1.

SYSTEM COMPONENTS
1.1 450 kV BI-POLAR X-RAY SOURCE
The 450 kV bi-polar, oil-cooled, X-Ray tube assembly with integrated radiation protection.
It comprises dual focal spot of 0.4 mm at 700 W and 1.0 mm at 1500 W, a high-power tungsten
anode and a directional beam and it is specifically designed for non-destructive imaging
applications.
Specifications of the X-Ray tube
Nominal tube voltage 450 kV
Continuous rating (non-cyclic) 700 W 1500 W
Recommended cyclic rating 700 W 1500 W
Focal spot acc. EN 12543 d = 0.4 mm² d = 1.0 mm²
Filament current(Max) 4.1 Amps to 4.2 Amps
Filament voltage(Typical) 2.3 Volts to 6.2 Volts
Inherent filtration 3 mm + 2 mm Beryllium
Target-angle 11°
Weight 95 gs

X-RAY TUBE with Beam Blocker & Filter Holder MP1 Controller

1.1.1. X-Ray Tube Warm Up:

The X-ray tube requires a warmup cycle depending on the length of time the tube has been
inactive. The MP1 Controller monitors this time so when it is turned on (key in center), and a
warmup cycle is needed, the “Warm Up” indicator lights red and program code of 100, 101 or
102 will be displayed in the Program Field.
1.1.1.1. If a warmup is required, the appropriate warmup must be run before an inspection can
be performed.
a. Program code 100 – 15 minutes.
b. Program code 101 – 30 minutes.
c. Program code 102 – 40 minutes.
1.1.1.2. To run a warmup manually:
a) Verify the Beam Blocker is closed.
b) With the MP1 key switch in position 2, press “SET”.
c) Use keypad to enter Program code (see above) then press “ENTER”

1.1.1.3. To start a Warmup, turn the MP1 key fully CW to position 3 (X-ray Enabled). The
following indicators on the MP1 will be:

a) X-RAY OFF pushbutton lit red = red unless x-ray is ON

b) Safety indicator lit green = safety and chiller interlocks are made
c) Mains indicator lit white = input voltage, interlocks and warning lamps are good

Press the XRAY ON (Green push button) to start warm up cycle. If a pre-warning time period is
set the blue PRE-WARN indicator will illuminate during the pre-warning time period. At the end
of this period the Yellow XRAY ON indicator will illuminate. Once the XRAY ON push button
lights Green and kV & mA fields begin incrementally increasing while the TIME field
incrementally decreases. This pattern continues until the Warmup is completed and x-rays
automatically turn OFF. The Red Warm Up indicator turns off and the Program Warm Up code
(100, 101, and 102) is replaced by the previous operational code (i.e., 4 for manual or 800 for
remote control). If warmup was run manually, enter operational code manually as above.

Note: Use beam blocker during the warmup procedure

1.1. DIGITAL IMAGING DETECTOR (DIGITAL FLAT PANEL DETECTOR) (DFPD)
The detector is a 17” Care Vision 4343HE-GOS Digital Flat Panel detector (DFPD) housed in a
radiation hardened cassette (Figure 3-4). The detector’s Specifications are listed below:

 17” x 17” field of view (430.08 mm x 430.08 mm)

 3072 x 3072 pixels @ 140μm pixel pitch.
 CsI scintillator.
 16-bit ADC (65,536 grey levels).
 Frame rates of 8 – 20 fps.
 Gigabit ethernet communications.
 Supports 32/64-bit Windows® OS.
 Steel-Lead-Steel shielded cassette.

Digital Flat panel Detector Radiation Hardened cassette

1.2. OBJECT MANIPULATOR ASSEMBLY.
The DR Manipulator Assembly consists of three major sub-assemblies, consisting of totally 4
motorized axes manipulation and both source and detector are fixed on the respective stands.
Parts of varying shapes and sizes can be inspected. The sub-assemblies allow in and out
movement for the Object, vertical movement for Object, relative movement between source
and detector (Magnification) for Object. The manipulator assembly also allows rotation of the
object along Y-axis.
Translation along Magnification along Vertical along Rotation (RY) –
Object X axis – IN / Out Z-axis –Left / Right Y axis – Up / Down Clockwise(CW /
Anti-clockwise (CCW)

Movement of the object manipulator can be controlled manually via software and Joystick
controls.
1.3. DETECTOR MANIPULATOR.
The Detector with shielding assembly is mounted over height adjustable aluminum column.
Only a slight height adjustment can be achieved to align detector in-line with source center.
1.4. X-RAY SOURCE MANIPULATOR.
The X-Ray source bracket is mounted over the inner wall of lead cabinet. Only a slight positional
adjustment can be achieved to align the source in-line with detector center.
1.5. Object Manipulator:
The Object manipulator provides four axes of motorized manipulations: Object Translation,
Object Vertical movement, Object magnification and Object Rotation.
Translation along Magnification along Vertical along Rotation (RY)
Object X axis Z-axis Y axis Clockwise(CW / Anti-clockwise (CCW)
IN / Out Left / Right Up / Down

NOTE: Vi3 software designates the “Object turn table” as “Object”.

1.6. Operator Station:
1.6.1. System Monitor – Vi3 software and system administration.
1.6.2. Control Panel –
1.6.3. USB Ports – External access to computer inside Electrical Cabinet.
1.6.4. Electrical Cabinet –

1.6.5. SYSTEM ON / OFF Key – Three-Position key switch. CW to ON, then release (returns to
Switch center), CCW is OFF. Key removable only in the OFF position.
1.6.6. System LT – White illuminated light that displays the system status.
1.6.7. X-RAY ENABLE Key – Two-Position key switch. CW (ON) enables x-ray control, CCW
Switch (OFF) disables x-ray control. Key removable only in OFF position.
1.6.8. PD Reset – Part Door reset push button to remove door error.
1.6.9. EMERGENCY STOP – E-STOP push button, when pressed, x-ray and motion systems are
disabled. Lights red when engaged. Press/Release to disengage and turn light OFF. Cycle
SYSTEM key OFF – ON to reset system.
1.6.10. CONTROL – Four (4) number, TWO (2) position Joystick, used to control manually the
movement of the part manipulator along Up/Down, In/Out, Left/Right and rotation
CW/CCW axes.
1.6.11. DOOR Open/Close – Illuminated pushbutton switch that opens and closes the Part
Door. Lights green when Door is unlocked. X-Ray and motion are disabled when lit.
1.6.12. Bulb Reset – Bulb reset push button is to remove bulb error.
Note: To turn ON the system, ensure system is free from bulb and part door errors

1.7. Acquisition Station

In addition to the Vi3 Acquisition workstation computer and monitor, the Acquisition Station
has the Operator Control Panel and MP1 X-Ray source controller.
RT Series motion control interface will be launched parallel with Vi3. RT Series motion control
Interface must be running for the pendent controllers to function.
2. SYSTEM OPERATION.
2.1. System Start-Up
This procedure is written with the expectation that the System is idle (System Shutdown).
2.1.1. Turn ON the UPS (press/hold power button, long beep then release. Rotate Disconnect
Switch CW direction to Turn ON the power.
2.1.2. At the Local Operator Console, insert the X-Ray Enable key and turn to the “Enabled”
position.
2.1.3. On the Local Operator Console insert System Key and turn three position key switch to
ON, then release the System key. At the Operator Control Panel, the Power lamp lights
and the key switch returns to center.
2.1.4. Power ON Acquisition monitor.
2.1.5. Log into Windows® on Acquisition computers
2.1.6. At Acquisition computer, launch Vi3 software from its desktop icon:

2.1.7. The Main Screen is displayed as below.

2.1.8. Start-Up complete.

2.2. Vi3 ACQUISITION SOFTWARE.
The 450 kV DR System provides specialized acquisition software to inspect Vacuum Interrupters
for verifying the electrical connections and filling of di-Electric media to ensure complete
coverage of electronics inside the capacitor.
2.2.1. Vi3 Acquisition
2.2.1.1. Launch Vi3 Acquisition:
 The Vi3 Acquisition Software is launched from its desktop icon and opens the Vi3.
 Main Screen with X-Ray controls on the left and free to move RT Series Motion Controls
at the center of the system screen.

2.2.2. Detector Calibration

2.2.2.1. Ensure there are no parts or other items in front of detector.
2.2.2.2. On the Vi3 menu bar, under Maintenance dropdown select “Full Calibration” option,
to launch the Calibration Wizard.
2.2.2.3. Follow instructions in Wizard for a total of 6 steps to complete Offset and Gain
calibrations.

NOTE: The X-Ray setting used for calibration should be the same setting used for inspection.
2.2.2.4. When the calibration is complete, select “Close” from message box to close the Wizard.

2.2.3. Vi3 Inspection

2.2.3.1. Turn “ON” Acquisition computer and monitor at the operator console.
2.2.3.2. Turn “ON” Review computer and monitor at the operator console.
2.2.3.3. Power “ON” camera multiplexer and surveillance monitor. Verify all cameras are
Operational by viewing the surveillance monitor.
2.2.3.4. Turn the SYSTEM key located on operator console to “ON”, then release (key
Returns to center). The POWER lamp lits white.
2.2.3.5. On MP1 X-Ray Controller, insert key and turn switch to position “3”. Unit powers
“ON”.
2.2.3.6. Place part to be inspected on the object manipulator and then move the object
Manipulator to the Inspection Station using the RT Series motion control or the Part
Translate joystick on the Operator Control Panel.
2.2.3.7. Once the Part is loaded, press the “Door Close” push button at local operator
station/Cabinet to close the Part Doors.
2.2.3.8. With the Status section of the X-Ray Controller showing both “Ready” and “Is Safety
OK” Green, set kV and mA (Demand section) to be used for the inspection, then
Turn “ON” X-Ray (Control section).
2.2.3.9. Select “Grab On” 0ption to display the live video of the part being inspected.
2.2.3.10. Use the Joystick Controls on the Operator Control Panel or the RT Series motion
control to inspect the entire object geometry.
2.2.3.11. Enter the default “Frame Average” value as “1” and “Snap Average” value as “16”
and Click on “Snap” option, the static image is displayed at the image displayer
window.
2.2.3.12. Define suitable “Archive Path” and enter the file “Name” at the text box provided.
2.2.3.13. Click on “Archive” option to save the image at the defined location.
2.2.3.14. After the completion of inspection, select “Grab Off” option to turn “OFF” the X-Ray.
2.2.3.15. At the local operator station/Cabinet, press the “Door Open” push button to open
the Part Doors.
2.2.3.16. Using RT Series motion control or the Part Translate joystick on the local Operator
Console to move the part towards the part door.
2.2.3.17. Use suitable mechanism or assistance to unload the part from the part manipulator.
2.2.3.18. Inspection gets complete. Repeat above defined steps for the next cycle of
operations.
2.2.3.19. The captured files gets saved at:
Acquisition computer – D:\Images\YY\VIType\VIBatchNo\VISerialNo-ScanCode.
Note: Additional information on the Vi3 tools is available in separately provided Vi3 Imaging Manual.

2.2.4. Close Vi3 Acquisition Software

To close the Vi3 Acquisition Software, including RT Series, select the “X” in the Upper-right
corner of the Vi3 window.
2.3. MANUAL CONTROL
2.3.1. RT Series:
RT Series provides motion control for manual and technique-controlled movements of object
manipulator sub-systems. The Power ON lamp (Local Operator Console) must be lit for the RT
Series to be active. The Four (4) sub-system movements of the object manipulator are:
2.3.1.1. Part Manipulator Part Up / Down.
2.3.1.2. Part Rotation Part Rotation CW / CCW.
2.3.1.3. Part Manipulator Part IN / Out.
2.3.1.4. Part Manipulator Part Left / Right.
The Axis Readout Position (shown in Red) turns Yellow when the axis is moving.
When the axis is homed, the Axis Position field turns Blue (displays the home position).
If the Axis Readout Position is displaying Counts vs. Inches, Millimeters or Degrees,
You can right click on the field and select the other measurement unit.

2.3.2. Home Individual Axis:

Each axis can be individually homed using the RT Series. To HOME an axis, select the (Home
symbol) option (may also be Green or Red). When the Home option is selected, a message will
get displayed asking for confirmation of the action.
Select “OK” message box to confirm the operation or “Cancel” message box to abort
2.3.3. Composite HOME:
The Composite HOME function orchestrates homing of all axes of the manipulator. To perform
a Composite HOME, do the following:

1. Select the “Maintenance” menu item on the RT Series GUI and select “Start Composite
HOME” from the dropdown menu.

2. Select “Yes” on the message box option displayed to confirm the operation or “No” on the
message box to cancel.

2.3.4. Manual Move

An axis can be moved manually with the (Jog) button. This button is bi-directional with the top
portion used to move the axis in one direction (positive of any axis) and the lower portion
moves the axis in the other direction (negative of any axis).
2.3.5. Part Library
2.3.5.1 The Part Library Tool-strip consists of standard part details which are already recorded
for future use.
a. Under maintenance, select part library from the dropdown.

b. Part Library displays all the available components, and consists of command options such as
Add, Edit, Delete, and Hide
2.3.5.2. Add Part to Part Library:
a. To add Part to Part Library, click on “ADD” on the message box option, the Part Library
dialog-box gets displayed with selected Part Data.
b. Enter all the Part Data and click on “OK” on the message box option, to add the part in Part
Library.

2.3.5.3. Edit Part details in the part Library:

a. To edit the Part, select the part that has to be edited from the Part Library and then click
on “EDIT” on the message box option, a Confirmation message pops-up, and click on “YES”
on the message box 0ption to display the selected Part Data.

b. Edit the Part data in the displayed dialog-box and then click on “OK” on the message box
option to save the update made in the Part Library.

2.3.5.4. Delete part details from the part Library:

a. To remove any Part details from the Part Library, select the Part Name which must be
removed from the Part Library, and select “DELETE” on the message box option.
b. A confirmation message pops-up and click on “YES” on the message box to “Delete” the
part from the Part Library.

c. After Deletion, the Part library gets updated with the updated Part Name list.
2.4. Technique Creation
Note: PART ROTATION requires a Technique, with the correct part Diameter/Dimension
loaded for accurate part movement.
a) Verify technique has the correct part diameter entered in its Part Profile.
b) On the RT Series menu bar, click on “Technique” Menu, then followed by “Teach” option
from the dropdown to open the Technique Definition window.

c) On the Technique Definition window, select the target Part Identification →Technique
Name → Revision then click on “Technique Point Details” button to open the Teach
Mode window.
d) The Part Identification, Technique Name and Revision selected are displayed on the Title
bar of the Teach Mode window.

e) To add the position, in the Teach Mode window, select “Show Pendant” and use the Jog
(translation or vertical or rotation or all three combinations) command to position the
component at the required orientation and use “Append” Command in the Teach Pendant
to add the position in the list.
f) Repeat step “d” to add more number of positions.
g) To edit the positional action, select position that to be edited and then click on “Replace”
command from the Teach Pendant, use Jog or Joystick to position the component according
to the requirement and then click on “Append” button.
h) To add a new position in already existing positional list, use “Insert Before” or “Insert After”
command, with reference a selected position.
i) After adding the positions, click on “Hide Pendant” in Teach Mode Window to Hide the
Teach Pendant.
j) To define the action that to be performed against each position, select the Drop down
against the respective “Point Type” and allocate the action as needed.
k) To close “Teach Mode” window and, “Technique Definition” window , click on “X” mark
at top right corner of the respective windows

2.5. System Shutdown & Power Down

This procedure is written to place the System in a dormant state for short to medium Time
frames, i.e., overnight, long weekends, etc. Power remains “ON” to the System, X-Ray and
manipulator motion are disabled and operational software is closed.
a) At the Local Operator Console, turn System Key “OFF” (CCW), Power Lamp turns “OFF” on
the Operator Control Panel in the Operator Control Room. Remove and control System Key
in accordance with local LOTO policy.
b) At the Local Operator Console, place the X-Ray Enable key in the “Disabled” position. Remove
and control X-Ray Enable key in accordance with local policy.
c) On the Acquisition Computer, close all the open software applications then log out of
Windows®. Shut down computer using Windows® Start button then turn monitor(s) “OFF”.
d) At the Main Electrical Cabinet, turn Disconnect Switch “OFF”.
e) Turn “OFF” the UPS unit.
f) Engage the E-Stop push button on the operator console.