Sec 06 - X-Ray Generator K751 and K774

S4 EXPLORER & PIONEER Service Manual X-ray Generators K751 and K774
6 X-ray Generators K751 and K774
6 X-ray Generators K751 and K774 ............................................................................6-1

Checking the X-ray Generator K751 .................................................................................................... 6-1
Testing the High Voltage Section..................................................................................................... 6-1
Replacing the HV Multiplier.............................................................................................................. 6-4
Checking the Heating Current.......................................................................................................... 6-4
Troubleshooting for the K751 X-ray Generator................................................................................ 6-5
Testing the Tube Insulation....................................................................................................... 6-7
Component Layouts ....................................................................................................................... 6-21
Component Layout of -B 20 (Integral Board).......................................................................... 6-21
Component Layout of -B4 (Voltage Regulation Board) .......................................................... 6-22
Component Layout of -B 100 (IGBT-Controller) ..................................................................... 6-23
Component Layout of -B 115 (Current Regulation Board) ..................................................... 6-24
Overview K751 ............................................................................................................................... 6-25
Spare Part List................................................................................................................................ 6-26
Error-Codes and Functions ............................................................................................................ 6-27
X-ray Generator K774.......................................................................................................................... 6-29
RS 232 Commands ........................................................................................................................ 6-29
Testing the High Voltage Section................................................................................................... 6-32
Troubleshooting for the K774 X-ray Generator.............................................................................. 6-34
Testing the Tube Insulation..................................................................................................... 6-36
Component Layout ......................................................................................................................... 6-50
Component Layout of -B 424 (Integralboard) ......................................................................... 6-50
Component Layout of -B 404 (Voltage Regulation Board) ..................................................... 6-51
Component Layout of -B 100 (IGBT-Controller) ..................................................................... 6-52
Component Layout of -B 415 (Current Regulation Board) ..................................................... 6-53
Appendix : ...................................................................................................................................... 6-54
Overview K774........................................................................................................................ 6-54
Generator Parts:...................................................................................................................... 6-55
Circuit Diagrams...................................................................................................................... 6-56
6 X-ray Generators K751 and K774
Checking the X-ray Generator K751

Testing the High Voltage Section
Problems in the high voltage section will be indicated by
• „kV overshooting“ (Error-Code : 3)

• „kV act. Value > 58kV“ (Error-Code : 6)
• „Voltage at thyodul > 480V“ (Error-Code : 7)
• Generator shut down without „Error-Code“.
In principle there are some components to cause the problem
• PCB C79249-A3054-B20
• PCB C79249-A3053-B4
• Inverter
6-1
X-ray Generators K751 and K774 S4 EXPLORER & PIONEER Service Manual
• HV transformer
• HV multiplier
• HV cable
• X-ray tube
To figure out the bad component the following procedure should be carried out
• Connect the „test adapter“ to X530 on the PCB –B20 (X530=connector on top of PCB)
• Switch kV limit to position ON
• Switch mA clearance to position locked
• If there is no „test adapter“ available

• Connect X530-19 to X530-22
• Connect X530-3 to X530-20
Step 1
• Setpoints for kV and mA : 0

- Manual Control Command: GV0
• Switch the generator to HV ON
- Manual Control Command: SA.. , ...
„Error-Code:3“ , „Error-Code:6“ , „Error-Code:7“ change PCB –B20
Step 2
• Setpoints for kV : 20 , mA : 5
- Manual Control Command: GV20 , GC5
- Manual Control Command: SA.. , ..
„Error-Code:7“ change PCB –B4
Step 3
• Switch OFF the generator

- Manual Control Command: SA0
- Turn key switch to OFF
• Remove the HV cable on the generator side
6-2
„Error-Code:3“ , „Error-Code:6“ , „Error-Code:7“ inspect HV transformer

or high voltage flash over and HV multiplier
The generator runs without shut down.

- Manual Control Command : GS6
to check „Voltage at thyodul“ to be about 70V...120V
if << 70V : see diagram 6

or replace generator

to check „kV“ to be about 8kV...15kV
if << 8kV : see diagram 6

or replace generator
Step 4
• Switch OFF the generator

• A component outside the generator has failed. replace tube or HV-cable
6-3
Replacing the HV Multiplier

• Unscrew front panel, back panel, metal cover of the multiplier (all M4 Torx)
• Unscrew the red wire on X6 (metal cover multiplier)
• Unscrew the metal strip on the HV plug
• Unscrew the white wire on K52 / 4 T2
• Disconnect X2 on the front side of the multiplier
• Unscrew the 2 red, 1 black wire on the front side of the multiplier
red
black
red
Checking the Heating Current

• Generator shut down with „Error-Code: 2“
• Check the varistors mounted on the tube side of the heat current cable.
There should be no short cut across the varistors.
The function of the varistors is to carry the discharge current to chassis in case of tube arcing.
WARNING
Take care on the HV cable when replacing the generator. The cable can nip.
6-4
Troubleshooting for the K751 X-ray Generator

ERROR CODE 1 : Heating current too small
Diagram 1
⇒ Switch off generator

⇒ Check fuse F 2 and replace if necessary
⇒ Firmly press X 523 on -B 20 board
⇒ Firmly press X 2 on high voltage multiplier B650
⇒ Switch generator on again
ERROR CODE 1 Generator functioning
⇓
⇒ Switch off generator, connect test adapter to X530
⇒ Test adapter : kV - Limit to " ON " (ea. kV-regulation
is
blocked at minimum)
switch mA release to "locked"
(preheating current)
⇒ Switch S4 to "operation"
⇒ Read heating current (HCU) in the S4-Tools
HCU ≠ 5,8....6,8 HCU = 5,8....6,8
⇒ continue with diagram 2

⇓ (tube isolation test)
⇒ Read actual mA value (S4-Tools)
mA = 0 mA > 0
⇒ Tube faulty
⇓
⇒ Remove heating cable from plug X75 (rear panel)
⇒ Measure the tube resistance at the removed end of the
cable
Low resistance High resistance
→ Heating cable faulty or

⇓ high voltage multiplier –B650
faulty
⇒ Measure the resistance of the generator at plug X75
6-5
Diagram 1 (continued)
Low-resistance High-resistance
⇒ Measure resistance at
⇓ pins 1+2 at plug X24 on
inverter –B115
low-resistance high-
resistance
⇒ Secure heating cable to X75 → Connection → replace
again X 75 to X 24 -B115
⇒ Switch test adapter to "act. heat. open circuited
curr.", kV limit to "OFF" and mA
release to "OFF"
⇒ Set generator to heating

position and read voltage on
DVM (digital voltmeter)
No voltage U ≈ 2,5 V
(Generator switches off again)
→
⇓ - replace -B 20
⇒ Switch generator to heating position and simultaneously

measure on plug X23 of B115 at pin 4 (+) and pin 1 (-)
(printed side) (see component layout)
→ Connection cable to
⇓ B20 is cut off
⇒ Switch generator to heating position and measure on tab

connectors X1 and X2 of B115 (Umains!!!)
(see component layout)
U = Umains = 230 V ∼ U = 0V
→ replace -B 115 → Power supply cables

are cut off
6-6
Testing the Tube Insulation

Diagram 2

⇒ HV-Multiplier (-B650) insulation test:
⇒ Remove HV-cable out of the –B650
⇒ Connect test adapter to X530
⇒ mA - release : locked
⇒ Potentiometer V-regulation: I (fully counterclockwise position
of control range)
⇒ Switch S4 to operating position
⇒ Set kV to 40 kV (GV40), using S4-Tools
⇒ Slowly rotate potentiometer V.reg. in clockwise direction until
40kV are displayed
⇒ Waiting time : 10 min
kV = 40 mA = 0 kV = 40 mA ≠ 0
B650 insulation ok. HV-multiplier has insulation fault
⇓
⇒ Insert HV-cable again
⇒ Connect test adapter to X530. kV-limit : ON, mA release :
locked
⇒ Potentiometer I - reg : 0 , V - reg : 0
⇒ Select Generator in the S4-tools
kV = 13 - 19 mA = 0 kV ≠ 13 - 19 mA ≠ 0
Generator switches off with
Error Code1 or kV – indication
is pending
6-7
Tube or cable has insulation

fault
⇓
→ Branch from diagram 1

⇒ kV - Limit : OFF , mA - release : locked
⇒ Potentiometer I – reg. : 0 , U – reg. : 0
kV = 20 mA = 0 kV ≠ 20 mA ≠ 0
Generator reacts as above

fault
⇒ Potentiometer U – reg. : I (fully counter clockwise position of

control range)
⇒ Send GV45 (HV setpoint at 45kV)
⇒ Slowly rotate potentiometer U – reg. In clockwise until
kV = 45 is displayed.
kV = 45 mA ≠ 0
kV = 45 mA = 0 Generator switches off with
Error Code 1
Tube insulation ok. Tube has insulation fault
6-8
ERROR CODE 2 : Heating current too large

Diagram 3
⇒ Switch generator to heating position

⇒ Read heating current
HCU > 7,5 A HCU : 5,8....6,5 A
⇒
⇓ ⇒
Test max. heating current:
Switch off generator
⇒ Connect test adapter
⇒ Set test adapter :
mA - release : clear
Potentiometer I – reg. : I
⇒ Observe heating current
⇒ Rotate pot. I-reg. in clockwise
direction
Generator switches Generator does not
off at 7,5 .... 8,5 A switches off or at
incorrect heat.
current
⇒ Check tube ⇒ -B 20 replace
characteristic:
HCU ( 20kV/
50mA)< 11A
⇒ Switch test adapter to "V. of mA clear"

⇒ Switch generator to heating position and read voltage on
DVM
U ≈ + 8 V (disabled) U ≈ - 8 V (enabled)
(briefly)
→ replace -B 20
⇓
⇒ Switch test adapter to act. Value heat. curr.
⇒ Rotate test adapter potentiometer "I-reg." to I
⇒ Switch generator to heating position and read voltage on
DVM
U > > 1,3 V U ≈ 1,3 V ( HCU ≈ 3,1)
→ replace -B 115 → replace -B 20
6-9
ERROR CODE 3 : kV-overshooting (go on with Diagram 7)

ERROR CODE 4 : mA - actual >110% of setpoint
Diagram 4

⇒ Check that X40 is plugged onto inverter (-B100)
⇒ Set generator to 30kV and 33mA
Generator repeatedly Generator functioning

switches
off with error code 4
⇓

⇒ Disconnect plug X 2 at B650 (HV-multiplier)
⇒ Measure resistance between pins X2.3 and X2.4
R = 100 R ± 1 % R ≠ 100 R ± 1%
→ replace -B 20 → replace B650
6-10
ERROR CODE 5 : Temperature monitoring of the inverter

Diagram 5
⇒ Leave generator switched off for 5 minutes

⇒ Switch to operating position again
Generator cannot be switched Generator can be
on switched on
→ Temperature monitor of
the inverter triggered
⇓
→ Check fan function and
replace fan if
necessary
⇒ Check fuse F 1 on -B 20 (Integralboard)
⇒ Check plug X 520 on -B 20 (Integralboard)
Fuse F 1 ok. Fuse F 1 defect
→ Replace fuse
⇓ → Replace B20 after
repeated faults
⇒ Disconnect all plugs from –B20 apart X501 and X511

⇒ Switch generator to heating position and measure the
voltages at the jumpers on the power supply
All voltages present At least one voltage not
present
→ replace - B 20
⇓
⇒ One after another connect all plugs to –B20 again,
and measure the voltages again after each plug
6-11
⎯ X 523 (HV-multiplier)
⎯ X 522 (voltage regulation (B 4) )
⎯ X 524 (S4-internal)
⎯ X 521 (inverter)
A voltage disappears
All voltages present following the connection
of a plug
→ Replace
corresponding
module
⇓
⇒ Check wiring of PTC resistor on inverter:
Disconnect plug X205 from –B100 and measure the
resistance at the end of the cables, correct value: R =
120 .... 480 Ohm
Generator cannot be switched Generator can be switched

on on
→ Check plug X520 on – → replace inverter

B20
6-12
Procedure in event of faults in high-voltage section.
WARNING
The diagram must be run through from the beginning again each time a component is replaced!
ERROR CODE 6: High-voltage > 55 kV (Continuation from diagram 6a)

ERROR CODE 7: UAK > 480 V (Continuation from diagram 7)
ERROR CODE 22: Automatic circuit breaker F1 switched off
ERROR CODE 23: Mains current too large (Continuation from diagram 8)
Actual kV - value = 0
Diagram 6

⇒ Check whether F1 has switched off. Switch on
again if necessary.
⇒ Test adapter: set switch "kV limit" to ON
⇒ Switch test adapter to U-AK
⇒ Switch high voltage on
Circuit
breaker F1 U - AK < 10 V U - AK ≈ 112 V U-AK ≈ 110
tripped or or kV ≈ 17 (15......20) V
mains U - AK ≈ 180V kV = 92
current or pending
becomes
too large
⇒ Thyodul ⇒ Switch off generator
→ go on with
Module
is faulty
⇓ ⇒ Test adapter : "kV-Limit" on OFF
Diagram 5
⇒ Check run-up
⇒ Then either the - inverter

- HV-multiplier
- HV-transformer
- HV-cable is faulty
- Thyodul
- Mains choke
⇒ Disconnect X23 from inverter –B100
6-13
U - AK ≈ 125 (125...135 V ) U - AK = 0
→ possibly –B4 faulty

check connection
⇓ from B4 to thyristor
module (firing pulse
lines)
→ possibly thyodul
faulty

⇒ Connect X 23 (inverter to U-AK)
⇒ Disconnect X 15 from inverter –B100 (inverter to
HV transformer)
U - AK = 0
U - AK ≈ 125 (125-135 V) or
U - AK ≈ 150 V
→ inverter faulty
⇓

⇒ Reconnect X 15
⇒ Disconnect HV-cable from generator
⇒ Test adapter : set switch" mA-release" to locked
U - AK ≈ 120 V U - AK = 0
→ Tube or HV-cable faulty → B650 faulty
6-14
ERROR CODE 6: High voltage > 56 kV

Diagram 6 a

⇒ Disconnect plug X2 from B650
R = 56 k ± 0,1% R ≠ 56 k ± 0,1%
→ Replace –B650
R = 27,4 k ± 1% R > 27,4 k ± 1%
→ Continue with diagram 6 → Replace –B650
6-15
ERROR CODE 3 : kV + 10%

ERROR CODE 7 : UAK > 480V
or
kV - setpoint ≤ 29 kV – act. value = 92

Diagram 7
⇒ Press X2 firmly onto –B650

⇒ Check X523 pin 6 on the counterplug for –B20 (Pin 6 must not be
loose)
⇒ Switch on high voltage
Generator switches off Generator is ok.
⇓
⇒ Switch test adapter to "UAK"
⇒ Test adapter: Switch "mA release" to "locked"
Switch "kV - Limit" to "ON"
⇒ Switch generator to operating position and test with following
kV - setpoint (mA-setpoint = 5mA) ;
read voltage at DVM : (1 V = 100 V UAK)
- kV : 20 UAK = 122 V
6-16
ERROR CODE 23 : Mains current too large

Diagram 8
⇒ Switch generator in operating position

⇒ Set various pairs of parameters and compare current values
with the following table
Imains = values in table Imains >> values in table
→ Continue with Diagram 6 → replace L 1
The diagram shows Imains dependent upon x-ray tube current and tension
(Umains = 230V and f = 50Hz).
U/ I/
kV mA 5 10 20 25 33 50
20 3,0A 10A 14,8A
30 3,4A 10,8A 12,6A
40 3,8A 11,4A
50 4,2A 10,4A
6-17
ERROR CODE 30 : Safety circuit open

Diagram 8 a
⇒ Find the reason in the S4-Tools (Capture FF)
Check contactors K52 and K53

Contacts of K52 and K53 don't switch
K52 or K53 are sticking simultaneously
⇒ Check contacts A1 and A2

⇓ (look for 24V dc) at K52
and K53
⇒ Check wiring of K52 and K53 ⇒ Check relays K54 and K55
⇒ Replace contactor if necessary
ERROR CODE 31 : Short circuit to ground (in safety circuit)

Diagram 9
⇒ Disconnect plug X541 from rear panel

⇒ Measure resistance against chassis on cable X541 pin 3 using a
DVM
R = 6 ....10 Ω otherwise
⇒ replace -B 20 ⇒ check safety circuit of S4
ERROR CODE 33 : Relays K 11 open
6-18
Diagram 10
⇒ S4 is in the position off

⇒ Send GR2 (status)
Answer = 1 Answer ≠ 1
→ replace -B 20 (Integralboard)
⇓
⇒ Send GR2 (= Status) , GR4 (= Relays) and GR5 (= Diag)
and check answers:
Status = 9 Diag = 15 Diag = 15 Diag ≠

Relays = 31 15
Diag = 15 Relays < 31 Status < 9
→ replace -B 20 →
⇓ continue
with
diagram
4
(branch
mark)
⇒ Switch S4 to operating position and send continuos GR2, if

last answer is:
6-19
Status = 15 Status = 16
→ Status 16 is the character
for switching off
→ The last number output
⇓ before status=16 is the
cause of switching off .
Diag = 31 Diag = 15
→ Contactor K 52 is faulty
or
⇓ → -B 20 is faulty
Relays = 191 or 255 Relays ≠ 191
→ Generator is ok. → replace -B 20
6-20
Component Layouts
Component Layout of -B 20 (Integral Board)
6-21
Component Layout of -B4 (Voltage Regulation Board)
6-22
Component Layout of -B 100 (IGBT-Controller)
6-23
Component Layout of -B 115 (Current Regulation Board)
6-24
Overview K751
B20 :
X 523 F1 X 20 X 501 X 511 X 512 X 522 X 524
X 520 X 521 X530
B115 :
X 24 . 1 + 2 X 23 . 1 + 4 X1 X2
B 100 :
X 40 X 23 X 15
B4:
X3 X4
6-25
Spare Part List

Nummer Teilenummer Bezeichnung
Number Part Number Description
1 C79249-A3053-B500 Wechselrichter (inverter)
2 C79249-A3053-B115 I-Stellglied (current regulation board)
3 C79249-A3054-D24 Integralplatte (Integral board)
4 C79249-A3053-B502 Kondensatorbatterie (capacitor battery)
5 C79249-A3053-B4 U-Stellglied (voltage regulation board)
6 W79024-A6122-T483 Thyodul
7 C79298-A3220-B650 HV-Erzeuger (high voltage multiplier)
8 C79298-A3230-C36 HV-Trafo (high voltage transformer)
9 C79298-A3230-C35 Speicherdrossel (mains choke)
10 C79298-A3230-B34 Netzfilter (ratio interference filter)
11 W75040-B14-A55 Netztrafo (mains transformer)
12 C79298-A3200-C42 Schutzschalter F1 (protective switch F1)
13 C79298-A3230-C39 Netzschütz 30A 24V (contactor 30A)
14 W75053-B1001-N402 Netzschütz 10A (contactor 10A)
15 C79298-A3200-C34 Relais 5A (relay module)
16 W79087-A2001-B160 Lüfter Wechselrichter (fan –inverter)
17 W79087-A2001-B50 Lüfter Rückwand (fan –rear panel)
The numbers in the picture refer to the spare parts list above.
1
5
16 6
9
2
4
10
3
11 14
8
12 13
17 15
6-26
Error-Codes and Functions

Automatic start up routine for new tubes
Start : GF1,1
Stop : GF1,0
Status : GF Antworten (GF3 : running , GF66 : ready , GF[>128] : stopped with error)
Error-Code
1 heating current too small
2 heating current too large
3 kV overshooting
4 mA overshooting
6 kV > 58
7 DC voltage regulation error (UAK > 480V)
10 Shut-off circuit open
15 Key switch HV-On was not turned until READY-LAMP was aktiv.
20 Generator switched off via key-switch
21 Power cut
22 Circuit breaker F1 switched off
23 Mains current too large
28 No sample in spectrometer chamber
29 Short circuit to ground in shut-off circuit
30 Safety circuit open
31 Short circuit to ground in safety circuit
33 Relay K11 open
37 Relay K12 open
38 Relay K13 open
40 Tube surges
41 High voltage in stand-by mode
42 DC voltage in stand-by mode
50 Stand-by function not parametrized
51 Generator type not identified
52 Eeprom type not identified
STATUS
0 -B20 board defective
1 Wait for key-switch "ON"
2 Check relay contacts K3 + K5
3 Check relay contacts K12
4 Check power supply
5 Check relay contacts K11 + K13 Check key-switch "ON"
6 Check safety circuit
7 Wait for "high voltage ON"
8...14 Internal use
15 Generator ready
RELAY
1 Relais K3 closed
2 Relais K5 closed
4 Relais K12 closed
8 Relais K13 closed
16 Relais K10 closed
64 Relais K14 closed
WARN
16 Current regulation out of range or generator in stand-by
6-27
X-ray Generator K774
RS 232 Commands
GS-commands
GS1 Operating mode control word
(decimal number resulting from the following bit significances ; meaning if set to 1)
Significance Meaning
1: Generator switched to position ON
2: XRAY ON (K52 + K53 closed)
4: kV actual value = kV setpoint
8: mA actual value = mA setpoint
16 : Remote control
32 : High voltage flashover
64 : Generator warning (see GR6)
128 : Generator in Standby mode (switch off circuit open, GV0 command)
GS2 High voltage actual value (kV)

GS3 Tube current actual value (mA)
GS4 Tube heat current (A)
6-29
GS5 0 (reserved)
GS6 Voltage at capacitor battery (UAK)
GS7 High voltage setpoint value (kV)
GS8 Tube current setpoint value (mA)
GS9 Main input current (A)
GS10 Operating hours
GS11 High voltage flashover counter (tube surges)
GR-commands
GR1 Program version (Firm:V..)
GR2 Generator status
Repetitive GR2-command will return a decimal number from 0 to 16 depending on the generator
status.
1. On board check when powering up : GR2 should return 1 after some seconds,
if not remove –B20 board
2. On board check when switching to ON: GR2 should return 7 after some seconds
3. Switching to XRAY ON : GR2 should return 15 after some seconds
GR3 Error-Code number
GR4 Status of relays on –B20 board
GR5 Status of supply voltage on –B20 board
1: +15V present
2: -15V present
4: -5V present
8: +14V present
16 : +24V present
GR6 Generator warning

16 : Current controller out of range (tube current actual value < setpoint value), for example in standby mode
(switch off circuit open).
GR Complete string GR1,GR2,....,GR6 will be transmitted
6-30
GP- commands
GP1 10 High voltage minimal value (kV)
GP2 50 High voltage maximal value (kV)
GP3 5 Tube current minimal value (mA)
GP4 50 Tube current maximal value (mA)
GP5 Tube power maximal value (see GF8 command)
GP Complete string GP1,GP2,....,GP5 will be transmitted
GF-commands
GF1,1 Start tube conditioning program.
GF-command will return:
GF3 as long as the conditioning program runs
GF130 will be returned. if an error occurs
GF66 will be returned, if conditioning program has successful been finished
GF1,0 Stop tube conditioning program
GF2,1 Display calibration: kV=27 and mA=40 for 1-2 min., when the calibration was successful :
kV=20 and mA=10 (always after replacing a B424 board)
GF2,0 End of calibration program
GF3,1 Disable error detection of Error-Code:1, Error-Code:22, Error-Code:27
GF3,0 Enable of error detection
GF4,1 Lock kV + mA regulator (High voltage locked to about 12kV and tube current = 0mA)
GF4,0 Normal operation
GF4 commands requires of the generator to be in standby mode to be executed or ?23 will be returned.
GF8,nnnn Input for tube power (in Watt) maximal value with nnnn = 0400 ... 4000
GF9,7 reset operating hours
GF9,8 reset tube surge counter
6-31
Testing the High Voltage Section

Problems in the high voltage section will be indicated by
• „kV overshooting“ (Error-Code : 3)
• „kV act. Value > 68kV“ (Error-Code : 6)
• „Voltage at thyodul > 480V“ (Error-Code : 7)
• Generator shut down without „Error-Code“.
In principle there are some components to cause the problem
• PCB C79249-A3054-B424
• PCB C79249-A3053-B404
• Inverter
• HV tank
• HV cable
• X-ray tube
To figure out the bad component the following procedure should be carried out
Send GF4,1 (Lock kV + mA regulator) via RS232 to the generator

STEP1
Setpoints for kV and mA : 0
- Manual Control Command: GV0
Switch the generator to HV ON
- Manual Control Command: SA.. , ...
„Error-Code:3“ , „Error-Code:6“ , „Error-Code:7“ change PCB –B424
STEP2
Setpoints for kV : 20 , mA : 5
- Manual Control Command: GV20 , GC5
„Error-Code:7“ change PCB –B404
6-32
STEP3
Switch OFF the generator
Remove the HV cable on the generator side
„Error-Code:3“ , „Error-Code:6“ , „Error-Code:7“ inspect HV tank

or high voltage flash over
The generator runs without shut down.

to check „Voltage at thyodul“ to be about 70V...80V
if << 70V : see diagram 6

to check „kV“ to be about 6kV...9kV
if << 6kV : see diagram 6
STEP4
Switch OFF the generator

A component outside the generator has failed. replace tube or HV-cable
6-33
Troubleshooting for the K774 X-ray Generator

ERROR CODE 1 : Heating current too small
Diagram 1
⇒ Check fuse F 2 and replace if necessary
⇒ Firmly press X 523 on -B 424 board
⇒ Firmly press X 1 on high voltage tank
⇒ Switch generator on again
ERROR CODE 1 Generator functioning
⇓
⇒ Send GF4,1 to generator
⇒ Switch S4 to "operation"
⇒ Read heating current (HCU) in the S4-Tools or send GS3
HCU ≠ 5,9....6,5 HCU = 5,9....6,5
continue with diagram 2
⇓ (tube isolation test)
⇒ Read actual mA value (S4-Tools)

mA = 0 mA > 0
⇒ Tube faulty
⇓
Switch off generator
⇒ Remove heating cable from socket X75 (rear panel)
⇒ Measure the tube resistance at the removed end of the
cable
Low resistance High resistance
→ HV- cable faulty or X-ray

tube faulty
⇓
6-34
Diagram 1 continued
Low-resistance
Secure heating cable again

Switch test adapter to "act. heat. curr.", kV
limit to "OFF" and mA release to "OFF"
Send GF3,1 to Generator
Set generator to heating position and read
voltage from test adapter on DVM (digital
voltmeter)
→
⇓ - replace -B 424
Switch generator to heating position and measure on tab

connectors X1 and X2 of B415 (Umains!!!)
U = Umains = 230 V ∼ U = 0V
→ replace -B 415 → Power supply cables

are cut off
6-35
Testing the Tube Insulation

Diagram 2

⇒ HV-tank insulation test:
⇒ Remove HV-cable out of the generator
⇒ mA - release : locked
Potentiometer V-regulation: I (fully counterclockwise position of control range)
Send GF3,1 to generator

⇒ Set kV to 40 kV (GV40), using S4-Tools
⇒ Slowly rotate potentiometer V.reg. in clockwise direction until 40kV are
displayed
kV = 40 mA = 0 kV = 40 mA ≠ 0
insulation ok. HV-multiplier has insulation

fault

⇒ Insert HV-cable again
⇒ Connect test adapter to X530. kV-limit : ON, mA release : locked
⇒ Potentiometer I - reg : 0 , V - reg : 0

⇒ Select Generator (X-RAY) in the S4-tools
kV = 10 - 15 mA = 0 kV ≠ 10 - 15 mA ≠ 0
Generator switches off with
Error Code1 or kV – indication
is pending
6-36
Diagram 2 continued

fault

⇒ kV - Limit : OFF , mA - release : locked
⇒ Potentiometer I – reg. : 0 , U – reg. : 0
kV = 20 mA = 0 kV ≠ 20 mA ≠ 0
Generator reacts as above

fault
⇒ Potentiometer U – reg. : I (fully counter clockwise position of control

range)
⇒ Send GV40 (HV setpoint at 40kV)

⇒ Slowly rotate potentiometer U – reg. In clockwise until
kV = 40 is displayed.
kV = 40 mA ≠ 0
kV = 40 mA = 0 Generator switches off with
Error Code 1
6-37
Tube insulation ok. Tube has insulation fault
ERROR CODE 2 : Heating current too large

Diagram 3
⇒ Read heating current
HCU > 8 A HCU : 5,9....6,5 A
⇒ Test max. heating current:

⇓ ⇒ Switch off generator
⇒ Connect test adapter
⇒ Set test adapter :
mA - release : clear
Potentiometer I – reg. : I
⇒ Observe heating current
⇒ Rotate pot. I-reg. in clockwise direction
Generator switches Generator does not
off at 7,5 .... 8,5 A switches off or at
incorrect heat. current
⇒ Check tube ⇒ -B 424 replace
characteristic:
HCU ( 20kV/
50mA)< 8A
⇒ Switch test adapter to "V. of mA clear"

⇒ Switch generator to heating position and read voltage on DVM
U ≈ + 8V (disabled) U ≈ -8V (enabled)

(briefly)
→ replace -B 424

⇒ Switch test adapter to act. Value heat. curr.
⇒ Rotate test adapter potentiometer "I-reg." to " I "
⇒ Switch generator to heating position and read voltage on DVM
U > > 1,3 V U ≈ 1,3 V ( HCU ≈ 3,1)
→ replace -B 415 → replace -B 424
6-38
ERROR CODE 3 : kV-overshooting (go on with Diagram 7)
ERROR CODE 4 : mA - actual >110% of setpoint
Diagram 4

⇒ Set generator to 30kV and 33mA
Generator repeatedly switches Generator functioning

off with error code 4

⇒ Disconnect plug X 1 at HV-tank
R = 100 R ± 1 % R ≠ 100 R ± 1%
→ replace -B 424 → replace HV tank
6-39
ERROR CODE 5 : Temperature monitoring of the inverter

Diagram 5
⇒ Leave generator switched off for 5 minutes

⇒ Switch to operating position again
Generator cannot be switched on Generator can be switched on
→ Temperature monitor of the

⇓ inverter triggered
→ Check temp. sensor on L1 (mains → Check fan function and
replace fan if necessary
choke). Press the red button on
the sensor (if the button "clicks"
check the fan over the L1!).
Switch to operating position

again

⇒ Check fuse F 1 on -B 424 (Integralboard)
⇒ Check plug X 520 on -B 424 (Integralboard)
Fuse F 1 ok. Fuse F 1 defective
⇓ → Replace fuse
→ Replace B424 after

repeated faults
⇒ Disconnect all plugs from –B424 apart X501 and X511
⇒ Switch generator to heating position and measure the voltages at

the jumpers on the power supply
All voltages present At least one voltage not

present
→ replace - B 424
⇒ One after another connect all plugs to –B424 again, and measure
the voltages again after each plug
6-40
Diagram 5 continued
⎯ X 523 (HV-multiplier)
⎯ X 522 (voltage regulation (B 404) )
⎯ X 524 (S4-internal)
⎯ X 521 (inverter)
A voltage disappears
following the connection of a
All voltages present plug
→ Replace
corresponding module
Check wiring of PTC resistor on inverter:

Disconnect plug X205 from –B100 and measure the resistance at the end of
the cables, correct value: R = 120 .... 480 Ohm
→ Check plug X520 on – B424 → replace inverter
6-41
Procedure in event of faults in high-voltage section.

The diagram must be run through from the beginning again each time a component
is replaced !
ERROR CODE 6 : High-voltage > 66 kV (Continuation from diagram 6a)
ERROR CODE 7 : UAK > 480 V (Continuation from diagram 7)
ERROR CODE 22 : Automatic circuit breaker F1 switched off
ERROR CODE 23 : Mains current too large (Continuation from diagram 8)
Actual kV - value = 0
Diagram 6
⇒ Check whether F1 has switched off. Switch on again if

necessary.
⇒ Test adapter: set switch "kV limit" to ON
⇒ Switch test adapter to U-AK
Circuit breaker
F1 tripped or
mains current U - AK < 10 V U - AK ≈ 70 V U-AK ≈ 70V
becomes too or
kV ≈ 8 (6......9) kV = 92
large
U - AK ≈ 180V or pending
⇒ Thyodul ⇒ Switch off generator

Module is ⇓ ⇒ Test adapter : "kV-Limit" on OFF → go on with
faulty
⇒ Switch high voltage on Diagram 5
⇒ Check run-up
⇒ Then either the - inverter

- HV-multiplier
- HV-transformer
- HV-cable is faulty
- Thyodul
- Mains choke
⇒ Disconnect X23 from inverter –B100
6-42
Continued Diagram 6
U - AK ≈ 125 (125...135 V ) U - AK = 0
→ possibly –B404 faulty

check connection from B404
to thyristor module (firing
⇓ pulse lines)
→ possibly thyodul faulty
⇒ Connect X 23 (inverter to U-AK)
⇒ Disconnect X 15 from inverter –B100 (inverter to

HV tank)
U - AK = 0
U - AK ≈ 120 (115-135 V) or
U - AK ≈ 150 V
⇓ → inverter faulty
⇒ Reconnect X 15
⇒ Disconnect HV-cable from generator
⇒ Test adapter : set switch" mA-release" to locked
U - AK ≈ 120 V U - AK = 0
→ Tube or HV-cable faulty → HV tank faulty
6-43
ERROR CODE 6 : High voltage > 66 kV

Diagram 6 a

⇒ Disconnect plug X1 from HV tank
⇒ Measure resistance between pins X1.5 and X1.6 (tank)
R = 20 k ± 0,1% R ≠ 20 k ± 0,1%
→ Replace HV tank
R = 20 k ± 1% R > 20 k ± 1%
→ Continue with diagram 6 → Replace HV tank
ERROR CODE 3 : kV + 10%

ERROR CODE 7 : UAK > 480V
or
kV - setpoint ≤ 29 kV – act. value = 92
6-44
Diagram 7
⇒ Press X1 firmly onto HV tank

⇒ Check X523 pin 6 on the counterplug for –B424 (Pin 6 must
not be loose)
⇒ Switch on high voltage
Generator switches off Generator is ok.
⇒ Switch test adapter to "UAK"

⇒ Test adapter: Switch "mA release" to "locked"
Switch "kV - Limit" to "ON"
⇒ Switch generator to operating position and test with following
kV - setpoint (mA-setpoint = 5mA) ;
read voltage at DVM : (1 V = 100 V UAK)
- kV : 20 UAK = 204 V
6-45
ERROR CODE 23 : Mains current too large

Diagram 8
⇒ Switch generator in operating position

⇒ Set various pairs of parameters and compare current values
with the following table
Imains = values in table Imains >> values in table
→ Continue with Diagram 6 → replace L 1
The diagram shows Imains dependent upon x-ray tube current and tension
(Umains = 230V and f = 50Hz).
U/ I/
kV mA 5 10 20 50 80 100
20
30
40
50
6-46
ERROR CODE 30 : Safety circuit 1 open

ERROR CODE 32 : Safety circuit 2 open
Diagram 8 a
⇒ Find the reason in the S4-Tools (Capture FF)
Check contactors K52 + K52 and relays K7 + K54

( in circuit diagram page 8)
Contacts of K52 and K53 don't switch
K52 or K53 are sticking simultaneously
⇒ Check contacts A1 and A2

(look for 24V dc) at K52 and
⇓ K53
⇒ Check wiring of K52 and K53 ⇒ Check relays K54 and K55
⇒ Replace contactor if necessary
ERROR CODE 31 : Short circuit to ground (in safety circuit)
6-47
Diagram 9
⇒ Disconnect plug X541 from rear panel

⇒ Measure resistance against chassis on cable X541 pin 3
using a DVM
R = 6 ....10 Ω otherwise
⇒ replace -B 424 ⇒ check safety circuit of S4
6-48
Diagram 10
⇒ S4 is in the position off

⇒ Send GR2 (status)
Answer = 1 Answer ≠ 1
→ replace -B 424 (Integralboard)

⇒ Send GR2 (= Status) , GR4 (= Relays) and GR5 (= Diag)
and check answers:
Status = 9 Diag = 15 Diag = 15 Diag ≠ 15

Relays = 31 Relays < 31 Status < 9
Diag = 15
→ replace -B 424 → continue with
⇓ diagram4
⇒ Switch S4 to operating position and send continuos GR2, if last answer

is:
Status = 15 Status = 16
→ Status 16 is the character for
switching off
→ The last number output before
status=16 is the cause of switching off
⇓
.
Diag = 31 Diag = 15
→ Contactor K 52 is faulty
or
⇓ → -B 424 is faulty
Relays = 191 or 255 Relays ≠ 191
→ Generator is ok. → replace -B 424
6-49
Component Layout
Component Layout of -B 424 (Integralboard)
6-50
Component Layout of -B 404 (Voltage Regulation Board)
6-51
Component Layout of -B 100 (IGBT-Controller)
6-52
Component Layout of -B 415 (Current Regulation Board)
6-53
Appendix :
Overview K774
9 8
7 6
10
14
13
12
11
6-54
Generator Parts:
1. Capacitor bank C79249-A3028-B74
2. Thyristor module W79024-A6122-T483
3. PCB: integral board C79249-A3053-B424
4. PCB: DC voltage regulation C79249-A3053-B404
5. Contactors K52 + K53 C79298-A3230-C39
6. Relays K7, K54 and K55 C79298-A3200-C34
7. Contactor K51 W75053-B1001-N402
8. Fuses F2 (1.6AT), F6 (4AM); 250Vac
9. Transformer T51 W75040-B14-A55
10. Fan (230V, 50/60Hz) W79087-A2001-B50
11. Mains choke W79041-A1505-C1
12. Inverter C79249-A3053-B120
13. Step switch W79024-A6122-T483
14. HV tank C79249-A3053-B125
15. Line filter Z1 K180-C15
16. Circuit breaker F1 K180-C12
17. 50Hz / 60Hz switch X33 at the rear panel
16
17
15
6-55
Circuit Diagrams
Page 1:
6-56
Page 8
6-57
6-58

Sec 06 - X-Ray Generator K751 and K774

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Sec 06 - X-Ray Generator K751 and K774

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S4 EXPLORER & PIONEER Service Manual X-ray Generators K751 and K774

6 X-ray Generators K751 and K774

6 X-ray Generators K751 and K774 ............................................................................6-1

6 X-ray Generators K751 and K774

Checking the X-ray Generator K751

Problems in the high voltage section will be indicated by

• „kV overshooting“ (Error-Code : 3)

In principle there are some components to cause the problem

• If there is no „test adapter“ available

• Setpoints for kV and mA : 0

„Error-Code:3“ , „Error-Code:6“ , „Error-Code:7“ change PCB –B20

„Error-Code:7“ change PCB –B4

• Switch OFF the generator

„Error-Code:3“ , „Error-Code:6“ , „Error-Code:7“ inspect HV transformer

The generator runs without shut down.

if << 70V : see diagram 6

- Manual Control Command : GS2

if << 8kV : see diagram 6

• Switch OFF the generator

Replacing the HV Multiplier

• Unscrew the red wire on X6 (metal cover multiplier)

• Unscrew the metal strip on the HV plug

• Unscrew the white wire on K52 / 4 T2

• Disconnect X2 on the front side of the multiplier

Checking the Heating Current

Troubleshooting for the K751 X-ray Generator

⇒ Switch off generator

⇒ continue with diagram 2

⇒ Read actual mA value (S4-Tools)

Low resistance High resistance

→ Heating cable faulty or

⇒ Measure the resistance of the generator at plug X75

⇒ Set generator to heating

⇒ Switch generator to heating position and simultaneously

⇒ Switch generator to heating position and measure on tab

→ replace -B 115 → Power supply cables

Testing the Tube Insulation

⇒ Switch off generator

B650 insulation ok. HV-multiplier has insulation fault

Tube or cable has insulation

⇒ Switch off generator

Tube or cable has insulation

⇒ Potentiometer U – reg. : I (fully counter clockwise position of

ERROR CODE 2 : Heating current too large

⇒ Switch generator to heating position

⇒ Switch test adapter to "V. of mA clear"

ERROR CODE 3 : kV-overshooting (go on with Diagram 7)

⇒ Switch off generator

Generator repeatedly Generator functioning

⇒ Switch off generator

→ replace -B 20 → replace B650

ERROR CODE 5 : Temperature monitoring of the inverter

⇒ Leave generator switched off for 5 minutes

Fuse F 1 ok. Fuse F 1 defect

⇒ Disconnect all plugs from –B20 apart X501 and X511

Generator cannot be switched Generator can be switched

→ Check plug X520 on – → replace inverter

Procedure in event of faults in high-voltage section.

ERROR CODE 6: High-voltage > 55 kV (Continuation from diagram 6a)

⇒ Switch off generator

⇒ Then either the - inverter

→ possibly –B4 faulty