SERVICE BULLETIN

Health Group Products

Eastman Kodak Company, Health Group, Rochester, NY 14650

February 2007

Kodak DirectView DR 3000/5000/5100/7100/7500/9000/9500

SYSTEMS
Service Codes: 5070, 1531, 4349, 4228, 8087, 1534, 2540

Article 1: Insulating the High Voltage Connections on all Kodak X-ray Systems
The purpose of this Service Bulletin is to clear some confusion in regards to the
purpose, and methods of insulating the high voltage connections found in our
Kodak DR x-ray systems. Additionally, a brief instruction and supporting
illustrations are provided to show the Kodak procedure for insulating these
connections at the x-ray tube and the High-Tension (HT) Tank.

The generators used in Kodak DR systems have the ability to produce a total x-
ray tube potential of up to 150,000 volts between the anode and cathode. This
means that at each connector of the x-ray tube or the high-tension tank, there
may be as much as 75,000 volts produced when referenced to ground. For this
reason, effective insulation must be used in the connectors to prevent short-
circuits between the connectors and ground. The goal is to eliminate all air gaps
between the high voltage and ground, as short circuits or arcs will occur across
the air gap, especially at the potentials produced in x-ray generation. Should a
short-circuit occur, an error relating to the KV and/or MA may result, since during
a short-circuit, the KV is driven to zero, and the MA may approach infinity.

The most popular methods of insulating the high voltage connections on x-ray
systems incorporate the use of the 3 items listed below:
• Insulating oil
• Vapor-proofing compound (often called dielectric compound or high
tension “grease”)
• Silicon washers (or wafers)

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The most effective insulator is insulating oil. Attributes of insulating oil is that it
easily flows or displaces around the high voltage connectors, and air is not easily
trapped in the oil, which could create a pocket that allows for a greater probability
of a short-circuit. Insulating oil’s main attribute of being able to flow around a
connector is also its largest downside, as using oil in places where the connector
may be tipped or turned will allow the oil to flow out of the connector, thus the
reason it is not popular for use at the x-ray tube connections.

On most systems, the x-ray tube can rotate, and in some cases be turned
completely upside down, therefore, an insulator that doesn’t flow or displace
easily is needed.
• Vapor-proofing compound or “grease” is the most common insulator for
use where the insulator needs to stay in place regardless of connector
orientation, due to its sticky grease-like consistency. Vapor-proofing
compound is very effective when used properly, but how it is used will
ultimately determine the effectiveness. Vapor-proofing compound is
available in a variety of different viscosities, and the “thicker” or heavier
the compound, the more difficult the compound will be to displace and get
to flow around the connector or “candlestick”. Typically, the viscosity of
the compound used in the “Federal” style connectors of a diagnostic x-ray
system is similar to that of toothpaste. If the compound is too thick and
heavy, the high-voltage connectors will not easily seat fully into the
connector, since the compound does not easily flow or displace around
the connector or “candlestick”. Another potential problem with using
vapor-proofing compound is that it can trap air, which may result in less
effective insulation, which could result in short-circuits to ground.
• Silicon washers are becoming more popular, and from a pure electrical
point of view, have proven to be as effective an insulator as vapor-
proofing compound. Since the silicon washers are far easier to use than
the vapor-proofing compound, and require no skill or special technique for
their use, their effectiveness has surpassed that of the vapor-proofing
compound in the field. Additionally, the silicon washers do not wear or
require frequent replacement, and may remain in use for the life of the x-
ray tube, although we recommend checking yearly, and replacing as
necessary. Companies such as Philips Medical Systems, who also
manufactures x-ray generators in addition to x-ray tubes, started using
silicon washers on x-ray systems that incorporate the use of tubes with
federal-style connectors (the type Kodak uses) in the early 1990s. The
only consideration that needs to be taken when using the silicon washers
is that a small cut needs to be placed into the perimeter of the washer in
order to allow air to be displaced as the connector is seated into the x-ray
tube. Some manufacturers of the washers provide a cutout when the
washer is manufactured, and others do not. (Kodak uses washers
manufactured by Claymount, and these do not have a notch cut into the
washer, so we need to place the notch when installing the washer.
Claymount is the same company that manufactures the high-tension
cables for our systems.).

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For Kodak systems, we use the following, and they are available in a kit that is
obtained by ordering TL5515:
• All connectors must be clean. Use alcohol to completely clean the
connectors on the cables, and the connectors at the HT Tank and x-ray
tube.
• Insulating oil in the High-Tension Tank connectors
o Use two (2) vials of oil in each connector of the HT Tank
Two (2) vials of oil in the HT Tank connections will result in the
level of the oil coming very close to the top of the connector.
Checking and cleaning the candlesticks is the biggest
consumer of oil in the connectors. If the candlesticks are
cleaned, make sure the oil level is still sufficient by fully seating
and then removing the candlestick to see the resulting oil level
on the side of the candlestick. The oil should reach at least 1/3
the length of the candlestick.
Due to the design of the HT Tank used on the CPI (5100, 7100,
7500, 9500) and Sedecal (3000) generators, oil must not be
drawn from those units. However, oil can be drawn from the HT
Tank used on the DR 9000 and DR 5000 (Fischer-based
systems), and used for the connections of the high voltage
cables in the HT Tank.
• Silicon washers in the x-ray tube connectors
o Use one (1) silicon washer in each connector of the x-ray tube only.
o Cut a small notch into the outside edge of the washer to allow air to
easily pass by as the washer and connector are inserted into the x-
ray tube. The notch is not absolutely required, as air will escape
around the washer as the washer and candlestick are inserted, but
the washer will be more difficult to remove at a future time, and will
likely stay in the bottom of the connector when the candlestick is
removed.
If desired, a drop or two of insulating oil can be placed on the
washer before installing the washer. Placing a thin film of oil on
the washer before installing it into the x-ray tube, will help
prevent the washer from sticking and make it easier to remove
at a later time should it be desired to remove the washer.
No additional oil is required. In fact, no oil at all is required for
use in the connectors of the x-ray tube, but as stated in the
previous bullet, a drop or two will help prevent the washer from
sticking in the bottom of the connector. EXCESS OIL FROM
THE VIAL MAY BE PLACED IN THE CONNECTORS OF THE
HT TANK, OR DISCARDED. DO NOT PLACE EXCESS OIL
IN THE X-RAY TUBE CONNECTORS.
When using insulating washers, USE ONLY ONE (1) WASHER
PER CONNECTION.
Carefully inspect the bottom of the x-ray tube connector to
ensure no washer is already in place. There have been cases
where the washer was left in place during manufacturing
testing, and was not noticed by the installer until they tried to
get the connector to fully seat.

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 If the notch cut into the washer is too large, the effectiveness of
the washer to insulate the connection may be decreased. A
very small notch is all that is recommended.

Additional information:
• Some x-ray service representatives have expressed their doubts about the
use of the silicon washers. Some of the reasons they may have may be
due to lack of knowledge on the washers or the fact they are simply
familiar and comfortable with the traditional method of using vapor-
proofing compound. Others claim that the washers prevent the cable
connector from fully seating into the bottom of the x-ray tube’s connector.
o The silicon washer does compress, allowing the connector to fully
seat in the receiving connector. The washer also conforms to any
irregularities found on either the x-ray tube’s connector or the
cable’s.
Due to the design of the Federal-style connector, there is a gap
that must be filled with some type of insulation, if a washer is
used, it only has to compress slightly when filling the gap.
o The silicon washer is stable, and does not shrink, dry, liquefy, or
harden with age or heat, as does vapor-proofing compound.
o Vapor-proofing compound tends to dry and shrink with age and
heat. In some cases and types, vapor-proofing compound may
liquefy, and displace, leaving an un-insulated connection.
• When installing the collars on the high voltage cables, hand tightening is
all that is required. The use of tools is not recommended, and if the cable
collars are over-tightened, damage to the connector may occur.
o After the x-ray tube has completed the cycle of heating and cooling,
the collars may allow for an additional amount of tightening. This is
especially true with new x-ray tubes or for new installations. It is
recommended to check the tightness of the collars any time service
to the equipment is performed, and especially at the completion of
an installation.
• On some systems, a gasket (usually black in color) is provided for use on
the high voltage cables, and when installed, it is located near the cable
collar. This gasket provides additional insulation, and seals the connector
to prevent any oil or grease from running out of the connector if these
insulating methods are used. This gasket is not absolutely required, but it
does add an extra level of protection. The gasket may make fully seating
the connector slightly more difficult.

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Jim Coyne, Service Engineer – Rochester, NY
For more information please contact:
Eastman Kodak Company
Health Group - TSC
6200 Tennyson Parkway
Plano, TX 75024, USA

1-800-328-2910 (U.S. Only)

972-805-1500 (Outside the U.S.A)

Kodak and DirectView are trademarks of Eastman Kodak Company.

Printed in the USA.

Eastman Kodak Company, 2007
Rochester, NY 14650 HEALTH GROUP

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