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GE

Measurement & Control


Solutions

X-ray

Radioscopic Inspection
System

x|
blade
Operating
Instructions

Operating Instructions x|
blade

1. edition, translated operating


instructions
Documentation
134184/EB. 0811
Published by GE Sensing
Technologies GmbH

no.:
&

Inspection

Reference: js
Date: 08/08/2011
Betriebsanleitung_X-Blade_e1.indd

File:

Printed in Germany
2011
In order to further develop our products, we reserve the right to change data and designs
without prior notice. All rights reserved, particularly rights relating to duplication,
Dissemination and translation excepted. No part of this publication may be reproduced,
processed or disseminated in any form (e.g. through photocopying, microfilming, electronic
data processing and/or storage or other means) without the prior written consent of GE
Sensing & Inspection Technologies GmbH.
In service situations, please contact:
Ahrensburg

Service Department

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Tel.: +49 (0)4102


807-117
Fax:+49 (0)4102
807-277

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III

Table of
Contents

Operating Instructions x|
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Table of
Contents
1 General
............................................................................................................................
.........................................1-1
1.1

Information relating to the operating


instructions..............................................................................1-1
1.2 Explanation of
symbols...................................................................................................
...........................1-2
1.3 Limitation of liability
...............................................................................................................
1.4 Guarantee conditions
...............................................................................................................
1.5 Copyright................................................................................................
......................................................1-3
Safey ..............................................................................................................
t
..........................................................2-5
2.1 Correct use, misuse
...............................................................................................................
2.2 Responsibility of the operator
...............................................................................................................
...2-6
2.2.1 Handling consumables
.....................................................................................................................................
... 2-7
2.3
2.4

2.2.2
SpecialSafety
dangers...................................................................................................
Personnel................................................................................................
................................................... 2-10

2.4.1 Requirements
.....................................................................................................................................
2.5 Personal protective
equipment...............................................................................................
2.6 EMERGENCY deactivation
...............................................................................................................
2.7 Work areas, traffic areas and risk
zones............................................................................................. 2-14
2.8 Layout of signs and pictograms
........................................................................................................... 22.9 Environmental protection
...............................................................................................................
3 Technical
data......................................................................................................................
................................ 3-17
3.1 Scope of delivery
........................................................................................................................
.............. 3-18
4 Assembling and function
.............................................................................................................................
...... 4-19
4.1 Brief
description.......................................................................................................
................................ 4-19
4.2 Overview of modules
........................................................................................................................
...... 4-20

Operating Instructions x|
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Table of
Contents

5 Transporting the x|
blade.....................................................................................................................
............... 5-21
5.1 Safety instructions for transportation
................................................................................................ 5-21
5.2 Transportation inspection
.....................................................................................................................
5-21
5.3 Control panel
........................................................................................................................
.................... 5-22

5.4

Fittig transport securing elements


ng
55.4.1....................................................................................................
Sliding

door..................................................................................................................
X-ray device
.........................................................................................................................
5.5 Preparation for truck
transportation..................................................................................................
. 5-23
5.4.2

6 Installation and
assembly...............................................................................................................
................... 6-25
6.1 Safety during installation and
assembly............................................................................................. 6-25
6.2 Installation
........................................................................................................................
........................ 6-27
6.2.1
6.2.2
6.2.3
7

Installation conditions, surface load and necessary clearance


.....................................................6-27
Control panel

installation........................................................................................................
Removing transport securing elements
....................................................................................................6-28
6.2.3.1 Sliding

Handling d
an
Operation.........................................................................................
7.1 Safety during
operation................................................................................................
7.2 Handling .................................................................................................
................................................... 7-31
7.3

7.2.1 Control system elements


Operation ...............................................................................................
................................................... 7-34
7.3.1 Switching on the system
...................................................................................................................................7
-34

7.4

MANUAL
mode......................................................................................................
7.5 AUTOMATIC mode
...............................................................................................................
7.6 Switching of
...............................................................................................................
7.7 Service
mask.......................................................................................................
8 Mantenance and
i
repair.......................................................................................................
8.1 Safety information in the case of maintenance and
repair............................................................. 8-44
8.2 Maintenance ...........................................................................................
.................................................. 8-46
9
Faults
...............................................................................................................................
...................................... 9-51
9.1 Safety instructions relating to faults
................................................................................................... 9-51
9.2 Faults
........................................................................................................................
................................. 9-52

10 Dismantling and disposal


.............................................................................................................................
... 10-53
10.1 Safety instructions relating to dismantling and disposal
.............................................................. 10-53
10.2 Dismantling and disposal
....................................................................................................................
10-55
Index.....................................................................................................................
........................................................ 11-57

Operating Instructions x|
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1

Genera
l

General
1.1

Information relating to the operating instructions


These operating instructions contain important information on the handling of the
system. Adherence to all of the safety information and handling instructions
stipulated is a precondition for safe working.
This machine may only be operated by trained and authorised
personnel.
These operating instructions should be viewed as an integral component of the
machine and always kept close to the machine (preferably in the storage pocket
behind the right- hand door of the control panel).
Documentation provided:
Radioscopic inspection system operating instructions
Test certificate for x-ray tube
Radioscopic inspection system test log
Installation and operating instructions for the x-ray device (e.g. ISOVOLT
Titan E) Operating instructions for the Digital Automatic Acquisition
System SABA 4000
Operating instructions for the water cooling pump (e.g.
WL3000SE)
Spare parts list
Circuit diagrams

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2-1

1.2

Explanation of symbols
Warnings are identified by symbols in these operating instructions. Instructions
are introduced using signal words which indicate the extent of any risk.
It is imperative that the instructions be adhered to and to act circumspectly to
avoid accidents, injury and material damage.
Warning: electrical voltage
Warning: ionizing radiation
Caution, warning of a
danger zone

Indication of unauthorized admission

Warning of hand injuries

Warning of hot surfaces


Warning of stumbling risk

Warning of slipping risk


Warning of irritating materials or materials damaging to health

Indication of special information


Do not drill

1.2.1

Safety symbols
Safety symbols should be affixed in a clearly-visible
manner.
The required size of safety symbols depends on the distance from which
they are viewed and is governed by the German appendix to DIN 48441:2005.
CAUTION
!

Signs such as pictograms and warnings/indications on the machine and in


the surrounding area should be permanently maintained in a legible
condition. Missing or damaged signs should be replaced immediately!

1.3

Limitation of liability
All details and instructions in these operating instructions have been
compiled taking applicable standards and regulations, the current state of
technology and our know-how and experience gained over many years into
consideration.
The manufacturer accepts no liability
damages due to:

for

Non-adherence to the operating


instructions
Incorrect
use
The use of untrained
personnel
Unauthorized
modifications
Technical
changes
The use of unauthorized
spare parts
The installation of software or hardware by
unauthorized persons

1.4

Guarantee conditions
The guarantee conditions
confirmation apply.

1.5

confirmed

in

the

order

Copyright
The operating instructions should treated with confidentiality. They are
intended solely for persons working with the system. Passing of the
operating instructions to third parties is prohibited without the written
approval of the manufacturer.
NOT
E:
The details, texts, drawings, images and other representations contained in
this documentation are protected by copyright and subject to commercial
rights of protection.
Any improper use is liable to
prosecution.

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25

Operating Instructions x|
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Safet
y

Safety
This section provides an overview of all the important safety aspects
required for optimum protection of personnel and safe, fault-free
operation.
Significant risks may occur if the handling instructions and safety
regulations in these
operating instructions are not heeded.

2.1

Correct use, misuse


The radioscopic inspection system is utilised for non-destructive material
testing of work- pieces and components made of metal, plastic or
ceramics using X-ray radiation, both during industrial production and
damage analysis of research and development equipment . Workpieces
should not exceed the maximum dimensions and weights:
Dimensions:
Weight:

diameter
height

150 mm
(5,9")
400
mm
(15,7")
8 kg (17.5

The system may only be operated for the purpose described previously
and in compliance with the safety instructions pursuant to Section 2.3 and
national laws and ordinances on the operation of x-ray systems.
Any other use of this system is
prohibited.
E.g
.
Medical use for humans and
animals
Luggage
inspection
The inspection of electrical devices or sensitive electronic
components
- Do not use the C arm for lifting
loads.
Components necessary for radiation protection should not be
drilled or damaged.

2.2

Responsibility of the operator


The system is used in a commercial/industrial area. The operator of the
system is therefore subject to the legal obligations relating to occupational
safety.
The operator should nominate a person with responsibility for the safe
operation of the
system and co-ordination of all work on the
system.
In addition to the occupational safety instructions in these operating
instructions, the safety, accident prevention and environmental protection
regulations valid for the area in which this system is used must be
followed. The following apply in particular:
-

The operator should be aware of pertinent occupational safety


requirements and determine through risk assessment any additional
risks that may occur as a result of particular working conditions at the
location in which the system is used.
These should be converted into operating instructions for the system.

During the whole period of use of the system, the operator should
check whether the operating instructions compiled by him/her
correspond to current rules and regulations, amend the instructions if
required.

The operator should ensure that all employees handling the system
have read and understood the operating instructions.
Furthermore, he/she should train personnel at regular intervals and
inform them of
potential risks.

The operator should not allow any employee to work on the system
whose reactions are impaired (e.g. through drugs, alcohol, medication
or similar).

Furthermore, the operator is also responsible for ensuring that the system
is at all times in a technically flawless state. The system should therefore
only be operated with correctly installed and fully-functional safety
devices. In addition to this, maintenance work listed in Section 8 should be
carried out at the intervals stipulated.
Pertinent radiation protection regulations should be observed for
this system.
X-ray units that are used in radiography to provide a rough
structural analysis of materials inspected always need a permit
according to Section 3 of the current version of the Radiation
Control Law and may need to follow additional national
regulations.
A new radiation protection test should be conducted by the authority
responsible each time it is transported and recommissioned.
Furthermore, a new radiation protection test should be conducted by the
authority responsible after work on parts relevant for radiation
protection.

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2.2.1 Handling consumables


Safety data sheets for consumables should be used, employees instructed
and information made accessible.
2.2.2 Safety symbols
The operator should ensure that all pictograms and safety symbols on the
machine and in the surrounding area are maintained in a legible condition.
Signs such as pictograms and warnings/indications on the machine and in
the surrounding area should be permanently maintained in a legible
condition. Missing or damaged signs should be replaced immediately!
2.2.3 Safety measures at the installation site

Safe access to the machine should be guaranteed at all times. Do not


block escape
routes
!

The operator should ensure that floors are level and not slippery and
the workplace
is
adequately
illuminated.

The operator should ensure that the immediate surroundings of the


machine and the
interior of the cabinet are kept
clean.

The control panel should be set up so that the operator has full view
of the entry opening.

The operator should identify the working area


pursuant to Section 2.7.

For safety reasons, unauthorized machine modifications are


strictly prohibited.

The guarantee issued by GE Sensing & Inspection Technologies


GmbH is rendered invalid in the event of any software and/or
hardware installation by unauthorized persons. The installation of
software and/or hardware can significantly interfere with the
operation of the system or bring it to a standstill.
Authorised persons are employees of GE Sensing & Inspection
Technologies GmbH
and personnel specially instructed for this
purpose.

GE Sensing & Inspection Technologies GmbH guarantees a virusfree system at the time of delivery, as the plant has been checked
using the latest virus identification files available at the time of
delivery.
The operator is responsible for freedom from viruses after delivery.
Please note that the operator also bears responsibility in this respect
when connecting to the company's own networks.

2.2.4 Behavior in case of accidents - frst aid


The operator should ensure that all employees handling the system have
been trained in and understood the behavior required in case of accidents:
Deactivate system, recover injured, inform first aid officers and
superiors, perform first aid.

2.3

Special dangers
Residual risks resulting from risk analysis are stipulated in the
following section.
Observe the safety instructions listed here and the warnings in the
individual chapters of these operating instructions to reduce risks to
health and avoid hazardous situations.
DANGE
R!
Risk of fatality from ionizing
radiation!
The maximum emitted radiation is identified in the
enclosed test log.
The radiation protection cabinet should not be entered
during operation.
A new radiation protection test should be conducted by the authority
responsible each
time
it
is
transported
and
recommissioned.
Following work that requires the removal or decommissioning of
parts relevant to
radiation, a new inspection should be realised prior to
recommissioning by the radiation
protection officer authorised by the
operator.
The radiation protection cabinet and sliding door should not be
drilled or damaged in
any
way.
The system should be shut down immediately and the radiation
protection oficer authorised by the operator notified and
informed with respect to further measures in the event of
accidents which damage components relevant to radiation
protection.
DANGE
R!
Risk of fatality from electrical
current!
There is a direct risk of fatality if live parts are touched. Damage to
insulation material or
individual components can be fatally
dangerous.
For
this
reason:
deactivate the electricity supply immediately if the insulation is
damaged and
immediately arrange for
repair.
only entrust work on the electrical installation to qualified
electricians.
Essential procedures
against reactivation

28

for

securing

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During work realised inside the machine, third parties may not be aware of
the presence of persons in the machine interior. In order to prevent
unauthorized activation of the machine, the following safety measures
should be taken prior to commencing work by the person supervising
those realising the work:
! GEFAHR

1. Shut down the machine.


2. The person responsible should turn the key switch to position 0,
remove the key and
keep it safe for the entire duration of work activities.
3. The person responsible should turn the main switch to position "0"
("OFF"), secure it with
a padlock and remove the key and keep it safe for the entire duration of
work activities.
4. Affix a warning sign (example on left) to the controls containing the
name of the responsible person who is entitled to reactivate the machine.

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The following measures should be realised on completion of work and prior


to reactivating
the machine:
1. Correctly reinstall all protective equipment and check that it is fully
functional.
2. Ensure that nobody is present in the machine or risk zone.
3. Only then remove the sign and release the main switch.
4. Key switch in position 1.

WARNIN
G!
Maintenance work should only be realised by the manufacturer's service
personnel or
trained specialists authorised by the
operator.
Work on the electrical installation and on live system parts and/or
devices should in all
cases only be realised by electrical
specialists.
Electrical specialists are specially trained for work on electrical
installations, recognise
the risks emanating from electrical current and can independently avoid
hazards through
correct
actions.
Personnel should be informed of the dangers present and wear prescribed
PPE during work.
DANGE
R!
Risk
of
injury
from
moving parts
Work on or in the machine should always be realised when the system is
shut down. Before recommissioning, fit all covers, screw fittings and safety
equipment in accordance with instructions and check that they are
functioning correctly.
The radiation protection cabinet should not be entered
during operation.
The temporary working area for loading and discharge should not be
entered during the inspection (opening and closing of sliding door).
DANGE
R!
Risk of burns from hot
surfaces
Contact with hot components can cause
burns. For this reason:
Wear protective clothing and protective gloves during all work close
to hot components.
Ensure prior to all work that all components have cooled to room
temperature.
DANGE
R!

Risk of injury from sharp edges and


pointed corners
WARNIN
G!
Improper handling of consumables can lead to damage to health. The
prescribed PPE should be used in accordance with the safety data sheets
(e.g. chemical-resistant protective gloves, protective glasses).

DANGE
R!
Risk of stumbling or
slipping.
Ensure that the working area is clean
and tidy.

2.4

Personnel

2.4.1 Requirements
DANGER!
Risk of injury due to insufficient qualification!
Incorrect handling can lead to significant injuries and material damage.
For this reason:
Special tasks should only be realised by the persons named in the
respective chapters
of
these
instructions.
The responsibilities for various tasks realised on the machine should be
clearly specified and observed at all times. Unclear responsibilities
constitute a safety risk.
-

In cases of doubt , consult a specialist .

The following qualifications for different task areas are stipulated in


the operating
instructions:
-

Instructed persons
have been instructed by the operator in the tasks allocated to them
and any possible risks associated with incorrect behavior.

Specialists
are capable of realising work allocated to them and independently
recognising any possible risks, thanks to their specialist training,
knowledge and experience and their knowledge of relevant
regulations.

Electricians
are capable of realising work on electrotechnical installations
allocated to them and independently recognising any possible risks,
thanks to their specialist training, knowledge and experience and their
knowledge of relevant standards and regulations.

2.4.2 Personnel qualifcations according to life stages and tasks


Transport , setting up:
trained and instructed
specialists Installation, initial commissioning: trained and
instructed specialists Operation:
instructed personnel
and specialists Cleaning:
instructed personnel
Troubleshooting:
trained and instructed
specialists Maintenance, repair:
trained and instructed
specialists Dismantling, disposal:
trained and instructed
specialists

DANGER!
Risk of fatality from electrical current!
Work on the electrical installation and on live system parts and/or devices
should in all
cases only be realised by electrical specialists.
Electrical specialists are specially trained for work on electrical
installations, recognise
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08/08/2011
1st edition, ID no.:
134184/EB.0811

the risks emanating from electrical current and can independently avoid
hazards through
correct actions.
Personnel should be informed of the dangers present and wear prescribed
PPE during work.

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215

2.5

Personal protective equipment


The operator should provide personal protective equipment (PPE) for
persons working on
the system.
He/she should issue operating instructions on the use of PPE.
He/she should ensure that personnel receive regular,
verifiable instruction. He/she should check that PPE is worn
during work.
Mandatory signs should be affixed on, in or close to the machine in a
clearly visible manner
and at all times maintained in a clearly legible state.
Personal protection equipment is to be worn which is prescribed in the
appropriate chapters.
List of used personal protective equipment
Protective clothing
Hand
protection
Foot
protection
Eye
protection

Head protection

Breathing protection
Apply protective skin cream prior to work and a skin-care product after
work.

2.6

EMERGENCY deactivation
In the event of a risk to persons or the system, on of the EMERGENCY
STOP buttons should be actuated.
EMERGENCY STOP buttons are installed in the system at the following
positions:
-

on the control panel


in the radiation protection cabinet behind the sliding door
on the robot control panel
on the robot switch cabinet

It should therefore be ensured that the EMERGENCY STOP button


can at all times be reached quickly, easily and at no risk.
All movements and radiation are deactivated with these buttons.

Control voltage remains active.

EMERGENCY STOP
buttons

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Release the respective EMERGENCY STOP button after the fault is remedied
and acknowledge
the fault on the control panel with the FAULT
ACKNOWLEDGEMENT button. The error messages on the
display disappear.
Actuating the START button twice on the control panel continues the
interrupted program at the point at which the EMERGENCY STOP button
was actuated.

CAUTIO
N:
X-ray systems which, due to special regulations, are equipped with a 2channel EMERGENCY STOP circuit are delivered without a control
module for the ISOVOLT.
Where an additional control module is operated on such systems
(including during temporary service operations), the additional control
module connected should, for safety reasons, not have an EMERGENCY
STOP button.
Control module without EMERGENCY STOP button: ID
no. 665415B.
CAUTIO
N
EMERGENCY STOP equipment should be inspected at
regular intervals

2.7

Work areas, traffic areas and risk zones

Work area ( ),
temporar y working area
for delivery and removal
of materials ( ), traffic
area ( ) and risk zone (
). The operating
point is arranged so that it
is located outside the risk
zones.
The
operator
must
identify the work areas,
(e.g. through black/ yellow
markings on the floor).

2.8

Layout of signs and pictograms

Rating plate
GE
Sensing & Inspection Technologies

TYP / TYPE:
IDENT
NO.:

X-CUBE COMPACT
AXXXXX
X XXXX

BAUJAHR
/
YEAR OF
CONSTRUCTION:

ISOVOLT
160 kV

X-RAYEQUIPMEN
T:

MADE IN GERMANY

Lead level sign


GE
Sensing & Inspection Technologies

GE
Sensing & Inspection
Technologies
STRAHLENSCHUTZKABI
NE RADIATION PROTECTION
CABINET
X-CUBE COMPACT / 160kV

TYP/TYPE:

X-CUBE

COMPACT SCHALTPLAN NR./

BLEIWERTE/LEAD VALUES:

IDENT NO.:

3mm Pb:
2mm Pb:
5mm Pb- BLEIGLEICHWERT/
LEAD EQUIVALENT:
6mm Pb:

08/08/2011
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584 89 0/23
ELECTRICAL
DRAWING NR.:

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2mm Pb- BLEIGLEICHWERT/


LEAD EQUIVALENT (30mm St):

AXXXXXX BAUJAHR/ XXXX


YEAR OF
CONSTRUCTION:
EINSPEISUNG/LINE: 3NPE 400/230V/50Hz
MAX. VORSICHERUNG

Bogenstrasse35A
41 D MAX. PRE-FUSING 35A
NENNSTROM/
L1 25A
NOMINAL CURRENT:

219

DACH/ROOF RCKWAND/REAR WALL VORDERWAND/FRONT WALL


SEITENWAND,LINKS/
SIDE WALL, LEFT (VORN,HINTEN/FRONT, REAR)
STRAHLENSCHUTZTR/
X-RAY PROTECTION DOOR
SEITENWAND,RECHTS/ SIDE WALL, RIGHT SEITENWAND,LINKS
(MITTE)/ SIDE WALL, LEFT (MIDDLE)
BODEN/BOTTOM BLEIGLASFENSTER/
LEAD GLASS WINDOW

BODEN/BOTTOM
MADE IN GERMANY

214

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Ratin
g

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plate on the
inside of the

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221

2.9

Environmental protection

This product contains a battery that cannot be disposed of as unsorted


municipal waste in the European Union. See the product documentation
for specific battery information. The battery is marked with this symbol,
which may include lettering to indicate cadmium (Cd), lead (Pb), or
mercury (Hg). For proper recycling return the battery to your supplier or
to a designated collection point .
What do the markings
mean?
Batteries and accumulators must be marked (either on the battery or
accumulator or on its packaging, depending on size) with the separate
collection symbol. In addition, the marking must include the chemical
symbols of specific levels of toxic metals as follows:

Cadmium (Cd) over


0.002%

Lead (Pb) over


0.004%

Mercury (Hg) over


0.0005%
The risks and
reducing them

your

role

in

Your participation is an important part of the effort to minimize the


impact of batteries and accumulators on the environment and on human
health. For proper recycling you can return this product or the batteries or
accumulators it contains to your supplier or to a designated collection
point .
Some batteries or accumulators contain toxic metals that pose serious risks
to human health and to the environment . When required, the product
marking includes chemical symbols that indicate the presence toxic
metals: Pb for lead, Hg for mercury, and Cd for cadmium.
Cadmium poisoning can result in cancer of the lungs and prostate gland.
Chronic effects include kidney damage, pulmonary emphysema, and bone
diseases such as osteomalcia and osteoporosis. Cadmium may also cause
anemia, discoloration of the teeth, and loss of smell (anosmia).
Lead is poisonous in all forms. It accumulates in the body, so each
exposure is significant . Ingestion and inhalation of lead can cause severe
damage to human health. Risks include brain damage, convulsions,
malnutrition, and sterility.
Mercury creates hazardous vapors at room temperature. Exposure to high
concentrations of mercury vapor can cause a variety of severe symptoms.

Risks include chronic inflammation of mouth and gums, personality


change, nervousness, fever, and rashes.

The X-ray tube assembly contains beryllium and should not be disposed of
as standard commercial or domestic waste.
Local disposal regulations should therefore be
observed.
The manufacture will assume responsibility for disposal if it is returned
carriage-paid.

DANGE
R!
Beryllium dust , beryllium vapour and beryllium compounds are toxic,
particularly dangerous to the respiratory organs and can be carcinogenic.
Use PPE in accordance with the safety data sheet (e.g. chemical-resistant
protective gloves, protective glasses, respiratory protection).

The radiation protection cabinet and sliding door contain lead and should
not be disposed of with normal commercial or domestic waste.
Local disposal regulations should therefore be
observed.
The manufacture will assume responsibility for disposal if it is returned
carriage-paid.

DANGE
R!
Ingested lead is toxic. Main routes of ingestion: ingestion of lead dust
through the respira- tory tract; ingestion of lead through the stomach due
to it sticking to the hands or particles being swallowed from the upper
respiratory tract . Direct absorbtion of lead through the skin is
insignificant . Lead harbours chronic risks. It accumulates in the body. It
may impair fertility and damage unborn children in the womb.
Avoid or minimise dust/smoke development . Use the P2 dust mask
during brief and unavoidable development of dust . Clean with damp
media where possible, do not stir up dust and do not use compressed
air for cleaning. Do not eat , drink or smoke in the working area. Wear
protective gloves wherever possible. Wear protective glasses. Change
contaminated clothing immediately. Clean hands thoroughly prior to taking
breaks and when work is completed. Ensure that preventive skin
protection/skin care practices are implemented and observed.
Use PPE in accordance with the safety data sheet (e.g. chemical-resistant
protective gloves, protective glasses, respiratory protection).

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Operating Instructions x|
blade
3

Technical
data

Technical data
Refer to the rating plate on the system for plant-specific data such as
the construction year, ID no. and others (see Section 2.8).
Radiation protection cabinet
Dimensions:

width (with backpack)


depth
height
door opening (WxH)

2,440 mm (96.1")
1,700 mm (66.9")
2455 mm (96.7")
650 x 1460 mm (25.6 x
57.5")
8 kg (17.5 lbs)

Maximum weight of object:


Electrical connected load:

Total weight of complete workplace:


lbs)

3 NPE 400/230 V, 50 Hz,


35 A TN-S or TN-C-S
network
approx. 4900 kg (10803

Permitted ambient temperatures during operation: +5 C to +40 C.


Storage temperature:

-30C to +70 C

(drain/blow out parts conveying water)

Maximal permissible humidity during operation:


Maximal permissible humidity during storage;
Sound level:
Max. duration of operation:

50 %
50 %
< 70 dBa

Suitable for 24 h operation


Designed for 10 years

"Warm-up" or "condition" the tube regularly to increase the service life of


the X-ray tube
(see separate operating instructions for the X-ray device).

3.1

Scope of delivery
The programmable x|blade fluoroscopy workstation consists of the
following main components (1x in each
case):
Radiation protection cabinet with robot and sliding door with
motorized actuation
ISOVOLT 225 kV industrial X-ray
device, complete
DXR
Detector
SABA 4000 Digital Automatic
Acquisition System
Control
panel
Robot control
panel
The actual scope of delivery may differ from the explanations and
representations described here in the case of special designs, the utilisation
of additional order options or due to the latest technical changes.

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Operating Instructions x|
blade
4

Assembling and function

4.1

Brief description

Assembling and
function

The radioscopic inspection system chiefly consists of a radiation protection


cabinet , X-ray detector, robot , water cooling pumps, X-ray unit and the
control panel with integrated control.
It is used for non-destructive material testing in industrial production and
during damage analysis of research and development equipment .
The radioscopic inspection system is suitable for use in indoor rooms
and containers.
Access to the radiation protection cabinet is enabled through a motorized
sliding door (T Y3) on the front . A lead glass window is integrated in the
sliding door which enables the user to safely view the interior of the
radiation protection cabinet .
The workpiece manipulator is a manual horizontal positioning device with
a rotating workpiece bracket (RZ) which can be fitted with a workpiece
holder on which the test material (workpiece) rests (up to 12 workpieces).
The second workpiece manipulator is a robot . The robot places the
workpiece into the
X-ray
beam.
The X-ray tube and DXR detector are cooled with two water cooling
pumps. The X-ray tube emits an radiation beam that strikes the detector.
The detector converts the X-ray image so that it can be illustrated on the
live image monitor. Further analytical functions for the evaluation of the Xray images can be realised on the two monitors with the aid of the
integrated SABA 4000 software.
The workpiece is placed manually on the workpiece holder while the
sliding door is open. The two workpiece manipulators are positioned after
the sliding door is closed so that the radiation beam can penetrate at the
desired position.
The TX2 axis of the workpiece manipulator and workpiece bracket can be
pulled manually out of the radiation protection cabinet for improved
loading and discharge of the work- pieces/holder.
The machine can
following modes:

be

operated

Automatic
mode

Manual
mode

Teaching (programming
mode)

in

the

4.2

Overview of modules

14

12

2
3

17
7
6

16

13

15

11
9

10

Module layout
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

420

Robot
Radiation beam
Detector
Sliding door
Lead glass window
Live image monitor
Operating monitor
Main switch
Control panel with control system (PLC)
Robot control panel with EMERGENCY STOP
Control elements with EMERGENCY STOP
Robot switch cabinet with EMERGENCY STOP
Workpiece manipulator
X-ray tube
Water cooling pump
X-ray device
Switch cabinet

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Operating Instructions x|
blade
5

Transporting the X|blade

5.1

Safety instructions for transportation

Transporting the x|
blade

CAUTION!
Damage caused by incorrect transportation!
Material damage entailing considerable expense can occur during
incorrect transpor- tation.
For this reason:
Proceed carefully and observe symbols on packaging when discharge
packaging units
on delivery and during internal transportation.
Only use load fastening points intended for this purpose.
Only remove packaging just prior to installation.
DANGER!
Risk of fatality from ionizing radiation!
A new radiation protection test should be conducted by the authority
responsible each time it is transported and recommissioned.
Identify the installation area and transport routes as risk areas
and cordon them of at a distance to prevent unauthorized access.
When setting up the cordoned-of area, ensure that there are
unobstructed detour routes which are as short as possible for
unauthorized persons in order to prevent access.
Only use permitted lifting gear, industrial trucks and slings with sufficient
carrying capacity. Use the load fastening points. Slings must be free of
tears or chafing. No persons should
be in the risk areas under suspended loads or on the transport route when
moving parts.
Symbols on packaging units should be observed. Packaging units should
only be opened
immediately prior to commencing installation.
Transportation should only be entrusted to personnel trained and
authorised for this purpose (e.g. crane operators, forklift
operators).
Protective clothing, protective gloves, safety footwear and helmets
should be worn to protect against falling parts.

5.2

Transportation inspection
Check the delivery immediately on receipt for completeness and
transportation damage.
Proceed as follows if visible transportation damage is detected:
Do not accept the delivery, or only accept the delivery under special
conditions.
Note the extent of damage on the transportation documents or the
carrier's delivery note.

Transporting the x|
blade

Operating Instructions x|
blade

Initiate the complaint procedure.

NOTE:
Lodge a complaint about every deficiency as soon as it is detected.
Compensation claims
can only be made without pertinent durations for registering complaints.

5.3

Control panel
Lift the control panel onto the transportation platform with a forklift and
fit transport se- curing elements.
When securing the panel to the
transporta- tion platform, the feet
on the panel should be unscrewed
prior to fixing the panel to the
platform with the four transport
secur- ing screws.

5.4

Fitting transport securing elements


Fit any wooden or metal transport securing elements provided (including
to generator). The transport securing elements illustrated below should
also be fitted.

5.4.1 Sliding door


Screw in the M6 screws (4)

Square profile as transpor tation


aid for
manual platform trucks
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Forklift pockets for secure


transporta- tion of the x|blade.
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Transporting the X|
blade

5.4.2 X-ray
device

Operating Instructions x|
blade

A hole (9 mm) should be drilled in the angle at the positions marked 1 in


the case of older systems without transport securing elements for the X-ray
device. The transport securing elements provided 3 should be secured as
illustrated to the positions marked with 1 and 2 using the screws provided
(with washers/stop washers).

3
2

3
1

5.5

Preparation for truck transportation


Pallet with pallet carton for small
parts, documentation and plates.

x|blade packed for transportation

The x|blade should be secured as


illustrated with tension straps for
transportation by truck.
The tension straps should be
protected on the edges with
suitable material.

Suitable material should be laid


between the floor of the truck and
the wooden planks and the planks
and feet of the x|blade to prevent
slipping.

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633

Installation and
assembly

Operating Instructions x|
blade

Installation and assembly

6.1

Safety during installation and assembly


CAUTIO
N!
Pertinent radiation protection regulations should be observed
for this system:
X-ray units that are used in radiography to provide a rough
structural analysis of materials inspected always need a permit
according to Section 3 of the current version of the Radiation
Control Law and may need to follow additional national
regulations.
The operator is obliged, inter alia, to retain the notification of approval or a
type approval,
if available, together with the operating instructions of
the x-ray unit .
A new radiation protection test should be conducted by the authority
responsible each
time
it
is
transported
and
recommissioned.
Following work that requires the removal or decommissioning of
parts relevant to
radiation, a new inspection should be realised prior to
recommissioning by the radiation
protection officer authorised by the
operator.
The radiation protection cabinet and sliding door should not be
drilled or damaged in
any
way.
WARNIN
G!
Risk of injury through incorrect
assembly
Incorrect assembly can lead to severe injuries and serious
material damage.
For
this
reason:
Ensure that sufficient clearance is available for assembly prior to
commencing work.
Components with exposed sharp edges should be
handled with care.
DANGE
R!
Risk of fatality from electrical
current!
There is a risk of fatality in the case of contact with live components.
Electrical components
that are activated may realise uncontrolled movements and lead to
serious injury.
For
this
reason:
Deactivate the electrical supply before commencing work and secure
against reactiva-

tion.

Operating Instructions x|
blade

Installation and
assembly

All the work on the electrical installation should only be entrusted to


qualified electricians. Electricians are capable of realising work on
electrotechnical installations and independently recognising any possible
risks, thanks to their specialist training, knowledge and experience and
their knowledge of relevant standards and regulations.
Only trained and instructed specialists are permitted to realise installation
and assembly work.
DANGE
R!
Risk of fatality from electrical
current!
Prior to commencing any work, the connection cable from the operator's
network should
be deactivated and de-energized and secured against
reactivation.
Close all protective coverings and check that they are correctly fitted
before switching on
the
electricity.
Compare the data of the supply network with the electrical connection
data of the machine
before connecting the machine. The machine should only be connected if
the data matches.

WARNIN
G!
Identify the installation area and transport routes as risk areas and
cordon them off at a
distance to prevent unauthorized
access.
When setting up the cordoned-off area, ensure that there are
unobstructed detour routes
which are as short as possible for unauthorized persons in order to
prevent access.
WARNIN
G!
Heavy components or tools should always be lifted by several people.
Follow regional oc- cupational safety regulations.
Only use permitted lifting gear, industrial trucks and slings with sufficient
carrying capacity. Use the load fastening points. Slings must be free of
tears or chafing. No persons should be in the risk areas under suspended
loads or on the transport route when moving parts.

Protective clothing, protective gloves, safety footwear and


helmets should be worn to protect against falling parts.

DANGE
R!
Risk of stumbling or
slipping.
Lay energy cables and media supply cables so that they do not constitute
a stumbling risk
or a barrier, thus causing
accidents.
If, due to particular local conditions of use, the existing workplace
illumination is insufficient , the operator should set up additional lighting in
accordance with local occupational safety regulations before work
commences.
Prior to activation, check that the installation of the machine meets the
installation condi- tions and compile an inspection log.
Before activating the electrical connection, check that the machine is laid
out correctly and
compile an inspection
log.
Check connections for tightness immediately after activating
the machine.

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6.2

Installation
Installation is realised in accordance with the enclosed installation plan
pursuant to Appendix
A. The electrical connections are stipulated in circuit diagram no.:
158755023.
The electrical supply is realised in the control panel:
L1:
X0:L1
L2:
X0:L2
L3:
X0:L3
N:
-X0:N
PE:
X0:PE

6.2.1 Installation conditions, surface load and necessary clearance


Before assembly, ensure that the installation site meets the following
requirements:
- Dry
- Dust-free
- Protected against frost
- Sufficient space for assembly and cleaning work

Necessary clearance and surface load

6.2.2 Control panel installation


Remove the control panel transport securing elements, lift the control
panel off the transportation platform with a forklift and position next to
the cabinet as illustrated in Section 4.2.
CAUTION:
A minimum safety clearance of 500 mm should be observed between the
control panel
and sliding door (see also 6.2.1 Installation conditions).

6.2.3 Removing transport securing elements


Remove any wooden or metal transport securing elements.
The transport securing elements illustrated below should be removed and
stored safely for future use.
CAUTION: Packaging material which cannot be re-used (e.g. film,
cardboard, etc.)
should be disposed of in an environmentally-friendly
manner.

6.2.3.1

Sliding door

4
Remove the M6 screws (4)

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Handling and
Operation

Operating Instructions x|
blade

Handling and Operation

7.1

Safety during operation


WARNIN
G!
Risk of injury through incorrect
operation!
Incorrect operation can lead to severe injuries and serious
material damage.
For
this
reason:
Realise all operating steps in accordance with the specifications in
these operating
instructions.
Prior to commencing work, ensure that all covers and protective
equipment are installed
and functioning correctly.
The operator should be sufficiently qualified for the task, instructed in
the possible risks and wear the prescribed PPE during work.
The operator should provide personal protective equipment (PPE) for
persons working on
the
system.
He/she should issue operating instructions on the
use of PPE.
He/she should ensure that personnel receive regular,
verifiable instruction.
He/she should check that PPE is worn
during work.
The operator should ensure that all employees handling the system
have read and understood the operating instructions.
Furthermore, he/she should train personnel at regular intervals and inform
them of potential
risks
.
DANGE
R!
Risk of fatality from ionizing
radiation!
The radiation protection cabinet should not be entered
during operation.
A new radiation protection test should be conducted by the authority
responsible each
time
it
is
transported
and
recommissioned.
Following work that requires the removal or decommissioning of
parts relevant to
radiation, a new inspection should be realised prior to
recommissioning by the radiation
protection officer authorised by the
operator.
The system should be shut down immediately and the radiation
protection oficer authorised by the operator notified and
informed with respect to further measures in the event of

Operating Instructions x|
blade

accidents which
protection.

damage

components

Handling and
Operation

relevant

to

radiation

DANGE
R!
Risk of fatality from electrical
current!
There is a direct risk of fatality if live parts
are touched.
Damage to insulation material or individual components can be
fatally dangerous.
For
this
reason:
deactivate the electricity supply immediately if the insulation is
damaged and
immediately arrange for
repair.
only entrust work on the electrical installation to qualified
electricians.
DANGE
R!
Risk
of
injury
from
moving parts
The radiation protection cabinet should not be entered
during operation.
The temporary working area for loading and discharge should not be
entered during the
inspection (opening and closing of
sliding door).
Condition precedent to be allowed to move the robot by the operation
panel a factory
training by the robot supplier with certificate is
required.

WARNIN
G!
Heavy workpieces and workpiece holders (> 50 kg) should be lifted by 2
persons or with a
crane
.
If, due to particular local conditions of use, the existing workplace
illumination is insufficient , the operator should set up additional lighting in
accordance with local occupational safety regulations before work
commences.
Prior to activation, check that the installation of the machine meets the
installation condi- tions and compile an inspection log.
Before activating the electrical connection, check that the machine is laid
out correctly and
compile an inspection
log.
Check connections for tightness immediately after activating
the machine. The operator should ensure that the work area is
clean and tidy.

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7.2

Handling
The x|blade is operated via the control panel.
The control panel operating areas are divided into function groups which
are depicted in the following illustration.
Control system elements are described in detail in Section 7.2.2.

3
5
4

Control
panel
1 Live
monitor
2 Operating
monitor
3 USB
connection
4
Keyboard
5 Control system
elements

Operating Instructions x|
blade

Handling and
Operation

7.2.1 Control system elements


The lower left-hand part of the control panel contains all switches, buttons
and signal lights necessary for the x|blade control system:

RADIATION ON signal light


The signal light flashes when the radiation is activated.
Key-operated switch 0 I
The X-ray device is activated with this key-operated switch:

= OFF
X-ray device is off *
= Standby X-ray device is in standby mode *
= ON
X-ray device is operationally
ready *

*) see also ISOVOLT operating instructions


Beam shader / beam shutter closed button
The signal light in this button illuminates if the beam shader/beam shutter
is closed.
The beam shader/beam shutter is opened and the signal light in the
button extinguishes if the button is actuated in manual mode.
Release Programming key-operated switch
The system can be programmed as described in Section 7.7 if the Release
Programming
switch is activated.
EMERGENCY STOP push button
The x|blade can be deactivated completely with the EMERGENCY STOP
button in an emergency
(e.g. high voltage and all electrical drives are deactivated).
Fault Acknowledgement button
The signal light in this button flashes if an error occurs.

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After remedying of the fault , the error is acknowledged when the button is
actuated and
the signal light extinguishes.

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745

Handling and
Operation

Operating Instructions x|blade

START button
The system is started and radiation activated by actuating the START
button.
STOP button
The system is stopped by actuating the STOP button (drives and radiation
are deactivated).
Two-hand operation buttons
The sliding door is closed and the program sequence starts in automatic
mode if the two- handed buttons are actuated simultaneously.
Where two-hand operation buttons is interrupted, the sliding door moves
in the same
direction as previously following renewed actuation.
Control Voltage OFF Button
The Control Voltage is turned off by actuating the Control Voltage OFF
button
Control Voltage ON key-operated switch
The Control Voltage is turned on by actuating the Control Voltage ON
switch
Control Voltage ON signal light
The signal light is on when the control voltage is on.

RADIATION ON signal light


The signal light flashes when the radiation is activated.
EMERGENCY STOP push button
The x|blade can be deactivated completely with the EMERGENCY STOP
button in an emergency
(e.g. all electrical drives are deactivated).

Operating Instructions x|
blade
7.3

Handling and
Operation

Operation

7.3.1 Switching on the system


1.

Switch the main switch on the control panel to the I position.

2. Unlock any EMERGENCY STOP push buttons which have been


actuated.
EMERGENCY STOP push buttons are installed at the following
positions in the system:
- on the control panel
- in the radiation protection cabinet behind the sliding door
- on the robot control panel
- on the robot switch cabinet
3. Switch the Control Voltage ON key-operating switch to the I position
3.

The installation control system is started when it is ready for


operation by actuating the illuminated START button.

4.

Switch the "


" to the position. The X-ray device is readied
for opera- tion as a result .

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7.3.2 Warming up the X-ray tube


Switch on the system according to Section 7.3.1.
The X-ray tube can be operated right away (up to) 110 kV.
If the X-ray tube is being warmed-up manually, the process 1. to 6.
described below should be performed.
If the manual warm-up is skipped, the warm-up program will automatically
follow as soon
as the test voltage exceeds the warm-up voltage. The warm up is the same
as performing
3. to 6. described below.
The warm-up program may only be started if the beam shader
in front of the
X-ray tube cover and the sliding door are closed!
1. Activate the ISOVOLT register in the main window if necessary.
The current values from the Main register are entered in the
corresponding
Voltage and Current fields.
2. Clicking the Warm-up button begins the warm-up procedure.

3. The question appears

If the question is answered by clicking the


button "Yes", the message "Enter the warmup voltage"
appears.

4.

Enter the expected maximum value of the


high voltage corresponding to the maximum
tube voltage with the numerical keypad in the
Start-up voltage field and press the ENTER
key

on the keyboard.

The entered value appears in the


Warm-up Voltage: XXX kV field.

Be sure the beam shutter in front of the X-ray tube cover is


closed !

The message appears on the display


5. Operating the illuminated
START button begins the warm-up
procedure.

The message appears on


the display

6. Once the program has finished, the message appears on the display
The tube has been
warmed-up! NOTE:
An active warm-up program is displayed in the message window with the
ISOVOLT warm- up program active message.
7. Clicking on the Main register chart opens the main window again.

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7.3.3 Operating mode selection


Select an operation mode with the mode dialer:
Automatic mode
Manual mode
The mode dialer has the same function as the button Manual or the
function key F5
respectively the button Auto or the function key F5. The function key F5
works as a toggle.
Setting the dial in the corresponding direction toggles between Manual and
Automatic mode.

7.4

MANUAL mode

In MANUAL mode - switched on by pressing the F5 key in the main


window or by clicking the MANUAL-mode button when a small rectangle is
shown for a short moment in green in the button - it is possible to change
all relevant test parameters such as position and X-ray parameters. The
robot has to be moved by the operation panel.
Condition precedent to be allowed to move the robot by the operation
panel a factory
training by the robot supplier with certificate is
required.
NOT
E:
The axes can not be moved if the sliding
door is open.
Cautio
n:
Changing positions by selecting individual positions and pressing function
key F6 or clicking on the field Recall may result in collisions.

Proceed
follows:

as

1. Position the work piece and start up the system as described in

Section 3.6.

2. The MANUAL operation mode is automatically pre-

selected after the Reset run.


NOT
E:
If the system is switched into automatic mode while in manual mode, the
selected program resumes at the current step.
To avoid that a selected program can
unintentionally be changed during the operation
(danger of collision), program selection can be
disabled by pressing the lock symbol.
In order to release the program selection
again, activate
the lock symbol again.
The
following
mask
appears:
By actuating the button with the check mark
the program
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751

Operating Instructions x|
blade

Handling and
Operation

selection
is
released.
By actuating of the button with the crossed
circle the program selection stays disabled.

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Handling and
Operation

7.5

Operating Instructions x|blade

AUTOMATIC mode

DANGER!
Risk of fatality from ionizing radiation!
The radiation protection cabinet should not be entered during operation.
DANGER!
Risk of injury from moving parts
The radiation protection cabinet should not be entered during operation.
The temporary working area for loading and discharge should not be
entered during the inspection (opening and closing of sliding door).
1.

Start the system as described in Section 7.3.1.

2. Activate the control voltage by turning the key-operating switch to the


ON position.
3.

Push the START button again.

4.

Turn the key-operating RELEASE switch to the ROTATION position

5. The Rotation table moved to the 0 position by pushing the two-hand


operation buttons
and place the work pieces on the work piece holder
6. Switch to Automatic mode by clicking on the Manual/Automatic
button of pushing F5

Operating Instructions x|
blade

Handling and
Operation

7.

Turn the key-operating RELEASE switch to the CHARGING position

8.

Close the Sliding Door by pushing the two-hand operation buttons

9.

The system starts to read the Part . No. and the S/N

10. Check the automatic reading of the Part no. and the S/N
a.
If the reading is correct click on OK
b.
If the reading is wrong but the numbers are readable correct
them and
click on OK
c.
If the reading is unreadable or the is no work piece click on
Unreadable

11. The values are transferred to the Redundancy Check list

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134184/EB.0811

Operating Instructions x|
blade

12. Steps 9.-11. are repeated 11 times to read the Part no. and S/N of all 12
work pieces
13. The system inspects all readable work pieces automatically

14. After the automatic inspection the inspected parts are marked in the
following window

15. Open the Sliding Door by pushing the two-hand operation buttons
16. Remove the work pieces and insert the new inspection pieces

17. Start the next inspection by point 8.

Handling and
Operation

7.6

Operating Instructions x|blade

Switching of
.1. The radiation is switched off. If basic position is deselected then
the axes remain stationary in the momentary position (last test
position).
Remove the work piece and if necessary the axis TX1 is pushed again
into the radiation protection cabinet and the sliding door is closed by
activating the two hand operation.
Pressing the STOP key stops the system.

2.

By pressing the "Shut down" button in the mode register the control
system will be run down.

3. After a cooling period of the x-ray tube for approx. 5 min., the entire
system can be
switched off with the main switch at the control desk.
If point 2 is not performed and shutting down is performed by
UPS, the life span of the UPS battery will be substantially
lowered so that possibly expensive service work becomes
necessary.

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Operating Instructions x|
blade
7.7

Maintenanc
e

Service mask

The service mask shows the actual status of the system and offers the
opportunity to edit the status.

Maintenance and repair

8.1

Safety information in the case of maintenance and repair


WARNING!
Maintenance work should only be realised by the manufacturer's service
personnel or
trained specialists authorised by the operator.
Work on the electrical installation and on live installation parts and/or
devices may es- sentially only be carried out by electrical specialists.
Electrical specialists are specially trained for work on electrical
installations, recognise the risks from electrical current and can
independently avoid dangers through correct actions.
Personnel must be instructed in the dangers and wear prescribed PPE
during the work.
DANGER!
Mortal danger from ionizing radiation!
The radiation protection cabinet should not be entered during operation.
After work that requires the removal or decommissioning of parts
relevant to radiation,
a new inspection should be realised prior to recommissioning by
the radiation protection
officer authorised by the operator.
The radiation protection cabinet and sliding door should not be
drilled or damaged in any way.
DANGER!
Mortal danger from electrical current!
There is a direct risk of death if you touch live parts. Damage to the
insulation or to individual
components can be highly dangerous.
For this reason:
deactivate the electricity supply immediately if the insulation is
damaged and
immediately arrange for
repair.
only entrust work on the electrical installation to qualified electricians.
Essential procedures
against reactivation

! GEFAHR

for

securing

the

machine

During work realised inside the machine, third parties may not be aware of
persons located inside the machine. In order to prevent unauthorized
switching on of the machine, the following security measures must be
taken by the person responsible for those carrying out the work before
work starts:
1.
Shut down the
machine.
2.
The person responsible should turn the key switch to position 0,
remove the key and
keep it safe for the entire duration of work activities.
3.
The person responsible should turn the main switch to position "0"
("OFF"), secure it with
a padlock and remove the key and keep it safe for the entire duration of
work activities.

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1st edition, ID no.:
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4.
Fasten a
warning
sign
(example
on
left)
to
the
controls
containing the
name of the
responsible
person who
is entitled to
reactivate
the machine.

844

The following measures should be realised on completion of work and prior


to reactivating
the
machine:
1.
Correctly reinstall all protective equipment and check that it is
fully functional.
2.
Ensure that nobody is located in the machine
or risk zone.
3.
Only then remove the sign and release the
main switch.
4.
Key switch in
position 1.

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08/08/2011
1st edition, ID no.:
134184/EB.0811

Operating Instructions x|
blade

Maintenanc
e

DANGE
R!
Risk
of
injury
from
moving parts
Work on or in the machine should always be realised when the system is
shut down. Before recommissioning, fit all covers, screw fittings and safety
equipment in accordance with instructions and check that they are
functioning correctly.
The radiation protection cabinet should not be entered
during operation.
DANGE
R!
Risk of burns from hot
surfaces
Contact with hot components can cause
burns. For this reason:
Before maintenance and repair work on hot components, switch off
the machine and prevent it being switched on again. Before starting
work, leave components to cool to max. 50 C.
Wear protective clothing and protective gloves during all work
close to hot com- ponents.
DANGER!
Risk of injury from sharp edges and pointed corners
Use PPE: Protective clothing, protective gloves, protective headgear,
protective glasses.
DANGE
R!
Carry out work with extreme care within the radiation
protection cabinet . PPE: Protective gloves, helmet .
If possible, only carry out work on or in the machine when it is at a
standstill. Before recom- missioning, fit all covers, screw fittings and safety
equipment in accordance with instructions and check that they are
functioning correctly.
DANGE
R!
Risk of stumbling or
slipping.
Ensure that the working area is clean
and tidy.
WARNIN
G!
Improper handling of consumables can lead to damage to health. The
prescribed PPE should be used in accordance with the safety data
sheets (e.g. chemical-resistant protective gloves, protective
glasses).

CAUTIO
N!

Operating Instructions x|
blade

Maintenanc
e

Only carry out work on low components in a squatting position and not
bent over. When working on a high component , maintain an upright ,
straight posture or use a ladder.
The operator should issue operating instructions on the use of PPE. He/she
should ensure that personnel receive regular, verifiable instruction. He/she
should check that PPE is worn during work.
If, due to particular local conditions of use, the existing workplace
illumination is insufficient ,
the operator should set up additional lighting in accordance with local
occupational safety
regulations
before
work
commences.
Before activating the electrical connection, check that the machine is laid
out correctly and
draw up an inspection
log.
Check connections for tightness immediately after activating
the machine.
The operator should prevent stress situations through the technological
and organisational
preparation
of
work.

8.2

Maintenance
If necessary, please inform the service of GE Sensing & Inspection
Technologies GmbH:
Service Department
Ahrensburg
Tel.: +49 (0)4102
807-117
Fax:+49 (0)4102
807-277
The following maintenance tasks *) should be realized at the intervals
specified:

Component

Tas
k

Cycl
e

Filter mats
for
fans
and
discharge
Fixing elements
and

Clean,
replace if
necessary
Check
for firm

brackets
Coolant lines and
connections
Coolant Fluid Level of the
DXR
Detector
Air Filter of the DXR

positioning
Check for leaks

Detector
CoolantPump
Fluid of the
DXR Detector
Pump
Sliding
door toothed
belt

Sliding door
X-ray device

Safety switches on the


sliding door

Weekly, more
often if needed

Check, refill if
necessary
Clean
Replac
e
Check tension
Grease lubricating
nippleMaintenance
(1)
Setting up

Descripti
on see
Section
1

Weekly

Weekly

Weekly

6.
(**

Monthly

7 (**

every 90 days

8.
(**

yearly

Annually

See X-ray
device user
manual
If necessary

5
9

Grease gun (No. 9821800)


*) Maintenance kit , Article No. 7261270.
Contents:
1 Tube silicon paste P4 for ISOVOLT high-voltage cable, Article No.
9440690
1 AFC grease cartridge for guides and racks, Article No. 9821810
5 Filter mats for ISOVOLT, control panel and switch cabinet , Article No.
9435700
08/08/2011
1st edition, ID no.:
134184/EB.0811

Copyright by GE Sensing & Inspection Technologies GmbH


22926 Ahrensburg

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1 Filter mat for industrial PC inside of the control desk, Article No.
9448250
2 Fail-safe bulb 24V for high-voltage warning lamps on control panel
and in the
radiation protection cabinet , Article No. 9030420
(** optional

846

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08/08/2011
1st edition, ID no.:
134184/EB.0811

1.

Clean the filter mats for the fans and outlet filters at the switch
cabinet at the radiation protection cabinet , control panel and the
industrial PC inside the control desk, replace if necessary
Article No.: 9435700 for switch cabinet + control desk
Article No.: 9448250 for industrial PC

2. Check all fixing elements and brackets for tightness


3. Check coolant lines and connections for leaks
4.

Grease the lubricating nipples (1) for the sliding door (see illustration
below) using the grease gun (No. 9821800) .
Grease: THK AFC grease (No. 9821810); 0.75 cm per carriage

NOTE:
In order to pump grease into the lubricating nipples (1) and to check the
toothed belt , unscrew the 5 hexagon socket bolts (2) and remove the
cover (see figure below).

5.

Maintenance of X-ray device components is described in detail in the


operating instruc- tions for the ISOVOLT X-ray device (Section 4 /
Maintenance).

DANGE
R!
Mortal danger from electrical
current!
Deactivate the electrical supply before commencing any work on electrical
power supply components subjected to high voltage and secure against
reactivation. Allow any residual voltage to dissipate, or short circuit .
Before recommissioning, refit all covers and safety equipment in
accordance with instructions and check that they are functioning
correctly
All work on the electrical installation should be executed only by qualified
electrical personnel. Electrical specialists are specially trained for work on
electrical installations, recognise the risks emanating from electrical
current and can independently avoid hazards through correct actions.
DANGE
R!
Mortal danger from ionizing
radiation!
After work that requires the removal or decommissioning of parts
relevant to radiation,
a new inspection should be realised prior to recommissioning by
the radiation protection
officer authorised by the
operator.
For maintenance of the tube-sided high voltage connectors at an x|
blade with 225 kV X-ray tube cover in a radiation protection housing,
the screws (1) displayed in the fol- lowing figure must be unscrewed.

848

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08/08/2011
1st edition, ID no.:
134184/EB.0811

After removal of the radiation protection element (already dismounted


in the upper il- lustration) realise plug maintenance as described in the
operating instructions for the ISOVOLT X-ray device (Section 4 /
Maintenance).

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1st edition, ID no.:
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867

After plug maintenance in accordance with the operating instructions


of the ISOVOLT X-ray device the above parts removed are to be
inserted in reverse order and considering the radiation protection again.
NOTE:
If this system is used as inspection equipment , ensure in the context of
quality assurance standards (e.g. ISO 9001) that during the course of
inspection equipment monitoring the system properties, e.g. tube voltage,
tube current , focal spot of the X-ray tubes and the image quality of the
image chain (X-ray intensifier, camera, image improvement {optional}
and monitor) are periodically inspected and the inspection results are
documented. Certain measures have to be implemented if defined limit
values are exceeded.
6. Check the fluid level of the DXR Detector Pump, refill if necessary (see
separate manual
or brief description of the DXR Detector Pump,
section 5.6. Coolant:

Coolant Fluid for

Detector, ID. no. 9458820


7. Cleaning the Air Filter of the DXR Detector Pump with warm soapy
water, (see separate
manual or brief description of the DXR Detector
Pump, section 9. Air Filter: ID. no. xxxxxxx
8.

Changing the coolant fluid of the DXR Detector Pump (see separate
manual or brief description of the DXR Detector Pump, section 5.6., 7.
and 8.
Coolant:

Coolant Fluid for Detector, ID. no. 9458820

Cap for coolant

Thumbscrew
Display
(Temperature / Low
fluid / Low flow)

Air Filter

Coolant Supply

Power Switch

Coolant Return

9.

Adjust the safety switch of the sliding door at the X|blade:


-

Push the door with the attached actuator against the frame profile
with a clearance of 1.5 mm at the tightest point (measured across
the entire door length) using two adjusting plates (1.5 mm thick, ID
no.: 8493660) (see figure, below).

Frame 1.5 mm
closed door

Use an adjusting plate (4 mm thick, ID no.: 8493670) to adjust the


switching element at the guide profile to the actuator with 4 mm
clearance and attach the switch holder (ID no.: 8485330) to the
guide profile (2 x 3 mm pin, ID no.: 9209730) (see figure, below).
Switch element

Actuato
r

Guide profile

Switch
holder

4 mm

CAUTION!
Settings should be checked and readjusted if necessary after any
tasks are performed on this switch.
DANGE
R!
Mortal danger from ionizing
radiation!
After installation and adjustment of safety switches, it is necessary that a
radiation protec- tion measurement be realised by the responsible
radiation protection officer authorised by the operator.
Due to work that requires the removal or decommissioning of
parts relevant to radiation, a new inspection should be realised
prior to recommissioning by the radiation protection officer
authorised by the operator.
08/08/2011
1st edition, ID no.:
134184/EB.0811

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Bogenstrasse 41

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969

Operating Instructions x|
blade
9

Faults

9.1

Safety instructions relating to faults

Fault
s

WARNING!
Troubleshooting work should only be realised by the manufacturer's
service personnel or trained specialists authorised by the operator.
Work on the electrical installation and on live system parts and/or devices
should in all
cases only be realised by electrical specialists.
Electrical specialists are specially trained for work on electrical
installations, recognise the
risks from electrical current and can independently avoid dangers through
correct actions.
Personnel should be informed of the dangers present and wear prescribed
PPE during work.
DANGER!
Mortal danger from ionizing radiation!
The radiation protection cabinet should not be entered during operation.
After work that requires the removal or decommissioning of parts
relevant to radiation,
a new inspection should be realised prior to recommissioning by
the radiation protection
officer authorised by the operator.
DANGER!
Mortal danger from electrical current!
There is a direct risk of death if you touch live parts. Damage to the
insulation or to individual
components can be highly dangerous.
For this reason:
deactivate the electricity supply immediately if the insulation is
damaged and
immediately arrange for
repair.
only entrust work on the electrical installation to qualified electricians.
Essential procedures
against reactivation

! GEFAHR

for

securing

the

machine

During work realised inside the machine, third parties may not be aware of
persons located inside the machine. In order to prevent unauthorized
switching on of the machine, the following security measures must be
taken by the person responsible for those carrying out the work before
work starts:
1.
Shut down the
machine.
2.
The person responsible should turn the key switch to position 0,
remove the key and
keep it safe for the entire duration of work activities.
3.
The person responsible should turn the main switch to position "0"
("OFF"), secure it with
a padlock and remove the key and keep it safe for the entire duration of
work activities.
4.
Fasten a warning sign (example on left) to the controls containing
the name of the

responsible
person who
is entitled to
reactivate
the machine.

Operating Instructions x|
blade

Fault
s

The following measures should be realised on completion of work and prior


to reactivating
the
machine:
1.
Correctly reinstall all protective equipment and check that it is
fully functional.
2.
Ensure that nobody is located in the machine
or risk zone.
3.
Only then remove the sign and release the
main switch.
4.
Key switch in
position 1.

9.2

Faults
If necessary, please inform the service of GE Sensing & Inspection
Technologies GmbH:
Service Department
Ahrensburg
Tel.: +49 (0)4102
807-117
Fax:+49 (0)4102
807-277
If faults occur during operation, the system stops and the blue illuminated
FAULT ACKNOWL- EDGE button on the control panel flashes.
A fault message with a corresponding message appears on
the screen.
The message is displayed in the window as long as the fault is
still occurring. Stop the system and secure against reactivation.

CAUTIO
N!
Persons inside the cabinet are exposed to a risk of crushing in
this operating mode.
The messages should be acknowledged by actuating the
illuminated F ault
ACKNOWLEDGEMENT button on the control panel after the faults
are eliminated.
The illuminated Fault ACKNOWLEDGEMENT button and the window on
the display are deactivated.
Press the START button at the control panel two or more times to switch
on the radiation and to continue with the inspection.
Where the system cannot be restarted after a fault , its remedying and
acknowledgement , it should be deactivated pursuant to Section 7.6 and,
subsequently, reactivated as described in Section 7.3.1.
The reasons for faults at the ISOVOLT X-ray device and their remedies are
described in the
ISOVOLT X-ray device user manual
(Section 7).
The X-ray tube should, depending on its condition, be warmed up as
described in Section
7.3.
2.
If the X-ray device displays the message 103 X-ray ON lamp faulty,
check the high voltage
lamp at the control
panel.
If the message 87 Flash lamp faulty appears, check the high voltage
signal lamp behind

952

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08/08/2011
1st edition, ID no.:
134184/EB.0811

the sliding door in the radiation protection


cabinet . Always replace lamps if they are
defective.
It is not possible to start the X-ray device if these lamps are
defective, because the lamps are integrated in the X-ray device
safety circuit .

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1st edition, ID no.:
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1073

Dismantling and
disposal

Operating Instructions x|
blade

10

Dismantling and disposal

10.1

Safety instructions relating to dismantling and disposal


DANGER!
Mortal danger by electric current when disconnecting and
removing the electric con- nection cable from the connection
terminals in the switch cabinet
There is a direct risk of fatality if live parts are touched. Damage to
insulation material or
individual components can be fatally dangerous.
For this reason:
only entrust work on the electrical installation to qualified electricians.
WARNING!
Dismantling and disposal work should only be realised by the
manufacturer's service per- sonnel or trained specialists authorised by the
operator.
Work on the electrical installation and on live system parts and/or devices
should in all
cases only be realised by electrical specialists.
Electrical specialists are specially trained for work on electrical
installations, recognise the risks from electrical current and can
independently avoid dangers through correct actions.
Personnel should be informed of the dangers present and wear prescribed
PPE during work.

Before beginning of any work, the connection cable from the


operator's network to the
switch cabinet should be deactivated and de-energized and
secured against reactivation.
Essential procedures for securing the machine against reactivation

! GEFAHR

During work realised inside the machine, third parties may not be aware of
the presence of persons in the machine interior. In order to prevent
unauthorized activation of the machine, the following safety measures
should be taken prior to commencing work by the person supervising
those realising the work:
1.
Shut down the
machine.
2.
The person responsible should turn the key switch to position 0,
remove the key and
keep it safe for the entire duration of work activities.
3.
The person responsible should turn the main switch to position "0"
("OFF"), secure it with
a padlock and remove the key and keep it safe for the entire duration of
work activities.
4.
Affix a warning sign (example on left) to the controls containing the
name of the responsible person who is entitled to reactivate the machine.

Operating Instructions x|
blade

Dismantling and
disposal

DANGER!
Risk of mechanical injuries such as scratches, puncture wounds, crushing
or bone fractures
during dismantling of parts, components or modules.

WARNING!
Improper handling of consumables can lead to damage to health.
Avoid contact with or inhalation of hazardous liquids, gases, mists, vapours,
aerosols, dust
or fibres

DANGER!
Risk of poisoning through incorrect handling of lubricants, insulating oils,
coolants, cleaning
agents and solvents:
The prescribed PPE should be used in accordance with the safety data
sheets (e.g. chemical- resistant protective gloves, protective glasses).
Consumables should be disposed of correctly.
DANGER!
Risk of stumbling or slipping.
Ensure that the working area is clean and tidy.

1054

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08/08/2011
1st edition, ID no.:
134184/EB.0811

10.2

Dismantling and disposal


Operator
obligations:
Develop safe technology for the dismantling of the construction under
consulting the manufacturer. Naming of persons responsible for
occupational safety, supervision and work realisation.
Monitoring of work and control for adherence to the given safety
precautions and instruc- tions.
Operator: inform the manufacturer prior to commencing dismantling
and request his
cooperatio
n.
Manufacturer
obligations:
Cooperation
with operator
requests.
Supply lines (e.g. mains connection, pneumatic connection) should be
disconnected by
specialist personnel and secured against
reconnection.
Dismantling is realised on the responsibility of the operator and
exclusively by his/her specialist personnel or personnel commissioned for
this purpose.
Operational safety measures and instructions of the operator should be
designed to reduce any possible risks during work.
It
is
recommended
-

that the X-ray device and associated components be entrusted to the


manufacturer for correct disposal.

switch cabinets, control desks and radiation protection cabinets be


entrusted to a certified disposal company for correct disposal.

1056

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08/08/2011
1st edition, ID no.:
134184/EB.0811

Operating Instructions x|
blade
Index

Beam shader 43
Button 43

SAFETY BRIDGED 43
STOP 44
Switch 43

C
Control panel 41

E
Electrical connected load 23
EMERGENCY STOP pushbutton
18, 46

F
Fault 44

T
Tube status 99
Two-hand button 45
Type 57

W
Warm-up program 47

X-ray device 93
X-ray tube 47

GOOD 45

H
High voltage 48

I
Indicator lights 43
Intermediate switches 44, 51

M
MANUAL mode 51

O
Operational controls 43

R
Radiation 43, 45
REJECT 45
REPEAT 44
Risk of being crushed 99
Risk to persons 18

inde
x

Operating Instructions X|
Blade

GE

Measurement & Control


Solutions

GE Sensing & Inspection Technologies


GmbH Bogenstrasse 41 22926
Ahrensburg Germany
www.gesensininspection.com
Tel.: +49 (0)4102/807-0
Fax: +49
(0)4102/807-189

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