Prodigy: Service Manual

PRODIGY
Service Manual
Part Number: LUN7396

Revision: C
This page left blank intentionally.
ii Prodigy Service Manual

This document contains confidential or proprietary information of GE-Lunar Corp. neither the
document nor the information is to be reproduced, distributed, used or disclosed, either in whole or
in part, except as specifically authorized by GE-Lunar Corp.
GE-LUNAR Corporation makes no warranty of any kind with regard to this material, and shall not be
held liable for errors contained herein or for incidental or consequential damages in connection
with the furnishings or use of this manual.
Read through this manual thoroughly before attempting to service any components. Unauthorized
service may void system warranties or service contracts. Consult the GE-LUNAR Customer
Support Department prior to attempting any servicing:
608-828--2663
608-826-7107 (Fax)
g is a registered trademark of General Electric Company.
PRODIGY® is a trademark of GE-LUNAR Corporation.
Windows NT® is a trademark of Microsoft Corporation
Copyright© 2000 by GE-LUNAR Corporation.
Madison, Wisconsin. All rights reserved.
Prodigy Service Manual iii

iv Prodigy Service Manual

READ THIS FIRST
Using This Manual:
A person who will be performing service work on the PRODIGY should use this manual in the
following manner:
Read the Safety and Overview Chapters to familiarize yourself with the scanner as a whole and
with the general function of the circuit boards.
Chapter 3 should be understood completely as it explains the Diagnostics Software (built in –

requires a password for access).
The Chapter 4 and Chapter 5 contain common procedures and troubleshooting information and
can be read as needed, but are good sources of information.
When a problem arises, Chapter 4 should be referenced. Check the table of contents for Chapter 4
to see if the problem being experienced is described. If so, refer to the appropriate page. If not, try
to generalize the problem (e.g. the Detector is repeatedly running into the front of the scanner and
reversing and then running back into the front of the scanner. This is a mechanical problem in
general, specifically with Transverse Mechanics, check that subsection of Chapter 4 for the
subsystem experiencing the fault.
This manual commonly references other Sections and pages of the manual as needed, so often
procedures in the Chapter 5 Appendix are referred to as ways to solve problems described in
Chapter 4.
Information Requested By GE-LUNAR:
When requesting assistance from GE-LUNAR, please provide the following information:
System Number (DF+xxxxx)
Institution or Doctor's name
Location
Complete list of symptoms
Names and part numbers of parts needed for service
Prodigy Service Manual v

In addition to the information above, an Error Log printout and QA’s and QA history or other failing
diagnostic test printout (Alignment Test etc.) will also help to improve the accuracy of our
diagnosis:
For problems with specific patient scans, it is recommended that you copy the scan files to
diskette, and send it, with a description of the problem, to the Applications Department at GE -
LUNAR.
vi Prodigy Service Manual

1 1
2 Safety
Chapter 1:Safety
This chapter highlights safety devices and features a Service
Engineer should know before servicing a PRODIGY system.
Chapter Contents:
1.0 General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

1.1 Symbols and labels found on the PRODIGY . . . . . . . . . . . . . . . . . . 1-15
1.1.1 External Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1.1.2 Internal Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
1.1.3 Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
1.2 Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
1.3 Laser Exposure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1.4 Shutter Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
1.5 Cautions, Warnings, and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
1.5.1 Caution Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
1.5.2 Warning Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
1.5.3 Note Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
1.6 Safety Concerns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
1.6.1 Pinch points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
1.6.2 Laser safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
1.6.3 Radiation safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
1.6.4 Scatter Radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
1.7 Controlling Computer and Accessories . . . . . . . . . . . . . . . . . . . . . . 1-26
1.7.1 Electrical Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
1.7.3 Peripheral Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
1.7.4 Standard room configuration (system no. DF+12000 and greater)1-
26
1.7.5 Small room configuration (system no. DF+12000 and higher) 1-27
1.7.6 Scanner power output configuration (system no. DF+11999 and
lower) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
1.7.7 Wall outlet configuration (system no. DF+11999 and lower) . . 1-27
Figure 1-1. The PRODIGY Display Panel . . . . . . . . . . . . . . . . . . . . . . . 1-19

Figure 1-2. Laser Warning Label (U.S. systems only) . . . . . . . . . . . . . . 1-20
Figure 1-4. Laser Warning Label (International systems only) . . . . . . . . 1-20
Figure 1-5. Source (x-rays) off - Shutter closed (green) . . . . . . . . . . . . . 1-21
PRODIGY Service Manual (Rev C - 2000) Safety113

Figure 1-6. Source (x-rays) on - Shutter open (yellow). . . . . . . . . . . . . . 1-21
Figure 1-7. Potential Pinch Points on the PRODIGY . . . . . . . . . . . . . . . 1-23
Figure 1-8. PRODIGY Iso-Dose Diagram . . . . . . . . . . . . . . . . . . . . . . . . 1-25
This document contains confidential or proprietary information of GE-Lunar Corp. Neither the document nor the information therein is
to be reproduced, distributed, used or disclosed, either in whole or in part, except as specifically authorized by GE-Lunar Corp.
1-14 Safety PRODIGY Service Manual (Rev C - 2000)

1.0 General Safety
• DO NOT attempt to service the PRODIGY without first reading this
manual.
• DO NOT attempt any repairs without prior instructions from authorized

LUNAR personnel.
• In order to maintain electrical safety and electromagnetic compatibility,

the Lunar PRODIGY is only to be connected to a computer, printer, and
peripherals that are certified to be compliant with IEC 950/EN 60950
Safety of information technology equipment, including electrical business
equipment and IEC 601-1-2 Medical electrical equipment, Part 1:
General requirements for safety, 2. Collateral Standard: Electromagnetic
compatibility - Requirements and tests.Emergency Stop Button
1.1 Symbols and labels found on the PRODIGY

1.1.1 External Symbols
• The following symbols are found on the PRODIGY, in the Operators

manual, and in the Service Manual.
Attention: contains important safety information such as the

location of a pinch point.
Emergency Stop Button: shows the location of the

emergency stop button.
Power On: shows the location of the Power On indicator and the
switch position for Power On.
Power Off: shows the switch position for Power Off.
Laser On: shows the location of the Laser On indicator. It is found

only on systems delivered internationally.
PRODIGY Service Manual (Rev C - 2000) Safety1-15

Shutter Open: shows the location of the Shutter Open indicator.
X-ray On: shows the location of the X-Ray On indicator.
Type B Equipment: shows that the scanner has Type B

protection against electrical shock.
1.1.2 Internal Symbols
• The following symbols are found inside the PRODIGY, and in the Service
Manual.
Protective Earth: shows the location of a Protective Earth

Terminal.
Functional Earth: shows the location of a Functional Earth

Terminal.
1.1.3 Labels
• The following labels are found on the PRODIGY Scanner.
Laser Caution Label: Shows that the scanner uses

a Class II laser. This label is not found on systems
shipped to Canada.
Laser Caution Label: Canada only

Tube Head Assembly Label (system number
DF+12000 and greater): This label gives tube head
assembly and x-ray source characteristics
information. It is located on the tube head assembly
and the foot panel of the scanner.
Tube Head Assembly Label (system number

DF+11999 and lower): This label gives tube head
assembly and x-ray source characteristics
information. It is located on the tube head assembly
and the foot panel of the scanner.
A definition of each symbol on this label follows:
Inherent Filtration
Tube Insert
X-ray Source
Focal Point
System Label (system number DF+12000 and

greater): This label gives system input power
requirements and compliance information. It is
located on the foot panel of scanners. The CE
mark shows compliance with UL/CSA and the
Medical Device Directive 93/42/EEC.
System Label (system number DF+11999 and

lower): This label gives system input power
requirements and compliance information. It is
located on the foot panel of scanners. The CE
mark shows compliance with UL/CSA and the
Medical Device Directive 93/42/EEC.

High Voltage Power Supply: This label gives
high voltage power supply (x-ray generator)
information. It is located on the positive and
negative power supplies, and foot panel of the
scanner.
X-ray Controller: This label shows x-ray

controller compliance. It is located on the foot
panel of the scanner.
Collimator Assembly: This label gives

collimator assembly information. It is located on
the collimator and foot panel of the scanner.
Warning Label and Radiation Symbol: The

Warning label shows that the system uses
ionizing radiation. It is found only on systems
delivered in the United States. Always obey
instructions for safe operation.
Radiation Label: This label shows that the system uses

ionizing radiation.
Grounding Reliability Label: This label states that

grounding reliability can only be maintained when using a
“Hospital Grade” or “Hospital Only” receptacle. It is only found
on systems delivered in the United States.

1.2 Emergency Stop Button
• The Emergency Stop Button is a round red button located on the scanner
display panel (see Figure 1-1). When pressed, power is removed from
the X-ray tube head, the laser, and the shutter is closed. Power is also
removed from the scan arm motors, allowing the operator/patient to push
the scan arm out of the way.
Figure 1-1. The PRODIGY Display Panel

1.3 Laser Exposure
• The PRODIGY is equipped with a Class II Laser device. This laser is
used for patient positioning. A Class II rating indicates a low power visible
laser that is not normally hazardous to eyesight but has the potential to
be hazardous if viewed directly for an extended period of time. Because
of this potential hazard, DO NOT stare directly into the beam while the
laser is in operation, and DO NOT allow the beam to shine directly into
the patients' eyes. No specific eye protection is required with a Class II
laser.
• A amber laser-on indicator, located on the front of the scan arm, is lit
when the laser is on. The program activates the laser during positioning
for an image acquisition. The program then turns off the laser when you
begin the scan. The emergency stop button will turn off the laser.
• There is a caution label (Figure 1.2) on the scan arm near the Display
Panel.
Figure 1-2. Laser Warning Label (U.S. systems only)
Figure 1-3. Laser Warning Label (Canadian Systems only)
Figure 1-4. Laser Warning Label (International systems only)
Note: DO NOT STARE INTO THE BEAM while the laser is

operating.

1.4 Shutter Indicator
• This symbol is used to indicate an open-shutter condition in accordance
with the safety standards established by the International
Electrotechnical Commission (IEC).
Figure 1-5. Source (x-rays) off - Shutter closed (green)
Figure 1-6. Source (x-rays) on - Shutter open (yellow)
• This symbol appears near the yellow X-ray shutter-open indicator light.
The X-ray shutter-open indicator light is located on the Display Panel on
the scan arm near the front.
Note: When the x-ray on / shutter open symbol appears in literature

associated with the PRODIGY scanner, it will be used to
indicate that the procedure being described results in an open-
shutter condition. During these times personnel should
exercise caution to avoid excessive exposure to the X-rays.
1.5 Cautions, Warnings, and Notes

• This manual contains warning and caution statements wherever
appropriate for your safety. The warnings and cautions used throughout
the manual are based on the safety standards established by the
International Electrotechnical Commission (IEC). In addition, the manual
uses notes to attract the reader's attention to important information.
1.5.1 Caution Statements
A caution statement reflects a condition

that, if not avoided, could cause
equipment or property damage.

1.5.2 Warning Statements
A warning statement reflects a potentially

hazardous condition that, if not avoided, could
result in serious injury.
1.5.3 Note Statements
Note: This symbol turns the reader's attention to important

information which may otherwise be overlooked.
1.6 Safety Concerns

1.6.1 Pinch points
The Warning label below identifies the location of possible pinch points
Because the PRODIGY Densitometer

contains moving parts, there are places
on the scanner where there is a danger
of pinching. Operators should be aware
of these pinch points to avoid injury to
the patient or themselves. When the scanner arm is in
motion, make sure possible pinch point locations are
clear at all times. Labels applied at the LUNAR factory
indicate the location of the pinch points. The pinch
points and their labels are shown in the figure 1-7.

Figure 1-7. Potential Pinch Points on the PRODIGY
Do not touch the AC Surge Suppressor

(located on the AC terminal block) it
may be hot.
Do not electrically connect the isolation

transformer bolt head to ground, doing
this will short out the transformer
Scan table isolated outlet strip must be

appropriately connected.
1.6.2 Laser safety
DO NOT STARE INTO THE LASER BEAM

during patient positioning and Quality
Assurance procedures.
The label that follows is located on the scanner arm and shows the location of
the laser aperture.

1.6.3 Radiation safety
X-ray exposure: The system makes radiation when electric voltage is

supplied to, and current flows through, the x-ray tube. During a measurement,
the shutter opens to let a beam of radiation pass through the scanner table
and patient. The radiation field at the table top is 19.2 mm x 3.3 mm. Lead
oxide shielding surrounds the x-ray tube insert inside the tube housing
assembly and reduces radiation levels around the scanner table.
Skin entrance dose: Table 1 of the PRODIGY Operators Safety and

Specifications manual shows irradiation times and skin entrance doses.
1.6.4 Scatter Radiation
• There is some scatter radiation from the PRODIGY when it is running.

Figure 1-8 shows the radiation dosages while the scanner is running at
3.00 mA at certain distances.
• These dosages are relatively insignificant as the allowed yearly dosage

for a person working with radiation emitting equipment is 5000 mRem.
Radiation however should be avoided when possible.

Figure 1-8. PRODIGY Iso-Dose Diagram

1.7 Controlling Computer and Accessories
1.7.1 Electrical Safety
IEC and UL/CSA certification
IEC: To maintain electrical safety, all computer equipment and accessories

connected to the scanner must meet all IEC requirements for safety, such as
IEC 950, "Safety of information technology equipment, including electrical
business equipment," and IEC 801-5, "EMC Surge Immunity Requirements."
The computer and all accessories must have the CE label.
UL/CSA: To maintain electrical safety, all computer equipment and

accessories connected to the scanner must have safety agency approvals for
UL/CSA.
1.7.2 Electromagnetic interference
Although the scanner meets safety standards regarding electromagnetic

interference (EN60601-1-2), you may still experience a loss of performance
under extreme electromagnetic conditions. Maximize the distance between
the scanner and other equipment, and use a dedicated power line, to avoid
interference to and from the scanner.
1.7.3 Peripheral Configurations
The correct connection of the computer and all

peripherals is necessary to maintain electrical
safety. The signal cable of the scanner is
intended only for connection to an approved
computer. Call LUNAR Support or your LUNAR
distributor before adding peripherals.
Note: The scanner's output power strip can be used to supply the
Host PC with isolated power. If it is to be used the following
conditions must be met. If the conditions cannot be met, the
scanner's output power strip cannot be used.
Note: See also Peripheral Block Diagrams - Section 2.2.3
1.7.4 Standard room configuration (system no. DF+12000 and

greater)
The computer, peripherals, and all other equipment must be located more
than 1.83 m from the scanner. Use an outlet strip to power the computer and
all peripherals. The outlet strip must be mounted off the floor so that it does
not touch other equipment. If your outlet strip was provided by LUNAR, it has
a maximum output of 15A, 120VAC. Only system-related equipment should
be powered by the outlet strip.

A modem and/or network connection can be made at any time if you are using
the standard room configuration.
1.7.5 Small room configuration (system no. DF+12000 and higher)
You must power the computer, peripherals, and all other equipment with an
isolating transformer if the room is too small to maintain at least 1.83 m of
separation between the scanner and all other equipment.
The isolation transformer supplied by LUNAR has a maximum output of 400/

500VA. Only system-related equipment should be powered by the isolation
transformer. Failure to use an isolation transformer can cause leakage
currents in excess of 100 microamperes.
A modem and/or network connection can only be made in the small room
configuration if all exposed metal surfaces of the computer and peripherals
are out of the patient environment.
1.7.6 Scanner power output configuration (system no. DF+11999

and lower)
LUNAR recommends that you use scanner power output to provide isolated
power to the computer and all peripherals. The power strip must be mounted
off the floor such that it does not touch other equipment. The computer and
ALL peripherals must be powered by the scanner. All other equipment must
not be powered by the scanner and must be located more than 1.83 m from
the scanner. Failure to use scanner power output can cause leakage currents
in excess of 100 microamperes.
If a network and/or modem connection is needed, refer to the wall outlet

configuration.
1.7.7 Wall outlet configuration (system no. DF+11999 and lower)
As an option to scanner power output, a wall outlet can be used to power the
computer and peripherals. Isolated power from the scanner must not be used
to power any equipment if a wall outlet is used. All exposed metal surfaces of
the computer, peripherals, and other equipment must be located more than
1.83 m from the scanner.
A network and/or modem connection can be made to the computer if power is

supplied from a wall outlet as described above.


2 1
2 System Overview
Chapter 1:System Overview
This chapter provides an overview of the PRODIGY system.
• In addition the chapter contains a brief discussion of major sub-

systems and illustrations of the PRODIGY power system.
• This Chapter contains the PRODIGY Block Diagrams
2.0 PRODIGY System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33

2.0.1 PRODIGY Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
2.1 Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
2.1.1 Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
2.1.2 Electronics Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
2.1.3 Scan Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36
2.1.4 Power specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36
2.2 PRODIGY Block Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
2.2.1 PRODIGY I (System numbers DF+11999 and lower) Power
Distribution Block Diagram (AC entrance) . . . . . . . . . . . . . . . . . 1-38
2.2.2 PRODIGY System Block Diagram PRODIGY I System Block
Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39
2.2.3 PRODIGY I Peripheral Configuration Block Diagrams . . . 1-40
2.2.4 PRODIGY II System / Power Block Diagram . . . . . . . . . . 1-41
2.3 PRODIGY Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42
2.4 PRODIGY I (system numbers DF+11999 and lower) Single Board
Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43
2.4.1 SBC Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43
2.4.2 SBC Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43
2.4.3 SBC / Host PC Interface . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44
2.5 PRODIGY II Combined Single Board Controller (cSBC) (systems
DF+12000 and greater) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45
2.5.1 cSBC System Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45
2.5.2 cSBC Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46
2.5.3 TRANS / LONG MOTOR Control and Status . . . . . . . . . . . . . 1-50
2.5.4 AGS ROLL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51
2.5.5 AGS DAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51
2.5.6 SCANNER RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52
2.5.7 GE-LUNAR Model 7861 X-ray Generator Errors. . . . . . . . . . . 1-53
2.5.8 DC FAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-54
PRODIGY Service Manual (Rev C - 2000) System Overview229

2.5.9 DCA / AGS / BIAS DAC's . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-54
2.5.10 KV/mA DAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-55
2.5.11 ARC/FIL DAC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-55
2.5.12 PEAK DAC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-55
2.5.13 MAX PLD Peripherals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-55
2.5.14 Interrupts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-56
2.5.15 MASTER RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-56
2.5.16 SUICIDE RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-57
2.5.17 MISC OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-57
2.5.18 MISC IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-57
2.5.19 Stepper Motor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-58
2.5.20 OMI Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-59
2.5.21 Patient Positioners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-59
2.5.22 Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-59
2.5.23 X-ray Source Control / Mechanical Interlocks . . . . . . . . . . . . 1-59
2.5.24 Shutter / Collimator Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-60
2.5.25 End of Exposure Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-60
2.5.26 Panel LED's . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-60
2.5.27 HVPS Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-60
2.5.28 ADC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-61
2.5.29 mA Low Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-61
2.5.30 Detector Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-61
2.5.31 Communications Ports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-62
2.5.32 Debug RS-232 Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-62
2.5.33 Diagnostic LED's . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-62
2.6 Power Distribution (PRODIGY II Systems DF+1200 and greater) . . 1-64
2.7 Tube Head and X-ray Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-65
2.7.1 X-ray generation and Spectrum. . . . . . . . . . . . . . . . . . . . . 1-65
2.8 X-ray Generator (High Voltage Power Supply(ies)) . . . . . . . . . . . . . 1-66
2.9 MAX Board (PRODIGY I systems DF+11999 and lower only) . . . . . 1-67
2.9.1 MAX Board Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-67
2.9.2 Dedicated +28VDC power supply . . . . . . . . . . . . . . . . . . . 1-67
2.10 XORB Board (PRODIGY I Systems DF+11999 and lower only). . . 1-68
2.11 Detector Sub System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-69
2.11.1 Detector Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-69
2.11.2 Detector Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-69
2.11.3 Detector Daughter Board Overview . . . . . . . . . . . . . . . . . 1-70
2.11.4 Detector Daughter Board Operation . . . . . . . . . . . . . . . . 1-71
2.11.5 Detector Mother Board Overview. . . . . . . . . . . . . . . . . . . 1-72
2.11.6 Detector Mother Board Operation . . . . . . . . . . . . . . . . . . 1-72
2.12 FOINK (PRODIGY I Systems DF+11999 and lower only) . . . . . . . 1-74
2.12.1 FOINK Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-74
2.12.2 Motion Control and Detection . . . . . . . . . . . . . . . . . . . . . 1-74
2.13 Display Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-75
2.14 Audible X-RAY OFF Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-77
2-30 System Overview PRODIGY Service Manual (Rev C - 2000)

2.15 X-Ray Collimator Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-78
2.16 PRODIGY Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-79
2.16.1 Component specifications . . . . . . . . . . . . . . . . . . . . . . . . 1-79
2.16.2 Functional specifications . . . . . . . . . . . . . . . . . . . . . . . . . 1-79
2.16.3 Maximum scan area (long x transverse) . . . . . . . . . . . . . 1-79
2.16.4 Programs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-80
2.16.5 Environmental specifications. . . . . . . . . . . . . . . . . . . . . . 1-80
2.16.6 Storage and transport environment. . . . . . . . . . . . . . . . . 1-81
2.16.7 X-ray generator (system no. DF+12000 and higher). . . . 1-81
2.16.8 X-ray generator (system no. DF+11999 and lower) . . . . 1-83
2.16.9 GE-LUNAR 8022 x-ray tube . . . . . . . . . . . . . . . . . . . . . . 1-85
2.16.10 GE-LUNAR 8743 x-ray tube head assembly (system no.
DF+12000 and higher) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-86
2.16.11 LUNAR 6838 x-ray tube head assembly (system no.
DF+11999 and lower) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-87
2.16.12 Laser specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-88
2.16.13 Compatible components . . . . . . . . . . . . . . . . . . . . . . . . 1-89
2.16.14 FDA Certified Components (USA Only) . . . . . . . . . . . . 1-89
2.17 Secondary Calibration / Daily QA . . . . . . . . . . . . . . . . . . . . . . . . . . 1-91
2.17.1 Secondary Calibration overview . . . . . . . . . . . . . . . . . . . 1-91
2.17.2 Starting the Daily QA (secondary calibration) . . . . . . . . . 1-91
Peak Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-92
2.17.3 Tests Performed in the Secondary Calibration . . . . . . . . 1-92
2.17.4 QA Database. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-94
Figure 2-9. PRODIGY System Exploded View of External Covers and

associated hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
Figure 2-10. PRODIGY I NTC thermistor on the Primary Terminal Block1-35
Figure 2-11. PRODIGY I Power Distribution Block Diagram . . . . . . . . . 1-38
Figure 2-12. PRODIGY I (systems DF+11999 and lower) Block Diagram1-39
Figure 2-13. PRODIGY I (Systems DF+11999 and lower) Peripheral
Configuration Block Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40
Figure 2-14. PRODIGY II System / Power Block Diagram . . . . . . . . . . . 1-41
Figure 2-15. Detector Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-69
Figure 2-16. Detector Daughter Board Operation . . . . . . . . . . . . . . . . . 1-71
Figure 2-17. PRODIGY Detector Module . . . . . . . . . . . . . . . . . . . . . . . . 1-73
Figure 2-18. PRODIGY display panel. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-75
Figure 2-19. Reference axis and target angles for tube head assembly 1-85
Figure 2-20. Anode heating/cooling curves . . . . . . . . . . . . . . . . . . . . . . 1-86
Figure 2-21. Cathode emission characteristics . . . . . . . . . . . . . . . . . . . 1-88
Figure 2-22. X-ray tube assembly heating/cooling curves . . . . . . . . . . . 1-88
Figure 2-23. PRODIGY Daily QA printout with expected values . . . . . . 1-95
Table 2-1. PRODIGY I (Systems DF+11999 and lower) Fuses . . . . . . . 1-42

Table 2-2. PRODIGY II (systems DF+12000 and greater) Fuses. . . . . . 1-42
Table 2-3. PRODIGY Component Specifications . . . . . . . . . . . . . . . . . . 1-79
PRODIGY Service Manual (Rev C - 2000) System Overview 2-31

Table 2-4. X-ray generator technical information. . . . . . . . . . . . . . . . . . . 1-81
Table 2-5. Table 4. X-ray generator technical information. . . . . . . . . . . . 1-83
Table 2-6. LUNAR 8022 X-ray tube technical information. . . . . . . . . . . . 1-85
Table 2-7. LUNAR 8743 x-ray tube assembly technical information. . . . 1-86
Table 2-8. LUNAR 6838 x-ray tube assembly technical information. . . . 1-87
Table 2-9. Laser specifications.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-88
Table 2-10. FDA certified components (system no. DF+12000 and higher).1-
89
Table 2-11. FDA certified components (system no. DF+11999 and lower).1-90

2.0 PRODIGY System
The PRODIGY includes the patient table and frame, X-ray tube, X-ray
generator, detector, and arm. Its physical specifications are summarized in
section 2.15.
The PRODIGY has a mechanical design with two separate motion systems
that are capable of simultaneous operation. These are transverse, and
longitudinal. Both motion systems are driven by stepper motors.
2.0.1 PRODIGY Electronics
The internal components of the scanner are safely secured by a number of

panels, including the scanner's tabletop.
Figure 2-9. PRODIGY System Exploded View of External Covers and

associated hardware
• The front and side panels are secured by screws from the inside.
• The rear panel is secured by screws from the outside.
• The table top is screwed down from the top.
Note: Primary Service access to the electronics of the scanner is

through the table top.

• The Detector electronics (in the scan arm) are secured by an upper and
lower shroud, held in place by screws.
• Each metal panel is grounded to the electronics pan.
It is not usually necessary to remove the front and back panels for most
service needs. However, if access is needed to the Front and Rear
Longitudinal Carriages, these can be removed.
The back panel is secured by hex socket head-head screws and must be slid
out of the way, for it is between the Arm Column and the frame.
If access is needed to the detector, Transverse Limit Switches or the other

components mounted above in the arm, the covers of the arm must be
removed.
• The upper scan arm shroud can be removed by loosening the two
screws holding it in place (on the back of the arm column) and tipping it
forward.
• The lower cover is held in place by four screws, two in the front and two
in the back, be sure to remove the ground wire for the metal portion of
the lower cover as well

2.1 Electronics
2.1.1 Cautions
PRODIGY electronics are static sensitive,

take static control precautions before
servicing scanner circuitry.
PRODIGY I electronics use Negative Temperature Coefficient (NTC)

thermistors to limit the in rush current of the AC isolation transformer and the
Detector Mother Board. These devices have a high resistance when cold and
decrease in resistance when warm.
Figure 2-10. PRODIGY I NTC thermistor on the Primary Terminal Block
• A cool down period of 30 seconds is required before power is turned on

on the system.
PRODIGY I ONLY: Failure to allow the

system to “cool down” may cause the
circuit breaker for the AC line to trip and /
or the + 12VDC for the Detector Mother
Board (DMB) will not come up to +12 VDC.
Note: The error log entry "DMB Power Cycle observed" is an

indicator that the DC power to the Detector Mother Board has
been interrupted and the system should be powered down for
30 seconds to restore power to the Detector Mother Board.
PRODIGY I ONLY: The NTC’s can get hot - they

are located on the AC terminal block and on the
DC terminal block be careful when servicing these
areas of the scanner.
2.1.2 Electronics Pan

The electronic components of the PRODIGY are mounted on the grounded
Electronics Pan which is horizontally fastened inside the frame.
Note: Appendix 2 A contains a layout drawing of the Electronics Pan

for PRODIGY I and PRODIGY II systems.
PRODIGY I Systems (System numbers DF+11999 and lower):
• There are four low-voltage linear DC power supplies (under 30VDC), and
two high-voltage DC power supplies (to supply 76kV to the x-ray tube) on
the pan.
• In addition to the power supplies, the electronics mounting chassis holds

four printed circuit boards, a stepper motor controller, the audible alarm,
an AC entrance/line filter/fuse holder, an isolation transformer and a
terminal strip for AC power distribution to the Host PC and peripherals.
PRODIGY II Systems (System numbers DF+12000 and greater):
• There is one low-voltage DC switching power supply (under 30VDC), and

one high-voltage DC power supply (x-ray generator - supplies 76kV to
the x-ray tube) on the pan.
• In addition to the power supplies, the electronics mounting chassis holds

one printed circuit board, a stepper motor controller, and an AC entrance/
line filter/fuse holder.
2.1.3 Scan Arm
• The scan arm contains one high-voltage power supply (1000VDC / +12
VDC input) is located in the upper arm near the X-ray detector and
provides power to the Detector Array.
• The scan arm also houses the detector and 5 associated printed circuit
boards, and a stepper motor contoller.
2.1.4 Power specifications
Leakage current
• Total System with Isolation Transformer: <100 microamperes.
• Scanner Table alone: <100 microamperes.
Scanner input power
• PRODIGY I ONLY: The scanner has 12 different nominal inputs: 100,

110, 115, 120, 125, 127, 200, 220, 230, 240, 250, and 254 VAC. During
installation, the scanner is configured for the nominal input which best
matches the voltage on site.

• PRODIGY II ONLY: The scanner can accept any AC input between 100
and 254 VAC.
• Voltage may fluctuate ±10% from the nominal value without a loss of
scanner performance.
• The nominal input (range of inputs) can be found on the system label.
• The rated power input is 1500 VA.
• The input power must meet IEEE 519-1992 for power quality and total
harmonic distortion (THD <5%).
Scanner output power (PRODIGY I system numbers DF+11999 and lower

only)
• The scanner has 3 different nominal outputs: 100, 120, 240 VAC.
• The nominal voltage output of the scanner is shown on the system label.
• The computer and all peripherals which use the scanner output power
must be rated for this voltage.
• The maximum power output is 400 VA.

2.2 PRODIGY Block Diagrams
The block diagrams for the PRODIGY system follow:
2.2.1 PRODIGY I (System numbers DF+11999 and lower) Power

Distribution Block Diagram (AC entrance)
Figure 2-11. PRODIGY I Power Distribution Block Diagram

2.2.2 PRODIGY System Block Diagram PRODIGY I System Block
Diagram
Figure 2-12. PRODIGY I (systems DF+11999 and lower) Block Diagram

2.2.3 PRODIGY I Peripheral Configuration Block Diagrams
Figure 2-13. PRODIGY I (Systems DF+11999 and lower) Peripheral

Configuration Block Diagrams

2.2.4 PRODIGY II System / Power Block Diagram
Figure 2-14. PRODIGY II System / Power Block Diagram

2.3 PRODIGY Fusing
PRODIGY I (system numbers DF+11999 and lower) Fuses
Fuse Rating Type*
F1 (Computer AC) T 2.0 AL 5x20MM

F2 (Computer AC) T 2.0 AL 5x20MM
F3 (+5, +/-12 VDC
T 1.25 AL 5x20MM
PS (1))
F4 (+5, +/-12 VDC
T 1.25 AL 5x20MM
PS (2))
F5 (+26VDC PS) T 2.5 AL 5x20MM
F6 (+28VDC PS) T 0.63 AL 5x20MM
F7 (+5, +/-12VDC
T 1.25 AL 5x20MM
PS (1))
F8 (+5, +/-12VDC
T 1.25 AL 5x20MM
PS (2))
F9 (+26 VDC PS) T 2.5 AL 5x20MM
F10 (+28 VDC PS) T 0.63 AL 5x20MM
MAX PCB F1 F 0.5 AL 1/4x1 1/4 in.
All fuses are 250V, low breaking capacity (25A minimum)
Table 2-1. PRODIGY I (Systems DF+11999 and lower) Fuses
PRODIGY II (systems DF+12000 and greater) Fuses
Fuse Rating Type

Condor PS
F3.15 AH 5x20 mm
F1
Condor PS
F3.15 AH 5x20 mm
F2
COndor PS
F3.15 AH 5x20 mm
F3
All fuses are 250V, low breaking capacity (25A minimum)
Table 2-2. PRODIGY II (systems DF+12000 and greater) Fuses

2.4 PRODIGY I (system numbers DF+11999 and
lower) Single Board Controller
2.4.1 SBC Functions
The microprocessor-based Single Board Controller (SBC) provides overall

operation and control of the scan table.
Control Functions
• Control of x-ray source power supplies, and shutter / collimator in a fail

safe manner.
• Provides control signals for two external stepper motor drives (Centent)
to scan patient in a fail safe manner and senses limit switch actuation at
the limits of travel (via FOINK see 2.11).
• Controls the detector array (communicates with the Detector Mother

Board, section 2.10.2).
• Responds to external scanner failure signals (interrupts generated by

SBC, FOINK see 2.11, and Detector Mother Board see 2.10).
Communication
• Communicates with PC host via an optically isolated RS-422 interface.
• Collects data from the detector array.
2.4.2 SBC Reset
All SBC circuitry resets when the microprocessor resets. This is done during
power up, and can also be done over the communication port (via the host),
through connections to other circuit boards (especially the Detector Mother
Board, as a fail-safe shutdown), the by pressing the reset button on the SBC,
by pressing the Emergency Stop Button on the arm, or when a fault is
detected by the SBC or the FOINK (section 2.11.1).
Error Conditions Sensed by the SBC:
• Loss of Communications with the Detector Mother Board (DMB).
• Loss of Communications with the Host PC.
• Limit Switch tripped when shutter is open.
• Limit Switch depressed when commands are being sent.
• Failure in x-ray source kV programming

• Interrupt sent by FOINK
The DMB will reset the SBC if it detects an error.
Error Conditions of the DMB sensed by the SBC:
• PLD programming failure
• Loss of +5 or +12 VDC
• Loss of Communications with SBC
• Corrupt FIRMWARE
• FLASH RAM Failure
• DTR Reset button on the DMB is pressed
2.4.3 SBC / Host PC Interface
The SBC communicates with the Host PC via an RS-422 interface. This is a
serial connection capable of transmitting more data than a standard RS-232
port. As it is not a standard serial port a RS-485 card must be installed into
one of the Host PCs expansion slots and the port must be configured correctly
for the PRODIGY to operate correctly (see DXPC2000 chapter 5 appendices).

2.5 PRODIGY II Combined Single Board Controller
(cSBC) (systems DF+12000 and greater)
The cSBC printed wiring board (PWB) is an eight layer rectangular board
measuring 7.400" x 8.100". The PWB is mounted in the via four mounting
holes located 1/4" from each corner and 2 additional interior mounting holes.
The components are primarily surface mount, with board connectors, headers
and a few single-style ICs being the only exceptions.
Four layers were dedicated for routing layers. Sensitive signals were noted
and routed manually and isolated from more powerful signals to reduce signal
interference and crosstalk on the same routing layer. The main power and
ground planes were stacked adjacently on the central inner layers to increase
inter-planar capacitance thus reducing ground bounce and power supply
noise. Traces on the top and bottom layers were kept as short as reasonably
possible and tapped down to an internal trace layer through vias.
Component placement is arranged to separate analog from digital circuitry.

Further isolation was achieved by segmenting the power and ground planes
into analog and digital sections and denying analog/digital plane overlap, thus
preventing digital noise from coupling into the analog section. All scanner
control I/O is run via connectors located on the +24V plane section. The +24V
plane is fully optically isolated from both the analog and digital plane areas to
prevent motor noise from coupling into the analog section, to prevent DC
switching noise from radiating on scanner cables, and to prevent ESD
presented at cable inputs from reaching the digital IC's.
2.5.1 cSBC System Architecture

The cSBC employs an Intel 80C251 micro-controller as its processor. This
processor provides 1K of on-board RAM and no on-board ROM. The
controller is clocked at 16 MHz using a crystal.
cSBC Memory Space
The cSBC is designed to support a JEDEC-standard, non-volatile FLASH

memory device up to 512K x 8 bits in size for code and fixed data. The board
supports either 128K or 512K SRAM memory device as needed for program
volatile memory. Complete address decoding is provided via the MAX PLD,
the CBSC bus master, allowing the address space to be arbitrary and
changed via the PLD code. The 80251 can address four 64K segments,
referred to as 0x00, 0x01, 0xFE and 0xFF as per Intel literature. The firmware
has the ability to map any FLASH or SRAM segment to any CPU segment via
SFR’s in the MAX PLD.
FLASH RAM

At startup the CPU executes the boots code which programs the FLEX PLD
and then maps in either NT or Prodigy runtime firmware as appropriate based
on the most significant bit of the CCA REV register. To switch from boot code
to run code the firmware jumps to SRAM and executes a code snippet which
pages the boot code out of 0xFF and the desired firmware into 0xFF. The
snippet then jumps from SRAM back to 0xFF to execute the firmware. A boot
jumper, JP4 is provided to optionally force the CPU to remain in the boot
code. When the boot jumper is installed the boot code runs the host port at
115.2KB.
SRAM
The cSBC contains a single 128K x 8 bit SRAM which provides read/write
memory. The SRAM's segments are arbitrarily mapped to any CPU segment
by the CPU mapping registers.
2.5.2 cSBC Functions
The microprocessor-based Single Board Controller (cSBC) provides overall

operation and control of the scan table.
FLEX PLD Peripherals
The majority of scanner related programmable logic functionality is contained

in the FLEX PLD, an Altera EPF6024AQC208-3 device. Device programming
is handled exclusively by the CPU. On each cold boot the CPU reprograms
the FLEX devices from an image stored in it's FLASH. As such a firmware
download of a new FLEX image is required to permanently upgrade the PLD
code.
The functional components of the programmable logic are discussed in the

following subsections. Polarity of operation can be inferred from bit names
and use of preceding slash for inverted logic bits.
Note that ports A-F are reloaded with default values at time of CPU reset and
remain in the default state until SCANNER_RESET has been cleared and
new values are written by the firmware. Defaults for port F and all other
registers are invoked at power up only.
PORT A
Bit Name R/ Def. Description

W
0 trans_enable R/W 0 Transverse motor enable – low blocks trans motor pulses and
forces Centent drive to standby current level.
1 /trans_fwd R/W 0 Transverse motor direction control.
2 /shutter_open_ctrl R/W 1 Shutter solenoid control.
3 trans_lsw_override R/W 0 Transverse limit switch override – prevent limit switch contact
from blocking step pulses at hardware level.

4 long_enable R/W 0 Longitudinal motor enable – low blocks trans motor pulses and
forces Centent drive to standby current level.
5 /long_fwd R/W 0 Longitudinal motor direction control.
6 long_lsw_override R/W 0 Longitudinal limit switch override – prevent limit switch contact
from blocking step pulses at hardware level
7 /collimator_open_ctrl R/W 1 Collimator solenoid control.

PORT B

W
0 /trans_front_lsw R N/A Transverse front limit switch position.
1 /trans_back_lsw R N/A Transverse back limit switch position.
2 /long_foot_lsw R N/A Longitudinal foot limit switch position.
3 /long_head_lsw R N/A Longitudinal head limit switch position.
4 trans_count_eq[0] R N/A Set when transverse step counter equals zero.
5 long_count_eq[0] R N/A Set when longitudinal step counter equals zero.
6 /shutter_open_sense R N/A Shutter limit switch position.
7 /collimator_open_sense R N/A Collimator limit switch position.
PORT C

W
0 /long_rev_pos R N/A Patient positioner (joystick) input.
1 /long_fwd_pos R N/A Patient positioner (joystick) input.
2 /trans_rev_pos R N/A Patient positioner (joystick) input.
3 /trans_fwd_pos R N/A Patient positioner (joystick) input.
4 /hvps_ac_relay R/W 1 Enable AC power to X-ray HVPS.
5 /motor_fail_enable R/W 1 Arm logic to shutdown scanner if OMI inputs not sensed.
6 ags_enable R/W 0 Enable detector automatic gain control feedback circuit.
7 /motor_power R/W 1 Enable 24VDC to the stepper motor drives (a.k.a. Centents).

PORT D

W
0 flex_max_i/o_[0] R/W 0 Output signal to MAX PLD (diagnostic use only).
4 flex_diag_3 R/W 0 Firmware controlled diagnostic LED.
5 pit_enable R/W 0 Enable Programmable Interval Timer output pulses.
7 /laser_on R/W 1 Patient locator laser control.
PORT E

W
0 low_range_dac R/W 0 Switches mA DAC from 2.048V to 0.500V reference.
1 trans_motor_accel R/W 0 Enables motor interrupt on every micro step.
2 low_range_adc R/W 0 Switches ADC from 5.000V to 0.500V reference.
3 long_motor_accel R/W 0 Enables motor interrupt on every micro step.
4 hvps_vendor_id R N/A For 7681 supply, 0 = Spellman, 1 = Bertan.
5 iq_hvps R N/A Set by resistor placement to indicate 0311/0312 supplies.
6 /hvps_enable_status R N/A Enable status monitor from 7681 supply.
7 /power_up R N/A Set to indicate cold boot.

PORT F

W
0 /motion_fail_enable R/W 1 Arm scanner shutdown if OMI pulses w/o step pulses.
1 long_motor_fail_axis R/W 0 Motor fail circuitry axis control, clear for transverse.
2 /hvps_enable R/W 1 Enable output to 7681 supply.
4 /arm_estop_sense R N/A Emergency stop sense bit.
5 spare_jmp_[1] R N/A Unused input, resistor or jumper selectable on CCA.
6 spare_jmp_[0] R N/A Unused input, resistor or jumper selectable on CCA.
7 cpu_p1_2 R N/A Firmware controlled diagnostic LED.
PORT G

W
0 adc_mux_[0] R/W 0 ADC analog MUX input selection control bit.
4 adc_mux_enable R/W 0 ADC MUX output enable control.
5 8ms_clock R/W 0 Clock output provided to MAX PLD.
6 unused N/A N/A For expansion.
7 unused N/A N/A For expansion.
2.5.3 TRANS / LONG MOTOR Control and Status
Dual axis stepper motor control is provided entirely by the FLEX PLD. To
make a typical move the firmware loads a starting velocity into the 16 bit
VELOCITY register, the total number of steps for the move into the 16 bit
TARGET register, and step at which to next interrupt the CPU into the 16 bit
STEP register. Velocity is in terms of periods of the 2.0MHz fundamental clock
per micro step pulse to the stepper drive. The drives provide 10 micro steps
per full step. The firmware can track move status by reading the 16 bit READ
register.

As part of the setup for a move the host and/or firmware must enable the
motors via the /motor_power, trans_enable, and long_enable outputs and
setup the trans_lsw_override, long_lsw_override, /motion_fail_enable, /
motor_fail_enable, and long_motor_fail_axis outputs as desired. If the system
is in scanner reset for any reason the FLEX PLD will over-ride the /
motor_power output and prevent 24V power from reaching the motor drives.
Addressing for the motor control interface is provided below.
2.5.4 AGS ROLL
This is a read only 8 bit register which returns the count of AGS roll-over
events since the previous read of the register. The AGS roll counter is reset
on read only - it is not tied to the PIT's sample clock.
2.5.5 AGS DAC
This port provides R/W access to the AGS circuit's 8 bit U/D counter. The
counter is tied via a dedicated 8 bit bus to the AGS DAC. The DAC's analog
voltage is tied to the gain control input of the variable gain amplifier (VGA)
used to control gain of the detector input signal. As such the firmware can
read this counter to determine the current DAC voltage level and hence gain
level. If ags_enable is low this port gives the firmware direct control of the
AGS DAC as a parallel R/W device. If ags_enable is high, the firmware can
write to the port but the DAC will continue to respond to UP/DOWN requests
from the AGS DCA circuitry and hence quickly return to the AGS current
operating voltage.
HE/LE COUNTERS
These read only ports provide access to the 16 bit event counters which are
incremented each time the DCA circuitry detects an input pulse within the HE
or LE windows (as defined by the LEL, LEH, HEL, and HEH DAC settings).
These counters are read in two 8 bit bus cycles, MSB then LSB. The event
counters themselves consist of a counting element and a bus element. On the
rising edge on the PIT output pulse the counting elements are latched to the
bus element. The PIT output is also tied to CPU external INT 1 and as such
the firmware interrupt handler then has until the next rising PIT edge to read
the counters before the bus elements are latched over with the next sample
count and data is lost.
PIT MSB/LSB

The PLD provides a programmable interval timer (PIT) to the CPU. The PLD
prescales it's input clock to generate a PIT base clock of 100KHz. The CPU
writes a 2 byte word to the PIT reload register MSB/LSB. The CPU then raises
the pit_enable bit to start the timer. In response to the rising edge on the
pit_enable, the PIT loads the reload word into it's counting element and
begins counting down. When the count rolls under the PIT asserts /
SAMPLE_INT, reloads the counting element, and begins another count down
sequence. The /SAMPLE_INT line is tied internally to the HE and LE event
counters and causes a synchronous latch of both counting elements. The /
SAMPLE_INT line is also tied to the processor's 2nd external interrupt line, /
INT1. The CPU interrupt handler reads the latched event counters and ships
the data to the host.
2.5.6 SCANNER RESET
The scanner reset register is used to provide failsafe shutdown operation of

the scanner. A falling edge on any of the inputs to this register will latch the
current value of the register and drop the /SCAN_FAIL_ANY output. The MAX
PLD latches the master reset register and raises CPU_RESET in response to
the falling edge on /SCAN_FAIL_ANY. The MAX PLD also provides
SCANNER_RESET as the logical OR of CPU_RESET and!/
SCAN_FAIL_ANY. The FLEX PLD uses it's SCANNER_RESET input as the
enable bit to the tri-state buffers used to drive all safety critical output lines
including shutter control, HVPS relay control, motor relay control, etc. As such
the scanner is locked into a fail-safe mode whenever SCANNER_RESET is
asserted.
The MAX's master reset register will remain latched until the next rising edge
on the HOST_RTS input. When the cSBC is latched into reset by a scanner
error it will remain in CPU reset until the host drops the RTS line and re-
asserts it. It will remain in scanner reset until the CPU reads the scanner reset
register following the next raising edge of the RTS line at which the condition
causing the /SCAN_FAIL_ANY has been cleared. The firmware passes the
value of the reset registers to the host to allowing the host to display
appropriate error messages to the operator. The host will be unable to
perform any scanner related operations until the SCANNER_RESET has
been cleared. Red diagnostic LED's (see 2.5.33) are provided for both
scanner and CPU reset lines. The CPU reset line is tied to the host CTS
output such that the host sees a CTS event when the cSBC enters CPU reset.
The host code provides a CTS event handler which reads the reset registers
and prompts the user accordingly.

The firmware can also initiate a reset sequence in response to fatal error
conditions by writing a 'death code' to the suicide reset register. Resets can
also be initiated by the manual push button on the cSBC and by a low 5VDC
power condition as sensed by the MAX705 supervisor. The scanner register is
also latched at the end of read cycles such that current status can be
ascertained by a double read. A bit map of the scanner reset register is
provided below

W
0 / R N/A Tube head thermostat over temperature.

thermostat_open_sense
1 /external_estop_sense R N/A Emergency stop input from external options block.
2 /dc_power_fail R N/A Loss of one or more of +5VDC,+12VDC,-12VDC, or +24VDC.
3 /long_motor_fail R N/A Motor failure detected on longitudinal axis.
4 /trans_motor_fail R N/A Motor failure detected on transverse axis.
5 /dmb_error R N/A DMB dropped it’s CTS indicating a DMB reset event.
6 /motion_fail R N/A OMI pulses detected without step pulse (manual arm motion).
7 /watchdog_reset R N/A Watchdog time-out indicates firmware crash.
2.5.7 GE-LUNAR Model 7861 X-ray Generator Errors
The HVPS error register is used to monitor the status of the 7681 X-ray
source HVPS. If the register value is not equal to 0xF when /hvps_enable is
low, the FLEX will raise the HVPS_ERROR_INT output to the MAX PLD. The
MAX PLD latches this into the IIR register and issues an interrupt to the CPU.
As such status of the HVPS is monitored when the unit is enabled. The
handler for HVPS interrupt reads this register to determine the cause of the
interrupt. The HVPS register is also latched at the end of read cycles such
that current status can be ascertained by a double read. A bit map of the
register is provided below.

W
0 /hvps_error_0 R N/A Error code bit from 7681 supply.
3 hvps_enable_status R N/A Set when /hvps_enable == /hvps_eanble_status
4 Unused N/A N/A Expansion room.

2.5.8 DC FAIL
The DC fail error register latches the status of the DC power monitors at the
time of reset. If scanner reset code indicates /dc_power_fail the firmware can
read this register to identify the specific DC source failure. The register is also
latched at the end of read cycles such that current status can be ascertained
by a double read.

W
0 /plus_scanner_fail R N/A Loss of +24V power input.
1 /plus_analog_fail R N/A Loss of +12V power input.
2 /minus_analog_fail R N/A Loss of -12V power input.
2.5.9 DCA / AGS / BIAS DAC's
The cSBC uses a single 10 bit octal DAC, the Linear Technology LTC1660, to
generate the AGS and DAC window reference voltages and the bias program
voltage. The DAC utilizes a serial interface and as such is not accessed with a
traditional CPU write cycle. To load the device the firmware writes to the DAC
address listed above, in response to which the MAX drops the /CS line to the
device. The firmware then manipulates the local serial bus clock and data
lines to load the DAC setting. The desired DAC channel address in encoded
into the first 4 bits of the output data word. A read is then made to the DAC
address, in response to which the MAX raises the /CS line. See device data
sheet and analog section below for further DAC details.

2.5.10 KV/mA DAC
The cSBC uses a single 12 bit dual DAC, the Linear Technology LTC1454, to
generate the HVPS kV and mA program voltages. The DAC utilizes a serial
interface and as such is not accessed with a traditional CPU write cycle. To
load the device the firmware writes to the DAC address listed above, in
response to which the MAX drops the /CS line to the device. The firmware
then manipulates the local serial bus clock and data lines to load the DAC
setting. Both DAC channels must be written together, CHA (kV) first followed
by CHB (mA) in a 24 bit stream packet. A read is then made to the DAC
address, in response to which the MAX raises the /CS line. See device data
sheet and analog section below for further DAC details.
2.5.11 ARC/FIL DAC
The cSBC uses a single 10 bit dual DAC, the Linear Technology LTC1661, to
generate the HVPS filament limit and arc detect threshold voltages. The DAC
utilizes a serial interface and as such is not accessed with a traditional CPU
write cycle. To load the device the firmware writes to the DAC address listed
above, in response to which the MAX drops the /CS line to the device. The
firmware then manipulates the local serial bus clock and data lines to load the
DAC setting. The desired DAC channel address in encoded into the first 4 bits
of the output data word. A read is then made to the DAC address, in response
to which the MAX raises the /CS line. See device data sheet and analog
section below for further DAC details.
2.5.12 PEAK DAC
The cSBC uses a 12 bit DAC, the Linear Technology LTC8043, to generate
the detector peak gain voltage. The DAC utilizes a serial interface and as
such is not accessed with a traditional CPU write cycle. To load the device the
firmware manipulates the local serial bus clock and data lines to output load
the DAC setting and then performs a write/read cycle to the DAC address
listed above to pulse the DAC's load line low. See device data sheet and
analog section below for further DAC details.
2.5.13 MAX PLD Peripherals
The programmable logic section is based on an Altera MAX

EPM7128STC100-15 device. The configuration pins for this device are taken
to a JTAG style 10 pin header to allow for in-circuit programming of the device
from the Altera Byte-Blaster. The MAX device is FLASH based (non-volatile)
and is programmed at the time of CCA assembly. The functional components
of the programmable logic are discussed in the following subsections.

2.5.14 Interrupts
The CPU's interrupt capacity is effectively increased by running several

interrupt signals to a register in the MAX PLD and tying the register output to
the CPU external INT 0 input. The firmware interrupt handler for INT 0 then
reads this register to identify the source of the interrupt and handles it
accordingly. The firmware then writes a bit masked '1' back to the IIR to clear
the bit of the interrupt it has serviced (the R/C in the table stands for READ/
CLEAR).

W
0 HOST_UART_INT R/C N/A Host UART interrupt.
1 DEBUG_UART_INT R/C N/A Debug UART interrupt.
2 DMB_UART_INT R/C N/A DMB UART interrupt.
3 HVPS_ERROR_INT R/C N/A HVPS error interrupt.
4 8mS_CLOCK R/C N/A 8ms clock tick interrupt from FLEX PLD.
5 POWER_FAIL_INT R/C N/A Power down pending in 5ms interrupt from DC supply.
2.5.15 MASTER RESET
The master reset register will force a CPU and scanner reset condition on the
falling edge of any of its listed inputs. The contents of the register will be
latched at the time of reset such that when the CPU next comes out of reset
the firmware can read the register to determine what caused the preceding
reset and report the appropriate code to the host. If the reset was cause by
the CPU_RST_WR input, the suicide reset register contains the specific error
code. If the reset was cause by the /SCAN_FAIL_ANY input, the scanner
reset register contains the specific error code.
The CPU and scanner resets will remain latched until the next rising edge of
the RTS input. At this time the CPU reset will be cleared if /POWER_RESET
bit is not asserted and the scanner reset will be cleared if /SCAN_FAIL_ANY
is high.

W
0 /POWER_RESET R N/A MAX705 supervisor detects VCC < 4.65V.
1 /HOST_RTS R N/A RTS reset request from host via comm line.
2 /MANUAL_RESET R N/A Push button pressed.
3 Unused R N/A Expansion room, reads as ‘1’.
6 CPU_RST_WR R N/A Write to the suicide register, read suicide reg for error code.
7 /SCAN_FAIL_ANY R N/A Scanner reset register latched, read scanner reg for error code.
2.5.16 SUICIDE RESET
The CPU Reset SFR is a byte register into which the CPU can write a failure
code. In response to the write the MAX PLD will store the failure code and
assert the CPU_RESET line. The CPU_RESET line will be released on the
next rising edge of the host RTS, at which time the CPU will be able to read
the bit code from this SFR to determine the cause of the previous reset.
2.5.17 MISC OUT
The misc. output register is used to control the misc. output functions listed in
the following table.

W
1 MAX DIAG_2 R/W 0 Firmware controlled diagnostic LED.
2 DMB HWPT R/W 0 Enable direct connect of host and DMB XCVR’s, bypassing
UART’s, for maximized scan data bandwidth DMB to host.
3 RESET OVERRIDE R/W 1 Enable override of CPU_RESET signal. Set to 1 on power-up such
that firmware can load the FLEX PLD at power-up regardless of
the host RTS state.

2.5.18 MISC IN
The misc. output register is used to control the misc input functions listed in
the following table

W
0 BOOT JUMPER R N/A JP4, placed to force firmware to remain in boot code.
1 CPU_P1_2 R N/A Input from CPU port 1, pin 2 (diagnostic use only).
2.5.19 Stepper Motor Control

The stepper motors use the same interface design as used on IQ and Prodigy.
The FET exhibits a lower voltage drop and hence provides more available
power at the drives for a given source voltage - essentially recovering the
voltage lost in dropping the DC supply from the 26V used on IQ/Prodigy to the
24V which is readily available in commercial switchers. Diodes are placed in
series on the Centent power lines to prevent back EMF generated when the
arm is moved manually from reaching the 24V planes and damaging the
cSBC. A dual FET circuit is used to minimize the voltage drop on the 24V
plane due to in-rush current when the motors are enabled. A circuit in the
FLEX implements a 2 stage turn on when the firmware lowers /motor_enable.
Q15 is enabled first to provide 24V to the Centents through R381 and R384,
thus limiting the in-rush current. After the current pulse has stabilized Q14 is
enabled to bypass the inrush limiting resistors. Q15 is then disabled and the
motors are at full power. An PTC is provided on the source of Q15 such that
the current limiting resistors will not be smoked if Q15 is inadvertently left
enabled.

2.5.20 OMI Input
The optical motion interrupt (OMI) sub-system connects to the transverse and
longitudinal OMI CCA's. The OMI CCA's are located on the far end (the gear
end farthest from the motor) of each drive axis. When the axis is in motion a
small toothed wheel spins through the OMI opto's beam and pulses are
sensed back on the cSBC. In this manner the system can sense a drive
circuit, motor, or belt failure which might otherwise result is a concentrated
exposure point during a patient scan. The OMI inputs are similar to those
used on the DPX-IQ. 74LS14's are added for hysteresis which provides a
clean direct interface to the PLD. As on Prodigy, logic in the FLEX PLD is
used to qualify the CH A and CH B inputs into a single 'valid motion' output.
Based on the phases of the square wave inputs on CH's A&B, the FLEX is
able to sense a change in direction. The circuit provides hysteresis to reject
false motion inputs resulting from scanner vibration when a wheel edge stops
in the center of the opto beam at the end of a move.
2.5.21 Patient Positioners

Four optically isolated inputs are provided for patient positioning. These are
used by the firmware to implement a joystick mode which is used in
conjunction with the laser to position the X-ray beam as desired over the
patient immediately prior to a scan. 74LS14 inverters are used to provide
hysteresis and isolate the FLEX PLD inputs from the slow rise times of the
opto output signals.
2.5.22 Limit Switches

Four optically isolated inputs are provided for limit switches. These are used
by the firmware to define the transverse and longitudinal table limits. 74LS14
inverters are used to provide hysteresis and isolate the FLEX PLD inputs from
the slow rise times of the opto output signals.
2.5.23 X-ray Source Control / Mechanical Interlocks

The cSBC is designed such that a high on the scanner reset net disables all
scanner functionality and assures a know, fail safe, state. All scanner control
outputs are driven by the FLEX PLD. The FLEX outputs drive the low side of a
PS2501 opto coupler emitter. The far side of all these opto circuits are
configured such that the opto has to be energized for the scanner function to
be active. As such the FLEX has to sink current to energize the opto and
activate the desired scanner function. Internally the FLEX code defines these
outputs as tri-state buffers, each of which has their enable line tied to the
scanner reset net. As such a scanner reset will force all these FLEX scanner
outputs to a high impedance state, de-energizing the opto's and disabling the
scanner.
The FLEX device is SRAM based and hence must be reprogrammed by the
CPU at power up. When the device is not programmed all I/O pins default to
the high impedance state. As such the scanner will also be in a fail safe state
when the FLEX is not programmed. The CPU port 1, pin 2 also runs directly to
the FLEX's ENABLE pin.

The cSBC provide a failsafe mechanism independent of the programmable
logic via the +5V_IO circuit. If one or more of either the E-stop, external E-
stop, or tube thermostat is open, the FET driving the +5V_IO net from the
+5VDC plane will be disabled. The +5V_IO net provides power to the emitter
anode of all opto's which drive critical scanner functions. As such the scanner
will enter a failsafe state in response to these mechanical interlocks, even in
the event of a PLD device failure. The +5V_IO FET will also be disabled by
either a HOST_RTS or CPU_RESET.
2.5.24 Shutter / Collimator Drive

The shutter and collimator solenoid drive circuits are the same as that used on
Prodigy I. The FLEX drives an isolation opto which in turn switches a pair of
FET's to control solenoid current. The first FET is used for an initial 'hard hit'
on open commands. It presents 24V directly to the solenoid for several
hundred msec's, resulting in a large initial current pulse to the solenoid. The
second FET provides the 'hold' current through a pair of current limiting power
resistors. The hold FET is tied directly to the /shutter_open_ctrl bit. Note that
the collimator drive is populated only for NT-A and IQ upgrades which use the
old style IQ collimator assembly. The nominal values of the power resistors is
changed between the NT and Prodigy II BOM's to support both the traditional
linear solenoid of IQ, and the rotary solenoid of Prodigy. A jumper or DNP'd
resistor is used to drive the IQ_SHUTTER line to the FLEX such that both
mechanical and optical shutter limit switches are supported.
2.5.25 End of Exposure Alarm

An on-board end of exposure alarm is provided. The alarm chosen is the
board mount equivalent of that used on Prodigy I.
2.5.26 Panel LED's
The 4 panel LED's, power on, X-ray on, source exposed, and laser on, are all
driven PS2501-2 opto's through 750R0 / 1W current limiting resistors.
2.5.27 HVPS Control
The HVPS analog control interface is designed to provide maximum

performance at minimum cost. A single, 16 channel multiplexed, 16 bit, high
accuracy, ADC is used in conjunction with several lower cost, lower bit
resolution DAC's. Absolute accuracy of DAC's is poor but errors are calibrated
out by the firmware which monitors the actual DAC output via the ADC. In this
scenario DAC integral non-linearity (INL) specs are not important, sufficient
differential non-linearity (DNL) is all that is required. Serial DAC's and ADC's
are chosen to conserve board space and simplify routing. Serial parts are
typically also lower cost as their maximum bandwidth is limited by the serial
baud rate.
The HVPS AC is enabled via a relay controlled by the cSBC. The line is
primarially used to disable the HVPS by removing the AC to the HVPS via the
relay. AC Power to the HVPS can be left on for up to one hour after
generation of x-rays to prevent AC cycling between concurrent scans.

A jumper and/or DNP'd resistor pad is provide to drive the IQ_HVPS line,
which the firmware reads to determine which HVPS it is intended to operate.
The PWB provides lemo style connector pads for use with the traditional 0311/
0312 HVPS and MAX CCA. For the 7681 HVPS the lemos are DNP'd and a
single DB-25 connector is used to control the HVPS. Tranzorb pads are
provide on the PWB and are expected to be populated only if deemed
necessary by EMC testing. An opto bank is also provided to support the digital
interface to the 7681. See Lunar dwg 7681-SPC for details.
2.5.28 ADC
The Burr Brown ADS8320 16 bit, serial, single channel ADC was chosen for
the cSBC for its high resolution, and excellent accuracy.
An Analog devices AD586 +5V voltage reference is used. The part was
selected for it low noise and high accuracy
Overall the ADC and reference give the cSBC +/-5mV analog accuracy 11.2
DAC's
A single LTC1454 12 bit, serial, dual channel, DAC is used to provide the kV
and mA program voltages. The part was chosen for it low cost, ready
availability at national distributors, and excellent DNL specifications. The DAC
is used in the x2 configuration such that the full scale output is twice the
reference voltage. Voltage outputs feed back to the ADC MUX such that
firmware can calibrate out DAC INL errors.
A single LTC1661 10 bit, serial, dual channel, DAC is used to provide the arc
threshold and filament current limit input voltages to the new 7681 HVPS. The
part was chosen for it low cost, ready availability at national distributors, and
reasonable DNL specifications. Voltage outputs are not fed back to the ADC
MUX as high accuracy is not required on these threshold inputs.
2.5.29 mA Low Range

To support future scan modes, an mA low range circuit is provided. The FLEX
PLD provides a control bit by which the firmware can switch the mA DAC
reference voltage from 2.048V to 0.5V, hence decreasing the LSB size, hence
allowing the firmware to take smaller voltage steps when ramping to low uA
settings. A second control bit is provided to switch the ADC from 5.0 to 0.5V
reference.
2.5.30 Detector Interface

The cSBC provides a RS-422 communications post to the Detector Mother
Board. The CSBC does not participate in any Detector data manipulation, all
analysis and Detector control is performed at the DMB.

2.5.31 Communications Ports
Host RS-422 Port
The host I/O port provides optical isolation per medical leakage requirements
of EN 60601-1-1, Annex BBB, section 7. QT's 6N136 opto's are used to
provide the required 115.2KB operational bandwidth and the required 2500
Vrms standoff at a reasonable price. Opto inputs and outputs are routed
through the MAX PLD to support the hardware pass though mode to the DMB.
A DB-9 female connector is provided on the host side of the isolation barrier.
RS-232 is supported by populating the XCVR U26. RS-422 is supported by
U21 and U37, the RS-422 XCVR's. A simple charge pump circuit is used to
generate +5V_ISO on the host side of the barrier. Prodigy II will populate the
RS-422 section and run at 115.2KB.
2.5.32 Debug RS-232 Port
The debug port is provided such that the firmware can echo status messages
and other information to a dumb terminal to support debugging, development,
testing, and servicing. The port is fully driven by a 16550 compatible UART is
fully connected to a DB-9 header using the standard PC comm port pinout.
The firmware can be configured to accept input from the debug port if
required. The port is expected to be depopulated in the final production BOM
to minimize cost.
2.5.33 Diagnostic LED's

16 diagnostic LED's are provided by the cSBC. Functionality is listed below
LE Color Function Description (status indicated when lit)

D
D13 Green +24V +24V DC input from supply present.
D15 Green -12V -12V DC input from supply present.
D16 Red FLEX CONFIG FLEX PLD not programmed.
D20 Red CPU RESET CPU in reset mode.
D19 Red SCANNER RESET Scanner in reset (failsafe) mode.
D27 Red AGS ROLL AGS roll over or under detected.
D29 Amber FLEX DIAG 1 Diagnostic LED for misc use by firmware, control reg in FLEX.
D31 Amber FLEX DIAG 2 Diagnostic LED for misc use by firmware, control reg in FLEX.
D22 Amber MAX DIAG 2 Diagnostic LED for misc use by firmware, control reg in MAX.
D28 Amber TRANS OMI Valid transverse motion sensed by OMI circuitry.

D22 Amber LONG OMI Valid longitudinal motion sensed by OMI circuitry.
D25 Amber HE COUNT Valid high energy photon event sensed by DCA circuitry.
D23 Amber LE COUNT Valid low energy photon event sensed by DCA circuitry.
D21 Amber HVPS ENABLE 7681 HVPS enabled.

2.6 Power Distribution (PRODIGY II Systems
DF+1200 and greater)
The PRODIGY II system reduces scanner cost by using a single switching DC
power supply which provides +5,+/-12, and +24VDC. The supply is connected
directly to the cSBC via J14. J13 is provided as a power out connector to run
power to the DMB for Prodigy II. 0R0 bypass resistor are provided to allow
flexibility in grounding and filtering schemes. The PWB is divided into 4
ground plane regions - DGND for +5V digital returns, AGND for +/-12V analog
returns, SCNGND for +24V returns, and ISO_GND for the host I/O island.
Large zeners and rectifiers are provided for over-voltage and reverse-voltage
protection. Standard capacitor filter banks are provided. For EMC all cable
exits other than host and DMB I/O are located over the 24V planes. The 24V
plane is separated from the 5V plane via optical isolation to prevent 5V noise
from reaching cables (radiated EMC) and to prevent motor noise and ESD
pulses from reaching the digital and analog IC's. The 24V plane contains
primarily power FET switches and power resistors used to control scanner
motors, X-ray source, LED, etc. The +/-12V planes contain analog electronics
used for detector and HVPS control. A +12V regulator is used to produce
12VDC for the Centent drives of off +24VDC, maintaining isolation from the
+12V plane. An additional +5V regulator is used to make 5V for the OMI's of
off +12V motors. 4 opto channels are used to sense the presence of the 4 DC
input voltages. The opto outputs are used to drive 4 green power on indicator
LED's and to allow the CPU to detect power outs.

2.7 Tube Head and X-ray Insert
The Tube Head consists of an oil-filled metal housing which contains a fixed-
anode X-ray Insert (essentially a vacuum tube diode), lead-type shielding,
collimating devices, a filament transformer, electrical connectors, and a
Cerium (K-edge) filter.
THe X-ray generator provides a constant 76kV potential. mA control circuit

regulates the fialment current via filament temperature to amintain the
programmed current emission. The X-ray generator only provides mA
monitor and mA limiting. PRODIGY I systems (DF+11999 and lower) have
MAX CCA, PRODIGY II systems (DF+12000 and greater have mA control
internal to the x-ray generator.
2.7.1 X-ray generation and Spectrum
• The X-ray Insert converts current into x-rays by accelerating the

electrons across a large potential from the cathode into a tungsten target
on the anode.
• The x-rays produced by the x-ray insert are filtered by the cerium filter to
produce a dual energy spectrum. The x-ray spectrum has peaks at 62
and 38 kV.
• Insert potential is provided by a/the High Voltage Power Supply(ies).
• The tube current is set by the (c)SBC at 0.15 mA or 3.00 mA depending

on the acquisition type.
• Tube Current is set by the (c)SBC and regulated by the MAX Board
(PRODIGY I) or the Power Supply (PRODIGY II systems).

2.8 X-ray Generator (High Voltage Power Supply(ies))
The PRODIGY X-ray production system combines a constant potential x-ray
generator (consisting of either one or two high voltage power supplies) and an
X-ray tube. The x-rya generator provides a continuous output of 38 kV each
and up to 5 mA (PRODIGY I) or 3.5 mA (PRODIGY II) to the X-ray tube. The
x-ray insert anode is composed of a tungsten alloy. The specifications of the
X-ray generation subsystem is outlined in section 2.16.7.
• The High Voltage Power Supply(ies) provide the anode/cathode potential

to the X-ray insert.
• PRODIGY I scanners use two high-voltage power supplies (±40kVDC).

During normal operation, 76kVp is applied (+38kV at the anode and -
38kV at the cathode).
• PRODIGY II scanners use a single high-voltage power supply

(±40kVDC). During normal operation, 76kVp is applied (+38kV at the
anode and -38kV at the cathode).
• The High Voltage Power Supplies are controlled by the (c)SBC.
• These power supplies are powered by the AC line voltage and have their
own built in fusing.
• The AC power is routed thru the isolation transformer (PRODIGY I Only)

and the supply(ies) are enabled via a relay (see section 2.1.1).

2.9 MAX Board (PRODIGY I systems DF+11999 and
lower only)
2.9.1 MAX Board Function
• The Tube Head and MAX Board work with the dedicated +28VDC power
supply to supply tube head current.
• The current is set by the SBC (see section 2.4).
• MAX board actually regulates current to the filament transformer in the

Tube Head.
2.9.2 Dedicated +28VDC power supply
• The +28 VDC dedicated power supply is switched on (for fail-safe

purposes) by a solid-state relay.
• When errors are detected by the SBC, (for example, loss of arm motion)
the relay will switch off and prevent production of x-rays.

2.10 XORB Board (PRODIGY I Systems DF+11999 and
lower only)
The XORB printed circuit board provides protection to various circuits (low
voltage) from transients within the HVPS and tube head (see 2.1.1 for
location).
• There may be occasional static discharges within the Tube Head. The
transients caused by these static discharges (arcs) are shunted to
ground through the array of transorbs present on the XORB board.
• There is no safety hazard to personnel, however, the electronics could be

damaged were no protection provided.

2.11 Detector Sub System
2.11.1 Detector Overview
• 16 individual CZT (cadmium zinc telluride) crystals which convert X-ray

energy directly to electrical charge
• The charge pulse generated by the individual detectors is directly

proportional to the photon energy that generated the charge pulse (see
2.16.9 for spectrum information).
• The array of 16 CZT crystals each act as pixel detectors, from which the
data is combined to form the densitometry data set.
• The Detector electronics amplify, discriminate and counts x-rays for all 16
detector elements.
• The detector communicates with the SBC.
• The Detector has 5 PCB associated with it, the Detector Mother Board
(DMB) and 4 identical Detector Daughter Boards (DDB’s).
• The detector has its own dedicated High Voltage Power Supply, used for
supplying detector bias.
2.11.2 Detector Operation
Figure 2-15. Detector Block Diagram

The Detector is held at 450 VDC bias. When a X-ray strikes the detector an
electron pair is created (small black arrows in the block diagram). This charge
pair induces a small amount of current in the CZT crystal.
A charge sensitive pre-amp then converts the current to voltage and passes
the signal along to the Detector Daughter Board for processing and analysis.
The signal out of the pre-amp is a +5 to +10 millivolt DC signal, each event on
each channel creates a small “blip”.
2.11.3 Detector Daughter Board Overview
• Each DDB processes the data from 4 of the 16 detector elements

simultaneously.
• Each detector element is handled as a separate channel.
• Each DDB is responsible for:
• Pulse Shaping
• Gain Adjust
• Energy discrimination (high or low energy)
• Event counting
• Each DDB is electronically identical

Figure 2-16. Detector Daughter Board Operation
2.11.4 Detector Daughter Board Operation
Gain Stage / Pulse Shaping
The Detector Daughter Board takes the +5 to 10 millivolt signal, strips off the
DC offset and shapes the pulse into a bi-polar pulse. This signal is further
amplified to 2.4 VDC and is then fed to a bank of 4 pairs of comparators.

The four fine gain control comparators are set up in two windows around the
High Energy signal. If the signal falls into the lower window a signal is sent to
the programmable logic (PLD). The PLD then sends an amplify signal to a
DAC which in turn increases gain slightly at the pulse shaping amplifier, so
that the High Energy Signal is +2.4 VDC. If the High Energy signal falls into
the upper window, the fine gain is adjusted down slightly by the same
mechanism at the pulse shaping amplifier, again so that the High Energy
Signal is + 2.4 VDC.
The fine gain adjust is applied to the entire signal on a particular channel at
the pulse shaping amplifier, therefore the Low Energy Signal’s gain is
adjusted along with the High Energy Signal.
The 4 comparators of the Gain Stage are set by digital to analog converters
(DAC’s) which use reference values stored in the Flash RAM of the Detector
Mother Board.
Energy Discrimination and Pulse Counting
The amplified and gain adjusted pulse is simultaneously fed to a second bank
of 4 comparators which are divided again into two sets of windows. The
windows of the Discrimination stage are centered around the High and Low
Energy pulses. These comparators are also set by DAC’s which are set by the
DMB Flash RAM.
Each time a pulse falls into the High Energy window, a counter in the
programmable logic (PLD) is ticked, the same happens for the Low Energy
window. These two data signals are then passed to the DMB, which transmits
the data to the SBC.
2.11.5 Detector Mother Board Overview
• Contains 4 slots for the DDB’s (see figure 2-9)
• Contains a slot for the Test Point Board (part of the PRODIGY tool kit see
figure 2-9)
• The Detector Mother Board provides +5 V, ±12 V plus digital and analog
grounds to the Detector Daughter Boards.
• The Detector Mother Board communicates with the SBC via RS-422 link.
• The patient positioning laser is controlled by the SBC via the DMB (See
figure 2-9).
2.11.6 Detector Mother Board Operation
The Detector Mother Board (DMB) contains a processor and Flash RAM,
which supplies programming data to the detector subsystem. The data for all
comparator settings is stored here (set values), detector Bias programming
data, firmware to program the PLD’s of the 4 DDB’s, the Peak value
calculation operation for the detector (see section 2.17 for a discussion of the
Secondary Calibration (QA)).

If the Flash RAM is corrupt, the DMB will read from the Firmware on the SBC.
The Flash RAM can be reprogrammed from the Host / SBC.
The DMB has a processor, which is responsible for performing the Peak
calculation during a Secondary Calibration (QA), programming the 4 DDB
PLD’s and handles all communications with the SBC. The DMB processor
sends the SBC status reports and echoes back all commands that are sent to
it.
The DMB will reset the SBC if it detects an error.
Error Conditions of the DMB sensed by the SBC:
• PLD programming failure
• Loss of +5 or +12 VDC
• Loss of Communications with SBC
• Corrupt FIRMWARE
• FLASH RAM Failure
• DTR Reset button on the DMB is pressed
Figure 2-17. PRODIGY Detector Module
1 = Test Point Board, 2 = Detector Daughter Boards (4), 3 = Patient Positioning laser and
Detector Mother Board Interface, The Detector Mother Board is the horizontal circuit board
that the DMB’s and Test Point Board are plugged into.

2.12 FOINK (PRODIGY I Systems DF+11999 and lower
only)
2.12.1 FOINK Functions
• The FOINK Board optically isolates control circuitry (SBC) from the rest
of the scanners electronics (see pan layout Appendix 2B).
• Shutter solenoid
• Scanner Motor Controllers
• Display Panel indicators and controls
• Monitors 5 different interrupts, all of which are capable of resetting the

SBC (shutting down x-ray production)
• Emergency Stop Switch - open circuit - (loss of signal - failsafe)
• Tube Head Thermocouple - circuit open (loss of signal - failsafe)
• Longitudinal Motion Interrupt - source open no movement (OMI)
• Transverse Motion Interrupt - source open no movement (OMI)
• Failure of the +28 VDC Power Supply
2.12.2 Motion Control and Detection
• Motor pulses, RUN/HOLD signals and direction are generated by the

SBC.
• The RUN/HOLD signals are optically isolated on the FOINK board before
being sent to the Centent motor drivers. The Centents supply current to
the stepper motor windings.
• Both the transverse and longitudinal drive systems have slotted disks
attached which pass through optical interrupters (OMI) for motion
detection. Should motion stop during patient scanning, the FOINK sends
an interrupt to the SBC, which is reset and x-ray production is halted.
• Limit switches at each end of the scanner and each end of the arm signal
the SBC whenever motion reaches either end or side of the scanner. If a
limit switch is tripped during a patient scan, the motor associated with the
tripped limit switch is halted, the SBC is reset and the shutter is closed.
• There is a dedicated DC power supply for the motion control circuitry,

supplying +26VDC. The +26VDC ground is isolated from the logic
ground to reduce noise (see section 2.1.1 for location)

2.13 Display Panel
• The Display Panel of the PRODIGY, located on the front face of the
upper arm, is the main operator interface outside the host computer.
Figure 2-18. PRODIGY display panel
• Four indicators display system status.
• A green Light Emitting Diode (LED) indicates a power-on condition; it

lights when the +26VDC power supply comes on.
Power on LED is lit whenever scan table power is on.
• A yellow LED indicates if the laser is on
The laser on LED is lit when the SBC signals the DMB to turn
the laser on, the LED is switched on by the DMB.
• An amber X-ray On LED indicates that x-rays are being produced

(current is flowing through the X-ray Insert), though exposure is not
necessarily taking place.
The X-ray on LED is lit when more than X current is flowing

through the X-ray insert.
• The yellow Shutter Open LED comes on is the Shutter open and
exposure possible.
The Shutter open LED is controlled by the SBC, the SBC will
allow the shutter to open even if the lamp is not lit (shutter
open indicator is also on the PC controller screen).
Note: It is not recommended that scanner operation be continued if

These LED's signal the operator of exposure to x-rays and
must be replaced as soon as possible.

• Rocker switches on the panel allow operator control of the beam
position.
The Rocker switches are enabled by the SBC via the FOINK.
Note: The rocker switches are also referred to as the joystick in the
PRODIGY Service Manual and the PRODIGY Service
Software.
• The Emergency stop button (red), is to be used only in emergency

situations; it resets the (c)SBC and halts x-ray production.
The FOINK or cSBC detects if this normally closed circuit is

opened (fail-safe operation).

2.14 Audible X-RAY OFF Signal
• An audible signal notifies the operator that there is a “safe” condition
when the Shutter is closed.
• The FOINK or cSBC board senses the closure of the Shutter or the
cessation of current through the X-ray Insert (+28VDC Power Supply or
Model 7861 HVPS) and switches on the audible signal if either of these
occur during an exposure.

2.15 X-Ray Collimator Subsystem
• The Shutter is actuated by a rotary solenoid using +26 VDC, the voltage
is reduced to a holding voltage of 12VDC after the shutter is opened.
• This solenoid is controlled by signals generated on the SBC, and

optically isolated through the FOINK board on PRODIGY I systems.
• An optical interrupter (OMI) detects the shutter open condition and

reports shutter position information back to the (c)SBC.
• This assembly is located on top of the X-ray Tube Head.

2.16 PRODIGY Specifications
2.16.1 Component specifications
Table 2-3 gives specifications for standard components shipped with the
PRODIGY system.
Table 2-3. PRODIGY Component Specifications

Component Specifications
Dimensions: 262.3 cm x 109.3 cm x 128.3 cm
Scanner table* Weight: approximately 272.16 kg
Maximum patient weight supported: 136 kg
Console table 78.5 cm x 63.3 cm x 48.1 cm
Greater than 266Mhz Pentium
128 MB RAM
Greater than 1GB hard disk
17” SVGA monitor (800x600x16-bit color)
LS-120 Super drive
Computer CD ROM
Modem
Windows NT version 4.0 operating system with service
®
pack 6
Internet Explorer version 4.01 with service pack 2
Fast Serial I/O board (LUNAR part number 7151)
HP DeskJet 930C
Printer
W x D x H—44.0 x 40.0 x 19.6 cm
*Depth is measured from the front edge of the scanner table to the back edge of the
scanner arm. Height is measured from the top of the scanner arm to the bottom of the
scanner arm.
*Width is measured from the front edge of the scanner table to the back edge of the
scanner arm. Height is measured from the top of the scanner arm to the bottom of the
scanner arm.
#Some languages may require 1024x768x16-bit color to fit the translated software text
on the screen
@GE-LUNAR Recommends Diskeeper Lite (Executive Software - http://

www.execsoft.com - Glendale, California, USA)
2.16.2 Functional specifications
General specifications
Focal spot to image receptor distance is 67 cm. Attenuation equivalence of

patient support table is 0.7 mm Al.
2.16.3 Maximum scan area (long x transverse)

• AP Spine Measurements
40.3 cm x 18 cm
• Femur Measurements
20.2 cm x 18 cm
• Dual Femur Measurements

20.2 cm x 18 cm (each femur - two scan areas)
• Total Body Measurements

197.5 cm x 60 cm measurement field
2.16.4 Programs
Note: Depending on the number of options purchased, not all of the

options listed below may be included with the PRODIGY
system software:
• AP spine measurement and analysis
• Femur measurement and analysis
• Total Body measurement and analysis.
• Forearm measurement and analysis
• Lateral spine measurement and analysis
• Quality Assurance
2.16.5 Environmental specifications
Operational environment
Adhere to the specifications that follow during scanner operation:
• •Ambient Space (Interior Subcomponents)–For scanner operation

and servicing, do not block the area around the scanner table. Make sure
there is a minimum clearance of 30.5 cm at the head and foot ends of the
scanner table, at least 15.2 cm for the arm side, and 45.7 cm for the
operator side.
• Ambient Space (Ventilation)–Do not block the cooling vents on the

computer and scanner table. Make sure there is 15.2 cm from the
console table to the wall for cable clearance and computer plugs.
• Dust, Fumes and Debris–Install the system in a clean, ventilated area.

Dust and other airborne debris can cause the diskette drive heads and
other sensitive mechanical components to malfunction. GE-LUNAR
recommends that smoking is not permitted in the scanner room.

• Humidity–Make sure the humidity for the scanner area is 20%–80%,
non-condensing.
• Static Electricity–Install and operate the system in a static-free area.

Adhere to minimum humidity requirements to prevent malfunctions
caused by static electricity.
• Shock and Vibration–Make sure the scanner table does not receive
shock greater than 1 G for more than 1 millisecond. Make sure the
scanner table does not receive vibrations greater than 0.25 G at 5 Hz.
• Temperature–Make sure the temperature during system operation is

65°F–81°F (18°C–27°C).
Note: When the system is turned off, or there is a power failure,

allow the system to be on and let it warm for one hour. After
one hour, complete a Quality Assurance procedure.
2.16.6 Storage and transport environment
Adhere to the specifications that follow for scanner storage and

transportation:
• Humidity, 0% to 95% non-condensing.
• Atmospheric pressure, 500 to 1060 hPa.
• Temperature, -40° to 70° C.
2.16.7 X-ray generator (system no. DF+12000 and higher)
Table 2-4. X-ray generator technical information.
Classification Class I Equipment IEC 601-2-7 5.1

Degree of protection against electrical
Type B equipment IEC 601-2-7 5.2
shock
Ordinary medical electrical equip-
Protection against ingress of liquids IEC 601-2-7 5.3
ment
Connection to supply mains Power supply cord IEC 601-2-7 6.1g)
Mode of operation Continuous IEC 601-2-7 6.1m)
Maximum X-ray tube voltage 76 kV IEC 601-2-7 6.1m)
Maximum X-ray tube current 3 mA IEC 601-2-7 6.1m)
Rated mains voltage 100-240 VAC IEC 601-2-7 6.1j)1
Number of phases in mains 1 IEC 601-2-7 6.1j)2
Mains frequency 50/60 Hertz IEC 601-2-7 6.1j)3

Required over-current releases 15 Amp dedicated service IEC 601-2-7 6.1j)5
X-ray tube dissipates 243W max.
into surrounding air through forced
Heat dissipative components air convection. Flow rate: 36 m3/h IEC 601-2-7 6.1t)
(approx.) Temp. rise of air stream
25° C (approx.)
Spellman SBD40PN280X2890 or IEC 601-2-7 6.8.1

Allowable high voltage supplies
Bertan 2907. and 50.2.101-102
IEC 601-2-7 6.8.1
Allowable tube head assemblies LUNAR model 8743 or equivalent
and 50.2.101-102
Original language of accompanying docu-
English IEC 601-2-7 6.8.1
ments
Maximum continuous kV, mA at nominal IEC 601-2-7 6.8.2
76 kV, 3 mA
rated kV 1)
Maximum intermittent kV, mA at nominal IEC 601-2-7 6.8.2
76 kV, 3 mA
rated kV 1)
Maximum continuous kV, mA at maximum IEC 601-2-7 6.8.2
76 kV, 3 mA
mA 2)
Maximum intermittent kV, mA at maximum IEC 601-2-7 6.8.2
76 kV, 3 mA
mA 2)
Continuous kV, mA for maximum electric IEC 601-2-7 6.8.2
76 kV, 3 mA
output power 3)
Intermittent kV, mA for maximum electric IEC 601-2-7 6.8.2
76 kV, 3 mA
output power 3)
IEC 601-2-7 6.8.2
Nominal electric power 0.243 kW
4)
0.20 mAs. Parameters: 76 kV, 0.10
IEC 601-2-7 6.8.2
Lowest current time product mA,
5)
2 seconds.
IEC 601-2-7 6.8.2
Nominal shortest irradiation times 2 seconds.
6)
Voltage divider in high voltage
Method of x-ray tube voltage measure- IEC 601-2-7
power
ment 50.106.1
supply.
Method of x-ray tube current measure- Shunt resistor in high voltage supply IEC 601-2-7
ment return line. 50.106.2
Line normal to the tube port, cen-
IEC 601-2-7
X-ray tube assembly reference axis tered
6.1j)5) 50.107.1
on tube port as shown in Figure 4.

8.21 x 105 Joules, 3 mA, 76 kV for 1 IEC 601-1-3
Reference loading conditions
hour. 29.204.2
IEC 601-1-3
Focal spot to Image Receptor distance 67 cm
29.203.2
Attenuation equivalence of patient support IEC 601-1-3
0.7 mm Al
table. 29.206.2
2.16.8 X-ray generator (system no. DF+11999 and lower)
Table 2-5. Table 4. X-ray generator technical information.
Classification Class I Equipment IEC 601-2-7 5.1

Degree of protection against electrical
Type B equipment IEC 601-2-7 5.2
shock
Ordinary medical electrical equip-
Protection against ingress of liquids IEC 601-2-7 5.3
ment
Connection to supply mains Power supply cord IEC 601-2-7 6.1g)
Mode of operation Continuous IEC 601-2-7 6.1m)
Maximum X-ray tube voltage 76 kV IEC 601-2-7 6.1m)
Maximum X-ray tube current 5 mA IEC 601-2-7 6.1m)
100, 110, 115, 120, 125, 127, 200,
Rated mains voltage IEC 601-2-7 6.1j)1
220, 230, 240, 250, and 254 volts
Number of phases in mains 1 IEC 601-2-7 6.1j)2

Mains frequency 50/60 Hertz IEC 601-2-7 6.1j)3
Required over-current releases 20 Amp dedicated service IEC 601-2-7 6.1j)5
X-ray tube dissipates 305W max.
into surrounding air through forced
Heat dissipative components air convection. Flow rate: 36 m3/h IEC 601-2-7 6.1t)
(approx.) Temp. rise of air stream
25° C (approx.)
Spellman X2112/X2113/ rev. K and
higher. Bertan 2411P and 2411N IEC 601-2-7 6.8.1
Allowable high voltage supplies
rev. A and and 50.2.101-102
higher. LUNAR p/n 0311 and 0312.
IEC 601-2-7 6.8.1

Allowable tube head assemblies LUNAR model 6838 or equivalent
and 50.2.101-102
Original language of accompanying docu-
English IEC 601-2-7 6.8.1
ments

Maximum continuous kV, mA at nominal IEC 601-2-7 6.8.2
76 kV, 4 mA
rated kV 1)
76 kV, 5 mA
kV 1)
Maximum continuous kV, mA at maximum IEC 601-2-7 6.8.2
61 kV, 5 mA
mA 2)
76 kV, 5 mA
mA 2)
Continuous kV, mA for maximum electric IEC 601-2-7 6.8.2
76 kV, 4 mA
output power 3)
Intermittent kV, mA for maximum electric IEC 601-2-7 6.8.2
76 kV, 5 mA
output power 3)
IEC 601-2-7 6.8.2
Nominal electric power 0.4 kW
4)
7.89 mAs. Parameters: 76 kV, 2.63
IEC 601-2-7 6.8.2
Reference current time product mA,
5)
3 seconds.
IEC 601-2-7 6.8.2
Nominal shortest irradiation times 3 seconds.
8)
No specific wait period was
imposed.
IEC 601-2-7
Repetition rate for loading during tests Time between tests was approxi-
50.104.4
mately
20 seconds.
Method of x-ray tube voltage measure- Voltage divider in high voltage IEC 601-2-7
ment power supply. 50.106.1
Method of x-ray tube current measure- Shunt resistor in high voltage supply IEC 601-2-7
ment return line. 50.106.2
Line normal to the tube port, cen-
IEC 601-2-7
X-ray tube assembly reference axis tered
6.1j)5) 50.107.1
on tube port as shown in Figure 4.
1.09 x 106 Joules, 4 mA, 76 kV for 1

Reference loading conditions IEC 601-1-3
hour.
Leakage radiation was measured at the
3mA, 76 kV IEC 601-1-3
following loading factors.
Focal spot to Image Receptor distance 67 cm IEC 601-1-3
Attenuation equivalence of patient
0.7 mm Al IEC 601-1-3
support table.

Figure 2-19. Reference axis and target angles for tube head assembly
2.16.9 GE-LUNAR 8022 x-ray tube
Table 2-6. LUNAR 8022 X-ray tube technical information.
Nominal anode input power 361 Watts IEC 613/1989

Maximum anode heat content 6000 Joules IEC 613/1989
Anode heating and cooling curves Refer to figure 5. IEC 613/1989
Anode target material Tungsten IEC 601-2-28
Reference axis Refer to figure 4. IEC 601-2-28
78° (reference to nor-
Target angle IEC 601-2-28
mal)
Nominal focal spot values 0.5 IEC 336/1982
Not Applica-
Maximum useful voltage 95 kVp
ble
Not Applica-
Maximum filament current 2.2 Amperes
ble

Figure 2-20. Anode heating/cooling curves
2.16.10 GE-LUNAR 8743 x-ray tube head assembly (system no.

DF+12000 and higher)
• Beam filtration is permanently fixed with a minimum 2.9 mm Aluminum-

equivalent.
Table 2-7. LUNAR 8743 x-ray tube assembly technical information.
IEC 522/
Inherent filtration >2.9 mm Al/70 kV
1976
IEC 613/
Filament characteristics Refer to Figure 6.
1989
76 kV - Anode to Cathode
IEC 613/
Nominal x-ray tube voltage 38 kV - Anode to Earth
1989
38 kV - Cathode to Earth
IEC 613/
Single load rating 228 W (3 mA, 76 kV) for up to 15 min.
1989
228 W (3 mA, 76 kV) for up to 15 min.
with a IEC 613/
Serial load rating
5 min. cool down time between mea- 1989
surements.
Maximum x-ray tube assembly heat con- IEC 613/
260 Kjoules
tent 1989
X-ray tube assembly heating and cooling IEC 613/
Refer to Figure 7.
curves 1989

243 Watts (3mA x 76kV + 15W fila- IEC 613/
Maximum continuous heat dissipation
ment) 1989
3.5 mm/19.4 mm at a distance from IEC 806/
Maximum symmetrical radiation field
the focal spot of 220 mm. 1984
IEC 601-2-
Dimensions 17 cm x 19.4 cm x 11 cm
28
IEC 601-2-
Weight 8.6 kg
28
2.16.11 LUNAR 6838 x-ray tube head assembly (system no.

DF+11999 and lower)
• Beam filtration is permanently fixed with a minimum 2.9 mm Aluminum-

equivalent.
Note: Beam quality has a minimum first half-value layer of 3.2 mm of

Al at 76 kV.
Table 2-8. LUNAR 6838 x-ray tube assembly technical information.
Inherent filtration >2.9 mm Al/70 kV IEC 522/1976

Filament characteristics Refer to Figure 6. IEC 613/1989
76 kV - Anode to Cathode
Nominal x-ray tube voltage 38 kV - Anode to Earth IEC 613/1989
38 kV - Cathode to Earth
361 W (4.75 mA, 76 kV) for up to 4
Single load rating min., IEC 613/1989
59 sec.
361 W (4.75 mA, 76 kV) for up to 4
min.,
Serial load rating IEC 613/1989
59 sec. with a 10 min. cool down
time between measurements.
Maximum x-ray tube assembly heat con-
260 kJoules IEC 613/1989
tent
X-ray tube assembly heating and cooling
Refer to Figure 7. IEC 613/1989
curves
Maximum continuous heat dissipation 361 Watts IEC 613/1989
3.5 mm/19.4 mm at a distance from
Maximum symmetrical radiation field IEC 806/1984
the focal spot of 220 mm.
Dimensions 17 cm x 19.4 cm x 11 cm IEC 601-2-28
Weight 8.6 kg IEC 601-2-28

Figure 2-21. Cathode emission characteristics
Figure 2-22. X-ray tube assembly heating/cooling curves
2.16.12 Laser specifications
Table 3-9 gives the specifications for the GE-LUNAR laser.
Table 2-9. Laser specifications.

Output Power <1mW
Wavelength 635nm
Beam Diameter at
4x1mm
aperture
Aspect Ratio 4.0 to 1
Divergence 24 degrees

Table 2-9. Laser specifications. (continued)
Radiant Exposure 0.0001 W
Integrated Radiance 46 W
Current Draw 105 mA
Voltage Input 4-6 VDC
Safety Rating Class II
2.16.13 Compatible components
For customers located internationally, make sure the computer is certified to

local requirements. The computer must meet the minimum requirements that
follow:
• Greater than 266MHz Pentium
• 128 MB RAM
• Greater than 1GB Hard Disk
• 8X CD ROM
• 14” SVGA monitor with at least 800x600x16-bit color
• Windows NT version 4.0 operating system with service pack
• Internet Explorer version 4.01 with service pack 2
2.16.14 FDA Certified Components (USA Only)
Tables 2-9 and 2-10 list components certified to the FDA for use with
PRODIGY scanners and is updated periodically. Contact GE-LUNAR for a
current listing of compatible components.
Table 2-10. FDA certified components (system no. DF+12000 and higher).
LUNAR Model
Component Description
#
X-ray Controller LUNAR single board controller 7635
Bertan1 Model: 2907

High Voltage Power 7681
Spellman2 Model:
Supplies 7681
SBD40PN280X2890
Tube Head Assembly LUNAR X-Ray Tube Head Assembly 8743
LUNAR PRODIGY Collimator Assem-
Collimator 8915
bly
1
Bertan High Voltage Corp., 121 New South Road, Hicksville, NY
2
Spellman High Voltage Electronics Corp., 475 Wireless Boulevard, Hauppauge, NY

Table 2-11. FDA certified components (system no. DF+11999 and lower).
Component Description LUNAR Model #

LUNAR PRODIGY single board con-
X-ray Controller 5447
troller
Spellman1 Models:
High Voltage Power
PTV40N200X2113 0311
Supplies
PTV40P200X2112 0312
Bertan2 Models:
2411 N 0311
2411 P 0312
Tube Head Assembly LUNAR X-Ray Tube Head Assembly 6838
LUNAR PRODIGY Collimator Assem-
Collimator 6893
bly
1
Spellman High Voltage Electronics Corporation Hauppauge, NY
2
Bertan Associates, 121 New South Road, Hicksville, NY

2.17 Secondary Calibration / Daily QA
2.17.1 Secondary Calibration overview
• Daily QA (Quality Assurance) tests the integrity of the scanner so

operator knows it is operating within specifications.
• Daily QA (Secondary Calibration) adjusts the calibration of the scanner to

offset any changes due to the tube aging, temperature varying, or when
certain components are changed.
• A third type of function, QC Phantom, is another method for testing

system performance. A QC phantom is scanned using standard software
and results are stored (aluminum spine in lucite).
• Daily QA ensures the system is operating properly by running 3 types of

tests:
• A peak test to adjust photon counting electronics.
• A functional test that checks the indicator lights, motion system,

shutter, tube output, and detector performance.
• A test that measures a secondary calibration object with different

bone chambers and tissue plugs which correct for system aging and
prevents long-term drifts.
• On many tests, the results must be calculated for all 16 detectors

separately. The display for the test will consist of the mean value.
• All tests are run all of the time. The tests are executed and test results
reported as each test completes. Test results include pass/fail and any
quantitative information when appropriate.
2.17.2 Starting the Daily QA (secondary calibration)
Operator presses [F5] to start [Daily QA] which presents a plot of the last used
parameter from the last Daily QA run. (Default display is the medium bone
chamber.) At this point operator can interactively manipulate the data in QA
database to create tables and graphs that can be printed.
Tech presses [Start] to start running Daily QA tests.
Software displays instructions to position calibration block on the table. Tech

places block on tabletop silk screen and click [OK] to start.
The UI locks out all other operations except Stop button.
Scan arm moves to the "Home" position. In this case, Home is always at head
of scanner for QA independent of user setting for Home.

2.17.3 Tests Performed in the Secondary Calibration
Detector Mother Board Self Test
The DACs and Flash RAM of the Detector Mother Board are tested.
Find Block
The scanner performs a scout scan to find the block. If block is not properly
positioned, the scanner will prompt the user to Reposition standard more
accurately.
The software automatically finds landmarks within the secondary phantom.

This reduces the need for exact positioning on the table top.
Peak Test
During this test, the shutter opens with the x-rays on.
This test adjusts the sensitivity of the photon counting electronics. The test
determines the optimal voltage setting for the detector amplifier so the
maximum number of photons are detected. With the shutter open the software
adjusts the voltage setting for the detector amplifier, acquiring counts at the
different amplifier settings.
The detector peak test then determines the optimal voltage setting for the
detector amplifiers based on the results. The actual peak setting is taken from
the high energy count rates, the low energy channel is essentially blocked by
the brass spillover piece in the QA standard.
Beam Stop test
Measures the movement of the source shutter. A functional test checks the
shutter LSW and ensures the shutter stops all photons.
Motor motion and limit switches
OMI Interrupt function - the OMI signal is tested by verifying the OMI Interpol
signal is present when the scan arm is stationary.
Each motor (transverse, longitudinal) will be run between hard limits and back
to home position. If the hard limits do not engage, this is a failure. Also
compare steps against predetermined scan window size.
If a failure occurs the number of steps taken, the expected value and the
direction the arm was traveling is noted in the error log.
Spillover test

Measures the effect of high energy photons registering as low energy
photons in the detector system. The beam passes through a brass piece that
stops all low energy photons. The detector then measures the number of low
energy photons detected as a measure of spillover. Spillover should be less
than 13%. Spillover with the CZT detector will degrade about 0.2% per year.
Spillover Stability test
As part of the secondary calibration, the change in spillover must be

calculated on a per element basis and smoothed over the last 3 passing QA's.
Daily QA measures actual spillover and stores it in QA database. As part of
primary calibration, the spillover value used during that calibration is stored.
The delta spillover calculation using the spillover from primary calibration and
the running average of the last five spillover measurements. This information
is in the scan file.
Reference Value Test
The output of the x-ray tube is measured as part of a Reference Value (old
term was air) measurement. This is measured at various currents between
3mA and 0.150mA.
Note: Not all currents that are ramped to / tested are used to perform
patient scans.
Reference Value measurement
The HE/LE counts are measured as the number of photons counted by

detector. This value is used in all bone density calculations. It must be stored
in the systems data file. Limits for low/high counts -
• Reference value measurements will be performed at various currents.

These reference values are stored separately for all detector elements.
• Reference Value measurements for all current settings are actually made
through lucite sections of the secondary calibration block.
Reference value ratio test
The HE/LE ratio for each reference value is calculated for each tube current
tested in reference value measurement.
Detector Pre-AMP test
The detector Pre-amplifiers are tested by removing detector bias and verifying
that the signal out lines of the detector are not noisy.
Tissue Value Test
Tissue secondary calibration
• The system measures two tissue eqivilent materials (lucite and Acetron).

• Store measured values for each chamber per element in QA database.
• The system determines the%fat for two different materials with different
compositions.
• Three%fat values are displayed - lean, mid and fat
• These calculated%fat values are compared against expected values and

checked against limits for the mean, standard deviation.
BM Chamber Measurements
The system acquires point measurements on the 3 bone chambers (approx

12 seconds / measurement) using the 3ma medium scan mode. The system
determines the bone mineral content for the three chambers of different sizes
and densities.
• Measured values for each chamber are stored on a per element basis in
the QA database.
• These calculated BM values are compared against expected values and

checked against limits for the mean, standard deviation.
• A slope is calculated and this adjustment is used as a secondary BMD

calibration to offset long term drifts in system performance.
Daily QA Results
At the end of Daily QA, a report is automatically printed. If printer is not on line
or fails, post an error to screen.
If Daily QA fails, post an error message that says "Unsuccessful QA -

Recommend repeating procedure."
• If a QA fails the error log will contain detailed information on the

failure.
Test results are saved automatically to a database.
Appropriate secondary calibration and Reference Value information is

recalculated from QA database using an average of the 3 previous passing
test results. This information is stored in each scan file.
A view with plot of medium bone chamber is generated, and user the user is
allowed to manipulate data interactively.
2.17.4 QA Database
A historical record of system performance is maintained by storing key QA

parameters in a database.
• 3mA Results - fat is hidden - only bone results are viewable

Lunar Corporation
726 Heartland Trail
Madison, WI 53717
1.051 Daily QA Measurement

Date 3/20/00
Time 9:07:32 AM
1.007 BMD Medium (High mA) 0.971g/cm

0.971g/cm
Deviation -0.82%
Trend Summary
0.957 Mean BMD Medium (High 0.971g/cm
CV
Total Sessions 3
0.907
1/17/00 2/8/00 3/1/00 3/23/00
_____________________________________________________________________________
Functional Tests Secondary Calibration
Test Value Status Test Mean %CV Status
Block Position Pass BMD

Peaking 1400-3300 Pass Large Batch1 or 2 <=1% Pass
Beam Stop <=15 Pass Medium <=2% Pass
Mechanical Test Small <=3% Pass
Transverse 620mm min Pass Tissue
Longitudinal 1980mm min Pass Lean <=50% Pass
Mean % Spillover 5% to 13% Pass Mid <=20% Pass
Spillover Stability -1% to 1% Pass Fat <=10% Pass
Reference Counts Calibration Status Pass
High mA 15% from Primary Cal System Status
Ratio at High mA Ratio Pass Pass
Detector Status Pass
*The BMD & Tissue values are Batch dependent and can be found in service options
*Transverse - Total counts/20 with the result in millimeters

*Longitudinal - Total counts/10 with the result in millimeters
*Spillover Stability is spillover with respect to time.

Prodigy
LUNAR (2.10)
Figure 2-23. PRODIGY Daily QA printout with expected values



3 1 Service Software
Chapter 1:Service Software
This chapter contains a discussion of the Service Software and
the Error Log.
3.0 Diagnostic Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-103

3.0.1 To Access the Service Software:. . . . . . . . . . . . . . . . . . . 1-103
3.1 The Tools Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-104
3.1.1 Spectrum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-104
3.1.2 Stability Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-104
3.1.3 Signal Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-104
3.1.4 Primary Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-104
3.1.5 Secondary Verification. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-104
3.1.6 Pileup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-104
3.1.7 Set Download Parameters . . . . . . . . . . . . . . . . . . . . . . . 1-104
3.1.8 enCORE Composer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-105
3.1.9 Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-105
3.1.10 Copy Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-105
3.1.11 User Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-105
3.1.12 Service Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-105
3.1.13 Outbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-105
3.1.14 System File Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-105
3.2 Tools / Diagnostics Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-105
3.2.1 Pileup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-105
3.2.2 Calibration Pileup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-105
3.2.3 Spillover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-105
3.2.4 Count Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-105
3.2.5 Scanner Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-105
3.2.6 Scanner Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-106
3.2.7 Scanner X-ray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-107
3.2.8 Lin/Rep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-108
3.2.9 Limit Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 1-108
3.2.10 Scanner Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-108
3.3 Diagnostic Scan Modes - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-108
3.3.1 Table Top Scan - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-108
3.3.2 Alignment Scan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-108
3.3.3 Beam Wobble scan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-108
3.3.4 Hacksaw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-108
PRODIGY Service Manual (Rev C - 2000) Service Software3101

3.4 Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-108
3.4.1 Printing the Error Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-109
3.4.2 Troubleshooting Help software . . . . . . . . . . . . . . . . . . . . 1-110
3.4.3 Reading the Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-112
3.5 Service Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-114
3.5.1 Measure Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-114
3.5.2 Analyze Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-114
3.5.3 QA Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-114
3.5.4 Serial Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-114
Figure 3-1. The Tools/Diagnostics Menu . . . . . . . . . . . . . . . . . . . . . . . 1-104

Figure 3-2. The Error Log Dialogue Box . . . . . . . . . . . . . . . . . . . . . . . . 1-109
Figure 3-3. Error log entry details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-110
Figure 3-4. enCORE Troubleshooting help screen capture. . . . . . . . . . 1-111
Figure 3-5. Sample PRODIGY Error Log . . . . . . . . . . . . . . . . . . . . . . . 1-112
3-102Service Software PRODIGY Service Manual (Rev C - 2000)

3.0 Diagnostic Software
Note: GE-LUNAR Diagnostic software options are not available to
the customer. This software is available to GE-LUNAR
authorized representatives only.
When the software is used in the

diagnostic / service mode, the Engineer
performing service must verify that the
scanner is taken out of service mode
before returning control of the scanner to
the customer. The software will return to operators
mode as soon as the software is exited and restarted.
The operator mode may also be changed under the
Tools/User Options menu.
The Service software gives the Technician

access to all areas of the
PRODIGYSoftware, DO NOT adjust AGS
subsystem settings.
• The Diagnostic Software is available through the User Options Tab
3.0.1 To Access the Service Software:

• Start the PRODIGYSoftware by double clicking the PRODIGY Icon on
the desk top
• Double click the Tools option on the menu bar
• When the drop down menu appears double click on User Options
• Double click on the Systems Tab on the dialogue box
• Click on Service under Display Mode
• When prompted enter the password Award (versions 2.05 and greater)
Smile versions lower than 2.05)
Note: the password is case sensitive
• The Tools option on the menu bar will now contain Service Options, and
Service scanning options will also be available under the F2 Measure
Option
PRODIGY Service Manual (Rev C - 2000) Service Software3-103

Figure 3-1. The Tools/Diagnostics Menu
3.1 The Tools Menu

3.1.1 Spectrum
Allows the service engineer to view and print the raw energy spectrum for the
detector. The detector can also be repeaked from Spectrum.
3.1.2 Stability Run

Used for the detection of arcing and testing the detectors performance
3.1.3 Signal Monitor

View count rates for low and high-energy channels for the detector.
3.1.4 Primary Calibration

Used to calibrate the PRODIGY scanner See DXAP@002 PRODIGY Primary
Calibration Procedure Chapter 5 Appendix C.
3.1.5 Secondary Verification

Used in the manufacturing process
3.1.6 Pileup
Used in the manufacturing process
3.1.7 Set Download Parameters

Download and verify the Firmware versions for the (c)SBC.
3.1.8 enCORE Composer

This is not a service tool - (Physical and Business Report Generator - see the
enCORE Operator’s Manual for information).
3.1.9 Error Log

Ability to view and print the contents of the diagnostic error log (see section
3.4)
3.1.10 Copy Configuration

Ability to copy the scanners Error log, Configuration Files and / or QA
Database to a drive on the host PC - useful when a host PC is replaced or
when diagnostic information needs to be sent to GE-LUNAR.
3.1.11 User Options

Set up user configured options for the scanner.
3.1.12 Service Options

Service Mode scanner configurations (see section 3.5).
3.1.13 Outbox
Configure Printing, E-mail and Faxing options.
3.1.14 System File Editor

Edit system settings for the enCORE software - do not alter these settings
without GE-LUNAR Customer Support authorization.
3.2 Tools / Diagnostics Menu

3.2.1 Pileup
Determines Detector parameters for multiple events occurring simultaneously
- not used for service.
3.2.2 Calibration Pileup

Not used for service.
3.2.3 Spillover
Perform and Acquire a Spillover Measurement (test of source spectrum and/
or detector resolution).
3.2.4 Count Rate

Acquire and print Reference Counts (count rate of detector must be
performed through lucite).
3.2.5 Scanner Motion

Control manually and perform scanner motion diagnostics and motion
configuration.
•Motion Tests Tab
•Limit Switch Monitor - used to verify limit switch status
•Limit to Limit Test - used to verify limit switch positions
• Configure check box- this box must be checked when limit to limit is
run to establish the scanners range of motion (scan window).
•Cable Stress Test - used to cycle Transverse and Longitudinal

Mechanics - can be used to check new cables / check for binding
•Home scanner - moves mechanics to Home position
•Motion Commands Tab
•Home Position - change Arm Parking position from head to foot -

does not effect where the daily QA (Secondary calibration) is
performed - Move to Home - sends scan arm to home position.
Note: When the Home position is changed from the head end of the
table to the foot or vice versa, the Limit to Limit test (see
Motion Tests tab above) must be run with the Configure box
selected.
•Move Steps - move the scan arm to a specific location on the table -
move Absolute moves an absolute distance from home, Move
Relative - move relative to last position
•Joystick and Laser - Enable and Control Scanner Motion manually,

change motor speeds, toggle laser on and off
•Lower portion of the screen displays the status of limit switches, scan
arm position, and positioning switch (joystick) status.
•Find Block Tab
•Secondary Calibration - can be used to find / verify that the scanner is

able to find the different chambers on the secondary calibration (daily
QA) block. THis tool can be useful for troubleshooting “cannot find
Block errors” and for Transverse binding issues.
3.2.6 Scanner Detector

•Detector Tests Tab
•Gain Control - adjusts the gain on the AGS amplifier used in the
detector peak setting - peak adjusts only the AGS amplifier.

•Bias Control - adjusts the bias of the detector. PRODIGY Systems
run with detector bias on demand (when x-rays are present) of
450VDC.
•DCA window settings - view DCA window settings - these settings

should not be edited.
•Detector status - allows the service engineer to view the detector

status real time - information displayed includes Peak setting Bias
setting, and DCA window settings.
•Detector AGS Tab
•AGS DAC control (verify AGS DAC settings), check on detector

rollover, and check on channel count rates.
DO NOT adjust the detector Bias, DCA

windows or AGS DAC settings -
changes in the Detector bias, DCA
windows or AGS DAC’s can change the
scanner’s results.
•AGS Mode - the operate / calibrate signal (disables the AGS systems
so that the detector can be peaked correctly) can be toggled.
3.2.7 Scanner X-ray

•X-ray Tests Tab-
•Manual Test - Control Manually the Shutter, X-ray on Indicator and

patient Positioning laser
•Automatic test - automatically toggle the Shutter, Laser and X-Ray

Relay
•X-Ray Source - Turn on source (ramp and make x-rays), warm up a

tube head at install or replacement.
•X-ray cycle test - cyclically ramp the source - (can be used to test
ramping failures or for arcing)
•X-rays Tab
•Ramp the kV and / or the mA of the x-ray generation system and view
feedback real-time. Faults are displayed and polled real-time in the
window on the right.
•Ports Tab - view status of and send commands to (c)SBC ports (see
section 2.4 for (c)SBC port definitions).
•Download Tab - identical to Set Download Parameters (section

3.1.7)

•Misc. Tab- not used for service.
3.2.8 Lin/Rep
Not Used for Service
3.2.9 Limit Switch Adjustment

Verify and Adjust Limit switch positions.
Note: When using Limit Switch Adjustment, DO NOT alter the

default settings.
3.2.10 Scanner Disconnect

Disconnect the scanner from the PRODIGY software (reset the (c)SBC).
3.3 Diagnostic Scan Modes -

Performed under F2 Measure - only visible when the scanner is in service
mode.
3.3.1 Table Top Scan -

Not used in Service
3.3.2 Alignment Scan

Verify that the Source and Detector maintain a constant count rate in all areas
of the scan table. Also useful for testing cables.
3.3.3 Beam Wobble scan

Quantifies beam movement relative to the detector when the scanners
mechanics are moving (see DXAP2010 Chapter 5 Appendices).
3.3.4 Hacksaw
Calculates and sets correcton factors to align bone edges in scans (see
DXAP 2007 Chapter 5 Appendices).
3.4 Error Log

• The PRODIGYwill maintain an error log file whenever the scan table is in
operation. All errors, fatal or nonfatal will be logged here. The Error log
gives a brief description of the error and if possible the origin of the fault.
• The error log is one of the best troubleshooting tools for scanner
malfunction.
Note: To aid in a quick and accurate response when requesting

assistance from GE-LUNAR, please have an error log
available for review by GE-LUNAR Customer Support.

The error log file is named errorlog.bin, this file is the current error log session.
Older sessions are named errorlog.1, errorlog.2 and so on up to errorlog.4.
When requesting help from GE-LUNAR, E-mailing the current error log file
and a description of the symptoms will aid in a rapid diagnosis (see Copy
Configuration in section 3.1.10 for information on copying the error log to an
E-mailable file).
3.4.1 Printing the Error Log.

Note: The scanner does not have to be in Service mode to view or
print the Error Log.
• The Error Log is located under the Tools dropdown menu. Left click on
Tools / and then on Error Log.
Figure 3-2. The Error Log Dialogue Box
• Session - The PRODIGYsoftware will maintain up to 10 “sessions” -

each session is up to 100 errors.
•A new session is created by shutting down and restarting the

enCORE software. A new session may also be started by clicking on
the button

•To view a session, left click on it, all errors (if present) will be shown in
the box below.
•The Errors list may be printed (click on print errors) or it may be

searched with the Find Error button.
•The details of the failure are shown when the error is highlighted and
then right clicked on.
Figure 3-3. Error log entry details
3.4.2 Troubleshooting Help software

This feature is found in software versions 2.26 and greater. When an error is
highlighted and the Troubleshoot button is clicked on, it opens an online
enCORE troubleshooting guide to assist the service engineer in
troubleshooting the system by error code.

Figure 3-4. enCORE Troubleshooting help screen capture.
How to use the Troubleshooting Help software:
This Help software is based on Fault Tree Analysis or FTA. The fault trees are
in an outline form. Each heading in the outline represents an “or” choice. For
example, the basic fault below “Shutter will not close” has three possible
causes: “Shutter stuck”, “Solenoid Return Spring not working”, or “Solenoid
powered when it should not be”. Each of these in turn lists their possible
causes.
Sample Fault Tree (from Prodigy Collimator):
Shutter will not close
I.Shutter stuck – move by hand to test
A.Slotted Wheel scraping OMI board
B.Shutter scraping Shutter Plate
II.Solenoid Return Spring not working – move by hand to test
A.Spring broken
B.Spring no longer anchored
III.Solenoid powered when it should not be
A.FOINK (PRODIGY I) problem – Test by disconnecting J1. If the shutter

closes, swap the SBC. If the shutter stays open, swap the FOINK.
B.(c)SBC problem – Test as above.


Note: This type of analysis is meant to identify all possible causes,
giving the user a complete list to work from when ruling out
possibilities. If a cause is not listed in the appropriate fault tree
analysis, please e-mail GE-LUNAR about the discrepancy.
3.4.3 Reading the Error Log
Figure 3-5. Sample PRODIGY Error Log

4 1
2 Troubleshooting
Chapter 1:Troubleshooting
This chapter contains troubleshooting techniques for diagnostic
failures, failing quality assurance tests, mechanical failures and
imaging problems.
4.0 Diagnostic Failure Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-119

4.1 Transverse Motion failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-119
4.1.1 Operator Induced - switch closed during scan . . . . . . . . 4-119
4.1.2 Mechanical Failures - Unusual noise or irregular motion 4-119
4.1.3 Loss of OMI signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-121
4.2 Longitudinal Motion failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-122
4.2.1 Limit Switch Tripped During a Scan . . . . . . . . . . . . . . . . 4-122
4.2.2 Longitudinal Binding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-123
4.2.3 Loss of OMI Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-125
4.3 Failure of the 28V power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-126
4.4 Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-127
4.5 Tube Head Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-127
4.6 Communication Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-127
4.7 Other Diagnostic Failure Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-127
4.7.1 Reasons For Invalid Diagnostic Failures. . . . . . . . . . . . . 4-128
4.8 Failing Quality Assurance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-128
4.8.1 Block Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-128
4.8.2 Beam Stop Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-128
4.8.3 Mean% Spillover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-128
4.8.4 Reference Counts and Ratio . . . . . . . . . . . . . . . . . . . . . . 4-129
4.8.5 Ratio Fluctuations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-129
4.8.6 Transverse or Longitudinal Mechanics . . . . . . . . . . . . . . 4-129
4.8.7 Tissue Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-130
4.8.8 Bone Mineral of the Standard Chambers . . . . . . . . . . . . 4-130
4.8.9 Symptoms of High and Low KV. . . . . . . . . . . . . . . . . . . . 4-131
4.9 Reference Counts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-131
4.10 Arcing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-134
4.10.1 Limit Switch Tripped During Scan . . . . . . . . . . . . . . . . . 4-135
4.11 Imaging Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-136
4.11.1 White, or Grey in the first or second scan line: . . . . . . . 4-136
4.11.2 Femur Scan Problems. . . . . . . . . . . . . . . . . . . . . . . . . . 4-136
4.11.3 AP-Spine Image Problems: Probable causes . . . . . . . . 4-137
DPX-NT Service Manual (Rev A- 1999) Troubleshooting4117

4.11.4 Broken Signal Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-137
4.11.5 Loss of tube head current . . . . . . . . . . . . . . . . . . . . . . . 4-137
4.11.6 X-Ray Relay Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-137
4.11.7 Unstable AC Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-138
4.11.8 Arcing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-138
4.12 Failing Alignment Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-138
4.12.1 Image. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-138
4.13 Indicator Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-140
4.13.1 X-ray On LED Blinking. . . . . . . . . . . . . . . . . . . . . . . . . . 4-140
4.13.2 Shutter Open LED Blinking . . . . . . . . . . . . . . . . . . . . . . 4-140
4.13.3 Shutter Not Operating . . . . . . . . . . . . . . . . . . . . . . . . . . 4-141
4.13.4 End of Exposure Alarm During Scan . . . . . . . . . . . . . . . 4-141
4.14 Communications Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-142
4.15 Viewing Quality Assurance Trends . . . . . . . . . . . . . . . . . . . . . . . . 4-142
4.15.1 What to Look for in the QA History . . . . . . . . . . . . . . . . 4-143
4.16 MAX Board Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-143
4.17 FOINK Board Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-144
4.18 OMI Board Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-145
4.19 SBC Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-145
4.20 XORB Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-147
4.21 Detector Motherboard Troubleshooting . . . . . . . . . . . . . . . . . . . . 4-148
4.22 Detector Daughter Board Troubleshooting . . . . . . . . . . . . . . . . . . 4-149
4-118Troubleshooting DPX-NT Service Manual (Rev A- 1999)

4.0 Diagnostic Failure Codes
The following conditions halt the operations of the scanner, and generate a
diagnostic failure message which is displayed on the monitor screen:
All of these interrupts are detected by the cSBC
• Transverse Mechanics Failure (4.1)
• Longitudinal Mechanics Failure (4.2)
• Emergency Stop Button activated (4.3)
• X-ray source over temperature (4.4)
• DC power supply failure (4.5)
4.1 Transverse Motion failure

Motion Detection
• cSBC / OMI fail to see transverse motion during a patient scan, an

interrupt signal is generated and the cSBC resets and closes the shutter.
• A slotted disk at the end of the arm rotates through an infrared beam
(OMI), and pulses are sent to the cSBC board when there is
transverse motion.
• The transverse and longitudinal motion detection system (on cSBC) is

operational during patient scans and the “find block” test of the daily
QA. If the problem occurs during a quality assurance, it may be high
voltage arcing or a problem with the OMI.
4.1.1 Operator Induced - switch closed during scan

• Cause: When scanning, a defect in the transverse mechanics or a mis-
positioned patient may cause one of the transverse limit switches to
close when the scanner is acquiring data. Closure of a limit switch
prevents further operation of the motor. The shutter will close, the shutter
open lamp will go out and the end of exposure alarm will sound. Seconds
later the error message will appear on the screen.
Solution: If the patient is not centered on the table top or if the region
being scanned is too close to a limit in transverse travel, the limit switch
switch may be close while scanning. Re position the patient on the table,
further away from the limit.
4.1.2 Mechanical Failures - Unusual noise or irregular motion
DPX-NT Service Manual (Rev A- 1999) Troubleshooting 4-119

If the Detector / Tube Head motion is irregular, or scraping noises are heard,
the Transverse Mechanics may be binding. This symptom will typically be
detected as a failure by the daily QA Mechanics Test.
• Symptom: If the Detector Array / Tube Head is not moving when

scanning check:
• Mechanics are free to move
• Centent
• Stepper Motor
Troubleshooting Binding
Turn off the power to the scanner and move the affected parts by hand. Feel
the motion for spots where the carriages are more difficult to move. Listen for
unusual noises.
The following are common causes for Transverse Binding
• High Voltage Cable Routing
One of the most common problems is a failure of the Source and Detector to
reach the rear Limit Switch due to the Tube Head running into its own high
voltage cables. These cables must have a hump formed at the Rear
Longitudinal Carriage that allows the lower portion of the Tube Head to pass
under the cables.
The High Voltage Cables can also impede transverse motion toward the front
Limit Switch. This is caused when the cables have been tied down without
enough play for the Tube Head and Detector to move all the way forward.
These problems should be investigated by manually tripping both Limit
Switches while inspecting for cable conflicts, binding, or tension problems.
• Check to see that the bottom of the Tube Head is not hitting the
Transverse Centent
• Wiring
In rare instances, the wires from the Shutter Solenoid and/or Fans can snag
on the bolts that protrude through the frame on the foot end of the scanner.
This is solved by properly tying down these wires.
• Transverse Belt
The Transverse Belt should not be excessively tightened or this will cause
excessive binding in the transverse mechanism. It should be possible to
deflect the belt by 4 cm when it is properly tightened. Sometimes the spare
belt material near the clamp on the Tube Head Carriage comes into contact
with the forward gear and prevents the scanner from going all the way to
Home position.
• Drive Wheels

The wheels that support the Tube Head and Detector Carriages must be
adjusted so that they come into perfect contact with the Transverse Rails.
These wheel are best inspected with the table top, front panel and arm covers
off so one can sight down the extrusions. However, it is possible to test the
wheels by preventing any wheel from turning and seeing if the carriage will
still move. By preventing any wheel from turning, you should be able to tell
that it slides along the extrusion while the others roll. This indicates that the
wheel has not been excessively tightened down. This is least likely to be the
source of transverse motion problems, as it is unlikely that the adjustment of
the wheels would have become any tighter over time. They would be more
likely to loosen over time and fail alignment tests (see Alignment Test, section
4.12). Adjustments can be made by loosening and rotating the eccentric
bearings of any of the lower wheels.
• Gear And Pulley Positioning
Check all appropriate gears and pulleys. Verify that the set screws are
tightened and the gears and pulleys are not out of position.
• Limit Switch Positioning
If the transverse motion seems to be acceptable, but the number of steps in

the Quality Assurance Test is failing, check the position of the Limit Switches.
On Total Body scans, a limit switch out of position could allow the Source/
Detector Carriages to hit the frame or panels before the Limit Switch is
actuated.
• Transverse Motor
Check the Transverse Motor for a broken wire in one of the internal coils, or a
bad electrical connection to its Centent Motor Controller.
• Transverse Centent
The Centent Motor Controller, if defective, will cause transverse motion

problems. Sometimes the controller works well enough to acquire some
scans, but it will not provide enough torque to complete every fast scan. The
CURRENT SET voltage at terminal 11 on a properly operating controller
should be 14 to 16 VDC (transverse motor wired in parallel).
The longitudinal and transverse Centents are identical, and can be

exchanged. If the problem remains, the Transverse Motor should be
replaced.
4.1.3 Loss of OMI signal

If the error occurs consistently on the first line of a patient scan or during the
find block portion of the daily QA, and the scanner is moving in the transverse
direction, then check the following:
Cause: The Interrupt signal is being lost.

Solution 1: The pulses that normally enter the cSBC board at J14 (the
black wire at the center of the connector) may have stopped. These
pulses are necessary to keep the cSBC from resetting. These pulses can
be seen on a cSBC board LED.
Use the DPX-NT service software (Tools/Diagnostics/Scanner Motion /

Motion Commands Tab) to set the joystick speed to 50 steps, enable the
joystick and watch the LED. If the OMI is working the LIght will flash
when the Transverse Motor is run. If the LED flashes when the
mechanics are engaged, but the error still occurs, the interrupt was
invalid. Check for arcing in the high voltage system or replace the cSBC.
If the LED D9 (B in figure 4-1) does not flash,
• Verify that the slotted disk at the front of the lower arm rail is in the
middle of the slot between the photo diode and photo transistor.
• The slotted disk must be completely flat and remain in the center of
the sensor slot during its entire rotation.
• If the slotted disk has been in physical contact with the optical sensor,
the sensor may have debris on it, disassemble this mechanism, and
clean the sensor and the slots of the disk.
• Check the Cable running from the cSBC to the OMI for a cable break
by checking the individual wires for continuity.
4.2 Longitudinal Motion failure

• cSBC/ OMI fail to see longitudinal motion during a patient scan, an
interrupt signal is generated by the cSBC which resets and closes the
shutter.
• A slotted disk at the foot end of the table on the pulley for the
Longitudinal Drive Belt rotates through an infrared beam (OMI), and
pulses are sent to the cboard when there is transverse motion.
• The transverse and longitudinal motion detection system (on FOINK) is

operational during patient scans and the find block portion of the daily
QA. If the problem occurs during a quality assurance, for instance, it may
be the high voltage system is arcing or the OMI may be malfunctioning.
4.2.1 Limit Switch Tripped During a Scan

• Cause: When scanning, a defect in the longitudinal mechanics (binding)
or a mis-positioned patient may cause one of the longitudinal limit
switches to close when the scanner is acquiring data. Closure of a limit
switch prevents further operation of the motor. The shutter will close, the
shutter open lamp will go out and the end of exposure alarm will sound.
Seconds later the error message will appear on the screen.
Solution: If the patient is not centered on the table top (length wise) or if
the region being scanned is too close to a limit in longitudinal travel, the
limit switch may be close while scanning. Re position the patient on the
table, further away from the limit.
4.2.2 Longitudinal Binding

• If the scan arm fails to move when scanning check the stepper motor,
and Centent, if arm motion is irregular, check for binding.
Turn off the power to the scanner and move the affected parts by hand. Feel
the motion for spots where the arm is more difficult to move. Listen for unusual
noises.
When moving the arm longitudinally, only

push on the arm column. Pushing on the
forward parts of the arm can ruin Tube
Head/Detector alignment.
• Cable Track
The major impediment to longitudinal motion is the plastic Cable Track that
runs through the trough at the rear of the scanner.
This track is attached at two points: at the Rear Longitudinal Carriage and to
the scanner frame (low, rear and center) each spot by 4 bolts. Also, adequate
slack must be left in the cables inside the Cable Track or they will stop the arm
from moving fully to the foot end.
Should the Cable Track detach from the scanner frame, it will slide freely in
the trough and will eventually cause trouble. This can allow the Cable Track to
get in between the Rear Longitudinal Carriage and the scanner frame on the
foot end preventing the tripping of the limit switch.
• Front Longitudinal Carriage Dragging
Check the distance between the front longitudinal carriage and the
longitudinal rail with a go/nogo gauge (See installation Procedure DXAP2000
Chapter 5 appendices). The carriage should not rub the front rail, if necessary
insert shims behind the front longitudinal carriage.
• Tube Head Cable Routing

Problems at the head end of the scanner can be caused by a limit switch
being out of position (thus the arm runs into the frame before the Limit Switch)
or because the High Voltage Cables are tied down incorrectly where they
snake around from the Rear Longitudinal Carriage to the panel under the
Tube Head (High Voltage Cable Trough). If the cables are tied down too far
toward the head end (at the point where the three tie downs are), they can run
into the Longitudinal Motor Assembly and hold the arm away from the head
end Limit Switch.
• Slip Clutch
A slip clutch is part of the longitudinal motion system to limit torque. This is a
feature to protect the patient should he/she pinch an arm or leg between the
back side of the scanner and the Arm Column. If the Slip Clutch is set too
loose, it will fail to move the belt and will just "slip" as the motor turns. This
may produce the following symptoms:
• failure of Quality Assurance scan Mechanics test
• compressed image in limited areas of the image
• a Longitudinal Mechanics diagnostic failure
• Gear and Pulley Positioning
Check all appropriate gears and pulleys. Verify that the set screws are
tightened and the gears and pulleys are not out of position.
• Limit Switch Positioning
If the longitudinal motion seems to be acceptable, but the number of steps in

the Quality Assurance Test is failing, check the position of the Limit Switches.
On Total Body scans, a limit switch out of position could allow the Source/
Detector Carriages to hit the frame or panels of the scanner before the Limit
Switch.
If the mechanical stop is reached before the Limit Switch is actuated, check
carefully to see which part of the Arm Assembly is in contact with the Table
Assembly. The front part of the Lower Transverse Extrusion is clamped to the
Longitudinal Drive Cable at the front of the scanner. If the Lower Transverse
Extrusion is not clamped in such a way that it forms a 90 degree angle with
the length of the table, the rollers at the front end of the Lower Transverse
Extrusion may strike the end of the scan table before the Limit Switch is
actuated.
• Longitudinal Motor
Check the motor for a broken wire in one of the internal coils, or a bad
electrical connection to the Centent Motor Controller.
• Longitudinal Centent

The longitudinal Centent Motor Controller may be the cause of a failure. The
current set voltage should be roughly 9-11 volts at terminal 11 on a properly
operating controller. If this voltage is not correct, replace the Centent
Controller.
The longitudinal and transverse Centents are identical, and can be

exchanged. If the problem remains, the Longitudinal Motor should be
replaced.
• Longitudinal Belt
The Longitudinal Belt should not be tightened too much or this will cause the
brackets holding the gears to deform at either end of the scanner. When the
belt is properly tightened, it should be possible to deflect the upper and lower
sides of the belt so that they touch within 8 cm of the gears at either end.
• Drive Wheels
The rollers in front and the wheels in back that support the Arm must be
adjusted so that they come into perfect contact with the Longitudinal Rails.
Test them by preventing any wheel from turning and see if the carriage will still
move. By preventing any wheel from turning, it should be possible to slide the
carriage along the rail with one wheel dragging while the others roll. This
indicates that the wheel has not been excessively tightened down.
Adjustments can be made by loosening and rotating the eccentric bearings of
any of the lower wheels.
4.2.3 Loss of OMI Signal

• If the Scan Arm motion is irregular, or scraping noises are heard, the
Longitudinal Mechanics may be binding. This symptom will typically be
detected as a failure by the daily QA Mechanics Test.
If the error occurs consistently after the first line of a patient scan, and the
scanner is moving in the longitudinal direction, then check the following:
• Cause: The Interrupt signal is being lost.
Solution 1: The pulses that normally enter the FOINK board at J (the
black wire at the center of the connector) may have stopped. These
pulses are necessary to keep the FOINK board from sending an interrupt
to the SBC. These pulses can be seen on a FOINK board LED.
For LED location see figure 4-1. Use the DPX-NT service software
(Tools/Diagnostics/Scanner Motion / Motion Commands Tab) to set the
joystick speed to 50 steps, enable the joystick and watch the LED. If the
OMI / FOINK is working the LIght will flash when the Longitudinal Motor
is run. If the LED flashes when the mechanics are engaged, but the error
still occurs, the interrupt was invalid. Check for arcing in the high voltage
system or replace the FOINK and SBC.
If the LED does not flash,

• Verify that the slotted disk at the foot end of the scan table is in the
middle of the slot between the photo diode and photo transistor.
• The slotted disk must be completely flat and remain in the center of
the sensor slot during its entire rotation.
• If the slotted disk has been in physical contact with the optical sensor,
the sensor may have debris on it, disassemble this mechanism, and
clean the sensor and the slots of the disk.
• Check the Cable running from the FOINK to the OMI for a cable
break by checking the individual wires for continuity.
4.3 Failure of the 28V power supply

The 28 VDC power supply is only enabled when the X-ray tube is ramped,
use the service software (Tools/Diagnostics/ Scanner X-ray) to attempt to
ramp the Tube Head.
When the Supply is ramping the Red and Green LED’s on the MAX board will
light.
If the LED’s illuminate and the go out:
• Measure the output of the 28VDC power supply, and verify that it remains
constant during the voltage ramping and scanning operations.
• Check the High voltage power supplies, insure they are not arcing (Error
Log - see section 3.2) and are ramping.
If the LED’s fail to light:
• This supply is turned on by the X-ray Relay, so verify that the Relay is
closing. If not, then either the Relay is bad or it is not receiving the signal
from the SBC via the FOINK.
• Check the continuity of the cathode, the filament may have broken, MAX
board TP 4, TP 5 and TP 13 should be continuous with the Tube Head
control cable connected.
• The Tube Head Thermostat is wired in series with the Relay, so if it has
opened, the Relay will not be able to close.
• The 28VDC should also be measured at the Terminal Block. If not, check
the continuity of the wiring and refasten all connections. Also, check the
wire tie-downs for excess tension they may be putting on the wires.
• It may be necessary to check the wiring from the Terminal Block to the
MAX board and to the High Voltage Power Supplies.

4.4 Emergency Stop Button
The Emergency Stop button is a normally closed circuit, if it opens the
Emergency Stop interrupt will be sent from the FOINK to the SBC.
• Verify that the emergency stop button is out. If it has been pressed in,
press it again to release it.
• If 26VDC can be measured on both pins of FOINK connector J17, the

Emergency Stop Switch and the wires connecting it to the FOINK board
are good and the FOINK board should be replaced.
• If 26 VDC is missing, the Circuit is open between the FOINK and the
Switch.
• Insure the switch is functional
• Check the continuity of the wires from the switch to the FOINK board.
4.5 Tube Head Thermostat

There is a thermostat inside the Tube Head. This thermostat is normally
closed, but opens when the Tube Head temperature is too high.
• The thermostat will close again automatically after a cool down period of
usually less than 30 minutes. If 0 VDC is measured on both pins of
FOINK connector J15, the Thermostat and the wires connecting it to the
FOINK board are good and the FOINK board should be replaced.
4.6 Communication Error

The computer is not communicating with the SBC board.
Verify communications with the SBC in the service software (Tools/Service

Options Comm tab - Test Communications).
If this is unsuccessful, verify that the I/O cable from the computer to the SBC
Board is secure. Also, verify that the comm port is configured correctly (see
DXPC 2000 Chapter 5 appendices) and that all required drivers are present. If
all fails, the SBC or computer serial port is defective.
4.7 Other Diagnostic Failure Codes

Multiple error codes are possible. These will be displayed one after the other,
but the first one displayed is probably the problem. The Error Log will always
show the failures in the correct order, the others are generated as a result of
the first failure.
4.7.1 Reasons For Invalid Diagnostic Failures

Arcing of the x-ray high voltage system releases a large amount of
electromagnetic energy. This energy creates noise in the electronic circuits
and may cause the SBC to do unpredictable things, such as give invalid
diagnostic errors. Arcing is usually accompanied by white, blue or black lines
across patient scans (See Arcing, section 4.10).
4.8 Failing Quality Assurance Test

See chapter 2 section 12, for explanations of the various tests that are
performed during the running of the Daily Quality Assurance.
If any of the QA test results fail, none of the results are considered valid. The
results will be stored in the Quality Assurance History file, but these values will
not be averaged with the other results for calibration purposes. In addition, the
software will prevent patient scans until a passing daily QA has been
completed. Recent valid QA's are necessary for accurate results.
4.8.1 Block Position

After starting a QA, the operator is prompted to place the QA standard n the
table, if the DPX-NT fails to detect the Block in the correct orientation the QA
will not progress.
• Check Block position and orientation
The scanner may not be finding the correct "Home" position. The correct
"Home" position aligns the center of the x-ray beam with the center of the
Brass Piece when the Standard is correctly positioned. The Air Counts must
be obtained outside of the QA standard, next to the Brass Piece. If the
Reference Counts are obtained with the x-ray beam passing through the
Brass Piece, the Quality Assurance Scan will fail.
• Verify that the scanner limit switches are set correctly with the DPX-NT
home position jig (see DXAP2000 - DPX-NT Installation Procedure
Chapter 5 appendices).
4.8.2 Beam Stop Action

The Beam Stop Action test verifies the ability of the lead shutter to attenuate
x-rays from the tube head by verifying that the Background counts when the
shutter is closed are lower than counts taken through the brass piece with the
shutter open.
4.8.3 Mean% Spillover

An increase in the Spillover percentage over time is an indication that the
detector is losing resolution, even if the Spillover test does not fail. A large
change in the Spillover can be explained in some cases by standard
positioning (or a small change in the home position of the scanner). If the
beam is not fully eclipsed by the brass piece during the Spillover test, the
Spillover value increases dramatically.
Spillover stability is a test of detector bias drift. if the detector bias is drifting,
the mean spillover value will also drift.
4.8.4 Reference Counts and Ratio

During this test the baseline is established which will later be used for
comparing with the values obtained during the scan of the standard. Care
should be taken that the x-ray beam is not missing the standard, nor being
obstructed by the brass piece on the standard during the High and Low Air
Count test.
The Ratio value should remain fairly constant over time.
4.8.5 Ratio Fluctuations

The ratio of High to Low Channel Air Counts is the way the bone density
measurement is calculated by the changes in the ratio of High to Low Channel
counts. The Ratio should remain constant as long as the x-ray beam quality
and the resolution of the detector remain constant.
It is possible to view the Ratio trends in the Quality Assurance History. Check
both the 3mA Ratio and the 150 Ratio to determine if the either Ratio has
changed significantly.
The problems which could cause a change in air ratio are:
· deterioration of the resolution of the detector
· current leakage through the transorbs on the XORB board
· a faulty High Voltage Power Supply (kV unstable over time)
· changes to the x-ray tube insert
These are very difficult to diagnose by a method other than substitution of new
components until the Reference Counts Ratio returns to normal.
Detector deterioration or unstable High Voltage Power Supply, will usually

cause the Alignment Test Scan to fail.
The specification for XORB Board transorbs is that they must allow less than
0.5 micro amperes reverse bias current. At LUNAR, each transorb is
measured by applying a 5 Volt reverse bias to the transorb and a 100 kW 1%
resistor connected in series. The voltage measured across the 100 kW
resistor must then be less than 50 mV.
4.8.6 Transverse or Longitudinal Mechanics

Failure of this test is caused by one or more of the following:

• Incorrect Limit Switch positioning
• Defective Limit Switch
• A mechanical constraint
• A defective Motor
• A defective Centent Motor Controller
The values recorded for these tests should remain fairly constant over time.
Variations between QA's of under 25 steps should not be a cause for concern
as 1 transverse step = 0.05 mm and 1 longitudinal step = 0.1 mm, so the
actual variation is only a few millimeters.
If the number of steps continually increases from QA to QA, this could indicate
an impediment to the scanner's motion and should be rectified (see 4.1
(Transverse) or 4.2 (Longitudinal)).
4.8.7 Tissue Value

The tissue value should not be the sole failing parameter. The failure of this
test is usually accompanied by problems with Bone Mineral values (see
below) or Reference Counts Ratio trends (see above). If this is failing alone it
is probably a problem with the counting system or high or low kV (4.8.9).
4.8.8 Bone Mineral of the Standard Chambers

The software contains values which it expects the scanner to measure for the
scan of each chamber. If the mean of the BM measurements made for the
chamber does not fall within the predefined software limits the QA will fail. If
the percent coefficient of variance is over 3%, the QA will fail.
These failures will always occur if the Reference Counts or Reference Ratio
test have deviated severely from normal results. However if the Reference
Count results look normal, and the values are approximately equal to the
numbers obtained during the scanner installation, then the counts may be
unstable.
Another cause of failing on the bone chamber measuremnts can be arcing

during the QA. This can be detected by examining the QA History graphically
and looking for variation of the Large BM values. Note the few data points that
vary. These are the early signs of arcing.
This will also be apparent (but not obvious) on the QA Results printout. The
arc occurred in the third standard scan and elevated the BM values. If a
customer reports a failing QA because of a bone chmaber measurement
being too high, be aware that this could be an early warning of arcing. Obtain
from the site the QA history file and error log for analysis. Look for variation of
the Large BM values.
It is very important to notice these early warning signs of arcing so that the
system can be re-greased before any damage is done to the high voltage
cable connectors or the tube head.

4.8.9 Symptoms of High and Low KV
It has been noted in a small number of cases that defective high voltage
power supplies, or an arcing tube head may produce a voltage other than 76
kV. The DPX-NT monitors kV once per scan sweep.
Note: :It would be prudent in both of these cases to take a positive

and negative power supply, AND a tube head. Also, the XORB
test points may look normal (indicating 76 KV) in each case as
well. This usually occurs where the power supplies are
defective and so the monitor voltages returned to the XORB
may not show the true voltage. When the tube head arcs
causing the voltage to go too high, then the XORB test points
may indeed show the actual voltages.
4.9 Reference Counts

4.9.1 Unstable Counts
To examine the scanner's ability to count detector pulses consistently over
longer periods of time, run the Alignment Test option from the service software
program.
• If the "End of Exposure Alarm" rings during the time the Alignment Test
scan is running, see "Alarm Pings During Scan" in section 4.13.4. If the
Shutter Open or the X-ray On lamps on the front panel blink, during the
test, see section 4.13 also.
• While the Alignment Test scan is running, measure the voltage at test
points 1, 2, 5 and 6 of the XORB board. They should have approximately
the following values respectively: -0.150VDC, 3.8VDC, 0.150VDC, and
3.8VDC.
• A pure DC voltage on an oscilloscope at test point 1 and 5 of the XORB

will verify that there is constant current through the filament of the X-ray
Insert.
• If there is AC ripple in excess of 0.2 Vpp, the power supplies should be

replaced.
• Start and stop the x-rays several times while observing the voltage at
TP3 and TP7 of the XORB board. This is the programming voltage from
the SBC, and although this voltage is dependent on the feedback
information returned to the SBC, the voltages at the XORB board test
points should be approximately the same each time the x-rays are
produced. The AC ripple on this signal must be less than 0.2 Vpp.
Replace the SBC board if the proper control signal is not present.

• When the x-rays are off between scans, verify that the shutter aperture
lines up with the aperture to the Tube Head beneath. Take some
alignment pictures and verify that the image is a bright, rectangular
image and the entire alignment box is visible. If the alignment box is not
visible, the shutter Tube Head and detector apertures are not aligned.
• Open and close the shutter to make sure that it returns to the same
position each time. Turn the x-rays back on, and make sure that you
obtain nearly the same count rate each time the shutter is opened.
4.9.2 No Counts
When the table to the right of the peak graph on the Quality Assurance
Results printout is entirely filled with zeros, use the Signal monitor program in
the Diagnostics (see section 5.1) to create x-rays at 76 kV and 150 uA and
open the Shutter for sampling. Then check the following items:
I.Is the amber X-ray On LED illuminated?
A.If it is, skip to part II.
B.If not, the voltage or current ramping has probably failed. Are both the red
and green LED's on the MAX Board illuminated?
1.Voltage or Current Ramping Failures
If not, is the red LED illuminated?
a.X-ray Relay or FOINK
If not, measure the output of the 28 Volt Power Supply. Check the operation of
the X-ray Relay or the FOINK Board which controls its operation. If all of the
above are working, the red LED may be defective.
b.MAX Board Fuse
If so, the fuse is blown on the MAX Board (see section 4.16).
2.If the red and green MAX Board LED's are illuminated, verify the following
test point voltages:
a.Current Ramping Failure
• XORB TP1 is approximately 0.150 VDC. If incorrect, go to step d. If this

test point is correct, verify that XORB TP5 is also approximately 0.150
VDC. If this voltage is incorrect, substitute a new Positive High Voltage
Power Supply.
b.Voltage Ramping Failure
• XORB TP2 and XORB TP6 are approximately 3.8 VDC. If these voltages
are incorrect, verify that the voltages on XORB TP3 and XORB TP7 are
approximately 3.8 VDC. If TP3 and TP7 are not equal the XORB jumper
at J26 is set in the wrong position. If they are equal but incorrect, test the
cable from the SBC to XORB, or substitute a new SBC Board.

c.X-ray On LED
Test the X-Ray On LED by inserting it into the Power On receptacle. Replace
if defective.
d.High Voltage System
• Current ramping has failed. If TP1 and TP5 are zero and do not change,
check the polarity of the High Voltage Cables. The X-ray Insert is
essentially a diode, and will not conduct current from the anode to the
cathode.
• If either of the test points is at 1.0 VDC, the High Voltage Power Supply is
delivering as much current as it possibly can, and has automatically
limited the voltage.
• Check TP2 and TP6. If the voltage is approximately 3.8 VDC, the voltage
has been set properly.
Feel the heat sinks on the back of the High Voltage Power Supplies. If one of
the power supplies is cold, this is usually the defective one. If one is warm and
the other is hot, replace the hot one. The best troubleshooting technique may
be to substitute power supplies.
• If either TP2 or TP6 are incorrect, the possibility exists that one of the
High Voltage Cables or the Tube Head is shorted. The short may be
possible to find with an ohm meter, but often it takes several kV to break
down the defective component. It will be difficult to troubleshoot this
problem by any method other than part substitution.
Do not attempt to ramp the power supply above 50

kv without a cable connected, or arcing will occur
near the connector.
• Ramping between 40 and 50 kV is a good way to determine whether the

power supplies are able to increase voltage from 0 to 50 kV.
4.9.3 Decreasing Reference Counts

A long term, continuous decrease in the Reference Counts unaccompanied
by a change in Reference Ratio is a serious problem. A count rate of at least
500,000 Low Channel Reference Counts is necessary to maintain precision of
results when scanning thick patients. Reference Count values should change
by less than 10% from the day of installation. The possible causes are:
I.Lead Filings - Shutter Wear

A rough edge around the shutter aperture may be wearing away on the tube
head below. The lead filings fall off the shutter aperture and gather on the filter
below, causing a reduction in x-rays over time. Any wear should be easily
visible on the underside of the shutter paddle. If there is visible wear, the lead
dust must be removed from the top of the filter. The Collimator assembly must
be removed, the filter cleaned, and then the Collimator assembly reinstalled
and realigned.
II.A Change in Current Control Settings
Use the Signal monitor option of the service software program to produce x-
rays (Tools/Diagnostics? Scanner X-Ray). Select 76 kV and 750 µA operation.
• Verify that the SBC is properly controlling the current. TP11 of the MAX
board should be approximately 0.75 volts. This voltage is dependent on
feedback information from the power supplies, which makes it difficult to
troubleshoot by any means other than SBC substitution.
• Check the current through the X-ray Insert. The absolute value of the
voltage at test points 1 and 5 on the XORB board is proportional to the
current through the X-ray Insert. 1 millivolt is equal to 1 micro-ampere of
current. A current setting of 750 µA should give a reading of 0.750 VDC
at test points 1 and 5. If either of these voltages vary from the expected
by more than 10 millivolts, the MAX board could be at fault. If TP1 and
TP5 are more than 15 millivolts apart, substitute new high voltage power
supplies.
4.10 Arcing
The X-ray Tube Head Insert is an evacuated glass enclosure. An AC current
is applied to the filament inside the insert. It glows like the filament in a light
bulb, and electrons are boiled off into the evacuated space. A high voltage is
applied between the anode and the cathode causing electrons to rush toward
the anode, striking it and creating x-rays. As long as the insert is properly
evacuated, there can be no internal arc. However, no insert can be totally
evacuated and impurities can be ionized creating a lightning like effect; arcing.
During the arc the resistance of the insert is dramatically decreased and a
large amount of current flows.
• The significant amounts of electromagnetic energy released inside the

scanner can cause problems with the electronics of the scanner system
and may result in abnormal operations of the scanner. An arcing scanner
will have one or more of the following symptoms:
• complete lock up of the system
• a diagnostic error code message which is undefined or inappropriate
• a vertical stripe or artifact in the image of the patient's scan (effects all 16
detectors at once)

• Transverse Motion Failure message.
To specifically locate the source of an arc, it is necessary to find out which

high voltage power supply provides the excessive current. This may be done
by recording the power supply current monitors at TP1 and TP5 of the XORB
board with a storage oscilloscope. An arc typically draws 1.5 mA from the
power supply for about 1 ms. The trigger voltage should therefore be set at
1.5V for TP1 and for TP5.
• Arcing can also occur inside the high voltage connectors. This will
usually result in a plainly visible black or brown carbon track through the
grease on the connector. In any case, once the high voltage connectors
have been removed from the Tube Head and the power supplies, they
should not be re-connected without first being cleaned and regreased
(see procedure DXSE0002 in the chapter 5 appendices).
• After cleaning the old grease off of the connectors, they should be
carefully inspected for carbon tracks. Look for these tracks on both the
rubber cable connectors and on the phenolic sockets of the Tube Head.
If such tracks are found after cleaning, the following are the options for
returning the scanner to service:
• If carbon tracks are found on the rubber cable connectors, they can be
removed by excising the damaged section with a sharp blade. Severe
tracks can burn quite deep into the rubber, so care must taken to remove
all the damaged rubber. After the carbon tracks have been removed,
additional grease must be used when repacking the connection to fill in
the volume of the removed rubber.
• If the above procedure requires too much rubber to be removed, or the

carbon track looks very severe, another option is to replace the high
voltage cable.
• Arc tracks will be impossible to see on the sockets in the Tube Head.
Therefore, if arc tracks are seen on the rubber cable connectors, the
sockets should be sanded with emory cloth as a precaution. After
sanding the socket, remember to flush the socket with cleaning solution
to remove any particles.
• If the tracking inside the socket is too severe or the carbon track cannot
be removed, another option is to replace the Tube Head.
Note: IT IS VERY IMPORTANT TO REMOVE ANY CARBON

TRACKS ON THESE SURFACES! Carbon tracks that are
simply covered by grease or not completely removed will still
provide a path for arcs to follow.
4.10.1 Limit Switch Tripped During Scan

If a Limit Switch is tripped during an install test, verify the Limit Switches'
location with the Service Software (Tools/Diagnostics/Scanner Motion). If this
problem occurs any time after install, see the problem description below.

If the transverse mechanics of the scanner become imprecise, it may cause a
Limit Switch to be tripped during a scan. This will usually only happen during a
total body scan or during an Alignment Test test since both of these scans
involve full-width scanning. Once the switch is closed, the motors stop, the
End-of-Exposure Alarm sounds, the amber SHUTTER OPEN lamp turns off
and after a few seconds a Diagnostic Failure appears on the screen.
• During full-width scanning, the Detector Carriage comes very close to the
Limit Switches, so any imprecision will cause a Limit Switch to be tripped
and the scan will be aborted with a Diagnostic Failure message for
Transverse Motion Failure.
A cause of this problem is a loosening of the first drive Reduction Belt which
connects the Transverse Motor to the first Reduction Pulley. This loosening
causes the belt to "walk" on the pulleys causing enough imprecision in the
motion to trip a switch. To tighten the belt, first remove the Pulley Shroud and
loosen all four nuts that hold the motor in place. Then, while holding the motor
such that the belt is pulled taught, tighten the nuts to secure the motor in
place. Replace the shroud and test the scanner (an Alignment Test test works
well).
If the Tube Head cables come into contact with the cable bundle entering the
cable track, it may be impossible for the scanner to complete all of the
necessary transverse steps away from the operator. Consequently, on each
scan line the detector will move closer to the front transverse limit switch, and
the switch may be eventually closed. Form the cable bundle exiting from the
cable track into an arch such that the Tube Head cables will move under the
arch rather than running into the bundle. This arch must not be too high. If it is,
there will not be sufficient slack in the Tube Head cable bundle to allow the
Tube Head to move to the front transverse limit switch. Also, if the arch is too
small, it may cause too much slack when the Tube Head is at the forward side
of the table. This causes the Tube Head cable bundle to rub against the inside
of the front panel causing a scraping noise to be heard. If the above does not
solve the problem then check the other mechanical components. Electrical
components that could cause such a failure are the Centent Motor Controller,
the Transverse Motor, the FOINK board or the SBC board.
4.11 Imaging Problems

4.11.1 White, or Grey in the first or second scan line:
The software is not perfect in its ability to determine the correct grey level of
the entire scan based on the first line of data. Sometimes the grey levels will
be set incorrectly during acquisition. During analysis the grey level is easily
adjusted to give a good image, and the results are not affected by this imaging
problem. This problem is most often found on very thin patients. Adding extra
tissue equivalent material (rice bag or saline solution) to a very thin patient
may be all that is necessary to cure the symptom.
4.11.2 Femur Scan Problems

Most image discontinuity problems occur in femur images performed at 3 mA
on thin or osteoporotic subjects. These lines usually occur in the trochanter
area where the x-ray beam is least attenuated by tissue.
These lines are caused by Automatic Gain Stabilizer (AGS) trying to adjust
the input signal which is at an excessively high count rate. However, the AGS
is not at fault, and the correct action is for the customer to attenuate the x-ray
beam. Lunar normally recommends placing a rice bag (on its side to create 12
cm of patient thickness in the x-ray beam) along the side of the patient's thigh
for thin or osteoporotic patients.
4.11.3 AP-Spine Image Problems: Probable causes

• the shutter closes (causes the shutter open lamp to go out, and the End
of Exposure Alarm to sound).
• increase or reduction of high voltage to the detector (causes horizontal

artifacts in the image).
• loss of the signal from the detector (this effects all 16 detectors at once)
• loss of current to the x-ray insert filament (28 volt power supply error
message, the orange lamp to go out, and the End of Exposure Alarm to
sound).
• bad x-ray relay contacts (providing power to tube head power supplies)
• reduction in AC Line voltage
• loss of proper high voltage on the x-ray tube
• faulty operation of the AGS system (white lines are short and found only
where scan lines move from air into tissue).
• arcing (may cause vertical artifacts in the image)
4.11.4 Broken Signal Cable

The cables which carry the voltage to the detector and return the signal from
the detector array are part of the upper and lower cable bundle assemblies.
Any break or significant pinch of the cable can cause reduction in counts in
either or both channels. This could result in horizontal artifacts which effect all
16 detectors at once.
4.11.5 Loss of tube head current

The tube head control cable contains the wires which provide power to the
filament transformer. If the wire to the transformer center tap breaks, the x-
rays will stop, the orange lamp will go off, and the end-of-exposure alarm will
sound. If either of the other two wires break, the MAX board fuse will blow.
Always ask the operator if a "ping" sound (the end of exposure alarm) is
heard, and whether the Shutter Open or X-Ray On lamp turns off. In the case
of a tube head current problem, the X-Ray On light will turn off.
4.11.6 X-Ray Relay Failure

See section 4.16.
4.11.7 Unstable AC Line

If the customer's AC line conditions are unstable, voltages 11% below the
scaners AC input configuration will begin to drop the high voltage on the x-ray
tube. The counts will drop significantly with only a change of a few kV.
However, this normally causes black or dark grey lines in the scan image.
4.11.8 Arcing
If the tube head is arcing, the arcs will be more likely to occur at the higher
current settings. Arcing generally also causes other strange symptoms such
as:
• Scanner stops in the middle of a patient or QA scan with no error

message or with transverse mechanics fail
• The QA scan fails intermittently on bone chamber measurements
• The scanner periodically leaves the message on the screen "Starting X-

rays Please Wait" for a longer than normal period of time (more than 10
seconds)
If you see arcing symptoms, try the following service action:
1.View the Quality Assurance History (see section 4.15). In particular note the
trend in BM Values as discussed in the Failing QA's section of this chapter.
If there is evidence of failures in the mean BM value:
2.Repack the high voltage connections as described in the chapter 5

appendices. Note if an arc track is visible in the insulation compound.
3.Replacement of the tube head if no arc tracks are discovered, or if the

repacking of the connectors does not eliminate all arcing symptoms.
Summary
Except for the x-ray relay, the cause of the problem will be difficult to find. Try
to obtain some additional information. If the customer is hearing the end-of-
exposure alarm, or seeing the yellow x-ray on lamp flickering, you can deduce
the tube head control cable is bad. Likewise, it is possible to decide on the
shutter/collimator/fan cable. In the case of no alarm or lamp indications, or in
the case where large deviations occur in the peak, the upper and lower cable
bundles should be replaced, as problems with the coaxial cable will be too
expensive to troubleshoot.
4.12 Failing Alignment Test Results

4.12.1 Image

The Image is a graphic illustration of the counts recorded during the
Alignment Test. A good image has a black field with evenly distributed grey
dots and perhaps a few randomly distributed dots of various colors (green or
blue usually).
Figure 4-6. Failing Ailigment Test
A poor Deviation Image will have lines, streaks or spots (indicating counts
higher or lower than expected). When the image is analized, click first on
points and then back to results, this will typically point type failing points (they
will have a yellow box around them).
• The information tab (see figure 4-2) will show the test outcome (pass /
fail).
• Lines or streaks going longitudinally in the image indicate an alignment

problem. Recheck the alignment of the scanner including the levelness of
the scanner. Also, check the scanner frame for any bending that may
have occurred at the site or during shipment.

• Lines or streaks going transversely across the Alignment Test image
indicate a problem with the AGS, on the Detector Daughter Board in the
detector array. Again, replace parts until a passing Alignment Test is
obtained.
• Troubleshooting tip: if the Alignment test can be run with the Alignment
Aperture on, this will make the test more sensitive as the beam will be
further collimated to the exact size of the detector. Any failures (beam
straying off the detector) will be exaggerated.
4.13 Indicator Failures

4.13.1 X-ray On LED Blinking
The amber X-RAY ON LED should glow steadily once it is illuminated, until
the x-rays are turned off. If the X-RAY ON LED blinks while the shutter is open
for a patient scan, the End of Exposure Alarm should sound.
The amber LED is controlled by a comparator on the FOINK Board. This LED
illuminates when approximately 40µA (or greater) of current is passing
through the X-ray Insert. On Spellman system scanners the amber light may
appear to fade out slowly when x-rays are ramped down. This due to the
Spellman power supplies bleeding off current and is not a problem.
If the voltage ramping fails, the High Voltage Power Supplies must be shut
completely off before a second ramping attempt is made. If the amber X-RAY
ON LED turns on momentarily, then turns off for a few seconds before coming
on steadily, the system is having difficulty ramping the high voltage. One of the
High Voltage Power Supplies may be defective.
The SBC does not monitor the Insert current once the proper level has been
reached. Therefore, if the current to the Insert is interrupted, the SBC will not
recognize the problem and will not alert the computer, or terminate the
exposure.
If the X-RAY ON LED blinks once the x-ray high voltage has been set, there
must be a problem in one of the following areas:
• Tube Head Control Cable-The most likely cause of an intermittent

problem in this circuit is a broken wire in the Tube Head Control Cable.
The Red wire is most likely the broken one, as a broken blue or black
wire should blow the MAX Board Fuse. Turn the scanner off and test for
continuity between MAX Board test points TP4, TP5, and TP13.
• MAX Board-The MAX Board may be operating intermittently. Substitute a

replacement MAX Board.
4.13.2 Shutter Open LED Blinking

The amber Shutter Open LED is controlled by the Limit Switch on the Shutter/
Collimator Assembly. If the Limit Switch is defective or improperly adjusted,
the Shutter Open LED may be switched on and off. This will usually be
accompanied by the sound of the End of Exposure Alarm if an exposure is
underway.
If the Shutter is actually opening and closing intermittently and uncontrollably,

the problem is either on the FOINK, or a broken wire between the FOINK and
the Shutter/Collimator Assembly. Remove connector J11 from the FOINK
Board and measure the resistance between pin 5 and pin 6. This will be a
measurement of the resistance of the Shutter Solenoid and the cable through
the Cable Track. If the problem occurs on every scan, run a scan while
making this continuity check. If the cable and solenoid seem to be working
properly, substitute a new FOINK Board.
4.13.3 Shutter Not Operating

If the Shutter Solenoid will not open, the problem may be caused by one of the
following:
• The Shutter Open LED-If the Shutter Open LED fails, a properly
operating FOINK board will prevent operation of the Shutter Solenoid.
Check the LED for continuity, replace it, or substitute a working amber
LED temporarily.
• Solenoid Cable-Remove J11 from the FOINK Board and check continuity
between pin 5 and 6 (see Shutter Open LED Blinking above).
• FOINK Board-Replace the FOINK Board.
4.13.4 End of Exposure Alarm During Scan

If the sharp "Ping" sound of the End of Exposure Alarm is heard during a
scan, look at the computer display to see if a Diagnostic Failure Code is being
reported. If so, see section 4.1.
If no Diagnostic Failure Code is reported, the scanner may still be in motion

continuing with the scan. Abort the scan and remove the patient from the
table. In any case, note the status of the SHUTTER OPEN light and the X-
RAY ON light.
• Both the SHUTTER OPEN light and the X-RAY ON light are on and
steady. This would indicate a faulty FOINK board. Replace it
The SHUTTER OPEN light is off. This could indicate the following:
• The LED becomes defective during the scan and since the shutter
solenoid and this light are wired in series, the Shutter closed and the
Alarm sounded.
• The cable to the amber Shutter Open light broke during the scan with the
same result as above.
• The shutter solenoid failed and the Shutter closed followed by the Alarm
sounding.

• The FOINK is faulty.
• The SBC is faulty.
The X-RAY ON light is off. This could indicate the following:
• X-ray production has halted. This turns off the X-ray On light and sounds
the Alarm.
4.14 Communications Failures

Should the scanner, host computer and or Detector Mother Board lose
communications with each other, there are a number of things to check:
A good troubleshooting tool is the COMM test in Tools/Service Options -

COMM tab.
Check
• the I/O cable connections at the serial port on the back of the Host
computer and at the SBC. Be sure both connections are tight and that
the thumb screws are used to hold the connectors firmly together.
• inspect the connector on the SBC. This connector is very fragile and may
have been damaged. Be very careful when connecting the I/O cables to
the SBC.
• Check and inspect the Signal Cable input at the SBC
• Check the Connection at the Detector Mother Board and the Bulkhead,
where the two halves of the signal cable meet.
• Verify the power LED’s on the SBC are lit (See section 4.19)
• Verify that the Power LED’s and PLD programming LED’s are lit on the
DMB (see section 4.21)
If the ports are properly configured and all power is present, and
communication still fails, then the probable causes are:
• A faulty I/O cable.
• A faulty SBC.
• A faulty serial port / serial port card.
Replacement of these parts is the best troubleshooting method.
4.15 Viewing Quality Assurance Trends

DPX-NT software includes the capability to view, print or graph data contained
in the Quality Assurance database. View and print display selected results of
many of the tests run during the Daily Quality Assurance in tabular form. The
graph feature will graph the results of only one of the Quality Assurance
parameters. All features allow for the user to select the time period to be
examined.
4.15.1 What to Look for in the QA History

All categories should remain steady over time. Check the PASSED column for
failed QA’s. If a failing QA is found, try to determine the cause, including
operator error.
The limit for % Spillover is 13%.
If any sudden jumps are noticed in the values of any of the categories,
determine first if these are due to service work such as a Tube Head
replacement. If service work causes a shift in the QA values, then compare
present values to those obtained only after the service.
4.16 MAX Board Troubleshooting

The MAX board controls the current through the X-ray Insert in the Tube
Head. DPX-NT scanners use MAX version 02B currently.
The current at a given kV across the insert is a function of insert filament

temperature. The MAX board adjusts the current by regulating the filament
temperature to provide the proper current as set by the SBC. The relationship
is Insert µA X 1000 = SBC input (in volts DC), so for an SBC input of 5VDC,
Insert µA = 5000.
The Positive High Voltage Power Supply has a current monitor output (mA
MONITOR); the voltage at this output is proportional to the current passing
through the X-ray Insert. This monitor voltage is connected to the MAX board
as feedback (mA FEEDBACK).
What to look for
• Make sure that all connectors are fully seated.
• Check Lemo connectors for loose parts.
• Check for loose wires on the insulation displacement connectors.
• Check the position of the shorting jumpers on pin headers JB1, JB2, and
JB3 for: Be sure pins 1 and 2 are connected as indicated by silk screen.
When the X-ray Relay is on, both the red and green LED's on the MAX board
should be illuminated. If both are out, no power is getting to the MAX board. If
only the red LED is lit, then the MAX board fuse is burned out or missing.
Electrical tests

When the board is powered up, and x-rays are being generated, the following
measurements may be performed:
With a VOM set on 200 VDC, you should measure about 18 to 21 VDC on
TP's 4, 13 and 5 referenced to TP3 (GND).
Note: If an oscilloscope is available, you should see about 18 to 21

VDC on TP13. However, TP 4 & 5 should have a 36 to 42 volt
peak square wave. A VOM will show the average value of the
square wave, i.e. 18 to 21 VDC.
4.17 FOINK Board Troubleshooting

The FOINK is a multipurpose interface board designed for use with the DPX-
NT. Operation is both analog and digital.
Optical isolation is used to isolate the +26VDC supply from the +5VDC and
+12VDC (logic) supplies, and eliminate interference between the motor
circuits and the event (detector) signals.
What to look for
Figure 4-7. FOINK Diagnostic LED’s
FOINK LED’s:
• A - (D10) Longitudinal OMI, when this LED flashes, the Longitudinal OMI
infrared beam is
• B - (D9) Transverse OMI, when this LED flashes, the Longitudinal OMI
infrared beam is

• C- (D8) X-ray on (28 VDC supply), when this LED is lit when the +28
VDC power supply is on
• D - (D7) Mechanics engage, when LED is out the motor(s) are enabled
• E - (D6) - Errors Clear, must be lit - out when FOINK detects an error
(failsafe)
• F - (D5) Reset when this LED is lit the SBC is in Reset
4.18 OMI Board Troubleshooting

The OMI board, being a rather uncomplicated device, has little in the way of
things to watch for in installation and use. There are three such boards, one
on the Front Longitudinal Carriage (transverse), at the foot of the scanner on
the longitudinal idler shaft (longitudinal), and on the collimator (shutter open
detect).
What to look for
• Check the connector to each board for proper seating.
• Examine the area where the wires attach to the board itself; it is possible
the may fray or break.
• Insure that the interrupter disk does not rub against the plastic detector
housing. If it does, adjust by loosening the two machine screws that
attach the plastic detector, reposition the detector and re-tighten the
screws.
Electrical tests
The signal from the OMI board is nominally rectangular in shape. The signal is
generated when the Interrupter Disk alternately passes and occludes a light
beam between the two posts on the photo-transducer. With the beam
occluded by the disk, the output signal should be about 5 VDC (close counts).
When the beam is allowed to pass through a slot in the disk, the signal output
is near ground potential (see FOINK troubleshooting 4.17).
Symptoms of possible OMI failure
• Scanner shuts down at the beginning of a patient scan.
• Scanner shuts down unexpectedly during a scan.
• Either condition above should be accompanied by a Diagnostic Failure

Transverse or Longitudinal (see section 4.0).
4.19 SBC Troubleshooting

The SBC consists of a single circuit board that uses the 8032 microprocessor
with a RS-422 interface to the Host PC and a RS-422 interface to the Detector
Motherboard (DMB)
The SBC is located on the electronics pan in the front center.
Figure 4-8. DPX-NT SBC highlight indicates the location of the diagnostic
LED’s
Figure 4-9. DPX-NT SBC Diagnostic LED’s
What to look for
• Green LED (C in figure 4-5) is on then you have +5VDC to the board.
• Red LED (A in figure 4-5) is on then you have +12VDC to the board.

• Amber LED (B in figure 4-5) is on then you have -12VDC to the board.
• Red LED (E in figure 4-5) is the DTR reset line, when this LED is lit, the
Detector, FOINK, or SBC are detecting an error.
When the DTR Reset Line is lit:
• Check the LED’s on the DMB (see section 4.21)
• Check the FOINK LED’s
• Check the Signal Cable
The Service Software can be used to verify communications between the

Host / SBC and the DMB.
Go to Tools - Service Options - Communications Tab - test

communications
• Red LED (D in figure 4-5) the scanner Reset, when this LED is lit, the
communications with the Host PC are in Reset.
• Verify port settings on the Host PC (See DXPC 2000, chapter 5

Appendices)
• Verify communications cable
• Green LEDs (G and H in figure 4-5) flash when data is being received by
the SBC
• Green LED (F in figure 4-5) is not assigned a function at this time.
The reset button near the communications cable connector causes a reset
signal at the SBC microprocessor. Also, disconnecting the serial cable will
cause a reset state until the cable is re-attached and communications
reinstated.
4.20 XORB Troubleshooting

The XORB board routes a number of important signals to the rest of the
system and protects the system from transients by shunting them to ground
with transorbs.
What to look for
• All connectors firmly seated.
• Check to see that all wires and cables are firmly affixed to their
respective connectors. Pay particular attention to Lemo connectors,
since the jam nuts on the connectors are prone to be loose.

• Check and tighten, if necessary, all mounting screws for the XORB
board.
Electrical Tests
• Measure impedance between XORB ground plane and the electrical

pan. It should be less than an ohm.
• There should be no low impedance (less than 10 ohms) reading between

any signal or signal ground and chassis ground on the XORB when the
as-associated signal connectors are disconnected.
The following test points should have the following readings:
Table 4-12. XORB Test Points
Test Point kV mA Limits

TP 1 76 .750 0.74 - 0.76
TP 5 76 .750 0.74 - 0.76
TP 1 76 3.00 2.97 - 3.03
TP 5 76 3.00 2.97 - 3.03
TP 2 76 .750 3.76 - 3.84
TP 6 76 .750 3.76 - 3.84
4.21 Detector Motherboard Troubleshooting
Figure 4-10. DMB Diagnostic LED’s

Diagnostic LED’s in figure 4-6
• A - (Green) Power +12 VDC Present
• B - (Green) Power - 12 VDC Present
• If the 12 VDC power LED’s are not illuminated power down the
scanner, wait 30 seconds and power back up (see section Chapter
2.1.2)
• Check +5, +/-12 VDC Power Supply 1
• C - (Green) DMB PLD Programmed and ready
• If the DMB PLD LED is not lit verify FIRMWARE version with the
Service Software (Tools/Set Download Parameters / Query), if
necessary download to the DMB.
• D - (Green) DDB 1 PLD Programmed
• Verify the DDB card is seated in its socket
• E - (Green) DDB 2 PLD Programmed
• F - (Green) DDB 3 PLD Programmed
• G - (Green) DDB 4 PLD Programmed
• H - (Red) Data Sent to SBC (should flash when acquiring data)
• I - (Red) Data Sent to SBC (should flash when acquiring data)
• J - (Green) Detector Reset
• Verify Communications with the SBC
• Verify All DC voltages are Present on the DMB
• K - (Green) +5 VDC present
• Check +5, +/-12 VDC Power Supply 1
• L - Detector Mother Board Reset Button
4.22 Detector Daughter Board Troubleshooting

Figure 4-11. Test Point Board
The Test point board gives the service engineer access to all of the signals for
the individual Detector Daughter Boards
The Test Point Board is broken into 2 areas:
Analog Signals
DMB Controlled Programming Information (same data to all DDB PLD’s

FIRMWARE from DMB Flash RAM)
• DCA REF - DCA Reference Levels - High and Low Energy Reference
Levels for event counting windows
LEL = 1.19 VDC
LEH = 1.66 VDC
HEL = 1.96 VDC
HEH = 2.79 VDC
• AGS REF AGS Reference Levels - High and low Energy
CENTER = 2.35 VDC
LOWER = 2.00 VDC
• Detector Bias Setting (BIAS =.450VDC)
• +5 VDC Ref (+5.00 VDC)
• - 5 VDC Ref (-5.00 VDC)

Individual Detector Signals (Stored in DMB Flash RAM)
• GAIN - combination of Peak and AGS signal gain - setting for Shaping
Amplifier - visible only with Oscilloscope
• AGS - AGS amplify or Attenuate signal - visible only with Oscilloscope
• BiPolar - Bipolar signal out of the shaping Amplifier
Digital Signals
• AGS ROLL - logic signal for AGS rollover - this signal is not currently
utilized by the software
• LE - Low Energy Event detected and counted
• HE - High Energy Event detected and counted
• SAMPLE - Sample clock signal
• AGS ENABLE - Operate Calibrate signal - locks out AGS for Peaking
operation

5 1 Service Procedures
Chapter 1:Service Procedures
This chapter contains procedures for testing and replacing parts.
The appendices are all uncontrolled copies of GMP documents

and as such are subject to change without notice.
5.0 Reloading LUNAR Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-155

5.1 Peaking the Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-155
5.1.1 Peaking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-155
5.2 Tube Head Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-156
5.2.1 Shelf Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-157
5.2.2 Mounting The Tube Head . . . . . . . . . . . . . . . . . . . . . . . . 5-157
5.3 Lower Cable Bundle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 5-157
5.3.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-157
5.4 Upper Cable Bundle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 5-160
5.4.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-160
5.5 Tube Head Control Cable Replacement. . . . . . . . . . . . . . . . . . . . . 5-162
5.5.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-162
5.6 Tests to Perform after Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-165
5.7 Returning Parts To LUNAR (For International Distributors) . . . . . . 5-166
PRODIGY Service Manual (Rev B - 1998) Service Procedures5153

5-154Service Procedures PRODIGY Service Manual (Rev B - 1998)

5.0 Reloading LUNAR Software
It is sometimes recommended in answer to a particular problem that the
software be reloaded. This can be accomplished by locating the latest version
of the Lunar Software. Please note, it may also be necessary to have the
customers system ID number and feature code.
Note: BE SURE OF WHICH VERSION OF SOFTWARE IS

PRESENTLY BEING USED! RELOADING OLDER
SOFTWARE CAN DESTROY IMPORTANT DATA.
• The about tab under the help menu of the Lunar Prodigy Software shows
which version is presently on the system.
• Insert the Lunar System CDROM into the CDROM: drive
• Double click on the My Computer icon on the Windows NT desktop
• Double click on the CD ROM Drive with the LUNAR Prodigy CDROM in
the drive
• Double click the Software Installation ICON
• Follow the instructions on the screen until a message is displayed

confirming a successful software load.
Note: When new versions of software are released they may not be
loaded in the above manner. BE SURE TO FOLLOW THE
LOADING INSTRUCTIONS THAT ACCOMPANY ALL
SOFTWARE UPDATES.
5.1 Peaking the Detector

The Prodigy Detector may need to be repeaked, this is a good diagnostic tool
to use when a detector is suspect.
The actual peak setting of each of the detector elements is done in the
software - on the Detector Mother Board with the data from the Detector
Daughter Board.
5.1.1 Peaking Procedure

1) Go to the Service Mode of the Prodigy Software, open the Spectrum Option
(Tools/Spectrum)
2) Place the brass spillover piece on top of the collimator aperture.
3) Click on the Peak button in the Prodigy Software toolbar.
4) Verify that all values are 2000 +/- 600.
PRODIGY Service Manual (Rev B - 1998) Service Procedures 5-155

5.2 Tube Head Replacement
When a replacement Tube Head is sent to a site in the field for replacement, it
is not ready for immediate installation into the scanner. Some parts from the
old Tube Head must be transferred to the new Tube Head (see list below and
figure 5-1).
These parts are: 1) tilt bar
2) lead ring (around filter area)
3) lead wrap
4) fan bracket
5) nuts, bolts and washers
6) collimator positioning hardware
7) the collimator assembly.
Figure 5-12. DPX Series Tube Head components
Verify that all necessary parts have been transferred to the new Tube Head
before shipping the defective. LUNAR has received defectives with the lead
ring, for example, still in them.

5.2.1 Shelf Life
Many distributors have asked about the shelf life on the Tube Heads in their
stock. The shelf life of the Tube Head is not accurately known, but we feel at
this time that it is over two years. Perform the following Tube Head
inspections on all replacements before mounting them:
1.Check the shelf for oil spots which would indicate that the Tube Head has a
leak. If oil is discovered, return the Tube Head for warranty replacement.
2.Shake the Tube Head and listen for the sound of an air pocket or bubble
inside. If a bubble is discovered, return the Tube Head for warranty
replacement.
Note: If a Tube Head has been on the shelf for three weeks or more,
perform the warm up procedure described in Procedure
DXAP2001 Prodigy Source Detector Alignment.
5.2.2 Mounting The Tube Head

Use procedure DXSE0000 in this chapter's appendix for repacking the new
Tube Head's high voltage connections, and refer to the installation
procedures, DXAP2001 and DXAP2002 (also in this chapter's appendix), for
tube head mounting and alignment procedures.
5.3 Lower Cable Bundle Replacement

Necessary tools:
• 1/8" and 5/32" Hex Wrench,
• Small Screwdriver
• Diagonal Cutters
• 3/8" Wrench
• Large and small wire ties.
5.3.1 Procedure
1.Shut off the power to the scanner.
2.Take off the table top by removing four screws (two at each end).
3.Remove the head and foot end panels. At the foot end of the scan table
unplug the A/C power cable to the scanner.
4.Move the scan arm to the head end of the table.
5. On your new lower cable bundle, use a diagonal cutters to cut the wire ties
holding the cable together, also unfold and read the LUNAR SERVICE
NOTES attached to the new cable bundle.

6.Lay the new cable bundle flat out on the floor. Locate the end with the (2) 16
pin connectors and the yellow and orange Lemo connectors, this is the end
that connects to the bulkhead, this is the end to start the install action from.
7.Locate the bulkhead on the scanner. There are (3) wire ties that hold the
cable bundle in place between the bulkhead and the cable track. Before
cutting any wire ties note the way the cable bundle is tied down and the way
the cable lays before it enters the cable track. The new cable must be
fastened in the same position and lay the same way.
8.Carefully cut the (3) wire ties between the bulkhead and the cable track with
your diagonal cutters. Disconnect the large RS232 connector (Detector Signal
Cable) by unscrewing the two screws on the connector.
9.Next disconnect the two white 16 pin molex connectors. These connectors
have a catch lock located in the center of the housing which must be
depressed to disconnect them from the bulkhead.
10.If you try to remove the cable bundle by pulling it back towards the cable
track you will notice a 3 conductor gray wire cable tied to the high voltage
cable bundle. This wire carries the transverse optical interrupt signal from the
front carriage (we will refer to this wire as the OMI cable). To find the location
of the OMI board and the front carriage follow the OMI cable. On your new
Cable bundle the OMI wire is connected through the bulkhead.
11.To remove the OMI cable push the x-ray tube head all the way to the
outside of the scanner (patients left side), then notice the clearance between
the front panel and the high voltage cable bundle connecting to the x-ray tube
head and the way the cables are tied down as you will need to wire tie them
back the same way.
12.Now you can cut the (4) large wire ties and the (2) small wire ties that hold
down the high voltage cable bundle and OMI cable. Then you can pull the
lower cable bundle back to where it enters the cable track.
13.Next take your small screw driver and pry open (20) of the cable track
plastic retaining clips that hold the cables into the track. These clips pivot at
the back of the cable track and can either be removed or left in the open
position so the cables can be removed.
14.Pull the old cable bundle out of the cable track towards the foot end of the
table.
15.Now install the (3) conductor OMI cable from the bulkhead to the OMI
BOARD. To do this you must remove the white 16 pin connector from the
bulkhead labeled bulkhead 2, this connector is a part of the upper cable
bundle and the new OMI cable will connect into this housing. Note the position
of the wire tie that holds the upper cable bundle in place and then cut it in
order to pull the connector out to install the OMI cable. Note the orientation of
the existing terminals in this bulkhead connector as they slide and lock into
the connector in one direction only. Where the wires enter the connector each
hole is numerically labeled. Put the green wire into hole # 11, and the black
wire into hole # 9, and the red wire into hole # 1.

16.Slide the connector back into the bulkhead bracket the way it came out and
fasten the upper cable bundle with a large wire tie the way it was before the
original wire tie was cut.
17.Route the new OMI cable in the same position as the previous cable and
connect it to the OMI board. Then tie the high voltage cable bundle and the
OMI cable down to the high voltage cable trough,(there are three large wire
ties near the bulkhead, two large wire ties put together to tie the high voltage
cables down at the center of the high voltage cable trough, and two small wire
ties to anchor the OMI cable down to the Bracket before it connects to the
OMI board). Before tightening the wire ties assure that the proper clearances
and no stress is applied at any of the connectors or wires. Tighten the center
cable ties first (two large wire ties put together and located at the center of the
high voltage cable trough). Be sure the high voltage cable bundle does not hit
the front panel when the tube head is all the way toward the outside of the
scanner (patients left). Then tighten the three wire ties near the bulkhead
making sure that the high voltage cables do not hang over into the cut out
space on the high voltage cable trough as they may hit the longitudinal motor
bracket and cause positioning problems.
18.Take the new cable bundle and connect it to the bulkhead by routing the
cable bundle the same way as the replace cable bundle, (note the connectors
are labeled bulkhead 1 and bulkhead 2) and fasten the cable bundle down in
the three spots between the cable track and the bulkhead with wire ties. Lay
the new bundle down into the cable track making sure all the cables lay
parallel to each other. Start replacing the clips to the cable track as far as you
can. Continue the process: remove a few clips, extract the old cable bundle,
add in the new cable bundle, and replace the clips.
19.To finish removing the old and installing the new cable bundle in the lower
portion of the cable track you must remove a screw located at the end of the
cable track. To do this use a 1/8" hex wrench and a 3/8" wrench. Once you
remove the screw you can lift the cable track out of the channel it rides in and
finish prying open the remaining clips. Remove the old cable bundle until it
reaches the cable entrance hole, where all the cables enter the electrical pan
area. Then finish installing the new cable bundle until you reach the cable
entrance hole, finish clipping all the clips and then replace the cable track hold
down screw (do not tighten the screw at this time).
20.Locate where all the wires from the old cable bundle terminate on the
electronics pan. All of the wires are labeled except for the wires that go to the
terminal block. Here is a list of wires that must be disconnected before
removing the cable bundle from the pan area. SBC(J-5), FOINK(J-17),
FOINK(J-12), FOINK(J-14), FOINK(J-5), FOINK(J-8), PMT/AGS(J-11)(J-11 is
the yellow Lemo connector), the orange Lemo connector (connected to the
H.V. Lemo box), then the last three wires connect to the Terminal block. Write
down the number where the orange, blue and yellow wires go to on the
terminal block and disconnect them with your small screwdriver. Carefully pull
the old cable bundle through the cable entrance hole from the pan area. The
old cable bundle may now be discarded.
21.Carefully feed (one connector at a time) the new cable bundle wires
through the cable entrance hole into the pan area. Connect the wires to their
proper locations.

22.Then move the arm all the way down to the foot end of the scan table. At
this time make sure that the Lower cable bundle and the high voltage cable
bundle have some slack where the cables enter the cable track near the
bulkhead area. Then make sure the cable track has at least 1/8" of clearance
from hitting the frame. To adjust this slide the cable track in the trough it rides
in to get the proper clearance, then tighten the screw that holds the cable
track in place with a 1/8" hex wrench and a 3/8" wrench. Move the arm up and
down the scan table to be sure there is nothing wrong with the cable track
motion. Leave the arm at the foot end of the table.
23.Leave a little slack in the cables from the cable track to the pan area to
allow all of the cables to be routed and wire tied exactly like the original
cables.
24.Reconnect the A/C power cord, put the table top, pad, and end panels
back on the scanner.
25.Turn on the scan table, computer, monitor and printer. Perform required
tests per section 6.9 of the Prodigy Service Manual.
5.4 Upper Cable Bundle Replacement

Tools Necessary:
• Small Phillips Screwdriver
• Small Slot Screwdriver
• Diagonal Cutters
• Hex Wrench Set
• Mini Molex Pin Extractor
• Large and Small Wire Ties.
5.4.1 Procedure
1. Turn off the power to the scan table.
2. Remove the table top by removing the two screws at each end.
3. Remove the front panel of the scan table
4. Lastly, remove the column cover of the arm held in place by screws.
5. Remove the upper and lower arm covers by removing the (8) screws that
hold it in place.
6.Open the cable track and cut the wire ties at the end of it. Disconnect all the
cables coming from the cable track and remove the cable bundle as far as the
top of the column (through the hole).

7.Place the new cable bundle in the cable track and connect all cables to their
appropriate positions. Close the cable track and wire tie the cables at the end
of it. Route the cable bundle through the hole in the top of the column.
8.Next locate the Laser On light and disconnect it. Remove this cable to the
top of the column cutting any necessary wire ties.
9.Route the new cable to the Laser On light and connect. Replace any wire
ties removed in step 5.
10.From the back of the arm column follow the cables vertically down and cut
all the wire ties holding the upper cable bundle to the other cable assemblies.
11.Carefully pull the upper cable bundle out towards the back of the arm and
down through the holes in the column.
12.Next cut the wire ties that hold the cables down near the bulkhead, these
are located in the lower rear portion of the arm.
13.Make sure the bulkhead connectors are labeled on both sides of the
bulkhead bracket and then disconnect them.
14.Next remove the two (16) pin Molex housing connectors that are attached
to the upper cable assemblies from the bulkhead bracket. Also disconnect the
large RS 232 connector from the bulkhead bracket. Pull the housings and the
Signal cable connectors out to work on them.
15.Use the mini Molex pin extractor tool and remove from bulkhead 1 pin16
and pin8. From bulkhead 2 (the lower connector) remove pin15, pin16, pin6,
pin7, and pin8.
16.Now remove the old cable bundle by pulling the cable out through the back
of the column. The old cable may now be discarded.
17.Next route the new cable bundle through the column wire tieing as you go.
18.Route the taped end of the cable through the hole at the bottom of the
column to the bulkhead area (follow the other cables that go to the bulkhead).
19.Carefully remove the masking tape from the cable exposing the mini Molex
pins and the Lemo connector. Note the orientation of the existing terminals in
the bulkhead connectors and the numeric labels at each hole of the
connector.
20.Replace the wires one at a time removing the wires from the old cable and
replace them with the wires from the new cable.
21.Insert the connectors into the bulkhead bracket the same way they were
removed and fasten the upper cable bundle with wire ties as original.
22.From the wire tie just fastened, the cables going into the arm column must
not have any slack in the cables (pull the cables from the column area to
remove any slack). Make sure that none of the cables hit any of the moving
parts in the narrow area where the cables come from the back of the column
out to the bulkhead.

23.Mount the column cover back in place and replace the top and bottom arm
covers. Replace the table top, table pad and the head and foot end panels
back on to the scanner.
24.Turn on the power to the scan table. Run Required tests as prescribed in
section 6.9 of the Prodigy service manual.
5.5 Tube Head Control Cable Replacement

Required Tools:
5.5.1 Procedure
1.Switch off the power to the scanner.
2. Remove the tabletop, head and foot end panels. At the foot end of the scan
table unplug the A/C power plug to the scanner.
3.Move the scan arm to the head end of the table.
4.Take the black tape off the high voltage cable bundle at each end of the
sleeving (open any cable track clips that are in the way as in step 8) as well as
any wire ties holding the bundle in place. Next, slide the sleeving away from
the tube head and remove the tape beneath the sleeving. Note the positions
of each cable before removing the tape. The cables must be returned to these
positions.
5.Disconnect the military-style connector and the ground wire (if one exists)
from the tube head and slide the cable out of the black sleeving toward the
cable track.
6.Unplug J3 and J5 on the XORB board. Also, trace the ground wire (if one
exists) from the control cable and disconnect it from the power supply. Cut the
wire ties holding the control cable to the pan.
7.Pry open the plastic retaining clips that hold the cables into the cable track.
These clips pivot at the back of the cable track and can either be removed or
left in the open position to remove the cables. The screw located at the end of
the cable track near the pan must also be removed. Once this screw is
removed the cable track can be lifted out of the channel it rides in and the
remaining clips can be opened. Mark the position of the cable track screw on
the frame to return the track to its original position.
8.Remove the old control cable. Note the position of all the cables in the cable
track. They will need to be returned to the same position during this
procedure.
If the cables are not returned to their

original positions, cable damage will
result.

9.Feed the new cable, military connector first, through the black sleeving on
the high voltage cable bundle starting near the bulkhead. The sleeving can be
expanded by pushing two parts of it together to better fit the connector
through.
10.Once the cable is through the sleeving, connect it to the tube head and
connect the ground wire (see figures 1 and 2). Position the cables next to the
high voltage cable bracket as in figure 1. The collimator control cable should
come out of the cable bundle between the two high voltage cables toward the
back of the scanner. Tape the cables together for several inches with three
layers of electrical tape starting as close to the bracket as possible. Continue
to spiral the tape around the cables as it was originally and finish by taping
three layers for several inches near the bulkhead. Tape the sleeving near the
bulkhead as it was originally. Pull the sleeving tight along the bundle and tape
near the tube head. Wire tie the cables to the tube head high voltage cable
bracket.
Figure 5-13. Profile Cable Routing Diagram

Figure 5-14. Top Down Cable Routing Diagram
11.Lay the control cable in the cable track in the same position as the original
one. Start replacing wire ties between the bulkhead and the tube head. Before
tightening the wire ties assure that there is proper clearance and no stress is
applied at any of the connectors or wires through the entire range of motion.
Tighten the center cable ties first (two large wire ties put together and located
at the center of the high voltage cable trough). Be sure the high voltage cable
bundle does not hit the front panel when the tube head is all the way toward
the front of the scanner. Make sure the high voltage cables do not hang into
the cut out space on the high voltage cable trough. Tighten the three wire ties
near the bulkhead.
12.Replace the clips to the cable track and reattach the track to the scanner
frame.
13.Move the arm to the foot end of the scan table. Check that the lower cable
bundle and the high voltage cable bundle have some slack where the cables
enter the cable track near the bulkhead. Check that the cable track has at
least 1/8" clearance of the frame. To adjust this, slide the track in its trough,
then tighten the screw that holds the track in place. Move the arm up and
down the table to verify that the cable track moves properly.
14.Reconnect the A/C power cord, and replace the table top and end panels.
15.Perform required tests as prescribed in section 6.9 of the Prodigy Service

Manual.

5.6 Tests to Perform after Service
Table 5-13. Tests to Be Performed after Service
Part Replaced or Secondary

Primary Phantom Alignment
Procedure Calibration /
Calibration Scans Test
Performed QA
+5, +/- 12 VDC

- 1 - -
Power Supply
26 VDC Power Sup-
- 1 - -
ply
28 VDC Power Sup-
- 1 - -
ply
Detector Mother
Board or Daughter 1 5 3 1
Board
Detector 1 5 3 1
Centent - 5 3 1
Collimator - 5 3 -
Laser - 1 3 -
Lower Cable Bundle - 5 3 1
MAX, FOINK, or
- 5 3 1
XORB Board
Motor, Belt, Pulley
- 5 3 1
or Gears
High Voltage Power
1 5 3 1
Supply
Tube Head 1 5 3 1
SBC - 5 3 1
Tube Head Control
- 5 3 1
Cable
Upper Cable Bundle - 5 3 1
System Move or
1 10 3 1
Installation

5.7 Returning Parts To LUNAR (For International
Distributors)
Return parts prepaid to Lunar. Please list our customs broker as intermediate
consignee:
Burlington Air Express
6023 S. Howell Ave.
Milwaukee, WI 53237-0140
Shipments of defective parts being returned to LUNAR from international

distributors should add the following instructions to the air bill and proforma
invoice:
DEFECTIVE EXCHANGE SERVICE PART, RETURN TO VENDOR.
NO DUTIES SHOULD APPLY. ALL PARTS ARE MANUFACTURED IN THE

UNITED STATES. FOR CUSTOMS CLEARANCE PLEASE NOTIFY THE
BURLINGTON AIR EXPRESS IMPORT DEPARTMENT:
BURLINGTON AIR EXPRESS IMPORT DEPARTMENT
PHONE:414-482-0700
FAX:414-482-0965
WATS:800-242-3821
Note: All parts must have a completed RMA tag with them.
Necessary information includes: which system they are from,
and the symptoms each part exhibited in failure should be
described.
NO WARRANTY OR EXCHANGE CREDITS WILL BE GIVEN UNTIL THESE

CONDITIONS ARE MET!
Parts must also be returned within 90 days of LUNAR opening a service

report for them (usually the day they are shipped). All parts not returned within
90 days (warranty or not) will be invoiced for at the distributor price.
Note: If it is the intention of a distributor to keep a part for their spare

parts stock, they should notify the LUNAR Customer Service
Department. This way, LUNAR may immediately invoice for
such parts and close service reports in a more timely manner.

6 1 Maintenance
Chapter 1:Maintenance
This chapter contains brief discussions of the Preventative
Maintenance procedure and Check Sheet as well as a discussion
on unusual sounds and a listing of change orders associated with
the Prodigy scanner.
6.0 Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-169

6.1 Unusual Sounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-170
6.0.1 QA History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-169
6.0.2 Repacking the High Voltage Cable Connectors . 6-169
6.0.3 Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-169
6.0.4 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-169
6.0.5 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-169
6.0.6 Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-170
6.2 Change Orders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-170
PRODIGY Service Manual (Rev B - 1998) Maintenance6167

6-168Maintenance PRODIGY Service Manual (Rev B - 1998)

6.0 Preventative Maintenance
• There are a number of items to be checked, cleaned and tested during a
PM visit to a site. See the Prodigy PM / Service Call Checklist in
Appendix 6-A.
6.0.1QA History
An important aspect of the PM is checking the QA History (see section ). This
is important because when a QA is run during the PM, it should be consistent
with the past QA's. Copy the QA history file to a diskette and send to the
LUNAR Customer Service Department.
6.0.2Repacking the High Voltage Cable Connectors

The major work of a PM is the repacking of the High Voltage Cable
connectors. See procedure DXSE0000 in the chapter 5 Appenices. It is
VERY IMPORTANT that this procedure be understood completely before
performing it!
6.0.3Wear
The scanner should also be checked for signs of wear. The Shutter Assembly
especially should be inspected.
Wear on these parts can cause lead shavings to fall on the filter in the x-ray
beam. This can cause a drastic decline in Reference Counts, causing QA's to
fail.
Also check all the scanner's moving parts for signs of wear.
• This would include wheels, pulleys, gears, bearings, belts, cables and
motor assemblies.
• INSPECT CAREFULLY cables that enter the plastic cable track. These
cables are subjected to a good deal of motion and thus have the potential
for breakage!
• Also, when performing the various tests listed below, listen for any
unusual noises that could be indications of wear.
6.0.4 Cleaning
Cleaning the scanner is important.
• Remove dust and any debris from the electronics mounting chassis.
• Clean the transverse and longitudinal extrusions. Small bits of debris

from the wheels may accumulate and impede motion.
• Clean the Shutter Assembly and the filter, if necessary (see 6.0.3).
6.0.5 Inspection
PRODIGY Service Manual (Rev B - 1998) Maintenance 6-169

• Inspect the scanner internally and externally for obvious damage and
loose connections.
• Check all PCB's for tight mounting screws.
6.0.6Tests
Run all other tests according to the Prodigy PM check sheet.
6.1 Unusual Sounds

A high pitched sound is normally heard when the scanner is in motion. This is
caused by the high frequency motor pulses being sent from the Centent Motor
Controller to the Transverse and Longitudinal Motors.
If the high pitched sound only occurs during motor operation, check the optical
interrupt disks and verify that they are not rubbing against the black plastic
transducer of the OMI board (see section 5.x). The disk should turn in the
middle of the transducer's slot.
For other sounds of an apparent mechanical nature, check all appropriate

gears and pulleys. Verify that the set screws are tightened and that the gears
and pulleys are not out of position. With the scanner turned off, move the
affected parts by hand to determine the exact source of the sound. Also look
for rusted or worn bearings and examine the V-wheels for wear. With age, the
longitudinal and transverse drive belts will dry out and start to cause noises.
Treating these belts with belt dressing is a short term solution until they can
be replaced.
Clicking or clunking sounds made during motor operation can be caused by

belts that are riding up on their pulleys, or by a too tight bearing support. The
bearing support is held to the carriage by a set screw from the rear. If this set
screw is so tight that the bearing and support have no play (i.e. can be rocked
1-2 mm), it can cause a clunking sound during transverse motion. If this
screw is loosened, it should be secured with Lock-Tite so it cannot work its
way loose.
Pulleys that have become defective can also cause clicking and squeaking/
squealing sounds. Try to isolate the movement of individual pulleys to locate
the defective part.
Scraping sounds can be caused by any of the moving carriages, cables or

cable track rubbing against an adjacent panel. Localize the sound and
investigate the appropriate areas.
6.2 Change Orders

As engineering changes are made to the Prodigy Scanner, they will be noted
herein future revisions of this manual.
6-170Maintenance PRODIGY Service Manual (Rev B - 1998)

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PRODIGY

Part Number: LUN7396

ii Prodigy Service Manual

g is a registered trademark of General Electric Company.

PRODIGY® is a trademark of GE-LUNAR Corporation.

Windows NT® is a trademark of Microsoft Corporation

Copyright© 2000 by GE-LUNAR Corporation.

Madison, Wisconsin. All rights reserved.

Prodigy Service Manual iii

iv Prodigy Service Manual

Chapter 3 should be understood completely as it explains the Diagnostics Software (built in –

Information Requested By GE-LUNAR:

System Number (DF+xxxxx)

Institution or Doctor's name

Complete list of symptoms

Names and part numbers of parts needed for service

Prodigy Service Manual v

vi Prodigy Service Manual

1.0 General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Figure 1-1. The PRODIGY Display Panel . . . . . . . . . . . . . . . . . . . . . . . 1-19

PRODIGY Service Manual (Rev C - 2000) Safety113

1-14 Safety PRODIGY Service Manual (Rev C - 2000)

• DO NOT attempt any repairs without prior instructions from authorized

• In order to maintain electrical safety and electromagnetic compatibility,

1.1 Symbols and labels found on the PRODIGY

• The following symbols are found on the PRODIGY, in the Operators

Attention: contains important safety information such as the

Emergency Stop Button: shows the location of the

Power Off: shows the switch position for Power Off.

Laser On: shows the location of the Laser On indicator. It is found

PRODIGY Service Manual (Rev C - 2000) Safety1-15

X-ray On: shows the location of the X-Ray On indicator.

Type B Equipment: shows that the scanner has Type B

1.1.2 Internal Symbols

Protective Earth: shows the location of a Protective Earth

Functional Earth: shows the location of a Functional Earth

• The following labels are found on the PRODIGY Scanner.

Laser Caution Label: Shows that the scanner uses

Laser Caution Label: Canada only

1-16 Safety PRODIGY Service Manual (Rev C - 2000)

Tube Head Assembly Label (system number

A definition of each symbol on this label follows:

System Label (system number DF+12000 and

System Label (system number DF+11999 and

PRODIGY Service Manual (Rev C - 2000) Safety1-17

X-ray Controller: This label shows x-ray

Collimator Assembly: This label gives

Warning Label and Radiation Symbol: The

Radiation Label: This label shows that the system uses

Grounding Reliability Label: This label states that

1-18 Safety PRODIGY Service Manual (Rev C - 2000)

Figure 1-1. The PRODIGY Display Panel

PRODIGY Service Manual (Rev C - 2000) Safety1-19

Figure 1-2. Laser Warning Label (U.S. systems only)

Figure 1-3. Laser Warning Label (Canadian Systems only)

Figure 1-4. Laser Warning Label (International systems only)

Note: DO NOT STARE INTO THE BEAM while the laser is

1-20 Safety PRODIGY Service Manual (Rev C - 2000)

Figure 1-5. Source (x-rays) off - Shutter closed (green)

Figure 1-6. Source (x-rays) on - Shutter open (yellow)

Note: When the x-ray on / shutter open symbol appears in literature

1.5 Cautions, Warnings, and Notes

1.5.1 Caution Statements