FR590

• Introduction
• Camera unit (Interface between FR590 and an old X-ray camera)
• Safety instructions Read these before using the equipment
• Specifications
• Installation.
• Pre-installation requirements
• Operation
• Maintenance
• X-ray tubes
• Disposal
• Troubleshooting
• Manufacturer and Service

Introduction

The FR 590 is a high voltage supply for a sealed X-ray tube and consists of:

• High voltage generator.
• Safety circuit, when connected to a Nonius goniometer
• Cooling water connections with
• Cock to empty the tube's water circuit.
• Water flow switch for check on minimal water flow. There is no check on the input water temperature.

• X-ray safety; see the instruction of the goniometer
• Beryllium
• Electrical safety

X-ray safety

• The equipment must be operated under the responsibility of an X-ray safety officer, as stated by local regulations.
• The equipment must be operated, serviced and maintained by qualified personnel who are trained with the hazards of and precaution against X-ray exposure.
• The equipment contains safety circuits which should not be overridden,
• The X-ray key should not be kept with the instrument, but under the custody of the X-ray safety officer in case X-ray is not allowed to be used.
• Safety circuits must be tested by service personnel or the safety officer at least every 12 months, as described in the manual of the goniometer.

The X-ray tube contain windows of beryllium which can be corroded. This corrosion is very poisonous. When removing the tube these can be reached and care must be taken not to touch these window. When by accident the beryllium is touched, wash with soap and water. See also the general explanation of Be hazards or the X-ray tube mounting instructions. From mid 2000 the X-ray tubes will be delivered with a protective cover :

• Remove bag and cover only just before installation in the system.
• When the tube is removed from the system for a short time, the cover should be put back on the tube.
• When removed from the system for a longer time or permanently the tube, with protective cover, should be packed in a plastic bag (after removing all cooling water). A spare bag is added with the tube

Electrical safety

Access to the area inside the generator is only allowed by qualified technical personnel. Open power terminals can be reached inside the generator. When a qualified technician wants to access these parts or the HV cable, first disconnect the power connector (don't touch the connector pins) and wait several minutes to allow discharge of all components.

 
Safety interlocks

• The shutter does not close.
• The high voltage cable is not connected to the X-ray tube (indicated by a link, attached to the cable)
• The X-ray on lamp is defect.

• X-ray on
• Standby power
• Remote control
• Special commands

• Switch the key (power) on.
• The green "system OK" lamp on the front panel will lit.
• Press: X-ray on.
• The X-rays on lamp on X-ray tube and the front panel will burn..
• The power relay switches on (audible).
• After approx. 5 s first kV and then mA will rise to the chosen value (minimum 20 kV 5 mA).

• To go to remote control (so an external program like KappaCCD or MACH3 can control the kV/mA):
• Press 590 <return> 9 <return> <return> (<return> mains while keep pressing 1 press <enter>)
• After the second <return> you will get : ........for a figure code (password). Normally don't use this.
• Leaving remote control :
• Press <return>, 2x <CR>
• When using a figure code (password): code, <return>, 2x <CR>

With special commands in the "590 mode", internal data can be read:

• Go into 590 mode with: 590 <enter>
• Choose the code with: code number <enter>
• Modify : keep the last number of the code number pressed during <enter>.
• When pressing <enter> the second number of the code will go up.
• One step back with: <CR>
• Go out of the 590 mode with: several <CR>

• Periodic maintenance.
• Internal power and fuses
• Cleaning of the outside.
• For cleaning use a damp cloth, moistened with water or isopropyl alcohol. No cleaning agent may enter the generator.
• X-ray tube
• Mounting
• Cleaning
• Parts
• Zero power RAM
• Water flow switch
• X-ray tube

A yearly check is advised, which contains:

• Check of the water flow, the water flow switch and the water temperature. Because the flow switch can be polluted, depending on water quality, it is advised to check this more frequently, like ones per month. This quick and rough test can be done by switching off the water cooling and then switch on the X-ray shortly, with the lowest setting 20 kV 5 mA.
• Clean the internal ventilator, when it is very noisy, it should be replaced.
• When combined with a goniometer with tube: Open the X-ray tube and clean the water filter and check the X-ray tube on overheating.
• Check the battery life Zero power RAM. When it is below 15%, it is advisable to replace.
• Check the safety with the goniometer safety check.

X-ray tube

See the instruction manual of the X-ray tube, which is delivered with every new tube (at the bottom of the box). A drawing is also in the last pages or on page 42 of the old 590 User manual. Some items:

• For long life time :
• Don't switch off from full power : first lower the mA, then the kV, then switch off.
• For power up: first set the kV, then the mA.
• When the tube is new or not used more then 24 hours a conditioning procedure is advised (see the Tube manual).
• When not used for a short time : leave the tube on 20 kV, 5 mA (Siemens tube) or 40kV 10 mA (Philips tube) instead of switching off.
• Regularly feel by hand the temperature of the tube. When it gets warm, clean the tube inside
• Clean the inside of the tube at least every 1000 hours of operation.
• Take into account there are long (B) and short (A) tubes. Long tubes needs an adapter. Nowadays short tubes are delivered, for which no adapter is used. Don't use a long tube without the adapter, because this will destroy the tube.

• Dismounting :
• Turn off the mains.
• Close the external inlet valve of the water supply (as an extra precaution).
• Turn the drain valve to the drain position.
• Connect the bicycle pump and pump until you notice a decrease in pressure. This will empty the tube's water circuit as far as possible.
• Remove the X-ray tube (don't remove the HV cable).
• Be careful: the X-ray tubes has beryllium windows which could cause safety hazards. See safety instructions
• Handled the tube by holding the cooling plate or by the cylindrical metal part between the glass/ceramic insulator and the window area. Do not handle the tube with the new safety cover, because it may slip away from it
• Take into account that not all water is removed.
• Check for leaks near the X-ray tube.
• Open and clean the tube
• Mounting :
• Make sure that the interior of the tube shield is dry and clean.
• With a new tube with safety cover : remove also the elastic ring
• Mount the tube
• Open the outside water inlet valve.
• Turn the drain valve to the cooling position.
• Turn the mains on. The system has noticed that a tube is changed and starts asking for the tube parameters.
• In case of a used tube: Select the proper tube number and press <enter> for the other parameters.
• In case of a new tube:
• Choose a new tube number (or just the default 0)
• Input the maximum tube voltage, mostly the default 60 kV with <enter>
• Input the maximum tube current, depending on the tube used (see the Tube manual: fine focus : 40 mA)
• Input the maximum tube power, depending on the tube used.
• Input the number of hours the tube has already been used  with <enter>
• If you made a mistake press <CR>.
• If you have made a mistake after all date is entered, just switch the drain valve on and off and start again.
• It is possible to check if the right values are set with the special commands
• Initialize  the new tube as described in the tube manual
• Siemens ceramic tubes and KappaCCD. The Collect program has a command: newtube [scenario] with executes this startup automatically. See the manual of Collect for a description.

See the Tube instruction manual delivered with tube :

• Remove the X-ray tube
• Remove the four screws in the top cap.
• 
• Remove the water nozzle but do not deform it (do not use pliers when the nozzle is stuck). Clean it, using methanol, a lint free cloth or Scotch Brit (type 7558).
• Remove the filter and clean it.
• When there is deposit on the anode cooling face (the gold pyramid structure) :
• Put the tube with the anode up.
• Fill the anode coupling space with acetic acid (10%).
• Scrub the pyramid with a small, soft brush with short hairs.
• Leave it for 20 minutes and scrub again.
• Flush the area with water and refill with acid.
• Repeat until the anode is clean.
• Fit the water filter.
• Mount the nozzle till  the position hole slides just over the positioning pin. Do no push it completely till the base plate, because during final mounting the nozzle must be pressed against the cooling surface of the anode.
• Place the tube on the base plate, ensure that the sealing rings are in place and tighten the four screws. One of these screws is positioned asymmetrically to ensure correct positioning.

• The HV tank contains oil without PCB's. A statement in Acrobat .pdf form can be retrieved
• The X-ray tubes contain beryllium windows. Disposal must comply with the national and local regulations governing beryllium.

Zero power RAM

Calibration values are saved in a memory with an internal battery : the Zero power RAM. When the battery is empty the values are lost and the error UNCALIBRATED appears. The battery live is about 3 years of non power buffering + time the generator is on, total mostly about 7 years. The software is calculating (not measuring) the life time which can be read out. It is advisable to change the Zero power RAM when it reaches 0%, although a longer life is possible. All the tube data and total timing data will be lost. When the battery is empty the generator will remain working, but after every power off/on the tube data must be input.

When ordering a new Zero power RAM, supply the serial number of the generator (you will find it at the back) so the RAM can be programmed in the factory.

The Zero power RAM is normally installed by a service engineer. If you would like it to be installed by your own qualified technician, this is possible, but there is then no warranty:

• Disconnect the mains power connector.
• Move the generator forward by means of the spindle at the rear. This spindle must fall in the second hole in the runner.
• Remove the small upper cover at the front.
• Remove the first board (in front).
• Replace the zero power RAM.
• Run the 590 modify option:
• For input of time: 1 0+enter
• For input of date: 1 1+enter

The water flow can be checked with a flow meter or with a bucket with litre lines. It should switch off below 3.5 l/min.

When the switch does not work properly:

• The switch is found behind the draining handle: remove the plate with four screws.
• 
• Check if the voltage on the wires is switching.
• Remove the dismountable part (first switch off the water) and check for pollution.
• When there is no pollution, a new switch must be ordered (only the removable part). Readjusting the switch normally does not help.

Internal power and fuses
 

• Power indicating lamps and fuses on the power unit. Slide the generator out of the cabinet and open the small top-front cover:

• Backside of the generator:
• F1, F2: 4A slow blow for mains power of electronic
• Automatic fuse: for mains of HV power.

• Error messages.
• Error history : retrieve with special commands
• Green System OK lamp flashing : press enter and check the error message
• Tube broken with water leaking
• Tube overheated

When an error occurs:

• The HV is switched off.
• Depending on the type of error the generator is retrying, showing the message SYSCHECK (without the type of error).
• After retrying the error message is shown. This message disappears after 1 minute, but the green System OK remains flashing and the error message can be can retrieved by pressing enter.
• If the error condition is removed, the message must be cleared by pressing clear, before operating can resume.
• As soon as an error occurs, it is saved in the error history. Because an error can be caused by preceding errors (and only the last is shown) it is advised to always read out the error history

ERROR 1/2: see Camera unit
.... V MIN
CAB TEMP
CABLE LINK
COMP ERR
DRAIN ERR
EXT XLAMP
MA MAX
OIL LEVEL
OIL TEMP
RAM ERR
SHUTTER
SPARK
UDC MIN
UFIL MIN
UNCALIBRATED
WATER
All kinds of error messages

MA MAX

X-ray tube defect (high voltage shortage between anode and cathode).

UDC MIN

• Automatic "Stotz" fuse at the back of the generator in the OFF position.
• Mains power is too low (below 180V) or unstable (when immediately after starting X-ray).
• Check in the error history if this error is preceded by another error (the real error, which switched off UDC)
• X-ray tube is defect.
• Please check and inform the service department:
• Measure the UDC in 590 mode (27). It starts at zero.
• Switch on HV and describe exactly what happens:
• Do you hear a large relay switching on
• Is UDC rising or not (should be about 350)
• Is the automatic fuse switching off? If it is, does it switch off immediate after switching HV on or after a short time.

Internal power voltage is too low. Check the power supply

UFIL MIN

Filament voltage is too low. Check the +15V/+28V supply.

CAB TEMP

Temperature inside the cabinet is too high. Check the fan in the Power unit (with the red lamps).

OIL TEMP

Oil temperature inside the HV tank is too high.

• Cooling water temperature too high.
• Cooling water flow too low.

Oil level inside the tank is too low. Check for oil leakage in the cabinet.

CABLE LINK

The dummy connector at the HV cable is not placed in the connector on the X-ray tube, indicating that the HV connector is not safely connected.

SHUTTER

The shutter is not fully closed (according the shutter switch the shutter is open, while is should be closed).

EXT XLAMP

The external X-ray on lamp on the X-ray tube is defect.

• Check  if the GON UNIT cable between FR590 and goniometer is connected (the X-ray lamp is electronic driven by the Goniometer Interface.
• Check the power inside the Goniometer interface (indication LED's on the back plane when the Interface is opened)

WATER

The cooling water flow is below 3.5 l/min.

• Clean the X-ray tube filter
• Check the water flow switch

Turn the generator off and on again. If no error is detected this time, normal operation is possible after confirmation of the previous RAM error.

SPARK

There were more then 255 HV flash-overs within an hour (it was about 6 in the past and in older manuals).

• Clean the HV connector in the X-ray tube.
• X-ray tube is defect.

The real kV and mA differ from the setpoints chosen.

• No mA. After X-ray on there is kV but no mA (shortly thereafter the kV slowly decrease). This indicates a bad connection with the tube or an absent filament current.
• Check if not a short tube was mounted with the long X-ray tube spacer.
• Clean the contact of the HV connector to the tube.
• Be sure the brass connector set is pushed in the connected inside the rubber tube. Remove and mount again
• 
• Pull out the brass connector and check if the connections inside are all right, also when pressed. If not, a new part should be ordered.
• Measure the resistance between the two connections of the tube (middle and ring, it needs long test probes). If should be low ohms. If not, the tube (filament) is defect.
• When a tube was overheated
• Defect X-ray tube.
• A comp error can also be caused by preceding other errors, so always read the error history.
• Please check and inform the service department:
• Measure the UDC in 590 mode (27). It starts at zero.
• Switch on HV and describe exactly what happens:
• Do you hear a large relay switching on
• Is UDC rising to about 350
• Are the setpoints rising to 20 kV, 5 mA?
• Are the outputs rising to 20 kV, 5 mA?

The drain valve is open during HV generation.

UNCALIBRATED

The battery inside the zero power RAM (IC 13 on the Control board) is empty. Replace the ZRAM
It is possible to continue working with the generator by entering, without change, all unknown parameters (do input the maximum voltage, current and power), but this must be done every time the generator is powered up.

Tube broken with water leaking

An old tube in which a hole is burnt in the anode. The leaking cooling water will have broken the hot glass.

Overheated tube

When for some reasons the tube has been overheated:

• The HV connector should be inspected for damage by heat. If the damage is not visible worse, check like described in Comp errors. If it is worse, new parts could be needed.
• Check all other parts inside the tube holder for damage.

With all kinds of not related error messages the cause can be electrical disturbance from HV flash over or sparks.

• Try a new tube.
• Check the HV cable on spark problems
• A combination with GX13 is always more susceptible for electrical disturbance.

• Shutters can be opened and closed with the clock or manual buttons. The LED's reflect the active state. A shutter can only be opened when the following items are fitted in place and are working properly:
• Collimator
• Radiation safety enclosure doors closed. Alternatively the doors can be open but a flashing warning device must be used.
• Shutter lamps

• Pause mode
• Led blinking when "HV ON" is started.
• 30 seconds delay.
• All shutters are closed.
• Clock time is at halt.
• The remote shutter control box can be used.
• Active shutters re-open en countdown is resumed when the pause mode is left
• Manual mode
• To enter: leave the clock/set point or pause mode first.
• When active the shutter will be opened and the timer starts counting up until the maximum of 199.59.59, then the shutter closes.
• When there is a shutter problem the shutter remains closed and the indication is "OFF"
• Clock mode:
• "ON" during clock mode.
• "OF" when time has elapsed.
• When activating the clock mode the shutter will be opened and the timer starts counting down until 000.00.00, then the shutter closes.
• When there is a shutter problem the shutter remains closed and the indication is "OFF".
• An error message is cleared when you leave the clock mode.
• Deactivating the clock mode will close the shutter end restore the clock set point
• Set point mode
• "ON" during set clock mode and set point recall mode.
• The set point button is used to recall the set exposure time
• Set clock
• Only active for one shutter at a time.  Two functions are possible:
• Initialize timer set-point (clock mode deactivated)
• Change time during experiment (clock mode active)
• Display: Maximum time 199.59.59 (hhh.mm.ss) for clock and manual mode. Timer input is at the blinking digit. Invalid input is ignored. Timer fields can be left by pressing a dot. You exit the set clock mode by pressing <enter>
• Led bar: Extinguishes gradually during the last 60 minutes.

Testing the displays and LED's:

• Press the key sequence: 5  9  0  enter
• The display will show: enraf nonius cu 590 rel 1.0
• Press key 1: all displays of each subsequent display section are on
• Press key 2: display driver test: the number 8 walks across the display
• Press key 3: segment driver test: the segments rotate
• Press key 4: led bar test

Errors

• ERROR1
• This is an error of minor importance and is kept local to the FR561 tube shield controller.
• No more attempts are made to open the shutter.
• The error message can only be cleared by remedying the error and subsequent repetition of the action which produced the error message.
• When a attempt has been made to open a shutter and the safety feedback is negative then the ERROR1 message will appear in the display. It can be caused by one of the following reasons:
• Defective shutter lamp (even one)
• Defective shutter: the shutter sticks in closed position.
• Radiation safety enclosure jumper connector not installed.
• Radiation safety enclosure doors not closed.
• Radiation enclosure flashing warning device defective.
• Collimator not installed.
• ERROR2
• The ERROR2 results from an unsuccessful attempt to close a shutter and shutter is not fully closed.
• The FR590 generator will shut down the HV and put the FR561 tube shield controller into a SYSTEM PAUSE for as long as the error conditions remains active.
• The error message remains on the display until the FR561 tube shield controller detects that the defective shutter has been closed.

BRUKER AXS B.V., P.O. Box 811, 2600 AV Delft, The Netherlands, Tel: 31 15 2152400 Fax: 31 15 2152500.

Service: see our web site: www.bruker-axs.com