NDT Portable X Ray Machine

Operation Manual

ZHONG YI NDT CO., LTD

www.zhongyi-ndt.com
 Attention
Dear Users:

NDT X-Ray equipment belongs to precision instrument, for your successful operation and safety,

special remind of following matters：

1. Operating in outdoor field, 2mm thick lead plate can be employed as protective shield. If no any

suitable radiation protection, please make sure that there will be nobody within 20m around area from

the focal spot when radiography exposure.

2. X-Ray machine should be at vertical direction while carrying and transportation because x ray tube

inside is easy effected or broken by crash and drop.

3. Operators must be trained and qualified , operation should be strict accordance with the manual.

Manufacturer don't take any responsibility for abuse use or force work caused damage.

4. X-Ray machine is safe work at 0.35-0.5 Mpa, prohibit operating less than 0.35 Mpa.

5. X-Ray tube inside should be treat most careful because pressure inside. Wrong method to open the

generator will damage x ray tube or HV coil, even make explosion of x ray tube.

6. Unauthorized installation, removal, and replacement of accessory is forbidden. For safety, operator

should contact manufacturer before repair and disassemble x ray generator , so that no damage or

operator injured by wrong repair steps.

7. Problem not caused by the quality of the equipment itself (such as drop, crash, drop into the water,

connect wrong power etc), manufacturer will deal it with charge.

 Contents

I、 General……………………………………………… 1

II、 Technical Data……………………………………… 2

III、 System Structure ………………………………… 3

IV、 Working Principle…………………………………… 4

V、 Installation & Operation…………………………… 5

VI、 Maintenance………………………………………… 8

VII、 Complete Equipment and Accessories…………… 9

VIII、Drawings…………………………………………… 9
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I. General
The frequency-converted and gas-insulated portable X-ray NDT equipment with ZY–3000 controller, is one of

upgrading generation of the products by ZHONG YI NDT CO.,LTD (Dandong Zhongyi Electronic Co., Ltd).

Besides of its advantages of small size, light weight, easy to use, simple operation and self-troubleshooting, this new

type of controller has the excellent performance of strongly interference-free capability, good working stability and

operating reliability. With the popularization and spreading application of this new type NDT X-ray equipment all

over the country, it has been recognized and welcomed by the customers from different industries

This portable X-ray NDT equipment can be used in the fields of ship-building, mechanical manufacturing, aviation,

railroad, pressure vessel, boiler, petroleum, chemical and national defense, performing the non-destructive testing,

especially at the construction site or high above the ground applications.

The X-ray NDT equipment is used to show the internal discontinuity or faults of materials, products or welding from

a radiographic image on a film, according to the principle of the different absorption of the X-ray for different

material depending on the different thickness of the materials. We can evaluate the quality of materials and products

based upon the characters, size and position of the discontinuity or faults.

In this series of products, the X-ray generator is furnished with SF6 gas as an insulation, electric fan for forced

cooling, the controller is equipped with the advanced microprocessor controlling system, SCR modules for voltage

regulation, converting modules to control the primary and secondary side of the SCR as well as the advanced

electronic circuits of voltage & current stabilization and interference-free .Thus, the performance of the complete

equipment has been improved remarkably.

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Ⅱ. Technical Data
Classify Model Tube voltage Capacity Focus Size Max. penetrate
(KV) (KW) (mm) A3 steel (mm)

XXQ-1005 40-100 ＞1.0 1.0*1.0 8

Glass tube
XXQ-1605 60-160 ＞1.5 1.5*1.5 20
Directional
XXQ-2005 80-200 ＞2.0 1.5*1.5 29
40°
XXQ-2505 130-250 ＞2.5 2.0*2.0 39
XXQ-3005 150-300 ＞3.0 2.5*2.5 49
XXQ-3505 250-350 ＞3.5 2.5*2.5 59

Glass tube XXH-1605 60-160 ＞1.5 1.0*2.0 18

Panoramic XXH-2005 80-200 ＞2.0 1.0*2.4 26
with flat XXH-2505 130-250 ＞2.5 1.0*2.4 36
Target XXH-3005 150-300 ＞3.0 1.0*3.4 46
360°*25° XXH-3505 250-350 ＞3.5 1.0*3.4 56

Glass tube XXHA-1005 40-100 ＞1.0 1.0*2.0 4

panoramic XXHA-1605 60-160 ＞1.5 1.0*2.5 15
with cone XXHA-2005 80-200 ＞2.0 1.0*2.5 24
Target XXHA-2505 130-250 ＞2.5 1.0*2.5 34
360°*40°
XXHA-3005 150-300 ＞3.0 1.0*3.5 40
XXHA-3505 250-350 ＞3.5 1.0*3.5 50

XXG-1605 60-160 ＞1.5 1.5*1.5 20

Ceramic tube XXG-2005 80-200 ＞2.0 1.5*1.5 29
Directional XXG-2505 130-250 ＞2.5 2.0*2.0 39
40° XXG-3005 150-300 ＞3.0 2.5*2.5 49
XXG-3505 250-350 ＞3.5 2.5*2.5 70（10 min）
Tube Current 5mA
Power Supply AC220V ±10% 50HZ
Controller Size 367×320×164(mm)
Insulating SF6 gas
Working -25°~ +40°
Temperature
Humidity ≤85%
Standard 1. Focus to Film : 600mm
Condition 2. Time of exposure :5min
3. Film :Kodak, intensified by double lead foil.
4. Treatment in the darkroom : temperature 20±2℃, 5min ,Density ≥1.5
Safe Pressure 0.35-0.50 MPa(Prohibition of use when it is lower than 0.35 MPa)

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III. System Structure

Each model of X-ray NTD equipment is composed of the controller, X-ray generator, power cable, connecting cable

and accessories bag.

1. Controller

The controller is shaped like a suitcase. All operative buttons are furnished on the front panel while the cable socket,

main switch and earthing terminal are located inside the control box on the right side of it.

The controller includes the parts as below internally:

A. Control board;

B. Main board;

C. Display board;

D. LC filter;

E. SCR voltage-regulation module

F. Primary and secondary SCR inverter system;

G. Cooling fan;

2. X-ray Generator

The X-ray generator is the module type. The X-ray tube, HV transformer and insulated gas (SF6) are encapsulated in

an aluminum shell of sylindrical shape. The fan and heat radiator are mounted on one end of the X-ray generator.

The X-ray generator mainly includes the parts as below

A. X-ray tube;

B. HV transformer;

C. Temperature relay;

D. Pressure meter for gas;

E. Socket for connecting cable;

F. Cooling fan for the X-ray tube;

G. Charge and discharge valve for gas.

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IV. Working Principle

1. The controller of the equipment adopts the single-phase SCR bridge-rectifying circuit and the rectified

voltage turns to the smooth dc voltage by means of the LC filter. This voltage converts to the

frequency-adjustable square-wave pulse with single flow direction, becoming the electrical supply of the

X-ray generator to power the HV pulse transformer.

The mA stabilizing unit will change the frequency of the single-phase pulse against the voltage increase or

decrease of the X-ray tube filament, to ensure the stable current in the X-ray tube.

The kV regulating unit can continuously control the voltage up and down, to meet with the different

radiographic requirements for different materials .

The interference-free circuit improves the shock- resistance capability to protect the control system from

the HV shock from the X-ray generator.

2. The X-ray generator is equipped with the electric shock absorber. The anode of X-ray tube is connected to

the ground and an over temperature protection device is furnished.. Once the over-temperature occurs, the

controller is able to shut off the HV automatically to prevent the X-ray tube being damaged from the over

temperature.

3. The voltage fluctuation of power supply can be regulated automatically by the controller itself, ensuring to

get a stable X-ray. The exposure time and operation status of the complete equipment is controlled by the

microprocessor. The longest exposure time can be set to 5 min.

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V. Installation & Operation

1. Installation

1st After unpacking, please check all items in the package according to the packing list, to see whether there is any
damage, shortage or any incorrect parts packed by mistake.

2nd Confirm that the gas pressure meter on the X-ray generator points the range of 0.40 ~ 0.45 Mpa (Very small
pressure variation caused by different environmental temperature ).

3rd Get the controller on a working desk, switch off the controller power, connect the power cable. Make sure that
the main power supply should be in line with the specifications.

4th Connect one end of the grounding wire to the earthing terminal of controller while another end of the wire links
to a humid ground or specialized earthing point.

5th Link the controller with X-ray generator by the connecting cable and ensure this connection perfect.

6th The protective shield should be equipped when operating this equipment. In case of operating in outdoor field,
2mm thick lead plate can be employed as protective shield. If there is no any suitable radiation protection, please
make sure that there will be no any body within 20m around area from the focal spot of the x-ray tube when
radiography exposure.

2. Operation

1st Turn on the power-supply switch, the Digital screen shows different models:

Model KV shows Time-delay shows

1005 ZY- 100
1605 ZY- 160
2005 ZY- 200
2505 ZY- 250
3005 ZY- 300
3505 ZY- 350

Buzzer will make sound with green lights on when equipment is ready, meanwhile the controller shows origin kv
value according to different models machine. Controller will show last exposure setting parameters next use.
Origin Parameter Value：
Model KV shows Time-delay shows
1005 040 05.0
1605 060 05.0
2005 100 05.0
2505 150 05.0
3005 200 05.0
3505 250 05.0
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2nd When the machine ready, system will automatic release the key of the button. Now setting the
different parameter .

3rd KV setting :
KV setting should be done in the standby mode.
Press the SET button once, KV light flashing and adjust the KV value as requirement with the decrease and increase
button, each stepping rate is 2KV.
After setting KV value, press the SET button , meanwhile TIME light start flashing, press SET button again for stop
the flashing.
Start-up HV and machine training can be proceed after setting.

4th Time setting :

Time setting should be done in the standby mode.
Press SET button once for KV light flashing, press again for TIME light flashing, then adjust the time value as
requirement with the decrease and increase button , each stepping rate is 0.1min.
After setting time value, press SET button once for stop the flashing.
Start-up HV and machine training can be proceed after setting

5th Time-delay function.

Start Time delay Function:
Time delay setting should be done in the standby mode.
Keep pressing the OFF button, time-delay screen will display 00.0 after 4 seconds, then value changed by stepping
rate 0.1min.. OFF button should not be release until reach quest value.
Cancel the time delay function :
Keep pressing the OFF button, time-delay screen will display 00.0 after 4 seconds, then release the OFF button ,
time-delay function canceled.

6th Start-up the High Voltage

High voltage can start-up in the standby mode ,after the value setting.
Green lamp on control panel will burn up.Pressing ON button to start-up the high voltage, meanwhile the red lamp
will flash one time each second,When necessary, the kv value can be adjusted by pressing the increase and decrease
button.

7th Training machine

When the machine did not working more than 8 hours, the machine will be need training.
Continuous pressing the ON button 6seconds, the machine will be goes to the automatic training function,
depending on the different model, the KV will be different.

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Model KV shows Time-delay shows

1005 040 05.0
1605 060 05.0
2005 100 05.0
2505 150 05.0
3005 200 05.0
3505 250 05.0

No need human operation during training,different models machine have different training times.
Model Time
1005 1
1605 3
2005 3
2505 3
3005 3
3505 3
The machine can automatic training to specific kv value. Eg: 2505 machine , setting kv is 184V, the machine will
automatic stop when training value reached 184V.

8th Protection function

X-ray machine has the self protection function
1 LA No mA warning
2 HA Over mA warning
3 LU Lower voltage warming
4 PU Over voltage warning
5 PT Over temperature warning
When the machine with above fault, the machine will be in self lock situation, buzzer will be sound on to alarm.
When you got this alarm, please press OFF button to close this alarm sound.

9th Mandatory Rest

When equipment power supply stopped during working or during machine rest time, the system will take mandatory
rest at next time opening, meanwhile green light flashing and rest 10 Min. as mandatory punish rest.

10th Notice
A. Frequently check the gas pressure in the X-ray generator. If it is lower than 0.35Mpa, the operation is prohibited.
B. For safely operation, verify the earth terminal on the controller to be connected with the ground reliably
C. Ensure the cable is under good contact condition and electric socket is clean.
D. The ratio between working and resting time of the equipment should strictly follow by 1:1. The main power
should not be cut off during resting time, so the cooling fan keeping rotation continuously.
E. The circuit may get protection when large voltage fluctuation takes place. This is not malfunction. The machine
can rework when voltage gets stable.

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VI. Maintenance
When failure occurs, the operation should be stopped and the failure reason should be found out.

1. When powering on, the cooling fan does not rotate and no indication on the Digitron:

A. Power cable failure;

B. Power switch damage;
C. 3A Fuse cutting off

2. The displayer shows the failure code with the meaning as below:

A. “LA” No mA warning;
B. “HA” over mA warning;
C. “PU” over voltage warning;
D. “PT” over temperature warning;

3. When pressing the ON button, power switch cut off or sometimes sounds unusual:

A. The X-ray generator failure;

B. The chopper in the controller damage;
C. Gas pressure in the x-ray generator lower than 0.35Mpa.

4. When pressing down the ON button, displayer shows “LA”:

A. Failure of connecting cable;

B. Failure of the X-ray generator;
C. Circuit failure in the controller;

5. When touching the equipment, there is a tingle sense in the hand.

A. Poor earthing connection;

B. Poor insulation.

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VII. Complete Equipment and Accessories

1 X-ray generator 1pc.

2 Controller 1pc.
3 Connecting cable 1pc.
4 Power cable 1pc.
5 Earthing wire 1pc
6 Fuse (3A) 5pcs
7 Bag to contain accessories 1pc.

Ⅷ. Drawings

Schematic drawing of X-ray generator and the relative dimensions

X-ray generator(glass tube ) X-ray generator(ceramic tube)

Picture 1：Cone target, Panoramic
Picture 2：Directional Picture 4：Directiona
Picture 3：Flat target, Panoramic

Picture 1 Picture 2

Picture 3 Picture 4

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Quality Warranty

1. 1 year free guarantee. If the product fails or became inoperative without evidence of misuse, abuse, improper
installation, or unauthorized repair, we will provide the spares for repair free .

2. Engineers will online assist for the repairing work , according to fault description and picture sent by users.

3. For difficult fault, users can send back the machine back to China for repair. Please pack the machine properly so
that it will not be damaged during transportation, meanwhile accompany by a fully completed Field Failure Report.
Engineer Provide Services in Working Site for training Product application method, maintenance work.

NOTE: For the users who visit factory for learning the technical:

A. Basic working principle, operating and attention of X-ray equipment.

B. Attentions for X-Ray Protection.

C. Deal with commonly fault independently.

D. Training Place: factory in China.

E. Training Time: 3 -5 working days.

F. All the accommodation and transportation expenses in China should bear by visitors .Factory will provide

working lunch for each day.

This manual is for reference only, if there is any change, without prior notice.

ZHONG YI NDT CO., LTD.

Tel:86-415-6135926
Email:alicelee@zhongyi-ndt.com
Web: www.zhongyi-ndt.com

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