Spellman XRV160P4000, XRV160P1800, XRV160N1800, XRV160P3000, XRV160N4000 Installation Manual

SPELLMAN HIGH VOLTAGE XRV SUBSYSTEM

INSTALLATION MANUAL

Table of Contents

General Safety ............................................................................................................................................. 4

Personal Safety ......................................................................................................................................... 4

X-Ray Tube Overview

X-ray tube data sheet ................................................................................................................................ 7

XRV Sub-system Overview ........................................................................................................................... 8

XRV 160kV Overview ............................................................................................................................... 10

XRV 225kV Overview ............................................................................................................................... 14

XRV 320kV & XRV 350kV Overview ......................................................................................................... 18

XRV 450kV Overview ............................................................................................................................... 20

I/O System Interface Box Overview ....................................................................................................... 24

XRVC Controller Overview ..................................................................................................................... 27

Coolers & Chillers Overview .................................................................................................................. 29

R24 & R28 HV Cable Overview .............................................................................................................. 31

XRV Setup & Installation ............................................................................................................................ 33

Unipolar System Diagram ....................................................................................................................... 34

Bipolar System Diagram ......................................................................................................................... 36

.................................................................................................................................. 5

Unpacking Generator ............................................................................................................................. 38

System Grounding .................................................................................................................................. 40

High Voltage Cable Installation (non-spring loaded) ............................................................................. 42

High Voltage Cable Installation (spring loaded) ..................................................................................... 48

System Grounding Detail and HV Cable Connections ............................................................................. 51

Cooler/Chiller Connections .................................................................................................................... 52

Interlock & Communication Connections (unipolar basic) ................................................................... 55

Power Connections (unipolar basic) ...................................................................................................... 60

Power Source Connections (unipolar basic) .......................................................................................... 64

Power & Feedback Connections (bipolar basic) ..................................................................................... 69

Power Connections I/O System Interface Box ........................................................................................ 70

Main Input Power Connections I/O Interface Box ................................................................................. 75

XRVC Control Box Installation ................................................................................................................ 78

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Table of Contents

GUI (Graphical User Interface) Installation ........................................................................................... 81

Software Communication ...................................................................................................................... 84

X-ray Tube Filament Calibration ............................................................................................................ 87

Accessory Test Kits ................................................................................................................................. 96

XRV Sub-system Nomenclature ............................................................................................................. 97

Drawing List ............................................................................................................................................ 98

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XRV Subsystem Installation Manual:

General Safety

It intent of this manual to identify and safely execute the installation of the XRV Generator and
subsystem components. “Caution” and “Warning” labels used throughout this manual to highlight
critical areas of the installation and operation of this equipment. Installation, maintenance and
operation should only be handled by qualified personnel. Failure to follow these guidelines may result in
hazardous operating conditions.

Personal Safety

It is the responsibility that the individual operating this equipment do so in a safe non-hazardous
manner. Training is required on a regular basis to prevent personal injury. It is extremely important to
monitor X-ray levels applying the use of dosimeters or alternate electronic measuring devices within
normal standard guidelines. Radiation measuring equipment requires calibration on a regular basis to
prevent personal injury. Do not use this equipment in an unsafe manner or for anything other than the
intended use. Contact Spellman High Voltage regarding questions about the safe operation or
installation of this equipment.

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X-Ray Tube Overview:

There are numerous X-ray tubes available depending on the user application. The tube requirement is
normally the first component selected for a specific application before any of the other subsystem
requirements. There are two basic types of x-ray tubes. One type is called a single ended or “Unipolar”
while the other is a double ended or “Bipolar”. The single ended tube only requires one high voltage
source and a filament supply in order to emit X-rays. The source voltage is usually negative with respect
to earth ground.

External cooling may be required during operation of the tube depending on the level of power output.
Single ended tubes are cooled by water circulation systems specially designed to remove heat from the
anode during operation. The circulation system consists of a water reservoir tank, pump, hoses and a
fan circulating over a radiator that is very similar to an automobile cooling system. The hoses from the
cooling system connect to the grounded side of the tube. The tube may have special fittings and will
identify the water input and output side. The flow rate and capacity of the cooling system will generally
rely on the recommendations of the tube manufacturer and operating power level. On higher power
tubes, a chiller subsystem may be required. The chiller utilizes a compressor and pump to maintain
lower water temperatures for higher wattage tubes. Both systems measure the input temperature with
respect to output temperature of the water and employ an interlock system to remove high voltage on
the X-ray tube preventing damage. Various Coolers and Chillers are available with the XRV Sub-System
and are described later in this manual.

Standard single ended tube operating voltages range from 75kV to a maximum of 225kV and may be
purchased through Spellman as part of the XRV Sub-System.

Higher voltage tubes are double-ended or “Bipolar” meaning a negative and a positive high voltage
source is required for operation. The tube operates in a similar fashion as the single ended tube with the
exception that the anode is at high voltage potential in addition to the cathode instead of being at
ground potential. Ground potential is located in the center of the tube rather than at one end. Bipolar
tubes require two X-ray generators as opposed to one.

Bipolar X-ray tubes require oil cooling as opposed to water -cooled systems. The oil serves as an
electrical insulation medium internal to the tube in addition to cooling the anode. Oil cooled systems
use a heat exchanger (oil to water) that is isolated from the oil circulation flowing through the tube. As
with water-cooled systems, the manufacturer will specify the heat removal capacity and flow rates.
These can be compared with the recommendations for X-ray tube thermal management set by the tube
manufacturer. Like the water-cooled system, these systems employ the use of thermal interlocks
terminating high voltage if the tube begins to overheat.

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X-Ray Tubes:

Various Unipolar or Bipolar metal ceramic X-ray tubes manufactured by Comet and Varian are available
for the XRV Subsystem. Contact Spellman High Voltage Corp. for more information.

Comet

Unipolar X-ray tube

Varian

Bipolar X-ray tube

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X-Ray Tube Data Sheets:

kV

Comet

Varian

160

225

320
350

450

MXR-160HP/11 MXR-160/22
MXR-225HP/11 FB MXR-161
MXR-160HP/20 MXRP-160C
MXR-160/20 MXR-165
MXR-160/21

MXR-225HP/11 MXR-225/26
MXR-225HP/11 FB
MXR-225/21
MXR-225/22
MXR-226

MXR-320HP/11 MXR-321
MXR-320HP/11 FB
MXR-320/23 MXR-320/23AX
MXR-320/23-90 MXR-320/26AX
MXR-320/26 MXR-320HP/11AX
MXR-320/26-90

MXR-350/23
MXR-350/23-90
MXR-350/26
MXR-350/26-90

MXR-351

MXR-322

HPC-160FB NDI-160/21
HPX-160/20 NDI-160/22
HPX-160/11 NDI-161

NDI-160/01
NDI-160/20

HPC-225FB NDI-225/22

HPX-225-11 NDI-225/FB

NDI-225/01 NDI-226

NDI-225/20
NDI-225/21

HPX-320-11

NDI-320

NDI-320/23
NDI-320/26

NDI-321

NDI-350

NDI-350/23
NDI-350/26

MXR-451HP/11
MXR-451/26
MXR-452/Y

For Comet X-ray Tube Specifications: www.comet-xray.com

For Varian X-ray Tube Specifications: www.vareximaging.com

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HPX-450-11
NDI-451

NDI-451 Be

NDI-452

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XRV Subsystem Overview:

XRV Generator:

The XRV Generator is available in several configurations for various X-ray tube requirements. The
generators are assembled in a compact chassis allowing for a minimum amount of space required for
installation but providing for the utmost safety. Military style circular connectors for the main and
auxiliary power input offers integration flexibility and safety. Additionally, the user has the option of an
analog, com port, Ethernet or a USB connection for local or remote operation. The Ethernet connection
is extremely useful when operating the supply remotely or in the unlikely event the generator requires
evaluation by Spellman High Voltage personnel. Utilization of this feature can save the customer hours
of downtime especially when assistance is required from a long distance.

An integrated microprocessor and resistor feedback network constantly measure and adjust the output

voltage and current to provide a stable highly regulated source. Models range from 1800 watts to 6000

watts of output power. A simple to use Graphical User Interface (GUI) or selectable analog control

provides for safe operation and customer integration. The GUI software supplied with each model of the

XRV generator can be custom programmed when placing an order for specific applications. Likewise, the

analog interface allows the user to integrate unique controls and monitoring equipment. A 25 pin

subminiature “D” connector (supplied with each XRV) is standard for interlock connections and user

controls. The GUI software can also serve as a remote monitor during analog operation.

A single ended or “Unipolar” X-ray tube requires a single XRV Generator. The XRV model will depend on

the X-ray tube selected. For example, a 160kV “Unipolar” tube operating at 3 kilowatts or less would

most likely use a standard XRV model XRV-160N-3000. The output voltage of the generator would be

negative with respect to ground due to the operating specifications of the X-ray tube. Additionally, an

isolated DC supply is included to power a large or small filament connection within the X-ray tube. The

DC filament current is adjustable via the software provided or analog input selection. Specific filament

voltage and current requirements are available upon request.

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XRV Generator:

A double ended or “Bipolar” X-ray tube requires two separate XRV Generators. One Generator has a

negative output with respect to ground while the other has a positive output with respect to ground.

The software provided or analog selection allows for the operation of both the positive and negative

outputs simultaneously with a minimal amount of imbalance. There are several models of the XRV

Generator available. These are listed below.

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XRV 160kV Overview:

XRV160kV Rear Panel

The 160kV XRV Generator measures a compact

7.16” W x 10.09” x H 24” D (excluding handles).
The rear of the chassis has all of the necessary
connectors for power input, controls, monitoring,
and kV output. Each connector on the rear panel
is clearly marked for installation purposes. The
main and auxiliary input includes an Amphenol
style mating connector with an additional DB-25
pin connector for the I/O analog connection. The
high voltage output mates with a standard R-24

type connector. These are available from Spellman
High Voltage Corp. in different lengths and configurations for installation of the X-ray tube. Standard
Graphical User Interface (GUI) software is included with the XRV 160 Generator. A personal PC is
required for installation. The user has the option of connection to a USB, Ethernet or Com Port. The
control and monitoring of the XRV160 also includes an analog I/O connector for custom configurations.
An additional optional touch screen controller (XRVC) is also available from Spellman High Voltage Corp..

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4kW Units

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XRV 160kV Overview : XRV160 (Front Panel)

The XRV160 front panel uses LED Indicators that
show the status of the Generator. Green
Indicators signify normal operational mode
while red indicators signify a fault condition. A
fault or red indication prevents high voltage
operation. Fault conditions are “latched”
meaning that a reset must be employed before
re-starting the generator. Once the fault clears,
the red indicator will extinguish. Additionally,
fault status and ready conditions are monitored
from the I/O connector on the rear panel and
the GUI Interface software. A removable air
filter keeps dust and dirt from entering the
chassis.

XRV160 Front Panel Indicators

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XRV 160kV Overview:

The 160kV XRV is additionally available in a 6kW version. The 6kW version uses a 208 Vac 3Ø power
input or a 400Vac 3Ø power input. The chassis overall size is the same as the 4kW version. The only
difference between the 6kW version and the 4kW version is the power input connections. Two
connectors separate the Mains from the auxiliary power input. Amphenol style power mating
connectors are included with all XRV models.

208Vac 3Ø Input

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XRV 160kV Overview:

400Vac 3Ø Input

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XRV225kV Overview: XRV225 (Front Panel)

The XRV225 front panel uses the same LED Indicators
as the XRV160 showing the status of the Generator.
Green Indicators signify normal operational mode
while red indicators signify a fault condition. A fault
or red indication prevents high voltage operation.
Fault conditions are “latched” meaning that a reset
must be employed before re-starting the generator.
Once the fault clears, the red indicator will
extinguish. Additionally, fault status and ready
conditions are monitored from the I/O connector on
the rear panel and the GUI Interface software. A
removable air filter keeps dust and dirt from entering
the chassis.

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XRV225 Front Panel Indicators

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XRV225kV Overview:

XRV225kV (Rear Panel)

The 225kV XRV Generator measures a compact 17” W x

18.90” (including castors) x H 30.72” D (excluding cable
well). The assembly includes lockable castors for easy
moving. The rear of the chassis has all of the necessary
connectors for power input, controls, monitoring, and kV
output. Each connector on the rear panel clearly marked
for installation purposes. The main and auxiliary input
includes an Amphenol style mating connector with an
additional DB-25 pin connector for the I/O analog
connection. The high voltage output mates with a
standard R-28 type connector. These are available from

Spellman High Voltage Corp. in different lengths and
configurations for installation of the X-ray tube. Standard Graphical User Interface (GUI) software is
included with the XRV 225 Generator. A personal PC is required for installation. The user has the option
of connection to a USB, Ethernet or Com Port. The control and monitoring of the XRV225 also includes
an analog I/O connector for custom configurations. An additional optional touch screen controller
(XRVC) is also available from Spellman High Voltage Corp..

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XRV225kV Overview:

The 225kV XRV is additionally available in a 6kW version. The 6kW version uses a 208 Vac 3Ø power
input or a 400Vac 3Ø power input. The chassis overall size is the same as the 4kW version. The only
difference between the 6kW version and the 4kW version is the power input connections. Two
connectors separate the Mains from the auxiliary power input. Amphenol style power mating
connectors are included with all XRV models.

XRV225kV 208Vac 3Ø 6kW Unit

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XRV225kV Overview:

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XRV225 400Vac 3Ø 6kW Unit

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XRV320 and XRV350 Overview:

XRV320 and XRV350 (Rear Panels)

The 320kV and 350kV XRV Generators are
specifically designed to operate bipolar x-ray tubes. The
X-ray tube requires a negative kV generator (cathode)
which includes a filament supply and a positive kV
output (anode) generator. Each generator on the
320kV system has a maximum voltage of 160kV. One is
positive 160kV with respect to ground while the other is
negative 160kV with respect to ground. Likewise, the
350kV model has a maximum of 175kV each with
respect to ground. Each generator measures 7.16” W x

10.09” x H 24” D (excluding handles). The rear of the
chassis has all of the necessary connectors for power
input, controls, monitoring, and kV output. Each
connector on the rear panel is clearly marked for

installation purposes. An interconnect cable on the cathode side supplies auxiliary power to the anode
generator. Two additional 25 pin DB style cables interface the anode generator feedback and inverter
signals to the main control board residing in the cathode generator supply. The mains input on the
cathode generator includes an Amphenol style mating connector and an additional DB-25 pin connector
for the user I/O analog control. Both the cathode and anode kV outputs mate with a standard R-24 type
connector. These are available from Spellman High Voltage Corp. in different lengths and configurations
for installation of the X-ray tube. Standard Graphical User Interface (GUI) software is included with the
XRV 320 or XRV350 Generator. A personal PC is required for installation. The user has the option of
connection to a USB, Ethernet or Com Port. The control and monitoring of the XRV320 and XRV350 also
includes an analog I/O connector for custom configurations. An additional optional touch screen
controller (XRVC) is also available from Spellman High Voltage Corp

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XRV320 and XRV350 Overview : XRV320 and XRV350 (Front Panels)

The cathode (negative) generator front panel of the
XRV320 and XRV350 models use the same LED
Indicators as the unipolar XRV160 showing the status
of the Generator. Green Indicators signify normal
operational mode while red indicators signify a fault
condition. A fault or red indication prevents high
voltage operation. Fault conditions are “latched”
meaning that a reset must be employed before re­starting the generator. Once the fault clears, the red
indicator will extinguish. The anode (positive)
generator does not have any indicators since all of
the monitoring and fault status indicators originate

from the control board within the cathode (negative)
generator. Additionally, fault status and ready conditions are monitored from the I/O connector on the
rear panel and the GUI Interface software. A removable air filter keeps dust and dirt from entering the
chassis.

Front Panel Detail

XRV320 and XRV350 Cathode XRV320 and XRV350 Anode

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XRV450 Overview :

XRV450 (Rear Panels)

The 450kV Generator is specifically designed to operate with
bipolar x-ray tubes. The X-ray tube requires a negative kV
generator (cathode) which includes a filament supply and a
positive kV output (anode) generator. Each generator on the
450kV system has a maximum voltage of 225kV. One is
positive 225kV with respect to ground while the other is
negative 225kV with respect to ground. Each generator
measures 17” W x 18.90” (including castors) x H 30.72” D
(excluding cable well). The rear of each chassis has all of the

necessary connectors for power input, controls, monitoring,
and kV output. Each connector on the rear panel is clearly marked for installation purposes. An
interconnect cable on the cathode side supplies auxiliary power to the anode generator. Two additional
25 pin DB style cables interface the anode generator feedback and inverter signals to the main control
board residing in the cathode generator supply. The mains input on the cathode generator includes an
Amphenol style mating connector and an additional DB-25 pin connector for the user I/O analog control.
Both the cathode and anode kV outputs mate with a standard R-28 type connector. These are available
from Spellman High Voltage Corp. in different lengths and configurations for installation of the X-ray
tube. Standard Graphical User Interface (GUI) software is included with the XRV 450 Generator. A
personal PC is required for installation. The user has the option of connection to a USB, Ethernet or Com
Port. The control and monitoring of the XRV450 also includes an analog I/O connector for custom
configurations. An additional optional touch screen controller (XRVC) is also available from Spellman
High Voltage Corp..

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XRV450 Overview :

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XRV450 Bipolar Cathode Generator

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XRV450 Overview :

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XRV450 Bipolar Anode Generator

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XRV450 Overview :

XRV450 (Front Panels)

The cathode (negative) generator front panel of the
XRV450 model uses the same LED Indicators as the
unipolar XRV225 showing the status of the
Generator. Green Indicators signify normal
operational mode while red indicators signify a fault
condition. A fault or red indication prevents high
voltage operation. Fault conditions are “latched”

meaning that a reset must be employed before re­starting the generator. Once the fault clears, the red indicator will extinguish. The anode (positive)
generator does not have any indicators since all of the monitoring and fault status indicators originate
from the control board within the cathode (negative) generator. Additionally, fault status and ready
conditions are monitored from the I/O connector on the rear panel and the GUI Interface software. A
removable air filter keeps dust and dirt from entering the chassis.

Front Panel Detail

XRV450 Cathode XRV450 Anode

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I/O System Interface Box Overview:

The XRV I/O System Interface Box provides easy
integration of the XRV Generator, XRV Touch Screen
Controller and Cooler/Chiller unit. The interface box
is enclosed in a 19” x 5.21” x 18” deep rack
mountable chassis and includes all the necessary
cables for a complete system setup and operation.

Power distribution includes a maximum 230Vac @
4kW XRV High Voltage Generator and encompasses
all the necessary X-ray safety requirements meeting
international standards. The XRV I/O Box
accommodates a variety of interface options that
are best suited for user requirements and mounting

configurations.

There are several models of the XRV I/O Box. These are capable of integrating different optional
accessories ranging from an XRV Touch Screen Controller to a “bare bones” setup allowing the user to
operate the XRV High Voltage Generator via connection to a personal PC. The user may also choose the
analog I/O interface control and monitoring as without the use of a personal PC. There are several
models of the I/O Interface Box for use with the 230Vac, 4kW XRV Generators. Other models for use
with high power Generators will be available in the near future.

XRV I/O Box Models:

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I/O System Interface Box Overview:

I/O System Interface Box Front Panel Detail

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I/O System Interface Box Overview:

I/O System Interface Box Rear Panel Connections Detail

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XRVC Controller Overview:

The XRVC Controller uses an embedded computing
system that runs a custom graphical use (GUI) interface
and allows the user to configure custom X-ray tube
profiles for any of the Spellman XRV series. The unit,
housed in a 19”W x 5.25” H x 13” D (ex. connectors)
features a 7” touch screen, RS-232 serial ports,
10/100/1000Mbit Ethernet and a 160GB hard drive. The
Intel Atom N270 CPU processor runs at an impressive

1.6GHz and includes 1GB of static Ram. The user has the
ability to create, save and load customized profiles for

use within the operating capabilities of the XRV
Generators. The intuitive, touch-centric, menu driven system allows ease of use with little or no learning
curve. Communication settings are stored after only one system configuration session. Parameter
settings on supported X-ray tubes may be automatically uploaded to the XRVC within the recommended
manufacturer guidelines. A comprehensive status and control screen continuously monitors
information on all critical operation parameters. An integrated on screen keyboard eliminates the need
for an external keyboard. The input voltage is 180-264Vac, 50/60Hz easily integrating with the Spellman
I/O System Interface Box.

XRVC Controller Front Panel Detail

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XRVC Controller Overview:

XRVC Controller Rear Panel Detail

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XRV Coolers and Chillers Overview:

The X-ray tube will generate a substantial amount of heat during
operation. It is important to remove as much heat as possible to
avoid damage to the X-ray tube. Various coolers remove heat
from a closed circulated water system flowing through the X-ray
tube at ground potential. The unipolar X-ray tube normally
specifies the water flow rate and ambient conditions required to
prevent damage to the tube. The capacity of the cooler to
remove heat through a water to air heat exchanger depends on
the difference between the ambient temperature and the water
outlet temperature. The coolant used could be either plain water

or a mixture of water and glycol usually specified by the
manufacturer. The inlet and outlet hose connections are specifically marked for correct flow through the
tube. A thermal switch monitors the outlet water temperature. If the outlet temperature exceeds the
recommended operating temperature, the switch will activate opening an interlock chain removing
power from the Generator. For optimal performance of the cooler, it is important not to obstruct or
restrict the air flowing through the vents. The ambient air temperature should be maintained according
to the manufacturers’ recommendations.

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XRV Coolers and Chillers Overview:

Chillers may be used with either Unipolar or Bipolar X-ray tubes. The
tube power and ambient temperature will determine if a chiller is
required in order to cool the X-ray tube. Chillers are much like air
conditioners whereas a compressor lowers the temperature of the
water or oil within a closed loop system. Oil coolant is used with a
Bipolar tube since the Anode section of the X-ray tube “Floats” at
high voltage potential and an insulation medium must be used to
cool it and provide isolation to ground. An internal thermostat
maintains the temperature. It constantly compares the water/oil
that returns from the X-ray tube to the water/oil supplied to the X­ray tube. If the difference is too great, the chiller will provide an
interlock signal (usually a dry contact switch) to shut down the high
voltage generator and prevent any damage to the X-ray tube.
Adequate clearance is necessary when installing a chiller to allow the

flow of air through the venting system.

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