 260

Fingerprint Reader and Bar Code Scanner
The XIS 320kV machines are compatible with a number of accessories, including
additional entry and exit roller beds (already covered in this manual), Fingerprint
Readers and Bar Code Readers.
USB Connection
Both the Fingerprint Reader and Bar Code Readers are USB peripherals. USB
peripherals are plugged into the cluster of outlets at end of the XIS beneath the entry
roller bed, as shown in Figure 257.
Figure 257: Cluster of Outlets
Because there are more USB peripherals than there are USB outlets, use a USB hub, as
shown in Figure 258, to plug in the Bar Code scanner, Fingerprint Reader and any other
USB peripherals, such as the PC keyboard.
M-75-13-15, Rev A Page 251 of 260

Figure 258: USB Hub
Note, neither the Fingerprint Reade

Readerr nor Bar Code Scanner are “hot swappable,” and
must be plugged in while the PC and the XIS are turned off. If you plug either device into
the USB port while the XIS and PC are on, you will receive an XrayClient error message
similar to the one in Figure 259
Figure 259: XrayClient Error Message
Barcode Reader
The Barcode reader, as the name suggests, reads barcodes. Specifically, certain cargo
pallets and packages have been pre-identified
pre identified with barcodes prior to arriving for
scanning by XIS machines. The XIS Operator or assistant uses the Barcode Reader to
scan those barcodes, which are then electronically attached to the image file that is
created by scanning that pallet or package.
The Barcode Reader is a two

two-part
part device, consisting of the scanner itself and the base
which acts as a charger. Figure 260 shows the Scanner and base.
M-75-13-15, Rev A Page 252 of 260

Figure 260: Barcode Scanner and Base
Figure 261 shows the Scanner and Base separately.
Figure 261: Scanner and Base Separate
Once the Operator or Assistant have scanned the barcode label on the pallet or
package, the Operator scans the object. When the image of the scanned object appears
on screen (as shown in an overhead scan in Figure 262) the barcode number appears
directly beneath the bag counter in the lower left hand corner of the slave monitor.
M-75-13-15, Rev A Page 253 of 260

Figure 262: Overhead Scan of Object, with Barcode Number
Once a Barcoded object has been scanned, the Barcode number beneath the bag
counter will reset to zero.
Figure 263: Barcode Set to Zero
Attaching the Barcode number to the image file allows that file to be retried at a later
date by entering Archive Mode and inputting the Barcode as shown in Figure 264.
Figure 264: “Input Bar Code” Field
M-75-13-15, Rev A Page 254 of 260

Figure 265: Bar Code Operational Flow Chart
M-75-13-15, Rev A Page 255 of 260

Fingerprint Reader
Figure 266: Fingerprint Reader
The Fingerprint Reader allows a user to log in using nothing but his fingerprints, as read
by the Fingerprint Reader. Thus, he must have his or her fingerprints “registered” on the
XIS system PC. This can be done only by someone who has the access and
permissions of an Administrator. Fingerprint Registration is accomplished as follows:
1. Log In to the XIS system as described in LOGGING INTO THE XIS on page 95.
2. Select “Administrator” and “Management” as shown in Figure 267.
Figure 267: Administrator/Management Modes
M-75-13-15, Rev A Page 256 of 260

3. Enter your Administrator Username and Password. Or, since the Administrator would
probably already have his or her fingerprints registered on the XIS PC, the
Administrator can simply place his finger on the reader and be automatically logged
in without having to manually input any user information (see below).
4. Once the Administrator has logged in either manually or via fingerprint recognition,
he or she will be in the Administrator Menu screen.
Figure 268: Administrator Menu screen
Select “Employee” which will bring you to the “Employee’s Record” screen.
Figure 269: Employee’s Record screen
M-75-13-15, Rev A Page 257 of 260

The “Employee’s Record” screen allows you to edit, delete or add employees to the
database.
Figure 270: Editing or Deleting Employee Records
In order to add an employee’s data and/or fingerprint to the database:
1. Click the “Add” radio button, which will bring you to the “Add New Employee” screen:
Figure 271: “Add New Employee” screen
M-75-13-15, Rev A Page 258 of 260

2. Complete the self--explanatory “Add New Employee” data fields (e.g. “ID Code,” “Job
Position,” “Hired Date,” etc.).
3. Once all fields are filled in, click on the “Register Fingerprint” radio button on the
middle right side of the screen.
Figure 272: “Register Fingerprint” radio button
The following prompt will appear:
Figure 273: Fingerprint prompt
4. Place your finger on the Fingerprint Reader.
M-75-13-15, Rev A Page 259 of 260

Figure 274:
274 Placing Finger on Fingerprint Reader
The following confirmation message will appear. If the prompt does not immediately
appear, move your finger slightly; roll it gently back and forth until the prompt does
appear.
Figure 275: “Fingerprint Registered” prompt
5. Click “OK,” and the prompt will disappear.

6. Make sure to click on the “Active,” checkbox, and then
hen click “Save and Exit.”
7. Log out and then back in order to enable the new fingerprint registration.
NOTE: The fingerprint reader has read one and only one of your fingers and that you
must place only that specific finger on the reader when logging in. T
The reader will not
recognize your ring finger if you registered your pinky finger.
When logging back in, simply place your finger on the reader. You will be taken
immediately to the next screen, bypassing the need to manually input user information.
M-75-13-15, Rev A Page 260 of 260

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TITLE XIS 320kV Installation and Maintenance Manual

Installation and Maintenance Guide for the Astrophysics X-ray

REVISION M-75-13.16, Rev. A

RELEASE August 2013

REV AUTHOR DESCRIPTION CHANGES

A Rob Tobin First Release First Draft

The information contained in this document is believed to be correct as of the date of

Confidential and Proprietary Notice

M-75-13-15, Rev A Page 2 of 260

VERY IMPORTANT OPERATIONAL INFORMATION is highlighted in yellow and

INFORMATION RELATED TO PERSONAL SAFETY is highlighted in red and preceded

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Astrophysics Astrophysics, Inc.

CDRH US FDA Center for Devices and Radiological Health

DAS Data Acquisition System

ER1 Entry Roller (Bed) #1

ER2 Entry Roller (Bed) #2

EX1 Exit Roller (Bed) #1

EX2 Exit Roller (Bed) #2

FDA United States Food and Drug Administration

LXDA Linear X-ray Detector Assembly

NRC United States Nuclear Regulatory Commission

PPE Personal Protective Equipment

XIS X-ray Imaging System

XRG X-ray Generator

XRT X-ray Tube

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• Lead shielded construction to minimize radiation leakage.

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• Password protected access to the application software.

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• Do NOT operate the unit when

• Clear the x-ray

• If material should become jammed during operation, the machine must be

• Although the system utilizes an extremely low xx-ray

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• Always perform a comprehensive radiation survey and safety inspection after

• Turn "OFF" the equipment as soon as an unsafe operating condition or

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• Perform a comprehensive radiation survey after servicing the XIS.

• In Canada, Health Canada requires registration of all baggage x-ray

• For service and support contact:

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• U.S. Food and Drug Administration, Department of Health and Human

• U.S. Federal Aviation Administration, Code of Federal Regulations Title 14

• U.S. Federal Aviation Administration, Code of Federal Regulations Title 14.

Local Regulatory Compliance

• Some jurisdictions require the registration of x-ray producing equipment

• Many jurisdictions require initial and annual radiation safety surveys.