THE INSPECTOR X-ray Solution Manual

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CONTENTS
ITEM
PAGE
1.0 Introduction………………………………………………………………………. 1
2.0 Description ………………………………………………………………………. 1
2.1 General ………………………………………………………………………. 1
2.2 X-Ray………………………………………………………………………….. 1
2.3 Inverter ………………………………………………………………………. 1
2.4 AC/DC Control
……………………………………………………………... 1
2.5 Control Circuitry ……………………………………………………………... 1
2.6 Controls, Indicators, and Connectors
……………………………………. 2
2.7 Power Requirements ……………………………………………………….. 2
2.8 System Specifications ……………………………………………………….. 3
3.0 X-Ray Tube Installation ………………………………………………………. 4
4.0 Operating Instructions ………………………………………………………….. 4
4.1 General ………………………………………………………………………. 4
4.2 Operating Precautions ………………………………………………………. 4
4.3 Operating Procedure ………………………………………………………. 4
4.4 Battery Charging …………………………………………………………….. 5
5.0 Maintenance …………………………………………………………………… 6
5.1 Preventative Maintenance
………………………………………………… 6
5.2 Unscheduled Maintenance ………………………………………………… 6
6.0 Troubleshooting ………………………………………………………………… 8
7.0 Warranty
………………………………………………………………………. 9
Spare Parts List ………………………………………………………………………. 10

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1.0 INTRODUCTION
THE INSPECTOR X-ray source is a complete, single
package, portable X-ray device which operates on
either AC or from its own self-contained,
rechargeable battery pack. The unit incorporates a
modular design concept facilitating easy
replacement of any of the five functional modules.
The self-contained battery pack feature makes it
ideally suited for field use.
THE INSPECTOR is a pulsed X-ray device which
produces a pulse of approximately 50 nanoseconds
duration, and has a maximum energy of 150 kV. It's
Figure 2
major components use solid state circuitry which
increases the system's reliability and reduces the
power requirements.
2.3 The inverter Module changes the 29-volt
battery supply to pulsating AC to drive the high
voltage power supply.
The module plugs into the AC/DC Control Module
and has a rear connector panel for the AC Cable
and Remote Cable. Two fuses are for the
protection of the circuits.
2.4 AC/DC Control. This module automatically
selects which power supply is to be used. It also
supplies the charging current for the battery pack.
The 115 or 230 volt AC power supply is selected
by a switch mounted on the circuit card and is
accessed through the battery compartment.
Over-voltage protection is provided by two fuses:
the GMW1/4 (figure 3) and the 8-amp fuse
Figure 1
(figure 5).
2.0 DESCRIPTION
2.1 This section describes the functional
modules and control functions of THE
INSPECTOR X-ray source Model 200.
2.2 The X-ray generator consists of two modules.
The smaller module located at the nose of the
unit is a high voltage charging transformer of
approximately 9 kV. It is connected to the control
circuitry by a printed circuit connector board and
to the second module by a high voltage terminal.
The second module (the larger one) is an oil filled
high voltage transient generator which develops
about 150 kV. The cold cathode X-ray tube is
installed inside the unit and is accessible from the
Figure 3
front.

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2.5 Control circuitry. The control circuitry
2.6.5 Time Delay Start. This push button is
consists of two printed circuit assemblies which
located under the handgrip and starts the
are mounted inside the handle.
periods of time delay selected.
They control the power applied to the high
2.6.6 Exposure Safety Indicator. This lamp
voltage transformer via the relay on the AC/DC
illuminates when either the time delay start
control board. The vertical board is essentially a
button has been activated or when the remote
programmable counter that counts the number of
control push button is depressed.
X-ray pulses selected, then removes the power to
2.6.7 Remote Control Connector. This is a
the high voltage transformer.
recessed four-pronged connector located on
The delay circuitry, for 15 or 60 second timing, is
the rear connector panel of the inverter
on the horizontal board, together with the Delay
module. This allows operation of the unit from
Start Button and the two indicator lamps.
up to 20 feet away by using the control cable.
The Master Power ON/OFF Switch is mounted
2.6.8 Power Cord Connector. This is a three-
on the vertical board and is key operated.
pronged recessed connector, located at the
rear panel of the inverter module. The Power
Cord is supplied with a USA type molded AC
plug, which may be replaced with a suitable
connector for different international locations.
An appropriate adapter may also be used.
2.6.9 Fuses. 8 amp ABC 8/15 amp ABC 15
2.7 Power Requirements. THE INSPECTOR X-
ray Source Model 200 may be operated from
either 115 VAC +/- 10% 60 Hz, 230 VAC +/- 10%
50-60hz, or from self-contained rechargeable
battery pack. The unit requires approximately
750 watts of power.
Figure 4
2.6 Controls, Indicators, and Connectors
2.6.1 Master ON/OFF Switch. This is a key-
operated switch that controls the power to the
unit.
2.6.2 Power Indicator. A red lamp illuminates
to show that power has been applied to the
unit.
2.6.3 Exposure Selection Switch. This switch
selects the number of pulses (from 0 to 99) to
effect an X-ray picture.
2.6.4 Time Delay Selector Switch. This is a
two-position switch for a delay of 15 or 60
seconds before X-rays are emitted.
Figure 5

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2.8 SYSTEM SPECIFICATIONS*
Size
4.25” (108mm) high x 4.25” (108mm) wide x 15” (381mm) long
Weight
17lbs (7.26kg) without battery
20lbs 8oz (9.3kg) with battery
AC Mode
80-125 V or 160-240 V, 50-60 HZ-switch controlled
DC Mode
29V removable, rechargeable nickel cadmium battery, 2200
pulses per charge
Output Dose
3mR @ 1’/pulse w/filtration equivalent of 2.5mm of aluminum
Pulse Rate
25 pulses per second nominal
Pulse Length
60 nanoseconds
Maximum Pulses
3,600 per hour
Radiation Leakage
2 mR for 100 pulses measured adjacent to side of unit
Exposure Control
Electronic counter provides 1-99 pulses
Source Size
2.2 mm nominal
Time Delay
2-position switch of 15 or 60 seconds delay-allowing time to
leave area before X-ray unit fires
Battery Recharge Time
17 hour recharge using built in charger or optional external
charger
Unit warranty
1year limited
Tube warranty
90 days or 20,000 pulse
*Specifications subject to change at manufacturer’s discretion
Figure 6

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3.0 X-RAY TUBE REPLACEMENT
3.1 X-Ray Tube Replacement. The X-ray tube
should give long, trouble-free service under
normal use. Should replacement become
necessary, simply follow these instructions:
A) Unscrew the plastic nose cap on the front
of the unit.
B) Carefully grip the outside perimeter of the
tube's end cap and pull the tube free from the
contact spring fingers. Be careful not to
damage the end cap's center; this is a thin,
delicate window.
Figure 8
C) CAUTION: Handle tube only by the metal
ring. Do not let hands come in contact with
4.0 OPERATING INSTRUCTIONS
glass. (Acid content in body oils may
permanently etch the glass, possibly causing
4.1 IT SHALL BE THE RESPONSIBILITY OF
decrease of overall life of tube.) If tubes are
THE USER TO ASSURE THAT ALL X-RAY
handled, use rubber or nylon gloves or paper
EQUIPMENT BE OPERATED ONLY BY
tissue. Tubes may be cleaned with alcohol.
PERSONS WHO ARE COMPETENT IN ITS
SAFE USE. IT IS IMPORTANT FOR THE
D) Place the tube on a pad of soft material.
OWNER TO ESTABLISH SAFETY GUIDELINES
E) Clean the nose cap and examine the "O"
AND OPERATIONAL RESTRICTIONS BASED
ring for possible damage. Replace if
ON INDIVIDUAL CONDITION AND NEEDS.
necessary. Screw the nose cap onto the
4.2 Operating Precautions.
cavity until the ring makes contact.
4.2.1
Any individual who could be exposed
to radiation from the XR200 should be issued
a personal radiation device such as a film
badge and/or a pocket dosimeter.
4.2.2
Always stand at a safe distance from
the X-ray source. Even though the X-ray
beam angle is only 40°, all personnel should
remain at least 20 feet behind the X-ray unit
while it is pulsing.
4.2.3
Turn the Master Power Key Switch to
the OFF position after each exposure.
4.2.4
Review and follow all applicable state
and federal regulations.
Figure 7
4.3 Operating Procedures
(CAUTION: Make certain that an X-ray tube
is properly installed in the tube chamber.
Failure to have an X-ray tube installed will
result in over-voltage which may cause X-ray
generator failure.)
4.3.1
DC Mode Procedures
4.3.1.1 Prepare the object to be
radiographed and verify that the film is
placed in position.
4.3.1.2 Check that the battery pack is
installed.

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4.3.1.3 Dial the number of pulses required
4.3.3
Duty Cycle Warning. Up to 200
to radiograph the object on the Exposure
pulses may be used without rest. After every
Control (see figure 5).
200 pulses, the operator should allow a rest
period of 4 minutes. This a light duty
Option A-Remote Hand Switch Operation.
machine. It is not made to pulse continuously.
4.3.1.4A Connect the Remote Control
4.4 Battery Charging. The power source for the
Cable to the four-pin connector on the rear
DC mode is a 29-volt, nickel-cadmium battery.
of the panel.
The life of a fully charged battery should be
4.3.1.5A Verify the exposure area is clear
approximately 2000 pulses at 68°F before
of all personnel.
requiring a recharge. Nickel cadmium batteries
of this type, however, do not remain charged
4.3.1.6A Turn Master Power Key Switch
during storage.
to the "ON" position and note that the
power indicator lamp is illuminated.
The battery pack is easily removed from the X-
ray source by grasping the recessed portion of
4.3.1.7A Depress and hold the hand
the cartridge and pulling, while pressing down the
switch down until the unit has completed
molded retaining clip. (see figure 9)
the exposure. The exposure lamp will
extinguish.
4.3.1.8A Turn the Master Power Key
Switch to the "OFF" position.
Option B-Timer Delay Operation.
(Remote Control Cable removed.)
4.3.1.4B Set the Timer Delay to the
required delay time, 15/60 seconds.
4.3.1.5B Verify the exposure area is clear
of all personnel.
4.3.1.6B Turn Master Power Key Switch
to the "ON" position and note that the
power indicator lamp is illuminated.
4.3.1.7B Depress the Start Button and
observe that the Exposure Lamp is
illuminated. When the exposure is
complete, the lamp will extinguish.
Figure 9
4.3.1.8B Turn the Master Power Key
To assure proper performance, the battery
Switch to the "OFF" position.
should be brought up to a full charge at least
4.3.2
AC Mode Operations
once a week. This will require 17 hours for a fully
discharged battery.
4.3.2.1 Set the AC Voltage Select Switch,
THE INSPECTOR X-ray Source Model 200 has a
accessible through the battery
compartment, to 115 or 230 volts.
built-in charger which operates whenever the AC
power cord is plugged in to a service outlet. For
4.3.2.2 Connect the power cable to the
safety reasons, the Master Power Key Switch
recessed three-prong plug on the rear of
should be kept in the "OFF" position during this
the unit.
process.
NOTE-AC OPERATION CAN BE
For easier battery maintenance and storage, the
ACCOMPLISHED WITH OR WITHOUT THE
Battery Charger/Conditioner Model 2100 is highly
BATTERY PACK INSTALLED.
recommended.
4.3.2.3 The remainder of the AC mode
procedures are the same as DC mode
procedures.

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5.0 MAINTENANCE
5.2.2.1.4
Remove the printed circuit
module.
5.1 Preventative Maintenance.
5.2.2.2 Inverter. (Part #1450)
The following suggestions will help maintain top
performance.
5.2.2.2.1
Remove the four #4 flat
head socket screws located around the
5.1.1
X-Ray Dose Measurement. Check
rear connector panel.
the X-ray dose of each new tube to establish
the average dose for that particular tube. The
5.2.2.2.2
Insert the AC cord into its
average X-ray dose can be obtained using a
connector, but DO NOT connect it to an
dosimeter, such as Victoreen Model 541R
AC outlet.
(200 mR or equivalent).
5.2.2.2.3
Insert the remote cable into
With the dosimeter located 1 foot from the
its connector
front of the case 9and in line with the center of
5.2.2.2.4
Use the connectors as
the CAP TUBE HOUSING), the reading for 30
handgrips to pull the module straight
pulses should be 90 +/-10 mR.
out of the rear of the unit. It will slide
It is desirable to periodically measure the
out because its circuit board is
output dose to verify system performance.
supported in slots. Do not use the
hinged door as a grip. You will damage
CAUTION: Due to the short pulse width,
the hinge.
Geiger Mueller counters cannot detect X-rays
emitted from THE INSPECTOR X-ray source
5.2.2.3 AC/DC Control. (Part #1430)
Model 200. We recommend using ionization
5.2.2.3.1
Remove the X-ray tube and
chambers such as the Victoreen 660 with
safely store.
660-I probe or Victoreen 541-R pocket
dosimeter. Film badges are also sensitive to
5.2.2.3.2
Unscrew the four #4 flat
the INSPECTOR radiation.
head socket screws located at the
bottom corners of the cover.
5.2 Unscheduled Maintenance
5.2.2.3.3
Pull off the cover, complete
BEFORE ATTEMPTING TO SERVICE THIS
with the handle.
EQUIPMENT, CONSULT A QUALIFIED
TECHNICIAN, OR CALL THE
5.2.2.3.4
Remove the Inverter
MANUFACTURER'S SERVICE DEPARTMENT:
Module.
(765)855-3493.
5.2.2.3.5
Turn the unit over (base
5.2.1 Tools Required
up) and remove the four remaining #4
flat head socket screws.
1/16", 5/64", 3/32", & 9/64" Hex Drivers
5.2.2.3.6
Lift off the Base Plate
1/4" Nut Driver
Assembly.
5.2.2 Module Removal
5.2.2.3.7
The AC/DC Control Module
In all cases, the unit must be disconnected
can now be removed by removing the
from the AC source and the battery pack
four #4 cap head screws. Note the
removed.
loose mounting bracket on the bottom
two holes of the card.
5.2.2.1 Control and Logic. (Part #1502)
5.2.2.4 High Voltage Charging
5.2.2.1.1
Remove the four #4 flat
Transformer. (Part #1400)
head socket screws and the single #6
at the front.
5.2.2.4.1
Remove the X-ray tube and
safely store.
5.2.2.1.2
Lift off the handle, taking
care not to damage Exposure Safety
5.2.2.4.2
Remove the cover
Lamp.
assembly.
5.2.2.1.3
Remove the four #4 hex
5.2.2.4.3
Remove the Inverter
nuts clamping the board to the case
Module.
top.

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5.2.2.4.4
Remove the Base Plate
Assembly.
5.2.2.4.5
Slide off the nose cover
plate.
5.2.2.4.6
Remove the two #8 socket
head bolts clamping the transformer to
the Transient Generator.
5.2.2.4.7
Carefully slide the High
Voltage Charging Transformer off the
lead nose piece.
5.2.2.5 High Voltage Transient Generator.
(Part #1470)
5.2.2.5.1
Remove the X-ray tube and
safely store.
5.2.2.5.2
Remove the cover
assembly.
5.2.2.5.3
Remove the Inverter
Module.
5.2.2.5.4
Remove the Base Plate
Assembly.
5.2.2.5.5
Remove the AC/DC
Control Module.
5.2.2.5.6
Remove the High Voltage
Charging Transformer.
5.2.2.5.7
Remove the Printed Circuit
Connector Board.
CAUTION:
DO NOT disassemble the High Voltage
Generator.

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6.0 TROUBLE SHOOTING
THE INSPECTOR X-ray Source should never be operated without either an X-ray tube or a shorting strip in the
tube cavity. For testing purposes it is preferable to use a shorting strip to prevent unnecessary radiation
emission. The shorting strip is a 1/2” wide x 6” long piece of copper connected from tube spring connector to
nose cone.
Before testing and repairing the X-ray unit, be sure that a well-charged battery is installed in the unit.
The X-ray unit produces very high voltage (150,000 volts DC). The handle may be safely removed for work on
the counter board without exposure to the high voltage. The top case, however, should NOT be removed,
except by a qualified technician.
SYMPTOM
TEST
ACTION
No “Power ON” light when AC
Check AC voltage 8 amp ABC (right)
Replace fuse
connected
Check AC fuse
Replace fuse

Check GMW 1/4 fuse
No “Power ON” light in battery
Check battery voltage
Charge/replace battery
mode
Check DC fuse 15 amp ABC (left)
Replace fuse
X-ray “ON” lamp not lit, but
Check bulb
Replace bulb
operating correctly
X-ray “ON” lamp lights, but
Check GMW 1/4 fuse
Replace fuse
X-ray does not fire
No X-ray output, but otherwise
Visually inspect tube
Replace tube
operating correctly
Black picture, but X-ray operating
Check if paper envelope removed
Remove envelope from film
correctly
negative
In dark place, fire X-ray at opened
Replace tube if no green light
cassette. Greenish light should show
on cassette screen.
No operation in AC or DC mode
Check all three fuses
Replace fuses
Replace key switch
Continuous counting
Check key switch
Replace counter board or return
unit
Oil leaking from unit
Return unit for repair
Battery not taking charge
Check battery
Replace battery
Read voltage on charging terminals
If OK, replace battery
If no voltage, replace fuses
Fuses keep blowing
Read voltage on charging terminals
Return for repair
INSTRUCTIONS FOR REPAIR
1. In most cases we offer a two or three day turn around for repair.
2. When returning a unit for repair, include a brief description of problem incurred.
3. Remove battery before shipping unit. Battery may be returned in package with X-ray unit.
4. Remove tube before shipping unit. If tube is to be checked, pack separately and mark FRAGILE GLASS.
5. Be sure unit is securely packaged for shipment.
6. Return address: Golden Engineering, Inc., 6364 Means Road, Centerville, IN 47330

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