PHILIPS Brilliance 6, Brilliance 10, Brilliance 16, Brilliance 16P, Brilliance 40 User Manual

Brilliance 6/10/16/16P/40/ 64 CT Scanner

G a n t r y R e p a i r a n d R e p l a c e m e n t M a n u a l

C S I P - 1

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This document and the information contained in it is proprietary and confidential information of Philips Healthcare ("Philips") and may not be reproduced, copied in whole or in part, adapted, modified, disclosed to others, or disseminated without the prior written permission of the Philips Legal Department. Use of this document and the information contained in it is strictly reserved for current Philips personnel and Philips customers who have a current and valid license from Philips for use by the customer’s designated in-house service employee on equipment located at the customer’s designated site. Use of this document by unauthorized persons is strictly prohibited. Report violation of these requirements to the Philips Legal Department. This document must be returned to Philips when the user is no longer licensed and in any event upon Philips’ first written request.

This document and the information contained in it is strictly reserved for current Philips Healthcare (“Philips”) personnel, Philips licensed representatives and Philips customers who have purchased a valid service agreement for use by the customer’s designated in-house service employee on equipment located at the customer’s designated site. Use of this document by unauthorized persons is strictly prohibited. This document must be returned to Philips when the user is no longer licensed and in any event upon Philips’ first written request.

© 2015 Koninklijke Philips N.V. All Rights Reserved. CSIP Level 1

Brilliance 6/10/16/16P/40/64 CT Scanner Gantry Repair and Replacement Manual CSIP-1

Safety and Legal Information

To the User of This Manual

The user of this manual is directed to read and carefully review the instructions, warnings and cautions contained herein prior to beginning installation or service activities. While you may have previously installed or serviced equipment similar to that described in this manual, changes in design, manufacture or procedure may have occurred which significantly affect the present installation or service.

Legal Manufacturer

Philips Medical Systems (Cleveland), Inc.

A Philips Healthcare Company

595 Miner Road

Cleveland, OH 44143

USA

Warranty Disclaimer

Philips provides this document without warranty of any kind, implied or expressed, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose.

Limitation of Liability

Philips has taken care to ensure the accuracy of this document. However, Philips assumes no liability for errors or omissions and reserves the right to make changes without further notice to any products herein to improve reliability, function, or design. Philips may make improvements or changes in the product(s) or program(s) described in this document at any time.

Password Notice

The PASSWORD is the property of Philips Healthcare and is provided for the exclusive purpose of providing access to selected service utilities which are described in this service manual as being associated with the password. Use of this password for any purpose other than for the access to the selected services utilities is strictly prohibited.

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Safety

!

WARNING: In addition to the warnings listed below, follow all safety guidelines as described in the Safety Manual. Failure to do so can result in severe personal injury.

Installation and Environment

Except for installations requiring certification by the manufacturer, see that a radiation protection survey is made by a qualified expert in accordance with NCRP 102, section 7, as revised. Perform a survey after every change in equipment, workload, or operating conditions which might significantly increase the probability of persons receiving more than the maximum permissible dose equivalent.

Diagnostic Imaging Systems - Mechanical-electrical Warning

!

WARNING: Before initiating a movement of the patient table or gantry, ensure that the area is free of obstructions such as tools, boxes, chairs, and step stools. Physical injury or damage can occur.

All of the moveable assemblies and parts of this equipment should be operated with care and routinely inspected in accordance with the manufacturer’s recommendations contained in the equipment manuals.

Only properly trained and qualified personnel should be permitted access to any internal parts. Live electrical terminals are deadly; be sure line disconnects are opened and other appropriate precautions are taken before opening access doors, removing enclosure panels, or attaching accessories.

Prior to any service and maintenance activities inside components:

•Switch off the system at the main power supply, and the uninterruptible power supply (UPS).

•Use lockout/tagout (LOTO) procedures to safeguard against the release of hazardous energy during installation, maintenance or service work on the system.

•Always use an ESD protection wrist strap when servicing any component in the system.

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Electrical-grounding Instructions

The equipment must be grounded to an earth ground by a separate conductor. The neutral side of the line is not to be considered the earth ground. On equipment provided with a line cord, the equipment must be connected to a properly grounded, three-pin receptacle. Do not use a three-to-two pin adapter.

Diagnostic Imaging Systems - Radiation Warning

X-ray and Gamma-rays are dangerous to both operator and others in the vicinity unless established safe exposure procedures are strictly observed.

Gamma radiation presents exposure risk to the operator and others in the vicinity of a radioactive source. Radiopharmaceutical-filled phantoms present the greatest risk, while sealed sources present lesser risk. Exposure mitigation procedures described in the GSS NA radiation safety documents can reduce this risk. Operators should use a combination of time, distance, and shielding techniques to reduce the exposure to themselves and others from sealed sources and injected phantoms. Philips employees are obligated to comply with the conditions in Philips GSS NA’s Radioactive Materials License, out of state license reciprocity agreements, and the customers’ radioactive materials licenses.

The useful and scattered beams can produce serious or fatal bodily injuries to any persons in the surrounding area if used by an unskilled operator. Adequate precautions must always be taken to avoid exposure to the useful beam, as well as to leakage radiation from within the source housing or to scattered radiation resulting from the passage of radiation through matter.

Those authorized to operate, participate in or supervise the operation of the equipment must be thoroughly familiar and comply completely with the current established safe exposure factors and procedures described in publications, such as: Subchapter J of Title 21 of the Code of Federal Regulations, "Diagnostic X-ray Systems and Their Major Components", and the national council on radiation protection (NCRP) no. 102, "Medical X-ray And Gamma-ray Protection For Energies Up To 10 Mev-equipment Design and Use".

Those responsible for planning of x-ray and gamma-ray equipment installations must be thoroughly familiar and comply completely with NCRP no. 49, "Structural Shielding Design and Evaluation for Medical of X-rays and Gamma-rays of Energies Up to 10 Mev". Failure to observe these warnings may cause serious or fatal bodily injuries to the operator or those in the area.

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Symbol Descriptions

		Warning symbol		Radiation warning symbol

Laser warning symbol

Biohazard warning symbol

		Magnetism warning symbol		Projectile warning symbol

Electrical warning symbol

Crush warning symbol

Do not touch

Recycle Label

Dispose of in accordance with your country’s requirements. This label indicates that there is material in the system that you must separately collect and recycle in accordance with the requirements of the European Waste Electrical Equipment (WEEE) Directive.

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Revision History

	ECO #	Revision	Date	Comments
		A	Dec, 2004	Release at revision A.
				Updated anode and cathode installation procedures, updated
		B	Apr 2005	references for firmware programming, deleted PPCV
				configuration from cover replacement.
		C	Jun 2005	Updated front cover for 64-channel configuration.
				Updated power up/power down procedure, added BR 40 lower
		D	Sep 2005	front cover fans R/R, BR 40 gantry intake duct fans R/R, BR 40/64
				triple output flatpac power supplies R/R, high speed starter R/R,
				and A-plane calibration version 2.0 procedures.
				Added section for mobile gantry parts replacement. Added
				mobile gantry information to power-up / power down section
	2013428	E	Apr2006	and cover removal and replacement section. Revised X-ray tube,
				main drive motor, optical transmitter, optical receiver, and 24V
				power supply R&R sections.
				Added A-plane collimator slice-width tests for 1.2.5 SW to A-
	2013775	F	Jun 2006	plane removal and replacement procedure. Removed other 1.2.5
				and 2.0 SW A-plane calibration information and directed to refer
				to the appropriate calibration manual.
				Added replacement procedure for Brilliance 40/64 5V / 24V DMS
	2013855	G	Jun 2006	power supply. Added motor controller commissioning
				procedure.

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	ECO #	Revision	Date	Comments
				Revised motor controller replacement and commissioning
	2014221	H	Aug 2006	procedures. Added instructions to flash KPMs and restore
				NVRAM to replacement instructions for boards containing one.
				Added front cover gas spring locks. Added instructions for
				saving generator data to a memory stick to cathode and anode
	2016019	J	Mar 2007	generator replacement procedures. Added CDMP power supply
				replacement procedure. Revised signal brush block replacement
				for new style brush blocks. Revised rotor drive motor and belt
				replacement procedures.
	2016889	K	Oct 2007	Added removal and replacement procedure for Dunlee CTR2150
				X-ray tube.
	2017606	M	Jan 2008	Modified the power brush block replacement procedure to reflect
				a new style block.
				Added modified wiring instructions needed for main drive
				motors from a different vendor. Added instructions to turn off
				room annunciator light power when working in the left gantry
	2018347	N	Jun 2008	column. Replaced the A-plane collimator replacement procedure
				with the previously approved procedure from Brilliance Big Bore
				Repair / Replacement Manual, revision G. Added replacement
				procedure for TDMS 48 V power supply.
				Corrected main drive motor part number. Revised motor
	2019486	P	Jan 2009	controller commissioning procedure to add instructions for
				changing the H parameter.

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	ECO #	Revision	Date	Comments
				Added replacement procedures for new data optical slip ring
				components. Added procedure for new R2D. Revised A-plane
	2020980	R	Jul 2009	collimator procedure and added saving offsets to loading
				calibration constants. Added procedure for unjamming
				collimator blades or Z-carriage and for recognizing and fixing an
				A-plane set problem from newsletter CT3596.
				Revised anode power module, cathode power module, high
	2022034	T	Mar 2010	speed starter, gantry motion processor, tilt actuator, A-plane
				collimator, RHost, Ghost, TDP, MDP, GMP, safety, and cover
				sections.
				Corrected typographical error for ParamData value in the
	2022301	U	Apr 2010	procedure “Setting the Motor Controller H Parameter” in the
				Rotor Drive Motor Controller Replacement section.
				The controller section was revised to remove the requirement for
				performing commissioning and the commissioning procedure
	2022668	V	Jul 2010	was removed from the motor replacement section. These sections
				were revised as a result of a DEFOA action item. The Anode
				Power Module and Cathode Power Module replacement sections
				were revised for a new shipping container.
	2023057	W	Nov 2010	Added section for checking rotor stopping speed and adjusting
				main drive motor brake.
	2023459	AA	Jul 2011	Update XRT replacement procedure.
	2024043	AB	Sep 2011	Add replacement procedure for the Emerson rotor drive motor
				controller.

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	ECO #	Revision	Date	Comments
	2024474	AC	Feb 2012	Added note about SpindleBlok 1.5 replacements to the
				SpindleBlok motor controller replacement section.
				Added replacement procedures for new optical slip ring
				components for BR16 systems. Added replacement procedure for
	2025644	AD	Apr 2013	the control board on the cathode power module. Added new
				RoHS compliant power brush assembly to the power brush
				replacement procedure. Added instructions for adjusting the new
				12V power supply in the FRC to the FRC replacement procedure.
				The manual was updated to resolve the Quick Release Latch
	E-036047	AE	May 2014	defect per CTUDT00366275. An appendix with the Quick Release
				procedure was added.
				Spellman Inverter Fan Replacement procedure, Clarify R2D
	E-049424	AF	December	board, new style, replacement procedure.
			2015	Updated OTR Tool section due to McAfee Whitelisting
				restrictions in 3.6.7+ software.

This document was prepared by CT/AMI Service Innovations.

For any additions, corrections, or suggestions, contact your next level of support.

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	Contents
Section 1 Safety Guidelines: .............................................................................		28
1.1	General Precautions...................................................................................................	28
	1.1.1 Remote Services ..............................................................................................	29
	1.1.2 Service Mode Precautions..................................................................................	29
	1.1.3 Explanation of Symbols.....................................................................................	31
	1.1.4 Servicing Electro-medical Systems and Equipment................................................	31
	1.1.5 General Visual Checks to Be Made Before Returning a System To Service ................	32
1.2	Personal Protection Measures (Occupational Safety).......................................................	33
	1.2.1 Mandatory Reporting ........................................................................................	33
	1.2.2 Working on Parts Supplied With Electrical Power...................................................	33
	1.2.3 Radiation Protection .........................................................................................	34
	1.2.4 Handling Heavy Loads ......................................................................................	35
	1.2.5 Handling Hazardous Substances.........................................................................	35
1.3	Service Precautions ...................................................................................................	36
	1.3.1 Precautions Against Mechanical Hazards..............................................................	37
	1.3.2 Rotor Rotational Precautions..............................................................................	37
	1.3.3 Safety Procedure: Securing Rotating Components ................................................	37
	1.3.4 Precautions Against Electrical Hazards ................................................................	38
	1.3.5 Precautions Against Thermal Hazards..................................................................	39
1.4	Attaching Fasteners, Screws, Bolts, and Nuts ................................................................	40
	1.4.1 Torque Specifications for Gantry Components ......................................................	41
	1.4.2 Using Loctite ...................................................................................................	44
1.5	System Specific Safety Precautions..............................................................................	45
	1.5.1 Gantry............................................................................................................	46
	1.5.2 Marker Laser Lights on the System.....................................................................	50
1.6	Using the Anti-Static Field Service Kit...........................................................................	51
	1.6.1 Anti-static Discharge (ESD) ...............................................................................	51
	1.6.2 Anti-static Discharge (ESD) Procedure ................................................................	53

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Section 2 System Power Down/Power Up: .........................................................		54
2.1	System Shutdown and Power Down .............................................................................	54
	2.1.1 Shutting Down Horizontal Servers ......................................................................	55
	2.1.2 Shutting Down a Vertical CIRS Server Running Windows XP...................................	57
	2.1.3 Shutting Down a CIRS Server Running Windows Vista...........................................	58
	2.1.4 Shutting Down the Host ....................................................................................	59
	2.1.5 Removing Power to the CIRS Cabinet..................................................................	60
	2.1.6 Gantry Power Down (Except for the Host and CIRS)..............................................	61
	2.1.7 Removing Gantry Rotor Power ...........................................................................	64
	2.1.8 Removing Stator Power.....................................................................................	66
	2.1.9 Removing Table Power......................................................................................	68
2.2	System Power Up ......................................................................................................	69
	2.2.1 Gantry Power Up..............................................................................................	69
	2.2.2 CIRS and Host Power-Up...................................................................................	74
Section 3 Gantry Covers Replacement: ..............................................................		80
3.1	General Information ..................................................................................................	80
	3.1.1 Releasing the Patient Support Subframe Quick Release .........................................	80
	3.1.2 Opening the Gantry Front Cover.........................................................................	80
3.2	Closing the Gantry Front Cover ...................................................................................	83
3.3	Gantry Front Cover Gas Spring Replacement .................................................................	84
	3.3.1 Gas Spring Removal .........................................................................................	84
	3.3.2 Gas Spring Installation......................................................................................	88
3.4	Gantry Lower Front Cover Removal..............................................................................	89
3.5	Gantry Lower Front Cover Installation ..........................................................................	90
3.6	Removing the Gantry Rear Cover.................................................................................	91
	3.6.1 Invisible Laser Specific Safety Precaution ............................................................	91
	3.6.2 Turning off Invisible Lasers when the Interlock Switch in the Service Position...........	96

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3.7	Installing the Gantry Rear Cover..................................................................................	97
3.8	Removing the Gantry Rear Cone..................................................................................	97
3.9	Installing the Gantry Rear Cone...................................................................................	98

3.10		Gantry RH/LH Upper Side Cover Removal ...................................................................	98
3.11		Gantry RH/LH Upper Side Cover Installation ..............................................................	100
3.12		Gantry RH/LH Lower Side Cover Removal .................................................................	102
3.13		Gantry RH/LH Lower Side Cover Installation .............................................................	106
Section 4 Gantry Cover Adjustments: ...............................................................			107
4.1	Front Cover Adjustments ..........................................................................................		107
4.2	Lower Front Cover Adjustments.................................................................................		109
4.3	Top Cover Adjustments ............................................................................................		110
4.4	Upper Side Cover Adjustments ..................................................................................		111
4.5	Lower side cover adjustments ...................................................................................		112
4.6	Rear Cover Adjustments...........................................................................................		113

Section 5 Gantry Front Cover Display and Control Panel Assemblies Replacement:115

5.1	Removal.................................................................................................................	115
5.2	Installation .............................................................................................................	116
Section 6 Gantry Rear Cover Switch Panels Removal/Replacement:...................		117
6.1	Removal.................................................................................................................	117
6.2	Installation .............................................................................................................	119
Section 7 Gantry Display/Switch Control Board Removal/Replacement: ............		120

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7.1	Removal.................................................................................................................		120
7.2	Installation .............................................................................................................		121
Section 8 Intercom Speakers And Microphone Boards Replacement: ..................			122
8.1	Gantry Intercom Speaker Replacement ......................................................................		122
		8.1.1 Removal .......................................................................................................	122
		8.1.2 Installation....................................................................................................	123
8.2	Gantry Microphone Board Replacement ......................................................................		123
		8.2.1 Gantry Front Microphone Board Removal...........................................................	123
		8.2.2 Gantry Front Microphone Board Installation .......................................................	124
		8.2.3 Gantry Rear Microphone Board Installation ........................................................	125
Section 9 Gantry Front Cover Interlock Switch Replacement: ............................			126
9.1	Gantry Front Cover Interlock Switch Removal..............................................................		126
9.2	Gantry Front Cover Interlock Switch Installation ..........................................................		127
Section 10 Gantry E-Stop Switches Replacement: .............................................			128
10.1		E-Stop Switch Removal (Gantry Front Cover) ............................................................	128
10.2		E-Stop Switch Installation (Gantry Front Cover).........................................................	130
10.3		E-Stop Switch Removal (Circuit Breaker Panel) ..........................................................	130
10.4		E-Stop Switch Installation (Circuit Breaker Panel) ......................................................	132
Section 11 Front Cover and Rotor Laser Module Replacement:...........................			133
11.1		Front Cover Laser Module Replacement ....................................................................	133
		11.1.1 Front Cover Laser Module Removal .................................................................	133
		11.1.2 Front Cover Laser Module Installation .............................................................	135
11.2		Rotor Laser Module Replacement .............................................................................	135

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	11.2.1 Rotor Laser Module Removal..........................................................................	135
	11.2.2 Rotor Laser Modules Installation.....................................................................	137
Section 12 Gantry Exhaust Fans Replacement : ................................................		138
12.1	Removal...............................................................................................................	138
12.2	Installation ...........................................................................................................	139
Section 13 6-16 Gantry Air Filters Replacement: ..............................................		140
13.1	Air Filter Removal ..................................................................................................	140
13.2	Air Filter Installation ..............................................................................................	141
Section 14 40/64 Gantry Air Filters Replacement: ............................................		142
14.1	Air Filter Removal ..................................................................................................	142
14.2	Air Filter Installation ..............................................................................................	145
Section 15 BR 40/64 Gantry Intake Duct Fans Replacement:............................		146
15.1	Removal...............................................................................................................	146
15.2	Installation ...........................................................................................................	149
Section 16 BR 40 Gantry Lower Front Cover Fans Repair/Replacement: .............		150
16.1	Removal...............................................................................................................	150
16.2	Installation ...........................................................................................................	155
Section 17 MRC 600 X-ray Tube Assembly Replacement: ...................................		156
17.1	OTR Tool ..............................................................................................................	157
	17.1.1 OTR Tool on Systems with McAfee Application Control (Whitelisting) ...................	157
	17.1.2 OTR Tool on Systems without McAfee Application Control (Whitelisting) ...............	160

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	17.1.3 View OTR Tool Data......................................................................................	162
	17.1.4 Report OTR Tool Issues .................................................................................	164
17.2	X-ray Tube Removal ..............................................................................................	166
17.3	Tube Installation ...................................................................................................	207
Section 18 Dunlee CTR2150 X-ray Tube Assembly Replacement: .......................		238
18.1	Process Overview for Dunlee CTR2150 X-ray Tube Removal and Replacement ...............	239
18.2	Tube Removal .......................................................................................................	241
18.3	Tube Installation ...................................................................................................	264
Section 19 MRC 600 Cooling Unit Replacement: ................................................		279
19.1	Removal...............................................................................................................	279
19.2	Installation ...........................................................................................................	295
Section 20 Heat Exchanger Fans Replacement: .................................................		307
20.1	Removal...............................................................................................................	307
20.2	Installation ...........................................................................................................	308
Section 21 A-Plane Collimator Replacement : ...................................................		311
21.1	A-Plane Collimator Removal ....................................................................................	311
21.2	A-Plane Collimator Installation.................................................................................	318
21.3	Loading A-Plane Calibration Constants (all software versions) ......................................	322
21.4	A-Plane Slice-Width Operation Test Procedure ...........................................................	328
	21.4.1 Test 1: Test for 'Phase Angle' problem ..........................................................	328
	21.4.2 Test 2: Test for 'Set' problem.......................................................................	337
21.5	Collimator Verification Procedure .............................................................................	341

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21.6	Calibrating and Returning the System to Normal ........................................................	349
21.7	Returning the Old Collimator ...................................................................................	350
21.8	Procedures to Un-jam Collimator Blades or Z-carriage ................................................	351
	21.8.1 Procedure 1: Un-jamming Collimator Using DMC Utility ....................................	351
	21.8.2 Procedure 2: Un-jamming Collimator Using DMC Service Switches .....................	354
	21.8.3 Procedure 3: Un-jamming Collimator Using Existing Vicor Power Supply ............	360
Section 22 Reference Converter Board Replacement: ........................................		366
22.1	Removal...............................................................................................................	366
22.2	Installation ...........................................................................................................	367
Section 23 FRC Assembly Replacement: ...........................................................		368
23.1	Removing the FRC Assembly ...................................................................................	369
23.2	Installing the FRC Assembly ....................................................................................	375
	23.2.1 Checking the 12V Power Supply on All Systems with First Style Optical Slip Rings and for 16-
	Slice Systems with Invisible Laser Optical Slip Rings .........................................	379
	23.2.2 Checking the 12V Power Supply on 64-Slice Systems with Invisible Laser Optical Slip Rings
	380
	23.2.3 Adjusting the 12V Power Supply on All Systems ...............................................	382
	23.2.4 Restoring the System to Operation .................................................................	391
Section 24 Cathode Power Module Assembly Replacement: ...............................		396
24.1	Saving X-ray Power Module Log Data to a Memory Stick .............................................	396
	24.1.1 Introduction ................................................................................................	396
24.2	Cathode Module Removal........................................................................................	399
24.3	Preparing to Install the New Module .........................................................................	413
24.4	Cathode Module Installation ....................................................................................	421

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24.5	Final Checks - New Cathode Module Installation.........................................................	429
24.6	Preparing the Old Module for Return.........................................................................	431
Section 25 Anode Power Module Assembly Replacement: ..................................		436
25.1	Saving X-ray Power Module Log Data to a Memory Stick .............................................	436
	25.1.1 Introduction ................................................................................................	436
25.2	Anode Module Removal ..........................................................................................	439
25.3	Preparing the New Module ......................................................................................	455
25.4	Anode Module Installation.......................................................................................	460
25.5	Final Checks - New Anode Power Module Installation ..................................................	469
25.6	Preparing the Old Module for Return.........................................................................	471
Section 26 Spellman Inverter Fan Replacement: ...............................................		476
26.1	Inverter Fan Removal.............................................................................................	476
26.2	Inverter Fan Replacement.......................................................................................	488
26.3	Final Checks .........................................................................................................	495
Section 27 RHost or KPM Control Board Assembly Replacement: .......................		496
27.1	Removing the RHost ..............................................................................................	496
27.2	Removing the Control Board....................................................................................	500
27.3	Installing the Control Board ....................................................................................	503
27.4	Installing the RHost Board ......................................................................................	506
Section 28 High Speed Starter Replacement: ....................................................		509
28.1	High Speed Starter Removal ...................................................................................	510

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28.2	High Speed Starter Installation................................................................................	514
Section 29 5 Volt Power Supply Replacement: ..................................................		517
29.1	Removal...............................................................................................................	517
29.2	Installation ...........................................................................................................	519
Section 30 Switching 12 Volt Power Supply Replacement:.................................		520
30.1	Removal...............................................................................................................	520
30.2	Installation ...........................................................................................................	522
Section 31 R2D Board Replacement (Newer Style):...........................................		523
31.1	R2D Board Removal ...............................................................................................	523
31.2	R2D Board Installation ...........................................................................................	525
Section 32 R2D Board Replacement (Old Style): ...............................................		526
32.1	Removal...............................................................................................................	526
32.2	Installation ...........................................................................................................	527

Section 33 BR 6/10/16 - 24 V CDMP Power Supply P/N 4535 670 80281 Replacement: 529

33.1	Removing the Supply .............................................................................................	529
33.2	Installing the Supply ..............................................................................................	532
Section 34 BR 6/10/16 CDMP Triple 5V Power Supply P/N 4535 670 80292
Replacement:..................................................................................................		533
34.1	Removal...............................................................................................................	533
34.2	Installation ...........................................................................................................	536

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Brilliance 6/10/16/16P/40/64 CT Scanner Gantry Repair and Replacement Manual CSIP-1

Section 35 BR 6/10/16 - 24 V DMP Power Supply P/N 4535 670 55321 or P/N 4535			670
55322: ...........................................................................................................		537
35.1	Removing the Supply .............................................................................................	537
35.2	Installing the Supply ..............................................................................................	540

Section 36 Replacing 5V/24 V DMS Power Supply P/N 4535 673 74152 (Brilliance 40/64): 544

36.1	Removing the Supply .............................................................................................	544
36.2	Installing the Supply ..............................................................................................	547
Section 37 BR 40/64 DMS Triple 5V Power Supplies Replacement: ....................		548
37.1	Removal...............................................................................................................	548
37.2	Installation ...........................................................................................................	551
Section 38 BR 64 TDMS 48V Power Supply P/N 4535 674 88921 Replacement: ..552
38.1	Introduction..........................................................................................................	552
38.2	Removing the Supply .............................................................................................	552
	38.2.1 Determining if the Shutdown Cable Must Be Replaced .......................................	557
	38.2.2 Replacing the Shutdown Cable .......................................................................	558
	38.2.3 Installing the 48V Power Supply .....................................................................	560
Section 39 Replacing 5V Reference Converter Power Supply: ............................		566
39.1	Removing the Supply .............................................................................................	566
39.2	Installing the Supply ..............................................................................................	570
Section 40 Rotor Drive Motor Replacement: .....................................................		571
40.1	Process Overview for Rotor Drive Motor Removal and Replacement ..............................	571

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Brilliance 6/10/16/16P/40/64 CT Scanner Gantry Repair and Replacement Manual CSIP-1

40.2	Motor Removal ......................................................................................................	572
40.3	Motor Installation ..................................................................................................	574
	40.3.1 Restoring the System to Operation .................................................................	578
Section 41 Rotor Drive Motor Brake Replacement: ............................................		579
41.1	Remove old brake assembly....................................................................................	579
41.2	Prepare to install new brake assembly ......................................................................	583
41.3	Reassemble brake assembly....................................................................................	587
Section 42 Rotor Drive Motor Brake Check and Adjustment: ..............................		593
42.1	Checking and Adjusting the Rotor Drive Motor Brake Air Gap .......................................	593
42.2	Checking the Rotor Stopping Time ...........................................................................	598
42.3	Adjusting the Stopping Time (Brake Torque) .............................................................	603
Section 43 Rotor Drive Belt Replacement: ........................................................		605
43.1	Process Overview for Rotor Drive Belt Removal and Replacement.................................	605
43.2	Belt Removal ........................................................................................................	606
43.3	Belt Installation .....................................................................................................	609
Section 44 SpindleBlok Rotor Drive Motor Controller Replacement: ...................		615
44.1	Removing the Controller .........................................................................................	617
44.2	Installing the New Controller ...................................................................................	620
44.3	SpindleBlok Motor Controller Commissioning .............................................................	622
	44.3.1 Checking/Setting the Motor Controller H Parameter ..........................................	629
	44.3.2 Restoring the System to Operation .................................................................	636

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Brilliance 6/10/16/16P/40/64 CT Scanner Gantry Repair and Replacement Manual CSIP-1

Section 45 Emerson Rotor Drive Motor Controller Replacement: ........................		637
45.1	Removing the Controller .........................................................................................	637
45.2	Installing the New Controller ...................................................................................	649
45.3	Emerson Commander SK Motor Controller Commissioning...........................................	660
45.4	Upload Drive Parameters ........................................................................................	670
45.5	Restoring the System to Operation...........................................................................	674
Section 46 Three-Phase Filter Replacement :....................................................		675
46.1	Removal...............................................................................................................	675
46.2	Installation ...........................................................................................................	678
Section 47 Motor Braking Resistor Replacement : .............................................		679
47.1	Removal...............................................................................................................	679
47.2	Installation ...........................................................................................................	682
Section 48 Tilt Drive Processor Board Replacement : ........................................		683
48.1	Removal...............................................................................................................	683
48.2	Installation ...........................................................................................................	684
Section 49 Tilt Drive Amplifier Boards Replacement: ........................................		686
49.1	Removal...............................................................................................................	686
49.2	Installation ...........................................................................................................	690
Section 50 Dual Tilt Drive Interface Board Replacement : .................................		691
50.1	Removal...............................................................................................................	691

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Brilliance 6/10/16/16P/40/64 CT Scanner Gantry Repair and Replacement Manual CSIP-1

50.2	Installation ...........................................................................................................	692
Section 51 Tilt Actuator Replacement: .............................................................		693
	51.0.1 Notes for Determining the Defective Actuator...................................................	693
51.1	Determining Actuator Loading .................................................................................	694
	51.1.1 Relieving Downward Pressure on the Actuator Using Gantry Power: ....................	697
	51.1.2 Relieving Downward Pressure By Manually Retracting the Actuator: ....................	700
	51.1.3 Relieving Either Stretching or Compression of the Actuator Using Jogging Buttons. 702
51.2	Removing the Tilt Actuator......................................................................................	706
	51.2.1 System Preparation ......................................................................................	706
51.3	Tilt Actuator Installation .........................................................................................	711
Section 52 Tilt Limit Switches Replacement: ....................................................		717
52.1	Removal...............................................................................................................	717
52.2	Installation ...........................................................................................................	719
Section 53 Tilt Lift Switches Replacement: .......................................................		720
53.1	Removal...............................................................................................................	720
53.2	Installation ...........................................................................................................	722
Section 54 Dual Tilt Pot Assembly Removal / Replacement: ..............................		723
54.1	Removal...............................................................................................................	723
54.2	Installation ...........................................................................................................	724
Section 55 Power Brush Block Replacement: ....................................................		725
55.1	Removal...............................................................................................................	725
55.2	Installation ...........................................................................................................	728

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Brilliance 6/10/16/16P/40/64 CT Scanner Gantry Repair and Replacement Manual CSIP-1

Section 56 Signal Brush Block Assembly Replacement: .....................................		733
56.1	Removal...............................................................................................................	733
56.2	Installation ...........................................................................................................	737
Section 57 Waveguide Assembly Replacement: .................................................		739
57.1	Removal...............................................................................................................	739
57.2	Installation ...........................................................................................................	741
Section 58 Optical Transmitter (TX) Module Box Replacement: .........................		743
58.1	Removal...............................................................................................................	743
58.2	Installation ...........................................................................................................	746
Section 59 Optical RX Module Box Replacement:...............................................		748
59.1	Removal...............................................................................................................	748
59.2	Installation ...........................................................................................................	750
Section 60 Laser Source Assembly Replacement: ..............................................		753
60.1	Removal...............................................................................................................	753
60.2	Installation ...........................................................................................................	756
Section 61 BR64 Stator Optical Slip Ring Optics Assembly Replacement: ...........		758
61.1	Removing the Stator Optics Assembly ......................................................................	760
61.2	Installing the Stator Optics Assembly .......................................................................	763
Section 62 BR 64 Rotor Optical Slip Ring Fiber Optic Cable Replacement: ..........		775
62.1	Removing the Rotor Fiber Optics Cable .....................................................................	777

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Brilliance 6/10/16/16P/40/64 CT Scanner Gantry Repair and Replacement Manual CSIP-1

62.2	Installing the Rotor Fiber Optics Cable ......................................................................	781
Section 63 BR64 Invisible Laser Optical Transmitter Replacement: ...................		790
63.1	Removing the Transmitter (Tx)................................................................................	790
63.2	Installing the Transmitter .......................................................................................	792
Section 64 BR64 Invisible Laser Optical Receiver Replacement: ........................		793
64.1	Removing the Receiver (Rx)....................................................................................	793
64.2	Installing the Receiver............................................................................................	795
Section 65 BR 16 Rotor Optical Slip Ring Fiber Optic Cable Replacement: ..........		796
65.1	Removing the Rotor Fiber Optics Cable .....................................................................	798
65.2	Installing the Rotor Fiber Optics Cable ......................................................................	805
Section 66 BR16 Stator Optics Assembly Replacement: .....................................		816
66.1	Removing the Stator Optics Assembly ......................................................................	818
66.2	Installing the Stator Optics Assembly .......................................................................	822
Section 67 BR16 Invisible Laser Optical Transmitter Replacement: ...................		832
67.1	Removing the Transmitter (Tx)................................................................................	832
67.2	Installing the Transmitter .......................................................................................	834
Section 68 BR16 Invisible Laser Optical Receiver Replacement: ........................		835
68.1	Removing the Receiver (Rx)....................................................................................	835
68.2	Installing the Receiver............................................................................................	837
Section 69 Main Drive Processor Board Replacement : ......................................		838

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Brilliance 6/10/16/16P/40/64 CT Scanner Gantry Repair and Replacement Manual CSIP-1

69.1	Removal...............................................................................................................	838
69.2	Installation ...........................................................................................................	839
Section 70 Gantry Motion Power Board Removal / Replacement: .......................		840
70.1	Removal...............................................................................................................	840
70.2	Installation ...........................................................................................................	841
Section 71 Gantry Motion Processor Board Replacement : .................................		842
71.1	Removal...............................................................................................................	842
71.2	Installation ...........................................................................................................	845
Section 72 GHost Board Replacement: .............................................................		846
72.1	Removal...............................................................................................................	846
72.2	Installation ...........................................................................................................	849
Section 73 Gantry Audio Board Replacement: ...................................................		850
73.1	Removal...............................................................................................................	850
73.2	Installation ...........................................................................................................	851
Section 74 I-Box Board Replacement: ..............................................................		852
74.1	Removal...............................................................................................................	852
74.2	Installation ...........................................................................................................	853
Section 75 Revolution Counter Replacement:....................................................		856
75.1	Removal...............................................................................................................	857
75.2	Installation ...........................................................................................................	858

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Brilliance 6/10/16/16P/40/64 CT Scanner Gantry Repair and Replacement Manual CSIP-1

Section 76 AC Control Unit Board Replacement:................................................		859
76.1	Removal...............................................................................................................	859
76.2	Installation ...........................................................................................................	860
Section 77 Main Contactor (MKD) And Soft Start Contactor (S/S) Replacement:.861
77.1	Removal...............................................................................................................	861
77.2	Installation ...........................................................................................................	862
Section 78 Utility Transformer Contactor (UTK) and Console Transformer Contactor (CTK)
Replacement: .................................................................................................		863
78.1	Removal...............................................................................................................	863
78.2	Installation ...........................................................................................................	865
Section 79 Main Drive Contactor (MDK) Replacement: ......................................		866
79.1	Removal...............................................................................................................	867
79.2	Installation ...........................................................................................................	868
Section 80 Mobile Gantry Parts Removal and Replacement: ...............................		869
80.1	Mobile Gantry Tilt Drive Disable Switch Replacement (RH or LH) ..................................	869
	80.1.1 Removing the Switch ....................................................................................	869
	80.1.2 Installing the Switch .....................................................................................	872
80.2	Gantry Tilt Annunciator Switch Replacement (RH or LH)..............................................	873
	80.2.1 Removing the Switch ....................................................................................	873
	80.2.2 Installing the Switch .....................................................................................	876
Section 81 Entire Gantry Replacement: ............................................................		878

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Brilliance 6/10/16/16P/40/64 CT Scanner Gantry Repair and Replacement Manual CSIP-1

Appendix A Patient Support Subframe Quick Release: .......................................		879
A.1	Releasing the Patient Support Subframe Quick Release ................................................	879
A.2	Engaging the Patient Support Subframe Quick Release .................................................	880
A.3	Testing Patient Support Subframe Quick Release .........................................................	882

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Section 1

Safety Guidelines

The safety precautions and procedures described in this section ensures the safety of all personnel during servicing and operation of the Gantry. For more information, refer to the Safety Guidelines Manual.

!

WARNING: READ ALL THIS SAFETY INFORMATION VERY CAREFULLY. THIS KNOWLEDGE COULD SAVE LIVES.

1.1General Precautions

This product was designed and manufactured to ensure maximum safety of operation and service. It should be installed, maintained, and serviced in strict compliance with the safety instructions contained herein.

•No changes to, additions to, or removal of any system accessories are permitted without the prior written approval of a local service manager.

•Do not leave problems unsolved that may affect the safety of the product. In case of doubt concerning the system's safe operation, call the service manager for further instruction.

•Do not allow unauthorized personnel access to the system. Only properly trained and fully qualified personnel are authorized to install and operate this equipment.

•Leave the site clean and orderly.

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Brilliance 6/10/16/16P/40/64 CT Scanner Gantry Repair and Replacement Manual CSIP-1

Section 1 Safety Guidelines

1.1.1Remote Services

!

CAUTION: All HIPAA and other privacy regulations must be adhered to when using any remote service tools.

Customers must be notified before use of any remote service tools that affect the performance of the system. All remote users must be train prior to the use of this tool. When using this utility, be careful of others signing on to your system while performing service or while remote session is in progress.

1.1.2Service Mode Precautions

!

WARNING: Patients MUST NOT BE SCANNED WITH THE SYSTEM IN THE service mode because of the difference in behavior of the system in this mode.

There is a special Service mode for diagnostic and service purposes in the system. It is accessed with a special password, and is intended for service personnel only. Verify in Service mode, a red always-on- top banner is visible on the screen.

This Service mode enables access to more diagnostic tools and utilities than are available in User mode. Service mode differs from User mode from the safety aspect as follows:

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Brilliance 6/10/16/16P/40/64 CT Scanner Gantry Repair and Replacement Manual CSIP-1

Section 1 Safety Guidelines

•There is a set of software service-defined switches that allow changes in system behavior for diagnostic purposes.

•There are diagnostic tests in semi-automatic mode that perform the following:

•Scans can be performed without the need to press the Manual or Auto buttons on the Scan Control

Box.

•Patient Table movement is possible without the need to press the Enable button on the Scan Control Box.

!

CAUTION: Caution: Only one scanning application may run at a time in the Service mode. Close all open studies or scanning applications before starting any new scanning application.

!

WARNING: SOME tests can cause the rotor to rotate, the x-ray tube to energize, perform scans, and enable patient table movement. Make sure that no one is in the gantry room when performing those tests.

!

WARNING: Before you return the system to the customer, perform the following:

•RETURN ALL SOFTWARE SERVICE-DEFINED SWITCHES TO THEIR DEFAULT SETTINGS.

•LOG OUT OF THE SERVICE MODE.

•REBOOT THE HOST AND RESTART THE SYSTEM.

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