FR591

• Introduction
• Safety instructions Read these before using the equipment
• Specifications
• Installation.
• Pre-installation requirements
• Operation
• Maintenance
• Part numbers
• Technical warnings
• Disposal
• Troubleshooting
• Manufacturer and Service

Introduction

The FR 591 rotating anode X-ray generator consists of a high voltage supply and an X-ray tube with a rotating anode. The hot filament in the cathode cup emits electrons that are accelerated by the high voltage. The bias voltage together with the shape of the focus cup focuses the electron beam in a small focal spot on the anode. The impact of the electrons on the anode generates X-rays of an energy/wave length depending on the type of material of the anode (Cu : 8 keV / 1.55 Å, Mo : 17,44 keV / 0.71 Å). Only a very small portion of the energy of the electrons is converted to X-rays, the rest of the energy is converted to heat. The rotation of the anode spreads the heat over a large area. This makes it possible to use higher loads than on tubes with stationary anodes. The anode rotates in vacuum and is internally cooled with water. A magnetic fluid seal around the anode shaft maintains the vacuum while rotating. Continuous pumping by a turbo molecular pump backed by a pre-vacuum pump maintains the high vacuum.

The generator consists of :

• Tube unit, with :
• X-ray tube. The proper position of the X-ray shielding around the cathode and the presence of the HV connector is monitored.
• Two shutters. Shutter 1 (left hand) is the default shutter. Shutter 3 is on the other ("water bridge") side.
• Anode motor, which drives the anode by a belt. The anode current is monitored.
• Turbo molecular pump, behind and in line with the tube. The controller electronics is located behind the connector panel on the front side of the tube cubicle.
• Vacuum gauge on top of the tube (red cap) which measures the vacuum.
• Safety key switches to disable the shutters or override the radiation enclosure safety.
• Two electric valves - one on top of the tube, the other one on the connector panel - enclose a volume of nitrogen gas in the hose between them. This volume is released automatically into the X-ray tube at power down. Flushing the X-ray tube with dry and clean nitrogen gas shortens pump down time.
• Connector panel.
• HV unit, with :
• ELCA module, a box with the electronics. The temperature of the electronics is monitored.
• High Voltage tank with a high voltage transformer submerged in oil. The tank casing is the same for the 9 kW and 18 kW version.
• Power generator. This can be 1 module (9 kW version) on one side or 2 modules (18 kW version) on both sides of the tank. The temperature of the heat sinks are monitored.
• Oil pump which pumps the oil through the HV tank and cathode for cooling these parts. The heat is transferred to the primary cooling circuit by a heat exchanger on top of the tank. The flow, temperature and oil level inside the tank are monitored.
• Auxiliary unit, with :
• Water pump to pump cooling water through the anode. The heat of this secondary cooling circuit is transferred to the primary cooling water by a heat exchanger. The primary water flow is regulated by an adjustable thermostatic valve, mounted in the heat exchanger. It stabilizes the temperature in the secondary circuit ( avoids condensation) and limits the flow when the output water of the exchanger becomes colder (when less power is used). It is only useful to limit water when using tap water. There is a small water vessel as a buffer. The flow, temperature and level inside the water vessel are monitored.
• Vacuum pump to take care of a pre-vacuum for the turbo molecular pump. It is placed beside the Auxiliary unit.
• Table / cabinet.
• The half cubicle of the Tube unit is extended by one or two table cubicles for carrying the X-ray measuring equipment.
• The radiation enclosure is a shield to prevent access to the radiation and to shield the low scattered radiation generated with regular diffraction experiments.
• The emergency switches on the outside of the table switch off the power of the system.

Safety instructions

• X-ray
• Beryllium
• Electrical safety
• Batteries

X-ray safety

The equipment can generate open X-rays, which can be hazardous when safety rules are not followed:

• The equipment must be operated under the responsibility of an X-ray safety officer, in accordance with local regulations.
• The equipment must be operated, serviced and maintained by qualified personnel who are trained on the hazards of and precaution against X-ray exposure.
• The equipment contains safety circuits which should not be overridden, other than with supplied: the enclosure key. These overrides may only be used for service and maintenance, i.e. X-ray alignment.
• The enclosure key should be kept under the custody of the X-ray safety officer, not with the instrument. This also applies to the X-ray- or shutter safety keys of the X-ray generator in case the X-ray port is not used or X-rays should not be used.
• Safety circuits must be tested by service personnel or the safety officer at least every 12 months, as described in this manual (chapter Maintenance).
• Beam stop block's must be mounted on output ports not in use. The blocks are delivered with the generator.
• When the equipment is delivered without an enclosure, the X-ray safety must be guaranteed by the user, by placing the equipment in a safety room.
• The radiation enclosure is a shield for only the weak scattered radiation, generated with normal diffraction equipment. When using other type of radiation or large samples the shielding capacity must be recalculated and additional shielding might be required.
• Also take into account the X-ray safety of equipment installed.

The X-ray tube contains windows of beryllium. In normal use these area's cannot be reached, but during maintenance, care must be taken not to touch the window. When by accident the beryllium is touched, wash with soap and water.

Fumes and dust from beryllium metal can be hazardous if inhaled. During use, corrosion of the beryllium window may occur, but it should not be cut, machined or otherwise removed. Disposal must comply with the national and local regulations governing beryllium.

Electrical safety

Access to the area under the table is only allowed by qualified technical personnel. Power terminals can be reached there on the outside of all modules. When a qualified technician wants to access these parts, first disconnect all automatic fuses and disconnect the mains supply before accessing any interior part of the generator.
 

Specifications

X-ray
Voltage	5 - 60 kV
Current	9 kW version : 2 -150 mA  18 kW version : 2 - 300 mA
Stability	Voltage and current : 0.01%
Power (kW)	9 kW (1 modules) or 18 kW (2 modules)  Focus Type Filament W Cu Mo Ag/Au Fe/Cr 1.0 x 10 mm BF3 broad 15.0 15.0 15.0 15.0 15.0 0.5 x 10 mm BF2 broad 15.0 15.0 15.0 11.0 9.0 0.3 x 3 mm FF3 fine 8.2 5.0 5.0 3.1 3.0 0.3 x 3 mm HBA FF3 fine 6.0 0.2 x 2 mm FF2 fine 4.5 3.0 3.0 1.7 1.8 0.1 x 1 mm FF1 fine 1.6 1.2 1.2 0.6 0.6 0.1 x 1 mm HBA FF1 fine 1.5 0.5 x 5 and 0,1 x 2 are in the list but are not configured, so cannot be used  HBA = High Brilliance Anode
Focus	Focus types : see Power
Stability focal spot position	<10 microns peak to peak
Focal height	522 m above working space, optional 300 mm
Window	0.25 mm beryllium
Take off angle	0° - 10°

Safety interlocks

• The shutter-open lamps are defect.
• The radiation enclosure is not closed.
• The goniometer is not properly placed in front of the X-ray port.
• An extra external safety switch is open.

• 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 tube cover is not in place
• The tube shield (around the cathode) is not in place (indicated by a link, attached to the shield)
• The X-ray on lamp is defect.

• A key switch can override the radiation enclosure safety. This state is indicated by the flashing Open-beam lamp. When the lamp is defect the override does not work.

• Shutter-open lamp: illuminated when the shutter is open or is not fully closed.
• Open-beam lamp: flashes when the radiation enclosure safety is overridden.
• X-ray lamp: illuminated when X-rays are generated.

Environmental, according to IEC 1010

Environment	Indoor use
Altitude	Up to 2000 m
Temperature, operating	°C (within specification)
Relative humidity	Maximum 80% if <31°C, decrease linearly to 50% at 40°C
Pollution degree	2, according to IEC 664 (normal clean environment).
Protection	IP 20, according to IEC 529 (limited protection to water).
Gasses	No explosive gasses are allowed.
Heat generation to air	9 kW : max. 1 kW; 18 kW : max. 2 kW
HV tank oil	Shell Diala D. The oil does not contain  PCB's. This oil is also used in FR571, GX21 and FR58.. generators
Power supply	Nominal 200V-240V (phase - neutral), 347V-415V (phase =- phase).
Fluctuations	±10%
Frequency	50 - 60 Hz. ±5%
Connection	Three phase Y (WYE or star), five wire (3 line, 1 neutral and 1 ground). No earth leakage relay / protectors can be used.
Mains fuses	9 kW : 3 x 35 A; 18 kW : 3 x 63 A
Power (kVA)	L1 L2 L3 Total 9 kW version 4.3 4.7 6.2 15 18 kW version 7.8 8.2 9.7 26
Installation category	II, according to IEC 664.
Water cooling
Flow and temperature	Normal Cu or Mo anode (until 1998): min. 15 l/min (9 kW, input 15 ºC) or min. 25 l/min (18 kW, input 15 ºC). New Cu High Power Anode:   Minimum temperature : +15 ºC ( to prevent condensation)
Water	Primary water : normal tap water quality. Secondary water : demineralized water.
Input pressure	2 - 6 Bar
Nitrogen	Advised for a clean vacuum system. Max. 10 l /year. Pressure: 0 - 0,3 bar
Weight	967 kg

Operation

• Start up
• Shut-off
• Shut down
• kV/mA ,bias and anode speed
• Control panel

• Switch on the power with the key switch Power (left switch) on the control panel.
• In a few seconds all electronics are started and after this the power up LED (yellow) goes on.
• The generator is now is status POWER UP which means the electronics are on, but all motors and pumps are still off.

• Press the stdby button (left yellow button) on the control panel. When pressing the red X-ray button the generator also goes to standby and proceeds automatically to GENERATE. The start up sequence is :
• Water pump starts.
• After 2 seconds the oil pump starts.
• After 2 seconds the anode motor starts to 600 rpm at the anode (the motor about half this speed).
• The tube is flushed with nitrogen for a few seconds.
• The turbo molecular pump and pre-vacuum pump start are started.
• When the turbo pump is above 50% of his final speed the vacuum gauge is started.
• Waits till the vacuum is below 4E-6 mBar.
• The generator is now in status STANDBY, which means it is ready to generate X-ray.
• Press the red X-ray button on the control panel.
• The generator is now in status GENERATE,
• Increase the anode speed corresponding to the set power.
• Switch on the HV generator, mA and kV will slowly rise to the setpoints. When they have reached the set points a HV stable signal is sent to the goniometer, indicating that the X-rays are stable and that data collection can be started.

Shut off procedure

• Press the red X-ray button on the control panel.
• The HV switches off immediately.
• The generator is now is status STANDBY.
• Anode speed goes to standby speed (600 rpm)
• Press the pwrup button (left yellow button) on the control panel or switch off the power key switch (then after status POWER UP proceeds automatic to power off.
• Waits 0 - 20 minutes, depending on the previous HV power, to cool down the tube.
• Switch off the turbo pump.
• Switch of the vacuum gauge.
• Waits 2 minutes till the speed of the turbo pump is low.
• Switch off the pre-vacuum pump.
• A small amount of nitrogen is enters the tube.
• After several seconds the anode motor, oil pump and water pump stop.
• The generator is now in status POWER UP
• Switch off the power with the key-switch Power on the control panel.
• All power is switched off.

Shut down

There are several ways to shut down the generator :

• Switch off the power with the key-switch Power on the control panel. The generator will now shutdown in a controlled way, which will take time.
• Emergency button. This will switch off all power at once.
• Error. Depending on the type of error the status can be demoted (Generate to Standby) or the generator can be shut off in a controlled or abrupt way.

kV/mA set

• The kV and mA are set from the control panel. After a new entry the value will slowly go to the new setpoint. Limits are chosen depending on focus size and anode material but the user can also choose lower limits with Setup / Tube
• The bias voltage is set automatically by the program, depending on kV and focus cup. It can be changed in the mean menu Operate / generator. But when changing kV or mA the bias returns to the default value.
• The anode speed is set automatically by the program, as a function of the power. It can be changed to a higher value with Operate. But when changing kV or mA the anode speed returns to the default value

Control panel.  purple: only in Microstar

Operate Setup Diagnose Service View Status           . . bits line .  . StdBy HotKey shutter 1 shutter 3 X-ray FR591, MICROstar

Buttons/switches:

• Key switches: The absence of the key prevents unauthorized access to the function.
• Power: to switch on the power. During the Standby and Generate status this switch is by-passed by the electronics to shut down in a controlled way, which makes it impossible to switch off at once using this switch. Immediate shut down is only possible with the emergency buttons at the front and rear of the table.
• X-ray: to enable the generation of X-rays (not to switch on the X-rays).
• Stdby: to switch to Standby status, or back to Power up status.
• Hotkey: the most often used window is opened : Operate > Generator
• Shutters
• X-ray: to switch on the High Voltage.
• When pressed in the Power up status the system will first go to the Standby status and then automatically to the X-ray on status.
• Switching HV on can be disabled by the X-ray key switch mentioned above.
• Enter / clear for the display commands.

Maintenance

• General warning
• Periodic maintenance
• Filament replacement
• Water seal replacement
• Shutter replacement
• Belt replacement
• Anode replacement
• Normal power anode (NPA)
• High power anode (HPA)
• Ferroseal replacement
• Recoil shield cleaning
• Anode motor brushes
• Vacuum measuring probe
• Pre-vacuum pump new oil
• Shutter replacement or exchange with shutter 3
• Safety test
• Cleaning.
• For cleaning use a damp cloth, moistened with water or isopropyl alcohol. No cleaning agent may enter the generator.
• Technical data
• Tube head overview
• Cooling and vacuum overview
• Electrical overview

General warning

The mechanical maintenance described is intended for customers who have attended a maintenance course. It comprises only a part of the required periodic maintenance. The skill of an experienced service man is required for items related to high power, delicate mechanics and vacuum. When problems arise with the described items please first ask Service department  for advise before using brute force. Bruker AXS cannot give free technical support for work outside what is described in this manual and is not responsible for the work, done by the customers.
 

Periodic maintenance

For a long lifetime of the generator a yearly preventive maintenance is strongly advised. Some moving parts have a limited life and can damage expensive parts when not replaced in time. A maintenance by Service consists of:

• Replacement of the ferroseal, filament, oil of pre-vacuum pump, turbo pump lubrication, carbon brushes, V-belt.
• Polish and clean the focus cup, recoil shield, anode, water bridge, vacuum gauge.
• Optional: refurbishment of the anode, or replacement by a new or a refurbished anode.
• Check of safety devices.
• Several other checks.

• The anode can only be polished, but sometimes grinding is needed. Wrong grinding can cause pollution to be pressed in the anode material, causing a bad vacuum by high de-gassing. Also the deposit inside the anode should be removed, otherwise the cooling becomes less efficient. This results in overheating of the anode, which is shown by a bad vacuum caused by high gassing. This refurbishment can only be done in the factory.
• The recoil shield can only be cleaned in situ, because of the risk of wrong remounting, causing vacuum leaks is too high.
• For parts yearly needed see the part numbers

Filament replacement

Filaments are supplied in a set together with mounting rod screws, clamp segments, Allen keys and cathode O rings.
 

General

• When mounting a new filament:
• Clean parts should be handled with lint free, powder free gloves.
• Filaments should be handled with plastic tweezers only.
• All parts around the focus should be mounted by hand, never using a tool other than the locking key, and never using force. When removing cannot be done by hand, put some acetone in the screw-thread. If it is still not possible to remove or mount the focus cup assembly, return the parts to the factory.
• Cleaning the cathode is occasionally necessary and should only be done by a service engineer. Ceramic parts should only be cleaned with a diamond file. Metal parts should be cleaned, first using Scotchbrite 07447 or 07448, and then they must be rinsed and brushed with acetone. It is important that no residues are left behind, since any residues will pollute the vacuum.

Preparations

• When a filament breaks, the control panel will show a message and the generator will go into the STANDBY status.
• Go to status POWER UP.
• After high power wait at least thirty minutes to cool down.
• Ventilate the tube with the control panel under command Service. Because this command only opens the valve 15 s, this should be done several times (approx. 10 times) till the vacuum is gone.
• Switch off the generator completely.
• Remove the HV connector. First loosen the small Allen screw.
• Confirm that the filament is broken by measuring the resistance in the HV connector with (long) measuring pins between the COMMON and FILAMENT contacts. A correct filament has a low resistance.
• 

Fine focus

• Remove the cathode.
• With the adjustable cathode (not needed for the new Microstar fixed cathode)
• Take care not to change S
• Measure D:
• 
• 
• Loosen the four Screws A, without removing them.
• Unscrew the height adjustment nut, while lifting off the entire focus cup assembly. A rocking motion may be necessary to remove the assembly.
• Remove two uppermost screws B, which hold the filament in its mounting rods and remove the filament.
• If a small screw is stuck, a way to remove is: Place the Allen key. Then get grip on it with a side cutter (not a pair of pincers) an turn it out.
• From the filament set, place two new Screws B with a new Allen Key.
• Place the new filament with the leads in the grooves. The spacing of the filament wires has a tolerance (maximum +/- 0.6 mm) so sometimes one wire must be pushed gently into the groove.
• Place the filament height setting jig and, using plastic tweezers, gently adjust the position of the filament such that the filament sits between the marks and against the top of the jig. Gently fasten the two screws B. This is the most important step for a good alignment! When fastening screws B the filament should not change position because there will be tension on the wire which resultsin position change, like rotate, when it becomes hot, causing a filament to cup error. If it does change while fastening the screws, check if the filament wires are mispositionend and check if the grooves are clean.
• Place the entire assembly over the filament on the cathode, taking care that the cup does not touch the filament. Screw the assembly in place.
• Check the right position of the filament:
• 
• If the focus cup needs to be re-aligned to the filament, loosen the locking ring (with the locking ring key), align the focus cup and tighten the locking ring again.
• Place the shorting key in the cathode.
• Carefully place the depth gauge on the focus cup, avoiding any damage to the filament. Adjust the height of the filament with the height adjustment nut till the LED in the depth gauge is just on.
• Tighten the four screws A so that the filament appears nicely in the centre of the cup. Do not use force on the screws, as this can deform the mounting tube, giving problems in removing it from the ceramic disk.
• Turn the height adjustment nut a little bit back, so it is not tightened but loose.
• Once the filament was at operating temperature, it can be a little bit curled, which is normally no problem. This is sometimes caused by the filament and sometimes by wrong tightening of the screws B as explained above: all must be tightened in the last stage.
• 

Broad focus

• 
• Unscrew (not entirely) the four screws C.
• Remove the focus cup.
• Loosen the locking ring with the special key.
• Unscrew the mounting tube and the locking ring entirely.
• Remove the two upper screws B, which hold the filament and remove the filament.
• Place two new screws B with a new Allen key, both out of the filament set.
• Place a new filament in the mounting rods with a plastic tweezers and fasten the screws B.
• Pull the spindle out of the filament, if present.
• Mount the mounting tube and the focus cup. Set the height, so that the filament is in the focus cup. This is done by rotating the mounting tube while keeping the focus cup by hand in position over the filament.
• Place the shorting key in the cathode.
• Fine adjust the filament height by using the depth gauge, so the LED is just on. Be careful not to damage the filament. If one side is not correct, this should be adjusted by lifting one of the filament feet in its mounting rod. The rods can be reached through the holes in the mounting tube.
• Lock the mounting tube with the locking ring and check the height again. Readjust if necessary.
• Lock the focus cup with the four screws C, while keeping the cup pressed down on the mounting tube.
• After reaching the operating temperature the filament will always be a little bit curled:
• 

Cathode mounting

• With the adjustable cathode:
• 
• Remeasure D and if needed: X, Y and AC from the table (if not noted during last replacement):

focus	0.1x1, Microstar	0.2 x 2	1.0 x 10	0.5 x 10	0.3 x 3
AC	8.5 mm	9.0 mm	9.0 mm	9.0 mm	10.0 mm

• Keep a log of the distances for future replacements: Y will never change, X will only change after an anode replacement.
• If D is within +/- 0.2 mm of the old value: remount the cathode without changing the setting of S
• If D is outside +/- 0.2 mm: calculate the new distance S = (AC + D + Y) - X
• FR591: and set the adjustable gauge for this distance.
• Microstar: adjust the threaded collars and adjust this distance with the slide-rule (delivered with the generator) before the cathode is placed against it. The distance S should be as good as possible, but at least with an accuracy of 0.2 mm.
• With the Microstar fixed cathode:
• Mount the cathode with the groove on the color, marked on the filament box.
• 
• Mount the cathode carefully.
• For horizontal tube and point focus the oil outlet is on top and the filament is about horizontal. Take care: If by accident the filament is mounted vertical the focus will be very thin and a groove will burn in the anode.
• Microstar: the filament must be visually horizontal.
• Remove the shorting key.
• Refit the HV cable connector and reconnect the interlock plug.
• Fasten the small Allen key of the HV connector.

Recrystallization

• Start the generator and start recrystallization from the control panel. It will take about 10-20 minutes for the procedure to complete.

There is no tool for a more optimal horizontal alignment of the focus. The previously used pin hole with fluorescent screen is not allowed anymore because of the X-ray background radiation. When you want to use your own safe tools, for instance using film inside a radiation enclosure, you should get permission from the local radiation safety officer. The radiation enclosure is designed to suppress only the weak scattered radiation and not the high intensity of the primary beam.

When there is a possibility to view the focal spot, the shape will be:

Water seal replacement

The water seal in the water bridge needs to be replaced at least every year.

Normal anode

• Switch off the generator completely.
• Remove the anode grounding brush, which is situated on top of the water bridge.
• Unscrew the three screws and take the water bridge straight off (when is has two screws, it is the new high power anode, see below). The tubes are not removed.
• 
• Press down the ring, for instance with two screw drivers, and replace the middle black ring (the seal) in its rubber holder (this needs a second person). Take care the rubber lip is properly positioned around the new water seal. A spare seal is delivered with the generator.
• Remount the anode grounding carbon brush. The screw must be fastened just not to roll-out, less then one turn, and fastened with the nut. Otherwise the spring is pushed to strong, which can cause fast wear of the pulley (where it slides on)
• When this does not solve the leakage, the other part of the seal (the face seal on the anode axis) should be replaced by a servicemen.

New High Power Anode

• Disassembly:
• Switch off the generator completely.
• Remove the anode grounding brush, which is situated at the bottom of the water bridge.
• Remove the water bridge supply section by unscrewing two screws. The tubes are removed.
• 
• Unscrew the inner stem retaining nut with the counterface seal key. This is a left-handed screw, so turn clockwise to unscrew.
• Remove the water bridge return section by unscrewing two screws. Take into account that it fits very tight, so should be removed exactly straight. If not, then it can stick. When it sticks, then push back and pull exactly straight, perhaps with some wiggling.
• Remove the water bridge water seal section by unscrewing three screws.
• The water seal can be taken out by pushing.
• Assembly:
• Remount the water seal section and fasten the screws loosely.
• Place the centring cylinder in place of the seal in the water seal section and fasten the screws. Align also by rotating the section till the sloping part is parallel to the part underneath
• 
• Sparingly lubricate the outside 0-ring of the seal with vacuum grease (delivered with the generator), but no grease should come on the flat sides.
• Place the guidance cone and mount the seal by hand. Don't use tools.
• Remount the return section. Align it with the section underneath, so the bottom, top and sloping sides are exactly aligned.
• Fit the inner stem retainer nut (left handed) with a torque of 8 Nm. The torque wrench is delivered with the generator.
• With a new anode check if the anode rotates smoothly. If not, then dismount and place a shim on the anode shaft (between anode and ferroseal,  two are delivered with new anodes).
• Remount the supply section. Align it with the section underneath, so the bottom, top and sloping sides are exactly aligned.
• Remount the connector to the temperature measuring device and remount the anode grounding brush.

Shutter replacement

• Switch off the generator completely.
• Remove all covers.
• Remove the shutter with the three screws.
• Disconnect the wires. The connector is in the half cubicle, under the X-ray tube. The colours and connection numbers are indicated nearby on a label. When removing the cable, attach a wire or string, with which the new shutter cable can more easily be drawn through the tubes.
• Mount in the reverse way.
• After mounting, check the shutter present (safety) switches in the control panel : View • Setup parameters. When it shows "not fitted", shift the shutter a little bit before tightening the screw, till the message disappears.

Anode drive belt replacement

The anode drive belt should be replaced every year.

• Remove the water bridge as explained in the Water seal replacement.
• Remove the old belt.
• Clean the pulleys with acetone.
• Mount a new belt.
• Adjust the tension of the V-belt by shifting the anode motor in the two slots. The tension is correct when the belt can be pushed down about one centimetre when applying a force of 0,5 kg near the motor. At too low tension the belt will vibrate. Take care: with high tension the bearing of the motor and anode will wear out.
• Remount the water bridge as explained in the Water seal replacement

Anode replacement for Normal Power Anode (NPA)
 

General

• This replacement can only be done by skilled personal, so by a service men or after a  course
• Clean parts which are in vacuum should only be handled with non-fluff, non-powdered gloves.

Rotorplate remounting

• Go to the status POWER UP.
• After high power, wait at least thirty minutes to cool down.
• Ventilate the tube with the control panel under command Service. Because this action only opens the valve 15 s, this should be done several times (approx. 10 times) till the vacuum is gone.
• Switch off the generator completely.
• Take the drive belt from the motor pulley.
• Disconnect the water hoses from the water bridge and rotorplate.
• Unscrew the three large screws fixing the rotorplate to the head, while holding the assembly in position.
• Withdraw the assembly : first move it slightly in the direction of the motor, then pull it straight out. The anode should not get scratched on the way out. Place the assembly with the flat side of the anode on a clean flat surface.

Anode disassembly

• Remove the water bridge with three screws and remove the V-belt.
• Clamp the anode retaining fixture into a bench vice and put the rotorplate assembly on it, while carefully guiding one of the anode's six allen screws (of the inner ring of screws) over the pin.
• 
• Unscrew the counter face seal with the counter face seal key and a 12 mm wrench. Place the assembly on a flat surface once the counter face seal is loose.

• 
• Take off the pulley and clamp ring.
• Pull out the anode. Some force may be required here to overcome the friction of the O ring in the bearing sleeve. Never use tools. If you don't succeed, contact the Service department.

Anode cleaning

• Cleaning of the anode is has limited use (see Yearly maintenance). When desired, it is done with lint free clothes with acetone. Extreme pollution can be removed with Scotchbrite 07447 or 07448. A convenient way is to polish the surface while it rotates in a lathe. Proper care should be taken to avoid scratches or damage to the shaft while it is clamped. After polishing the anode must be washed with acetone.

Anode remounting

• Place the anode with its flat side on a horizontal flat surface.
• Carefully put the rotorplate assembly over the shaft, without an O-ring in the bearing sleeve, just to check if it fits. The anode should fit smoothly without any friction. Do not use force if there is friction.
• Fit a sparingly lubricated (with vacuum grease) new O-ring (part number 2132162) into the groove in the bearing sleeve. Put also a tiny bit of vacuum grease on the anode shaft.
• Place the rotorplate assembly over the anode shaft while making sure that this shaft is absolutely straight in the bearing sleeve. There should be no force required until the O-ring is reached. A gentle tap on top of the rotorplate should be sufficient to overcome the friction, after which the rotorplate can be lowered to its proper position.
• Place the clamp ring.
• Fit sparingly vacuum lubricated O-rings (part numbers 2132162 and 2132163) in the pulley and bring the pulley into position on the anode shaft. Take care not to damage the O-ring while doing this.
• Place the anode on the anode retaining fixture.
• Mount the counter face seal and tighten it with a torque of 18 Nm.

Rotorplate mounting

• Clean all parts with Scotchbrite 07447 or 07448 and clean afterwards with acetone. Leave sufficient time to dry.
• Put a slightly lubricated new O-ring (part number 2132963) to the head.
• Carefully insert the anode into the head.
• Shift it a little in the direction of the cathode to the right position. Check if the O-ring is still properly positioned.
• Fasten the rotorplate with its three screws.
• Refit the belt.
• Check if the inner water injector tube of the anode is properly centralized before proceeding with the water bridge. If it is slightly out of the centre it may just be bend back.
• Remount water bridge.

Anode replacement for High Power Anode (HPA)
 

General

• This replacement can only be done by skilled personal, so by a service men or after a course.
• Clean parts which are in vacuum should only be handled with non-fluff, non-powdered gloves.

Rotorplate remounting

• Go to the status POWER UP.
• After high power, wait at least thirty minutes to cool down.
• Ventilate the tube with the control panel under command Service. Because this action only opens the valve 15 s, this should be done several times (approx. 10 times) till the vacuum is gone.
• Switch off the generator completely.
• Remove the anode speed sensor holder at the motor pulley.
• Take the drive belt from the motor pulley.
• Disconnect the water hoses from the water bridge and rotorplate.
• Unscrew the three large screws fixing the rotorplate to the head, while holding the assembly in position.
• Withdraw the assembly : first move it slightly in the direction of the motor, then pull it straight out. The anode should not get scratched on the way out. Place the assembly with the flat side of the anode on a clean flat surface.

Anode disassembly

• Place the anode in the anode retaining fixture.
• Remove the water bridge as described in the Water seal replacement
• 
• Unscrew the counter face seal with the counter face seal key and a 12 mm torque wrench.
• 
• Take off the pulley.
• Pull out the rotorplate. Some force may be required here to overcome the friction of the O ring in the bearing sleeve. Never use tools. If you don't succeed, contact the Service department.

Anode cleaning

• Cleaning of the anode is has limited use (see Yearly maintenance). When desired, it is done with lint free clothes with acetone. Extreme pollution can be removed with Scotchbrite 07447 or 07448. A convenient way is to polish the surface while it rotates in a lathe. Proper care should be taken to avoid scratches or damage to the shaft while it is clamped. After polishing the anode must be washed with acetone.

Anode remounting

• Place the anode with its retaining fixture.
• Carefully put the rotorplate assembly over the shaft, without an O-ring in the bearing sleeve, just to check if it fits. The anode should fit smoothly without any friction. Do not use force if there is friction.
• Fit a sparingly lubricated (with vacuum grease) new O-ring (part number 2132162) into the groove in the bearing sleeve. Put also a tiny bit of vacuum grease on the anode shaft.
• Place the rotorplate assembly over the anode shaft while making sure that this shaft is absolutely straight in the bearing sleeve. There should be no force required until the O-ring is reached. A gentle tap on top of the rotorplate should be sufficient to overcome the friction, after which the rotorplate can be lowered to its proper position.
• Fit sparingly vacuum lubricated O-rings (part numbers 2132162 and 2132163) in the pulley and bring the pulley into position on the anode shaft. Take care not to damage the O-ring while doing this.
• Mount the counter face seal and tighten it with a torque of 18 Nm.
• Remount the water bridge as decried in the Water seal replacement

Rotorplate mounting

• Clean all parts with Scotchbrite 07447 or 07448 and clean afterwards with acetone. Leave sufficient time to dry.
• Put a slightly lubricated new O-ring (part number 2132963) to the head.
• Carefully insert the rotor plate assembly into the head.
• Shift it a little in the direction of the cathode to the right position. Check if the O-ring is still properly positioned.
• Fasten the rotorplate with its three screws.

Anode speed sensor

• Refit the belt at the anode motor.
• Adjust the tension of the V-belt by shifting the anode motor in the two slots. The tension is correct when the belt can be pushed down about one centimetre when applying a force of 0,5 kg near the motor. At too low tension the belt will vibrate. Take care: with high tension the bearing of the motor and anode will wear out.
• Mount the speed sensor holder with the align tool and fix with the two screws.
• 
• Mount the speed sensor and its coil.

Ferro seal replacement for Normal- or High Power Anode

• Remove the rotorplate assembly and anode as described in Anode replacement.
• Remove the bearing plate and all shims from the rotorplate.
• 
• Place the puller in vertical position on a flat table and put the empty cartridge and the rotorplate over the shaft. The empty cartridge is delivered with a new system and should kept for returning the ferroseal.
• 
• Place the large bush and the pin
• Rotate the puller (hold the rotor plate by hand). The cartridge will be pushed out of the rotorplate into the container. At the end the pin should be placed in a lower hole, to pull out the ferroseal completely.
• Check the rotorplate for burrs or damage. Make sure that the vacuum side is clean.
• Put a tiny bit of vacuum grease on the inner surface of the rotorplate, but not in the water channels.
• Take the cover from the new cartridge. There are two types of cartridges:
• With a protruding plug at the bottom. Push with this plug the ferroseal out a bit.
• Without the plug. During mounting, first place thin distance holders, like coins under the sides of the cartridge (take care: not under the ferroseal). Pull out the ferroseal a little bit. Remove the coins and proceed.
• The protruding part of the ferroseal is needed as a guide into the bore of the rotorplate.
• Place the rotor plate and the new cartridge reverse on the puller and mount the small bush and pin.
• If needed pull out the ferroseal a bit as described above and remove the coins.
• Pull the ferroseal completely into the rotorplate. At the end the pin should be placed in a lower hole, to pull in the ferroseal completely.
• Remove the rotorplate from the puller and check if the cartridge is pulled in completely. There should be no space left between the bottom of the rotorplate and the first seal body.
• Place the rotorplate back on the puller. Never place the rotorplate on the table, otherwise there is a risk of damaging the ferroseal.
• Measure the protrusion D of the cartridge from the face of the rotorplate, using a vernier caliper and determine the number of shims required. If D is less than 0.10 mm and not zero then no shims are necessary. If D is more than 0.10 mm then one shim has to be placed. If D is more than 0.20 mm then two shims, and so on. Place the (clean) shims.
• Normally 3-4 shims are used. When you need more, then the seal is not pulled in fully. Check for any obstruction. With too many shims the seal has free space, can move and the O-ring does not fit. This can cause leakage and defect of the ferroseal.
• Place the bearing plate and clamp ring. Centre the bearing plate on the clamp ring and tighten the bearing plate with three screws.
• Remount the anode and rotorplate assembly as described in Anode replacement
• A ferroseal should be run in at standby speed for one hour.

Recoil shield cleaning

• Cleaning of the recoil shield should be done once a year, combined with the replacement of the ferroseal.
• This maintenance can only be done by skilled personal, so by a service men or after a course.
• Remove the cathode as explained in Filament replacement.
• Remove the rotor plate as explained in Anode replacement.
• 
• Remove the cathode holder.
• Remove O-ring A.
• Place the puller with the its parts and place the pin.
• Rotate the puller till the end. The complete set can now (carefully) be shifted out of the tube head and the recoil shield removed from the puller.
• Remove O-ring B and clean the recoil shield with Scotchbrite 07447 or 07448. After polishing the anode must be washed with acetone.
• Fit a sparingly lubricated (with vacuum grease) new O-ring B (part number 2132529). This must be mounted from the widest side (not the output port side) to prevent that parts, which are in vacuum are contaminated with grease.
• Remount the recoil shield by hand, so that the key in the tube head slides into the groove of the recoil shield. Be careful, that O-ring B is not damaged by the key.
• When in good key position, push the recoil shield in by hand. Never use tools.
• Fit a sparingly vacuum lubricated new O-ring A (part number 2132634).
• Mount the cathode holder.
• Mount the rotorplate as explained in Anode replacement.
• Mount the cathode as explained in Filament replacement.

Anode motor brushes

The four brushes should be replaced every year or when they are less than eight millimetres long. (when new they are 23 mm long)

• Remove the covers, first the top cover with the lamps.
• At the back of the anode motor are four brush holders. Replace the brushes one at a time (when loosening two, the wire connection is loose).
• For a technician it is possible to open the motor:
• Both the unit with the brushes and the plate on the side of the motor can be opened to clean the motor.
• First make a mark from brushes unit to motor unit to be sure to remount in the same position.
• Check if the brushes slide easy in their holders or clean it.

Vacuum measuring probe for FR591 (red type)

The clamp under the vacuum measuring probe can be opened to enter air into the head.

The vacuum measuring probe can be inspected when it does not start up. Do this only when asked by the Service department. One can remove the measuring probe by rotating it anti clockwise and lift (bayonet) without loosening the clamp.

Checks to get the vacuum measuring head starting:

• When the vacuum is too high:
• Fill the head with nitrogen or with air by dismounting the probe with the clamp and start again.
• Touch the probe with your fingers. This will add enough contamination to work for at least several months.
• Check if the connector is all right.
• Check if the probe is polluted. If so, clean it.
• Check is the gap is approx. 0.4 - 0.7 mm. Be careful with the thin metal foil.

Pre-vacuum pump oil change for FR591 pre-vacuum-oil pump

• The oil should be replaced every year
• 
• Open the Out (side, bottom) and In (top) connection so the oil will run out. The oil pump must be placed on a higher level.
• Close the Out connection and fill the pump with 1 litre of oil. In the indicator the level will be half way between min and max.
• Close the In connection.

Shutter replacement or exchange with shutter 3

• Replacement
• Be sure the power is off. The shutter can be removed with three screws (2 long, 1 short). The shutter cable is connected to the connector rails under the tube.
• When mounting, first place the thin lead plate, then mount them together on the tube. Mount with the screws loosely fitted.
• Power on and read the shutter fitted switch (safety) in the control panel : View • Setup parameters. Rotate the shutter till the status is not absent. Then fasten the screws.
• There is a list of cable connections close to the connector.
• Exchange with shutter 3. When shutter 1 is defect it is possible to exchange with shutter 3, which is mostly not used. This is not useful when the shutter fitted switch is the error (shutter "absent").
• Exchange shutter 3 and shutter 1.
• Exchange the cable connections of shutter 3 and 1.
• Don't exchange the GCU connector: this remains on shutter 1.

Safety test

Shutter safety, with the FR590 or FR591.

1. Switch off the X-ray high voltage
2. Open the shutter. Check both shutter-open lamps.
3. Check if the shutter will not open after activating the next unsafe conditions :
• Radiation enclosure open (and Open beam key switch disabled).
• Shutter-open lamps removed.
• Radiation enclosure safety (Open beam) override with the key-switch under the table, Beam-open lamp removed and enclosure open.
4. Check the flashing Open-beam lamp when the radiation enclosure safety (Open beam) is override by the key-switch.

1. Switch on the high voltage to minimum: 20 kV 5 mA
2. Check the X-ray on lamps.
3. Check if the high voltage falls off when:
• The X-ray on lamps are removed.
• The safety connector of the HV connector is removed.
• The safety connector of the tube shield is removed. After placing the connector go to menu Setup • Tube and enter the same anode material again.
• The main shutter is manually opened with a small screw in the centre of the shutter indication: take care not to come in the vicinity of the primary beam!

Technical data

Cooling, vacuum FR591

Cooling, vacuum Microstar

Microstar (Ultra)

FR591

 

Position of (anode) water flow switch in Microstar, FR591 new , FR591 old

FR591

Part number list

Next items are advised to keep on stock or buy before yearly maintenance. The table gives the numbers delivered with a new system in the spare parts kit and the yearly use. Check if the part is for the normal power anode (NPA) or the new high power anode (HPA). For expensive components it is advised to buy when needed, to prevent the part is out of warranty when it is used.

The next items we advise to keep on stock:
 

Kit	Use  yr	Part number	Description
	5	0571842 0571843	Fine focus filament set (5x) including mounting parts and tweezers or Broad focus filament set (5x)
2 1	1	2985013 2134044	Water seal in water bridge, the standard replaced item for NPA or: Water seal for HPA
1	1	3590003	Anode motor brushes, set of 4
2	1	2692023	Brush for anode grounding in the waterbridge
5	1	4010071	Silicone oil and  washer for the HV connectors
5		2603050	Shutter lamp, inside the shutter. 5 V 60 mA
10	5	2603335	Shutter lamp, on the head. 24V 50 mA
10	5	2603212	X-ray on lamp. 12V 120 mA
5		2603235	Open beam lamp. 12V
1		4000014	High vacuum grease for O-rings
		0591114R	Shutter, revised. Optional. This is an expensive part, but take into account that because of the high radiation environment and with high use the shutter is vulnerable to wear and for safety reasons it is not possible to use a generator with one shutter missing, also on a port which is normally not used.

For customers who execute the yearly maintenance (partly) themselves, we advise the next items will be bought:
 

Kit	Use  yr	Part number	Description
	1	Depends on type	Anode. It is possible to Send the anode to the factory for refurbish (grind when needed, polish, internal chemical cleaning) Buy an anode and return the old anode. Buy a refurbished anode and return the old anode. This is only possible when on stock. The lifetime of an anode is five years.
	1	0571355	Ferro seal.
1	1	0571319 0168374	Counter face water seal, on the anode axis for NPA or: Counter face seal for HPA
1	1	2033114	V-belt
1	1	4010021	Oil for the pre-vacuum pump, 1 ltr
5	2	2132162	O-ring 17.10 x 1.60 mm, for the anode pulley and shaft
5	1	2132163	O-ring 19.10 x 1.60 mm, for the pulley face seal
5		2132310	O-ring 31.42 x 2.62 mm, for the water bridge for HPA
5		2132429	O-ring 37.77 x 2.62 mm, for the water bridge for HPA
2		2132528	O-ring 56.82 x 2.62 mm, between measuring flange and head
5		2132431	O-ring 47.0 x 5.34 mm, for cathode
2	1	2132529	O-ring 58.42 2.62, for the recoil shield
2	1	2132634	O-ring 66.35 2.62, for the recoil shield front
5	1	2132963	O-ring 94.97x1.78, between the rotor plate and head
	1	2140073	Grease cartridge for the turbo pump

Technical warnings
 

• Water leakage ferroseal

Disposal
 

• The HV tank contains PCB-free oil. A statement in Acrobat/.pdf form can be retrieved
• The Tube Controller Board contains a battery which should be regarded as chemical waist according local regulations.
• Beryllium windows

Troubleshooting

• Errors mentioned on the control panel
• Startup errors
• Shutter doesn't open
• Low vacuum
• Communication problem with computer or goniometer
• Service program

• Generator does not go to the Power up status (but no error is shown).
• Display does not light
• Check the red safety push buttons on the side of the cabinet (below the table). They can be pressed by accident. Release them with the keys.
• Check the manual fuse (elca) on the electronic cabinet.
• Check the main power (installation fuses or switches)
• Open the electronic cabinet and inspect the two power supplies on the left. Both should have a green LED burning. If not: then this power supply is defect.
• Display works, but Power on LED (yellow) is not on : Go to standby and see what error message appears.
• Generator does not go to the Standby status (but no error is shown).
• Check the status on the display :
• "Power up" : check in menu Setup • Management X-ray should be set to "Panel".
• "Standby - Power up" : the generator was going back to the Power up status (for instance after an error) and will first finish this sequence before going to the standby status again.
• Check in menu View • Operating parameters of the Oil circuit is "ready". If not : contact the Service department
• Check if the X-ray on lamps are all right : replace them for new ones and try again.
• Shutter problem.

• A normal vacuum is:
• 1E-7 - 9E-7 without power.
• below 9E-7 with medium power (for instance 3 kW)
• below 5E-6 with high power.
• A bad vacuum is mostly caused by leakage, which should be resolved by a service man. Please check:
• Check if the prevacuum pump is really running
• Switch to standby (low anode speed and no HV). When vacuum is too low there is probably a leaking O-ring. Because it is difficult to find which O-ring, we advise a maintenance. In most cases it is the cathode O-ring. Take into account that with every remounting of the cathode a new O-ring must be fitted.
• Adjust the anode speed to 5500 (will show 6000, takes about a minute to speed up) but with HV off. When the vacuum is too low or not stable probably the ferro seal is worn. Take into account that the ferro seal has a limited life time of about a year.
• Switch on the HV.
• If a 13-16 (Vacuum alarm) occurs directly after HV on (before HV or mA are raising) then check with the PC FR591 service program the error history, if there are other errors preceding the vacuum alarm.
• Set power on 20kV, 1 mA. When the vacuum is too low then probably the focus cup is polluted.
• Set power to maximum. When the vacuum is too low probably the anode is polluted. This can be caused by:
• The anode internal deposit is not removed for some time. This can only be done in the factory during refurbishment.
• Wrong procedure of cleaning the surface of the anode, giving pollution pressed in the anode material.
• Be sure you have not changed anything in the cooling water circuit, like wrong connection of the cooling tubes.

• Run  the service program and check in the shutter window which item is red.
• Shutter lamps defect (FR591) or lamp current (Microstar, service must check) is too low.
• For Microstar, see message above the shutter button:
• Hardware: This is no error, but indicates that the shutter cannot be opened by the panel, but by a goniometer electronic signal ("hardware"). This can be changed in the SETUP menu, Shutters ("Software" means operating by the panel)
• Gone:  The "shutter present" switch is not activated. This message is only present during X-ray on.
• Switch off the X-rays. Ask an experienced mechanical engineer to loosen the shutter (screws) a bit and shift the shutter housing till the "Gone" sign disappears.
• The shutter has to be returned for repair.
• LockX:  A safety per shutter is active.
• Check if the goniometer detecting switch (hoover safety) is in correct position (if present). This magnet/reed switch is mounted close to the X-ray port /monochromator to detect that the goniometer is placed in front of the X-ray port.
• LockA:  A safety for all shutters is active.
• The doors are not closed. Test by switching the Open beam key switch under the table, so the Open beam lamp flashes (if not flashing,  replace the lamp). When the shutter can now be opened the enclosure was not closed (detected by safety switches in the doors).
• Key:  The shutter key switch under the table is disabled. Switch to position enable (key horizontal).
• Remote:  Safety of an external goniometer is active (through the GCU cable). This message is only present during X-ray on.
• Check the Goniometer safeties : KappaCCD, MACH3 or CAD4
• Error:  Unknown error.
• Shutter does not close or closes too slowly.
• Close'd:  The panel is not set as shutter manager but to external manager
• Stuck:  The shutter is mechanically stuck open (HV switches off too). The shutter must be repaired. This message is only present when the panel is not the manager.
• Set:  The shutter does not open with a shutter open command. This message is only present when the panel is not the manager.
• Input bayonet not fitted.
• Clear 1:  Because of a wrong status of the shutter the circuit goes into error condition. Check with the service program which is wrong (red). Contact the service department.
• Clear also appears when in Standby trying to open the shutter while the shutter key is off. That is no error, just an not expected condition.
• For FR591, look at the shutter status in the control panel : View • Setup parameters
• "Absent" : see "Gone" above.
• "Key-switch" : see "Key" above.
• "Interlock" :  see "Lock A/X" above.
• "Error" : An 13-08 error as occurred.
• Check the shutter setup (also when generating X-rays) in the control panel :

	Shutter opened from goniometer	Shutter opened from Control panel
Setup • Management	shutters are set to "No management" or "RS232"	shutters are set to "panel".
Setup • Shutter	shutters are set to "GCU enabled"	shutters are set to "GCU disabled" When normally opened by the goniometer (setting on a board) and HV=on then the shutter must also be opened by the goniometer (for the goniometer shutter safeties)

• Check if the X-ray port bayonet coupling (if present) is in good position. The mechanical safety slot inside the shutter can prevent opening.
• In the service program State bit = 1 and after HV on:
• Sequence error:
• Open the shutter by hand or:
• Press the shutter open switch two times very quickly.
• Now the State bit = 0 and the shutter will work till next powerdown/up. This error can occur now and then is caused by timing error/bug
• State bit = 1 directly after HV on
• Check ST23/24 on the Tube controller board: When the new shutter PALs are mounted (TUBE1CA, TUBE1CB, TUBE3CA and TUBE3CB,  PCN24) and when Nonius equipment is used then ST23/24 must be open.

Selection of errors from the control panel. For other error message contact the Service.

Look at the second numbers of the error, for instance (0x13, 0x08) is 13-08 :

12-06 12-40 12-41 12-43 12-44

13-01 13-02 13-03 13-07 13-08 13-0B 13-0C 13-12 13-13 13-16 13-43 13-56

14-0A 14-0D 14-0E 14-42 14-4B 14-4C 14-55 14-56

Errors without error number:  Internal error: Input buffer overrun Anode bushes wear No mA

12-06 EMERGENCY PUSHBUTTON

The red emergency button on the outside of the cabinet is pressed

12-40 NOT STANDBY FOR HV

Not ready to generate HV (Generator is not in Standby status).

12-41 kV NOT RECHARGED

Action taken, for instance HV ON, when the kV wasn't fully discharged after the HV OFF. Wait some seconds and repeat.

12-43 BAD VACUUM RECRYST

Starting recrystallization when the vacuum is too low. Wait till the vacuum is high and the recrystallization will continue automatically.

12-44 AUTOMATIC FUSE AUX (Microstar)

The automatic fuse of the auxiliary unit (with pumps etc.) is off

13-01 LOOSE HT CABLE END

The "HT cable present" connector on the tube is not placed.

13-02 LOOSE TUBE COVERS

The white tube cover with the red lights is not in place, detected by a reed switch with magnet in the cover. The signal is latched in a battery powered circuit, so even if the covers are in place again or power has been off, the electronics will show this error. The only way to reset is to choose the (same) anode target (Cu or Mo) again from the control panel.

13-03 LOOSE TUBE SHIELD

The connector of the tube shield is not placed, indicating the metal tube around the cathode of the X-ray tube is not in place. The signal is latched in a battery powered circuit, so even if the connector is placed again or power has been off, the electronics will show this error. The only way to reset is to choose the (same) anode target (Cu or Mo) again from the control panel.

13-07 TEMP ALARM COOLWATER

The temperature of the cooling water at the secondary output of the heat exchanger is too high. Check the input water flow and the temperature. The temperature is shown in menu View / Operating parameters.

After restoring the cooling the temperature of the secondary water can still be too high, preventing the water pump to start. It has to cool down on its own, which can take some time. It is  possible to start the water pump by a service command. Use this command only when needed, because wrong use can start other parts without safety.

• Get service management
• Go to Service, IO and choose Write and  Tube controller
• Write (indifferent data) to address FF6B. The water pump will start.
• Be careful: the pump is now running  without any safety, so after cooling down start again from power down.

One of the shutters doesn't open, doesn't close or the safety shutter fitted switch is not activated.

• When the error is permanent one can track it with the Service program:
• If the shutter fitted is red, you could try to loosen the three screws of the shutter a little bit and shift the shutter till it is green again. If you don't succeed then the shutter must be refurbished.

13-0B ANODE DRIVE OVERRUN (FR591) or ANODE DRIVE CURRENT (Microstar)

Start again and go in smaller steps to the kV/mA power.

13-0C VACUUM GAUGE FAILS

Vacuum gauge doesn't work. Possible causes:

• Vacuum is too high. The gauge doesn't start when it is too clean.
• Ventilate the head with nitrogen and start again.
• Check if you are not out of nitrogen.
• Ventilating with air (loosen nitrogen tube).
• With technical experience this can be done by disconnecting carefully the vacuum measuring probe with the clamp.

Cooling water level in the vessel is too low. Refill the vessel with demineralized water (first read electrical safety)

13-13 FLOW ALARM TUBE

No water flow through the anode. Causes:

• Water pump doesn't run.
• Check if the water hoses for kinks.
• During start after the water was filled : not enough water yet. Ask Service for instructions to start the water pump and leave it running for at least 15 minutes, till the water flow doesn't switch off. Start again in the normal way.

Check the low vacuum list

13-43, 56  TURBO SPEED FAILS or TURBO PUMP TIMED OUT

Turbo pump speed too low or Turbo pump did not reach the right speed after 4 minutes.

• After several years of operating the Turbo pump bearings can be are worn. A service man can check this by inspecting the grease cartridge . The advise is to refurbish the turbo pomp, which is not expensive. One can choose to do this through the local Balzers/Pfeiffer representative.

The heatsink is located in the power module, situated left of the HV tank. This is cooled by two thin brown tubes.

• Check if the primary water pressure is above 2 bar. A too low water pressure is first noticed by this error.
• Check the input and output water cooling connection on the power module. Both must be cold. When the output is warm you can try to disconnect and clean by flowing water through the power module in two directions.

The oil level in the HV tank is too low. Check if there is oil leakage on the floor.

14-0D XRAYS DISABLED

Trying to generate X-ray while the X-ray key switch is in position disabled.

14-0E XRAYS LAMP FAILS

Both red X-ray On lamps are defect.

14-42 FILAMENT SET FAILS

This can be caused by:

• The tube current should not be too low: at least 10 mA.
• Broken filament. When the generator is switched off and on it should come with a broken filament message.
• Many trips rapidly after each other.
• Sudden manual change from bias high to low.

• For a 9 kW generator: Go to Setup, Generator and check if it is setup for module 1. If not, change to that.
• Check if the manual fuse 9kW1  (module 1) is on. If it switches off again there is a technical problem and the Service department must be contacted.
• The check circuit can be temporary switched off through the Control panel: Service • Modify • Write: Gen-ctrl, RAM, address 1B7B, data 07. First get service management. Do this only after instructed by the Service department. When this does not help, the electronics is defect.

Filament current too low, most probably a broken filament

14-55 AUTO

The Stotz switch of a 9 kW module is switched off. Switch it on again.

14-56 SHORT

A short circuit between the filament and the bias cup. The filament has to be replaced. If it is caused by a rotation of the filament, then check with the next filament that it does not change during fastening (see description  filament replacement)

Internal error: Input buffer overrun

This error is a communication error on the digital bus and is mostly caused by electrical disturbance. This can be:

• Strong HV trips. In time the generator head gets polluted and trips gets more heavy, till they disturb the electronics. A maintenance visit is then needed.
• Power instabilities. After 1997 a new version of IC80 on the Main controller board, called  version MCN4C makes the FR591 less sensitive for very short power dips. This helps however only when power dips are the cause.

Communication problem with computer or goniometer

• Check if the RS232 communication parameters are right with : Service • Read • node : Main-ctl, address $81C6 and $81CA
•  For KappaCCD : (1200 bd, 8 data bits, 1 stop bit, no parity, no handshake)
• $81C6  -  $  0     not used (hand shake)
• $81C7  -  $  4     1200 bd, for 9600 bd: $ 25
• $81C8  -  $B0     1200 bd, for 9600 bd: $ 80
• $81C9  -  $  8     databits
• $81CA  -  $  1     stopbit
• $81CB  -  $  0     parity = none
• If the values above are not setup (all different values) the software will automatically choose 9600 bd.
• Don't look to the view menu, because the RS232 parameters shown are not right.

The anode brushes should last at least a year. When they wear in a too short time you could clean the motor inside and  track the length for some time. When new, the brushes are 23 mm long. If cleaning does not help, probably the motor is worn and should be replaced.

No mA

Open the tube and check if the filament does not touch the focus cup.

Service program

A service program is available which reads the internal registers and values for trouble shooting the FR591. The program runs on a PC under Windows95/98.

• Retrieve the self-extractable program and start the file, which will install the program.
• Connect the PC with a RS232  0-modem cable with the FR591 RS232 connector inside the Electronic unit.
• It is advised to order a short cable to bring this connection outside the Electronic unit for easy connection (part number 0591.826).
• For use with WIN 2000 retrieve the patch and read 00INF.TXT

Manufacturer and Service

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