Frequency-converted and

Gas-insulated
Portable X Ray Machine
Operation Manual
ZHONGYI NDT CO., LTD.
www.zhongyi-ndt.com
Attention
Dear Users:
NDT X-Ray equipment belong to precision instrument, for your successful operation and safety,
special remind following matters:
1. 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.
2.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.
3.X-Ray machine is safe work at 0.35-0.5 Mpa, prohibit operating less than 0.35 Mpa.
4.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.
5.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.
6.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
1. General.................................................................................................1
2. Technical Data......................................................................................2
3. System Structure..................................................................................3
4. Working Principle................................................................................4
5. Installation & Operation.......................................................................4
6. Maintenance.........................................................................................6
7. Complete Equipment and Accessories.................................................7
8. Drawings..............................................................................................7
9. Quality Warranty..................................................................................11
NOTEIf this manual do not tally with the actual contents because of technical level escalating,
please in kind prevail, our company reserves the final interpretation.
1
1. General
The frequency-converted and gas-insulated X-Ray machine with ZY2000 controller, is upgrading
generation by ZHONG YI NDT CO.,LTD ( Dandong Zhongyi Electronic Co., Ltd).
Portable X-ray machine is used to show the internal discontinuity or faults of materials, products or
welding from a radiographic image on a film; 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. Besides of its advantages of small size, light weight, easy to use, simple operation and
self-troubleshooting, this machine has excellent performance of strongly interference-free capability,
good working stability and operating reliability.
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.
2
2. Technical Data
Model 100 KV 160 KV 200 KV 250 KV 300 KV 350 KV
Power supply AC220V10% 50Hz
Power (kW) >1.0 >1.5 >2.0 >2.5 >3.0 >3.5
Tube voltage (kV) 40-100 60-160 80-200 130-250 150-300 200-350
Max. Tube current 5 mA
Focal
Spot
(mm )
XXQ 1.0*1.0 1.5*1.5 1.5*1.5 2.0*2.0 2.5*2.5 2.5*2.5
XXG 2.02.0 1.5*1.5 2.02.0 2.52.5 2.52.5
XXH 1.0*1.5 1.0*2.0 1.0*2.0 1.0*2.4 1.0*2.5 1.0*2.5
XXHA 1.0*3.5 1.0*3.5 1.0*5.0 1.0*6.0 1.0*6.0
XXGH 1.0*2.0 1.0*2.0 1.0*2.5
Generator
Weight
(kg)
XXQ 10 15 23 35 43 44
XXG 14 25 31 37 38
XXH
XXHA
11 15 22 31 41 44
XXGH 20 32 37
Controller Weight 13 kg
Radiation
Angle
XXQ/G 40
XXH 360X25
XXHA 360X40
XXGH 360X25
Max.
Penetrate
(mm)
XXQ 8 20 29 39 49 59
XXG 20 29 39 49 59
XXH 6 18 26 36 46 55
XXHA 15 24 34 40 50
XXGH 26 36 46
Insulation SF6 gas
Temperature -25-40
Relative Humidity No more than 85%
Working Conditions 1. Focus : 600mm, exposure time: 5 min.
2. Film: KODAK , intensified by double lead foil.
3. Treatment in the darkroom: Temp. 20 2C, 5 min. density 2.0
Safe Pressure 0.35 ~ 0.50 Mpa
(Operation will be prohibited in the case less than 0.35 Mpa)
3
3. System Structure
Each model of X-ray NTD equipment is composed of the controller, X-ray generator, power cable,
connecting cable and cable accessories.
3.1 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 schematic drawing of the controller refers to the Drawings.
The controller includes the parts as below internally:
A. kV control board;
B. mAcontrol board;
C. Microprocessor control board;
D. Protective circuit board;
E. SCR Voltage-regulation modules;
F. LC filter;
G. Primary and secondary SCR inverter system;
H. Cooling fan;
3.2 X-ray Generator
The X-ray generator is of 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. When the warning lamp lighting on, it means the X-ray NDT
equipment is under the stand-by condition and X-ray will be produced (The warning lamp keeps
lighting on in the whole course of producing the X-ray). The schematic drawing of the controller
refers to the Drawings.
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. Warning lamp;
G. Cooling fan for the X-ray tube;
H. Charge and discharge valves for gas.
4
4. Working Principle
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.
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.
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.
5. Installation & Operation
5.1 Installation
1
st
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.
2
nd
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 ).
3
rd
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.
4
th
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.
5
th
Link the controller with X-ray generator by the connecting cable and ensure this connection perfect.
6
th
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.
5
5.2 Operation
1
st
Turn on the power-supply switch, the Digitron shows HH; cooling fans of the controller and
X-ray generator starts; warning lamp of X-ray lights on, and then, buzzer sounds. About 15 sec.
later, the Digitron shows the setting value that the time knob selects, the buzzer stops sounding
and lamp of stand-by lights on.
2
nd
Adjust the kV knob to a required value, adjust the time knob to a required exposure time.
3
rd
Before operation, the equipment should go through the training procedure. The details of it
refer to the tables as below:
Periods of
not working
8H-16H 16H-2.5D 2.5D-3Weeks
3Weeks or
more
Training time
for one
voltage
increment
0.4min 0.8 min 1 min 2 min
Values of the voltage increment refer to the table as below:
Phases
Model
Low kV range
10kV for each increment
High kV range
5kV for each increment
2005 80-150 150-200
2505 130-200 200-300
3005 150-250 250-300
4
th
When pushing down the HV on button, the HV indicating lamp lights on, and several seconds
later the X-ray generator begins to emit X-ray. The computer gets into the timing mode
automatically and Digitron shows the digressive time.
5
th
When the Digitron showing 0.0, the exposure time is up; equipment turns off the HV
automatically; buzzer sounds; stand-by lamp lights on, HV lamp dims out and the Digitron
begins to show the count down (Period time for rest). As soon as the count down range ends, the
stand-by lamp lights on and the Digitron shows the setting value that the time knob selects,
getting ready for the next exposure .
6
th
The equipment has the time-delay function.
(A). Setting up the time-delayed value :
After the Stand-by lamp lighting up, push down the HV button and three seconds later, the
equipment enters into the time-delayed setting mode. The time-delayed period will be 0.1~5 Min.
The time-delayed period will increase automatically until releasing the button, and then, the
equipment will record this time-delayed value automatically. When the Digitron re-shows the
exposure time, push down the HV button once more and the equipment enters into time-delayed
status. The buzzer sounds, and Stand-by lamp flashes as well as the dot on the Digitron flashes. The
Digitron counts down , until the preset time-delayed is up. As soon as the time-delayed period is
up, the HV will be on.
6
(B). Release from the time-delayed value:
Shut off the main power and turn on again, then, the equipment enters into non-time-delayed mode.;
Or press the HV button twice, then, release the pressed-down HV button when the Digitron
shows00, this time the equipment enters into non-time-delayed mode too ---- i.e. The
time-delayed mode is dismissed.
7
th
. Notice
A. Frequently check the gas pressure in the X-ray generator. If it is lower than 0.35Mpa, the operation
is prohibited.
B. Verify the earthing terminal on the controller to be connected with the ground reliably, ensuring
the safe operation.
C. Check whether 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 with 1:1. The
main power should not be turn off during resting time, so as to ensure the cooling fan keeping
rotation continuously.
E. The protective circuit may start when large voltage fluctuation takes place. This will not be
considered as abnormal phenomenon and the equipment can operate normally.
6. Maintenance
When failure occurs, the operation should be stopped and the failure reason should be found out.
6.1 When powering on, the cooling fan does not rotate and no indication on the Digitron:
A. Electric cable failure;
B. Main switch damage;
C. 3AFuse off
6.2 The Digitron shows the failure code with the meaning as below:
A. LA No mAwarning;
B. HA mAover warning;
C. PU over voltage warning;
D. PT over temperature warning;
6.3 When pressing the HV on button, the 20A fuse burns up or main switch trips or
sometimes sounds:
A. Failure of the X-ray generator;
B. Damage of the chopper in the controller;
C. Gas pressure in the x-ray generator lower than 0.35Mpa.
6.4 When pressing down the HV on button, Digitron shows LA:
A. Failure of connecting cable;
B. Failure of the X-ray generator;
C. Circuit failure in the controller;
D. 20AFuse off.
6.5 When touching the equipment, there is a tingle sense in the hand.
A. Poor earthing connection;
B. Poor insulation.
7
7. Complete equipment and accessories
1 X-ray generator 1pc.
2 Controller 1pc.
3 Connecting cable (10 cores) 25m 1pc.
4 Power cable (2cores) 10m 1pc.
5 Earthing wire 5m 1pc
6 Fuse (3A) 5pcs
7 Bag to contain accessories 1pc.
8. Drawings
Schematic drawing of controller
1Stand-by lamp
2HV lamp
3Showing window of Digitron
4Time knob
5Denotation of failure code and curves of exposure
6kV presetting knob
7HV on button
8HV off button
9Main switch
10Connecting cable socket
11Power cable socket
123AFuse (3A) socket
13Earthing terminal
8
Schematic drawing of X-ray generator and the relative dimensions
Photo1glass tube cone target, Panoramic
Photo2glass tube Directional
Photo3glass tube Flat target, Panoramic
photo4ceramic tube directional
Model
Size
No.
Glass tube X-ray generator Ceramic tube X-ray generator
2005 2505 3005 2005 2505 3005
Amm 280 320 340 280 320 340
Bmm 230 240 280 130 130 130
Cmm 655 720 820 605 650 715
9
10
Schematic Circuit
11
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.
4. 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:86-415-6133688
Email:alicelee@zhongyi-ndt.com
Web: www.zhongyi-ndt.com
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