MELODY TECHNICAL MANUAL

CHAPTER 4
PERIODICAL MAINTENANCE
TROUBLE SHOOTING

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PERIODICAL INSPECTIONS SUGGESTED EVERY 6 MONTHS,

RECOMMENDED EVERY YEAR

MELODY s/n_____________
PLACE OF INSTALLATION ________________________________________
DATE OF INSTALLATION _____________________________________________
INSTALLATION COMPANY ________________________________________
RESPONSIBLE CONTACT PERSON ________________________________________

1) CHECK OF EXTERNAL DAMAGES []

2) -----------
3) Check of oil leakage from AT generator []
4) Check the correct insertion of boards into the CPU []
5) Check the correct insertion of connectors []
6) Check of phase/neutral/earth connections []
7) Check the available voltage and any reconfiguration of the voltage selector
(see relevant chapter) Vac___ []
8) Operation of emergency buttons []
9) Calibration of LCD contrast []
10) Set hour/date []
11) Operational check of all buttons []
12) Collection of storage data of the last 1300 exposures []
13) Check of UP/DOWN C-arm travel end A[] B[]
14) Verify the integrity of Gas Piston for arm moving and
possible replacement V [] S[]
15) Check the “Chain - Reducer - Gears - C-Arm” mechanical system []
16) General check of the mechanical status of the C-Arm group []
17) Verify the arm rotation brake and any calibration V[] T []
18) Check the UP/DOWN compression movement A[] B[]
19) Verify the compression power and any calibration V[] T []
20) Mirror off screen function (under preparation) []
21) Check the beam Centring []
22) Check Rays/Light collimation []
23) Check the Contact of collimator presence and tube temperature sensor []
24) Verify the rotating anode safety and any calibration V[] T []
25) Verify the kV and any calibration V[] T []
26) Verify the anodic current and any calibration V[] T []
27) Verify the Offset A.E.C. and any calibration V[] T []
28) Verify the parameter [r] with dummy and any calibration V[] T []
29) Verify the linearity of blackening and any calibration V[] T []
30) Verify the Dosemeter and any calibration V[] T []
31) Check the potter operation 18x24[ ] 24x30 [ ]

SIGNATURE

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As per items:

1,3,4,5,15

execute visual checks.

6,7,8,9,10,11,12,19,21,22,24,25,26,27,28,29,30

refer to instructions contained in the manual:

13) Check of UP/DOWN C-arm travel end

The moving system of the arm is controlled by two normal travel end contacts, A/B MW3 and
MW4, and by two over-travel contacts, MW1 and MW2, which directly act on the engine
supply, permanently locking it.
Over-travel contacts check is carried out by manually actuating them when the arm is
moving. For obvious safety reasons, for people carrying out the check, it is in the most
remote position from the contact to be checked.

14) Verify the integrity of the Gas Piston

The Gas piston has a vertical impulse power able to compensate the weight of the arm.
In case its power is reduced or annulled, due to a loss of internal pressure, the effort of the
motor rises in the upward movement.
The good state of the piston is pointed out by the possibility to move the arm upward starting
from a position at less than 10 cm from the upper limit.

16) General check of the mechanical status of the C-Arm group

Rotate the arm to all positions verifying that there are no clear symptoms of loosening of the
assembled mechanical parts.

17) Verify the arm rotation brake and any calibration

The arm rotation brake, see Fig.1, consists of a disc brake + pincers actuated by the motor
MT5 through a lever (E).
Two contacts (A,B), actuated by a cam, detect the lock/unlock position of the brake.
Calibration of the brake power is carried out acting on the screw (D) after having released the
lever (E) by the fixing screw (C) in the correct position. The screw (D) has a clearance of
approximately 3 or 4 tenths of millimetre with respect to the lever (E).
In Fig.1 the brake is shown in a position of locked brake (at rest).

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MT 5

D E

Fig. 1

18) Check the UP/DOWN compression movement

When the equipment is off, check that the carriage is free and that it slides without
constraints.

20) Mirror off screen function (under preparation)

When the equipment is off and in preparation/rays the mirror shall be in vertical position.

If this does not occur, verify that:

DIP3 SW2=OFF PCB 01-170
the mechanical movement of the control levers is free, with machine off
with machine on, the system offers resistance to any attempt to move the mirror
manually.

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23) Check the Contact of collimator presence

Insert a cassette in the potter and verify that the display shows the word READY, remove the
collimation plate and verify that the word READY disappears from the Display.
Activate the technical video and verify that the tube temperature is correct.

31) Check the Potter operation

After having closed the room door and having verified that the collimation plate is present,
insert a cassette in the potter and verify that the display shows the word READY and that the
Green LEDs on both sides are lit.
Remove the cassette and verify that Yellow LEDs are lit.
Check the Grid movement by simultaneously pushing the buttons :

REPLACEMENT OF CENTRING DEVICE LAMP

To reach the halogen lamp of the collimator, you need to disassemble the centring device
mask and open its lower cover.
Replace the lamp exclusively with an original spare part having the same filament orientation.

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TROUBLE SHOOTING
You can efficiently and quickly solve failures when you have a number of spare parts
available: the higher the number of equipment to assist, the higher the number of spare parts
available.

BOARD CONFIGURATION
In case of failures or defects to functions different from those of normal use or if they appear
after the replacement of an electronic board, it is recommended to accurately verify the
configuration of the board(s) involved and check fuses integrity.
For an easy reference, here are all information relevant to configuration of the boards existing
in the equipment.

CPU MOTHER BOARD

92-082-X
JP1 = CLOSED to exclude the inverter power supply safety during tests
RV1 point of alarm threshold of the inverter power supply, set by manufacturer at 1,05 Vdc on TP1
JP2 = CLOSED stand-by led ON when the unit is OFF
JP3 = OPENED for stand-by LED
JP4 = CLOSED & F11 missing for configuration with standard tension at friction
JP4 = OPENED & F11 1A for configuration with increased tension at friction

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FILAMENT SUPPLY ROTATING ANODE STARTER

92-073-X 92-074-X
R16 = Anodic current sensor resistor 1Vdc=10mA RV1 = Calibration of capacitive phase safety circuit
(0.5Vcc=5mA options 5kW or bimetallic tube) RV2 = Calibration of direct phase safety circuit
RV3 = Calibration of voltmeter safety TP1 = test-point of capacitive phase current
RV6 = Calibration of large focus filament safety TP3 = VTP1 – 30%
RV7 = Calibration of small focus filament safety TP2 = test-point of direct phase current
LED1 = Board ON & filament OK TP4 = VTP2 – 30%
LED2 = Anode W JP1 = OPENED braking enabled
LED3= lit with small focus selected JP3 = OPENED braking time 6”
LED4 = lit with filament ON JP4 = OPENED safety enabled
LED5 = lit with circulating anodic current LED1= ON during anode rotation
LED2= ON during braking or alarm
LED3= ON during braking
LED5= ON when the board is ON
LED6= ON when the rotation is OK

INVERTER
TP1/TP2 = Tension test during exposure
DL1 = power supply B.T. OK DL2 = lit exposure ON
RV1 = regulation kV
RV2 = regulation maximum output current

FUNCTIONAL BLOCKS
For a better understanding of the unit, it is worth to know that this unit is subdivided into
several operational blocks:
1) Main CPU, mother board
2) Control keyboard and display
3) Rotating Anode Starter
4) Filament Supplier
5) High Tension Supplier
The main CPU (1) and the control keyboard (2) are equipped with independent
microprocessors, connected among them by a serial interface.
Blocks (3), (4) and (5) are connected to the main CPU by Optoisolated digital interfaces.

SUPERVISION CIRCUIT AND LED 1

A general supervision circuit heading to LED 1 of the CPU mother board 92-082, together
with single dedicated circuits, check the integrity of various fuses and complete functional
blocks whose state is indicated in the TECHNICAL MENU.
---------------------------------------------
VILLA SISTEMI MEDICALI MELODY
---------------------------------------------
------------------CPU---------------------
F2=OK F4=OK F1=
--------------INVERTER----------------
POWER=GOOD SERVICE=OK
--FILAMENT POWER SUPPLY---
>>GOOD<<
------------ROTOR SUPPLY----------
>>GOOD<<
---------------------------------------------
SOFTWARE REV MELODY XX TUBO
Tube Housing kJ xxx 25°C…….
……… .../…/… ………..
---------------------------------------------

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BLOCKS SIMULATION
Blocks (3), (4) and (5) can be isolated from the main CPU for test purposes.
To isolate a block, it is necessary to close the supervision circuits from the CPU side so that it
detects a normal condition.
Here follow the necessary connections to simulate:

ROTATING ANODE Starter 92-074 CN3

CN5 PCB 01-170

Filament Power Supply 92-073 CN2

CN4 PCB 01-170

Inverter
CN1
CN3 PCB 01-170

CN1, CN2, CN3 refer to board 01-170

Connections can be realized directly on the board 92-079 excluding the flat connection
cables or directly at the end of the flat cable to also include it in the test.
Under these conditions, it is NOT possible any exposure.

1. SWITCHING ON PROBLEMS
Check if one or both emergency buttons are active.
Check the main fuse of the switch or fuses referred to board 92-082 and relevant switching
on circuit. Refer to the special section in Chap. 3 on this manual.
The operation failure of the main CPU is pointed out by the appearance on screen of the sole
frame and by LED 1 of mother board 92-082 in off position.
The operation failure of just the display is pointed out by LED 1 of mother board 92-082 in on
position and by operation of all keys to which a mechanical action or a checking Beep is
associated.

2. COMPRESSOR PEDALS LOCKED

BRAKE BUTTONS LOCKED
ARM BUTTONS LOCKED

The control button of the concerned function remained locked.

Unlock it to reset normal functions.

3. APPEARANCE OF TECHNICAL MENU

Verify the indicated Fuse or Block.
A quick alarm sound indicates that the problem still exists, a slow sound indicates that the
problem disappeared but, in this case, the cause which generated it remains on screen.

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In case of problems concerning a functional block, refer to relevant section in Chap. 3 of this
manual.

4. ARM MOVEMENT IS BLOCKED

If the arm is not at the travel end, verify Fuses F7 and F8 of the board 92-082 and contacts
MW3 and MW4.
In case of intervention of the over-travel contact, the motor remains blocked and it does not
react to normal controls. To take it back within the limits of its normal travel, you need to
manually rotate the wheel on the upper part of the arm.
If the arm went to over-travel position, it means that the travel end contact did not work and
you need to remove the cause after having taken the arm back within the limits of its normal
travel.

5. COMPRESSION SYSTEM
In case it is no longer possible to actuate the lowering movement of the compressor, verify
the integrity of relay K2 situated on the CPU mother board 92-082.
In case the compression power is insufficient, refer to relevant section in Chap. 3 of this
manual.

6. EXPOSURE METER PROBLEMS

Ensure that DIP2 SW2 of board 01-170 is on the position corresponding to DETECTOR used
on the unit.
In case of Film blackening problems, verify that on control panel the appropriate Film/Screen
is selected and that parameters [o] and [r] with test dummy are correct.
The unit is equipped with a simple and efficient auto-diagnosis system based on a calibrated
dummy allowing verifying its calibration and stability with an appropriate number of shots.
A failure to (partially or totally) tilt of the luminous centring device mirror results in a visible
reduction of parameter [r]
For parameters control and any possible calibration, refer to relevant section in Chap. 3 of
this manual.
7. PROBLEMS TO POTTER AND GRID VISIBLE ON IMAGES
If the grid does not move, verify that the resistance of each phase of the motor is of about
10Ω a lower resistance by more than 10% means that the motor is damaged and it is to be
replaced.
If the motor is sound, check the connection cable and if necessary replace the board 93-107.
If the potter moves, Motor Cable and board are sound and operating but you see the grid on
images, verify the internal components and slides as per procedure available on request.

8. BREAKAGE OF INVERTER OF HIGH TENSION GENERATOR

A lack of tension on TP1 and TP2 during exposure time means that the inverter broke.
Refer to relevant section in Chap. 3 of this manual.

9. BATTERIES OF RAYS REMOTE-CONTROL

In case of spontaneous interruption of exposures and appearance of the message
“ANTICIPATED BUTTON RELEASE”, verify the alignment of the infrared rays beam and
batteries of the remote-control, if installed.
Carry out verification tests with the traditional rays buttons.

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10. VARIOUS PROBLEMS NOT WELL DEFINED TO CPU

Dirt on contacts of DIN connectors of boards or disturbances generated by the inverter
following the breakage of R19 or R20 can cause an exposure interruption, sometimes
accompanied by message “ANTICIPATED BUTTON RELEASE”.
Connectors contacts can be cleaned with 90° ethyl a lcohol and resistors R19 and R20 can be
checked using an ohmmeter with unit off and after having opened the lower cover of the
inverter.

11. COMMUNICATION PROBLEMS WITH PC

Refer to relevant section in Chap. 3 , Automatic Exposure Meter, of this manual.

12. UNIT SWITCHING OFF DURING EXPOSURE

This problem can occur when you work at kV values near to the maximum value and when
network voltage, during exposure, drops below the acceptable limit.
In this case you can simply carry out verification at reduced power using the small focus.

13. UNIT SWITCHING OFF AFTER EXPOSURE

This problem can be generated by disturbances produced by the compressor motor during
the upward movement after exposure.
To carry out verification, block the up movement of the compressor at the end of the
exposure using the special button.
Verify the 100Ω 5W resistor in parallel to motor and the presence of protection diodes.

14. CONTACT OF COLLIMATOR AND TUBE TEMPERATURE SENSOR

The safety and collimator plates detection contact is connected in series to circuit 02-171-0 to
measure tube temperature.
When contact is closed, rays are enabled only if voltage at board ends
02-171-0 is equal to 2.732Vdc +10mV x °C of tempera ture.
The correct operation of this circuit is pointed out by the word READY appearing on control
panel, provided that the cassette is correctly inserted in the potter and that the contact on the
room door is closed.
A failure of the contact or of board 02-171-0 is pointed out be the error message “MISSING
COLLIMATOR” on an exposure attempt.

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