Frequency-converted andGas-insulated

Portable X Ray Machine

Operation Manual

ZHONGYI NDT CO., LTD.

www.zhongyi-ndt.com

AttentionDear 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 tubeinside 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 thegenerator 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, operatorshould contact manufacturer before repair and disassemble x ray generator , so that no damage oroperator injured by wrong repair steps.

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

※ NOTE：If this manual do not tally with the actual contents because of technical level escalating,please in kind prevail, our company reserves the final interpretation.

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1. General

The frequency-converted and gas-insulated X-Ray machine with ZY–2000 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.

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2. Technical Data

Model 100 KV 160 KV 200 KV 250 KV 300 KV 350 KV

Power supply AC220V±10% 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

FocalSpot(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 2.0×2.0 1.5*1.5 2.0×2.0 2.5×2.5 2.5×2.5

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*2.5GeneratorWeight(kg)

XXQ 10 15 23 35 43 44

XXG 14 25 31 37 38

XXHXXHA

11 15 22 31 41 44

XXGH 20 32 37

Controller Weight 13 kg

RadiationAngle

XXQ/G 40º

XXH 360ºX25º

XXHA 360ºX40 º

XXGH 360ºX25º

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 ±2ºC, 5 min. density ≥ 2.0

Safe Pressure 0.35 ~ 0.50 Mpa(Operation will be prohibited in the case less than 0.35 Mpa)

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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 whilethe cable socket, main switch and earthing terminal are located inside the control box on the right sideof it. The schematic drawing of the controller refers to the Drawings.

The controller includes the parts as below internally:A. kV control board;B. mA control 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 onone end of the X-ray generator. When the warning lamp lighting on, it means the X-ray NDTequipment is under the stand-by condition and X-ray will be produced (The warning lamp keepslighting on in the whole course of producing the X-ray). The schematic drawing of the controllerrefers to the Drawings.

The X-ray generator mainly includes the parts as belowA. 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.

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4. Working Principle

The controller of the equipment adopts the single-phase SCR bridge-rectifying circuit and therectified voltage turns to the smooth dc voltage by means of the LC filter. This voltage converts tothe frequency-adjustable square-wave pulse with single flow direction, becoming the electricalsupply of the X-ray generator to power the HV pulse transformer. The mA stabilizing unit willchange the frequency of the single-phase pulse against the voltage increase or decrease of theX-ray tube filament, to ensure the stable current in the X-ray tube. The kV regulating unit cancontinuously control the voltage up and down, to meet with the different radiographicrequirements for different materials .The interference-free circuit improves the shock- resistancecapability 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 isconnected to the ground and an over temperature protection device is furnished.. Once theover-temperature occurs, the controller is able to shut off the HV automatically to prevent theX-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 equipmentis controlled by the microprocessor. The longest exposure time can be set to 5 min.

5. Installation & Operation

5.1 Installation

1st After unpacking, please check all items in the package according to the packing list, to see whetherthere 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 ofthe 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 suitableradiation protection, please make sure that there will be no any body within 20m around area fromthe focal spot of the x-ray tube when radiography exposure.

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5.2 Operation

1st Turn on the power-supply switch, the Digitron shows “HH”; cooling fans of the controller andX-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 soundingand lamp of “stand-by” lights on.

2nd Adjust the kV knob to a required value, adjust the time knob to a required exposure time.

3rd Before operation, the equipment should go through the “training” procedure. The details of itrefer to the tables as below:

Periods ofnot working 8H-16H 16H-2.5D 2.5D-3Weeks 3Weeks or

moreTraining timefor onevoltageincrement

0.4min 0.8 min 1 min 2 min

Values of the voltage increment refer to the table as below:

PhasesModel

Low kV range10kV for each increment

High kV range5kV for each increment

2005 80-150 150-2002505 130-200 200-3003005 150-250 250-300

4th When pushing down the “HV on” button, the HV indicating lamp lights on, and several secondslater the X-ray generator begins to emit X-ray. The computer gets into the timing modeautomatically and Digitron shows the digressive time.

5th When the Digitron showing “0.0”, the exposure time is up; equipment turns off the HVautomatically; buzzer sounds; “stand-by” lamp lights on, HV lamp dims out and the Digitronbegins 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 .

6th 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, theequipment 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, theequipment will record this “time-delayed” value automatically. When the Digitron re-shows theexposure 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. TheDigitron counts down , until the preset “time-delayed” is up. As soon as the “time-delayed” period isup, the HV will be on.

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(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 Digitronshows“00”, this time the equipment enters into non-“time-delayed” mode too ---- i.e. The“time-delayed” mode is dismissed.

7th . Notice

A. Frequently check the gas pressure in the X-ray generator. If it is lower than 0.35Mpa, the operationis prohibited.

B. Verify the earthing terminal on the controller to be connected with the ground reliably, ensuringthe 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 keepingrotation continuously.

E. The protective circuit may start when large voltage fluctuation takes place. This will not beconsidered 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. 3A Fuse off

6.2 The Digitron shows the failure code with the meaning as below:A. “LA” No mAwarning;B. “HA” mA over 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 orsometimes 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. 20A Fuse off.

6.5 When touching the equipment, there is a tingle sense in the hand.A. Poor earthing connection;B. Poor insulation.

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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 1pc6 Fuse (3A) 5pcs7 Bag to contain accessories 1pc.

8. Drawings

Schematic drawing of controller1、“Stand-by” lamp2、HV lamp3、Showing window of Digitron4、Time knob5、Denotation of failure code and curves of exposure6、kV presetting knob7、HV on button8、HV off button9、Main switch10、Connecting cable socket11、Power cable socket12、（3A）Fuse (3A) socket13、Earthing terminal

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Schematic drawing of X-ray generator and the relative dimensions

Photo1：glass tube cone target, PanoramicPhoto2：glass tube DirectionalPhoto3：glass tube Flat target, Panoramicphoto4：ceramic tube directional

ModelSizeNo.

Glass tube X-ray generator Ceramic tube X-ray generator

2005 2505 3005 2005 2505 3005A（mm） 280 320 340 280 320 340B（mm） 230 240 280 130 130 130C（mm） 655 720 820 605 650 715

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Schematic Circuit

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Quality warranty

1. 1 year free guarantee. If the product fails or became inoperative withoutevidence of misuse, abuse, improper installation, or unauthorized repair, we willprovide the spares for repair free .

2. Engineers will online assist for the repairing work , according to fault descriptionand 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 duringtransportation, meanwhile accompany by a fully completed Field Failure Report.

4. Engineer Provide Services in Working Site for training Product applicationmethod, 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.comWeb: www.zhongyi-ndt.com