Troubleshooting the data transfer path file:///D:/EQUIPOS MEDICOS/TAC SANTANDER/CDS/MANUAL D...

Troubleshooting the data transfer path

General
This doc ument desc ribes a detailed service procedure to track and identify problems regarding data transmission paths.
Global architecture of the high-speed data paths in P20 scanners
The data transmission paths connect the RCOM board in the DMS to the DOM board in the C-BOX and to the PCI receiver in the IRS via a high-speed data slip ring. The global architecture of data paths is illustrated in the figure below:
Fig. 33 D ata path architecture

There are two main data path segm ents :

1. RCOM to DOM is a simplex optical link high-speed connection.
2. RCOM to IRS is a duplex connection with error recovery. This link consists of a forward optical connection via the high-speed slip ring and a low-speed electrical feedback connec tion (the comm_ok line) via the control-data slip ring.

The two RCOM optical outputs are identical and transmit the same data s tream at 200 Mbits/sec. They are interchangeable for debug purposes at any time.

Theory of operation

The RCOM board in DMS gathers all measurement and bias (offset) data from all GI cards and builds a serial bit-stream that is sent in packets to the DOM and IRS. One packet contains all values for a complete row of 672 detectors. Both DOM and receiver board in IRS differentiate between bias and measurement pac kets and perform the bias c orrection. The receiver further performs the logarithmic conversion on the bias-corrected data used for image reconstruction in IRS. The DOM board uses the bias-corrected data to build an angular attenuation profile used for online modulation of the radiation profile applied to the patient.
The RCOM -> IRS communication is more s ensitiv e to transmission errors due to the slip ring joint between the rotating and stationary gantries . For this reason, this link is equipped with an error recovery mechanis m called RESEND. The receiver in IRS checks every packet for CRC errors. If the CRC code is good, the receiver acknowledges the las t packet by toggling the comm_ok line (NRZ modulation). If the last packet was bad, the comm_ok line remains still (no ACK) and RCOM will send it again. As a result, RCOM implements a retransmission buffer to accumulate packets that were not yet acknowledged.
Depending on the integration time, there is a margin of at least 10% for error recovery; this means more than 10% of packets may be resent in case of errors. For 0.5 s ec/rot, the retransmit margin is 40% . In case the error rate is greater than the available reserv e margin, the error recovery mechanism may fail because the retransmit buffer in RCOM will slowly overflow. A second limitation is related to long transmission gaps. In case of s everal errors in a short period of time, the retransmit buffer in RCOM overflows quickly.
The RCOM -> DOM communication is less sensitive to errors. In addition, DOM uses only a frac tion of the whole data. For this reason, the link has a less complicated error recovery mec hanism in that the packets with errors are interpolated.

Relationship between MCU_84 and CT_ITW error m essages

The receiver in IRS aborts the scan by pulling down the safety line acq_ok to MCU, producing an MCU 84 error in the logbook. The reason for this abort is reported to HOST via IRS and occ urs later in the logbook as a CT_ITW xx error. Not every MCU 84 error is related to data trans mission problems.
· Only the CT_ITW codes listed below are related to data transmission problems:
- MCU 84 followed by CT_ITW 15 , E00_INVALID_BIAS_READINGS, Bias readings are invalid
- MCU 84 followed by CT_ITW 16 , E00_READINGS_NOT_CONTINUED, Timeout occurred while waiting for next reading
- MCU 84 followed by CT_ITW 4 7 , E00_BAD_READING_NO, Bad reading number
- MCU 84 followed by CT_ITW 48 , E00_BAD_SLICE_NO, Bad s lice number
CT_ITW 15 usually occurs when the data path is completely broken, i.e. the receiver does not receive any data and the RED LED on the receiver is permanently ON or blinks frequently.
CT_ITWs 16, 47 and 48 usually occur because of trans itory errors causing the RCOM retransmission buffer to overflow. In most cases, these errors are related to defective electronic modules on the slip ring, a defective data slip ring or unusually high electromagnetic interference inside the gantry that in turn disturbs the RF link between slip ring and antenna system.

Troubleshooting guide
Fig. 34 Troublesh ooting Guide

Troubleshooting static errors

Bias (offset) acquisition check

General
In every scan before starting the X-ray, the receiver D22 in the IRS acquires the bias (detector offset values) required to create the bias correction tables used during radiation to correct the detector values for offset. The bias data is transmitted from RCOM to IRS via the same data slip ring used for radiation data. In bias transmission mode, the IRS receiver is muc h more tolerant to data transmission errors. It acc epts any number of errors as long as enough good bias data was received to complete the bias correction tables.
If the time to start the radiation is reached before the REC has completed the bias acquisition, the MCU aborts the scan with error MCU 84 02 01.. or MCU_84 02 02..
If the SW watchdog timer on REC expires before the bias tables are completed, the receiver aborts the scan with error code CT_ITW 15 , "E00_INVALID_BIAS_READINGS, Bias readings are invalid".
In both cases, the data transmission path is either broken (no data is received at all) or under massive perturbations.

Tr oubleshoot as follows:
If the RED LED is permanently ON and the error counter is frozen (i.e. the green LEDs do not change s tatus), the data path is broken.
· Possible causes are:
- Missing power at/or defective RCOM output
- Missing or broken optical cable between RCOM and transmitter at slip ring
- Missing power at/or defective slip ring transmitter/receiv er modules in the gantry
- Missing or broken optical cable between receiver in gantry and receiver D22 in IRS or optical coupling in left gantry stand
- Defective feedback path for comm _ok line from receiver to MCU via control-data slip ring to ACU and finally RCOM

Isolating the problem:

Risk of accident!
Use Static Modes only with the following steps!

Step 1:
To is olate the problem, bridge the data slip ring using a direct connection between RCOM and REC D22 in the IRS. It is also poss ible to use DOM output instead of ACQ output. If the system is functioning with the direct connection, data path RCOM -> Receiver D22 in the IRS is OK.
If not, check/r eplace:
1. Fiberoptic cable RCOM -> TX Transmitter
2. Receiver/transmitter (it is important to follow C-MOS (ESD) guidelines when changing these parts)
3. Fiberoptic cable Receiver -> IRS
4. Check power supplies

Step 2:
Defective feedback path for comm_ok line from receiv er to MCU via control-data slip ring to ACU and finally RCOM. Check cable c onnections D22 -> MCU, ACU error LED and error log, cable ACU -> RCOM.

Pr ess the reset button on the receiver after each modification so that the receiver retr ies to open the connection. Alternatively, you can plug and unplug the optical cable at the receiver input. Check if the RED LED on the receiver goes OFF. In this case, the link is OK.
If both the RED LED and the error counter blink frequently, ther e are massive pertur bations in the data path. Follow the same debug pr ocedur e as for infrequent err ors.

Troubleshooting sporadic errors

Step 1: Check "Resend" error

General
The error recovery (RESEND) feature covers mos t transmission errors, and the scan will be aborted only in serious cases when the retransmission buffer in RCOM overflows. This may cause transitory scan aborts.
The safes t way to detect transmission errors is to check the error counter on the rec eiver (D22 in IRS) using the status displayed by 7 green LEDs on the upper side of the receiver board (see below image)
Fig. 35 R eceiver in IRS towe r and indicator LED's

This c ounter counts every error detected by the receiver, even if recovered by the retrans mission mechanism, either during or outside the scan. RCOM sends dummy packets in the pauses between scans to keep the link synchronous; the receiver check s every packet and updates the error counter. The counter is automatically reset at the beginning of each scan. This counter is also useful to determine if errors are related to the gantry angular position, e.g. when rotating the gantry by hand or at lower rotation speeds .
Additionally, the RED LED on the receiver back plate will blink briefly for each error. However, infrequent errors are hard to detect when looking at the RED LED only. On the other hand, when the link is broken and no data flow occurs, this LED is permanently ON and the error counter is frozen.

Step 2: Collect raw data

Many data transmission problems are related to failures in the slip ring antenna system. The slip ring transmits the data by means of an electromagnetic field between a rotating circular micro-strip sender antenna and a stationary bow-shaped rec eiving antenna. Lack of mechanical prec ision, high mounting tolerances or degradation due to transport and mechanical/temperature stress result in a degradation of the ov erall antenna symmetry that in turn reduces the capacity to reject external RF perturbations. To locate these problems, it is useful to know if the transmission errors are related to the gantry rotation angle.
To extract this information, you have to export the raw data in DICOM format onto CD-ROM and send it to service headquarters in CS HSC22 in Forchheim/Germany for analysis . This should be done as soon as possible.
Perform a spiral sc an with 5-10 rotations and observe the error counter on the receiver (see:(Fig. 35) . If the counter was inc remented during the scan, export the raw data onto CD-ROM. Try different rotation s peeds and many spirals. Sometimes, errors occur only for faster rotation speeds (0.5 sec/rot), sometimes only for lower rotation speeds.
The raw data analysis provides a diagram as follows:
Fig. 36 Example results from raw data analysis

The diagram above depic ts the first 4.5 rotations of a spiral showing the o"c lock position of the x-ray tube in the upper trace and the RESEND counter in the lower trace. The transmission error occurs exclusively when the X-ray tube is in the 6 o"clock position during each rotation. This suggests that the antenna s ystem has an asymmetry at that position.

Step 3: Replace the receiver/transm itter of the data path

Replace the receiver and transmitter of the data path as described in "Replacement of parts for Gantry", CT02-021.841.01.xx.02.

Risk of damage!
Follow C-MOS (ESD) guidelines when handling receiver parts. The receiver, in particular, is extremely sensitive and will be destroyed by touching the housing, whether the part is installed or not. An ESD-damaged part will result in an increasing number of errors until it completely fails and has to be replaced after approx. 4 weeks.

According to our experience in the field, most problems should be solved by performing the steps described above. If not, continue troubleshooting as follows:

Step 4: Visual inspection of data slip ring sender antenna str ucture (m ounting, glueing)

Risk of damage!
Follow C-MOS (ESD) guidelines when handling receiver parts. Especially the receiver is extremely sensitive and will definitely be destroyed when touching the housing, whether the part is installed or not. An ESD-damaged part will result in an increasing number of errors until it completely fails and has to be replaced after approx. 4 weeks.

The rotating s ender antenna is a circular micro-strip structure mounted around the inside of the blue ring. This micro-strip, flexible PCB has to be perfectly glued into the grooved channel. In some cases, a "peel-off" effect occurs, bending the micro-strip inside the ring. This results in a reduced air gap to the receiving antenna.
Fig. 37 Example of peeled-off segment on the send er antenna

The sender structure must be glued in as well. This means the structure surface must be at equal lev el with or deeper than the inside diameter of the blue slip ring module, around the entire diameter. Exception: the area of termination resistors and solder points of transmitter connections are positioned slightly deeper inside the grooved c hannel. The sender structure may not extend bey ond the rim of the blue module. In addition, the structure may not touch the receiving antenna. This type of error is c haracterized by data transmission errors occurring only in small angular sectors once per revolution and always at the same position.
Hint: For better visibility, it may be necessary to remove the stator ring.
What to do: Mark the position of the defect on the blue ring. Try to push the s tructure back against the blue ring body. The data transmission errors should disappear. If errors persist, the slip ring must be replaced. Obs erve the system behavior.

Step 5: Check the antenna air gap

Risk of damage!
Follow C-MOS (ESD) guidelines when handling receiver parts. The receiver, in particular, is extremely sensitive and will be destroyed by touching the housing, whether the part is installed or not. An ESD-damaged part will result in an increasing number of errors until it completely fails and has to be replaced after approx. 4 weeks.

History: Some systems may exhibit a problem with the gap between the antenna and the sender structure of the data link. In particular, the receive antenna and sender struc ture surface are not parallel or the gap is too small. This situation may cause spurious transmission errors. If replacement of elec tronic modules does not correct the problem, the antenna gap must be checked.
Necessary equipm ent: ESD protection kit, metal feeler gauge (range 0.3mm up to 1.0mm), screwdriver, Allen wrench 3mm, flashlight.
What to do: The CSE must connect himself to the stationary ring using the ESD kit. Remove the electronic module (Receiver Unit) from the stationary ring and store it in a place free of ESD. Use the metal feeler gauge 0.7mm and check the gap between antenna and sender structure at different angles (360 degrees). The nominal antenna gap is 1.0mm with a tolerance of +/- 0.3mm. The antenna gap is vis ible between the blue ring and the antenna carrier when inspected from the back of the slip ring module. The 0.7mm gauge should fit smoothly at the position indicated. In this case, the antenna gap is considered good. Carefully install the rece

Risk of damage!
Be careful not to use force when checking the gap! Avoid damage to the sender structure!

Fig. 38 Mea suring th e antenna air gap

If the gap is smaller than 0.7mm, the antenna carrier itself must be c hecked. Call CS HSC22 for more information.

Step 6: Visual inspection of sender antenna structure (etching, cor rosion)

Risk of damage!
Follow C-MOS (ESD) guidelines when handling receiver parts. The receiver, in particular, is extremely sensitive and will be destroyed by touching the housing, whether the part is installed or not. An ESD-damaged part will result in an increasing number of errors until it completely fails and has to be replaced after approx. 4 weeks.

Check for solder bridges or not completely corroded short circ uits between pads (meander - use a magnifying glass). A maximum of 3 pads may be connected laterally, if followed by 20 correct pads, without causing problems.
Fig. 39 Example of short circuit betw een pads due to incomplete corrosio n

What to do: Try to remove the solder bridges or short circuits us ing a sharp knife or small screwdriver. If data transmission problem persists, the slip ring must be replaced.

Step 7: Electrical test for termination resistor s

Risk of damage!
Follow C-MOS (ESD) guidelines when handling receiver parts. The receiver, in particular, is extremely sensitive and will be destroyed by touching the housing, whether the part is installed or not. An ESD-damaged part will result in an increasing number of errors until it completely fails and has to be replaced after approx. 4 weeks.

The output of the electronic sender module is applied to two semi-circ ular micro-strip structures connected in parallel to the output of the electronic module. Both semi-circular sender structures are terminated using two 16 ohm res istors to ground. In some cases, one resistor is damaged due to mechanical stress. This may c ause massive trans mission errors over 180° when the receiving antenna is positioned ov er the non-terminated micro-strip.
Fig. 40 Mea suring th e termination resistors

What to do : Remove the sender electronic module. Use a digital multimeter (e.g. Fluke77) to measure the resistance values at the following test points ((Fig. 40) ).

Pin 2 / 3 to A 8 Ohm +/-1

Pin 7 / 8 to A 8 Ohm +/-1
Pin 2 / 3 to 7/8 16 Ohm +/- 2
Pin 2 / 3 to B 0 Ohm + 0.3
Pin 7 / 8 to C 0 Ohm + 0.3

In cas e of resistance readings outside the tolerance values, replace the slip ring.

Step 8: Install ground cable

P20 systems are equipped with a special ring motor that is located in clos e proximity to the data slip ring. Sometimes the frequency inverter that prov ides power to the ring motor generates a higher level of electrical interference causing noise between rotating and static GND planes (over the PE carbon brushes and ring). This ground noise may induce errors in the data path.

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What to do : Install ground cable with part no. 71 09 999 as described in Instructions CT02-021.812.06.01.02.

Step 9: Check X-ray r elated problems

The system noise level may be increased as a result of contact problems, e.g. UDC line contact problems or power connection contact problems between the E-box and H1.
Another reason of an increased noise lev el may be an insufficient ground connec tion between the stationary and rotating parts of the gantry.
How to check if the problem is r elated to radiation :
Perform scans with similar parameters with and without X-ray's (high/low power). Check the error counter on REC D22. Try to determine if the number of errors is related to the X-ray level.

Risk of danger!
The system has to be switched off completely using the onsite ON/OFF switch before performing the following checks. Make sure that the s ystem is secured against accidental switch-on! Before working on the XRS parts, wait until the capacitor bank has been discharged!

Perform the following checks :

1. Check UDC line for bad connection as follows:
- In the PDC on board D450 X7, X8, X9, X10 -> tighten with a torque of 4.8Nm .
- In right gantry stand terminal block X303 .
- Back of gantry X382 s lip ring brus h holder (also check if brushes are OK).
- On E-box D440 X1,X2 . Check that the UDC cable connection is arranged in the order: connection block -> cable -> washer -> nut and is tightened with a torque of 4.8Nm .
2. Check power line from E-box to H1. Check that the power cable connec tion on D432 X1, X2, X3 ,X4 on H1 is arranged in the order: connection block -> cable -> washer -> nut and is tightened with a torque of 4.8N m .
3. Check the ground connection from the stationary to rotating part as well as the ground carbon brushes and the ground contact ring.
4. Check the ground connection between the gantry and PDC.
5. Check the ground connection on the E-box X603. Tighten it with a torque of 4.8Nm .
6. Replace the E-box. Before replacing the E-box, contact CS HSC22.

A table with different torques for screws/nuts is located in the Instructions: System Safety Information - CT02-021.860.01.xx.02. For more information about power and ground connections, refer to the Installation and Setting Instructions - CT02.021.814.01.xx.02.

Step 10: Check the (comm_ok) line

The data transmission path between RCOM and IRS is equipped with an error recovery feature (refer to(Theory of operation) ). Howev er, this feature makes isolating trans itory errors more difficult. Perturbations injected in the feedback path, e.g. the comm_ok line, disturb the handshake protocol and result in data trans mission errors . Fortunately, in practice the c omm_ok line proved very reliable.

To determine if the errors ar e related to the comm _ok line:

1. Check the logbook for ACU errors/warnings.
2. Check the error LED on the ACU board (LED V3 / K.MCU should normally be switched off).

If you deter mined that the errors are related to the com m_ok line:
1. Check the cable between REC D22 and MCU for bad contacts, check/replace both boards.
2. Check/replac e ACU.
3. Check/replac e RCOM.

Step 11: Unusual problem s

1. Check fiberoptic coupling adapter in the left gantry stand for a bad c onnection.
2. Large mechanical movement (not enough rigidity between optical receptacle and housing) at RCOM optical outputs -> change RCOM.
3. Partially broken optic al cable on rotating gantry.
4. Dirty/damaged carbon brushes or UDC/power slip rings c ause increased electrical interference.
5. Carbon dust on circ ular micro-strip antenna at slip ring -> clear out using ESD protection kit. Dis connect the stationary electronic module first!

Step 12: Call CS HSC22 if none of the above has solved the problem .

REQUIREMENT:
Complete the following report form and send it to CS HSC22 in the following cases :
- After success ful debugging of data transmission problems based on troubleshooting guide.
- Difficulties debugging/solving data transmiss ion problems based on troubleshooting guide
This action is intended to enhance the knowledge on debugging the P20 data path to:
- Speed up debugging in similar cases
- Enhance the troubleshooting guide with useful hints.
Ta b. 14 Data transmission report form
1 Reporting E-mail addres s:..........................................................
person Phone, cell phone:..................................................
(position and Name:...................................... Position:...................
contacts)

2 Details on CT Country:................................. City:............................

system System Serial. No.:................... Software Version:......
3 Which CT_ITW :...................................................................
CT_ITW c ode ...................................................................................
follows the ...................................................................................
MCU_84 error
(e.g. CT_ITW
15, 16, 47,)?
4 Previous Changes:.....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
service
intervention to
this system on
high power
parts, e.g.
replacing
E-box, HV
tank or slip
ring and
electronic
modules at
slip ring
(please
specify what
and when)?
5 Can you ...............................................................................................................................................................................................................................................................................................................................................................................................................................
relate the
oc currence of
data
transmission
problems to
replacements
of other parts
in this
system?
6 Is the raw File name:..................................................................
data available Scan date:..................................................................
to send to CS Time:..........................................................................
HSC22 in
case of abort?
(Specify file
name, scan
date and
time).
7 Is the raw File name:..................................................................
data available Scan date:..................................................................
to send to CS Time:...................................................................................................................................................................................................................................................................................................................................
HSC22 in
case of
transmission
errors, i.e.
LED counter
on D22 board
incremented
during the
scan?
(Specify file
name, scan
date and
time).
8 Are the errors ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
X-ray related?
In this cas e,
the LED
counter on
D22 counts
only during
ac tive X-ray.
Please
provide
additional
details if
av ailable such
as scan mode
(e.g. topo,
spiral,
sequence in
patient mode
or ROT &
STATIC in
service
mode).
9 Are the errors ............................................................................................................................................................................................................................................................................................................................................
related to the
X-ray level,
i.e. do errors
oc cur more
frequently at
increased
X-ray power?
10 Are the errors ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
related to the
rotation
driver? In this
case, the LED
counter on
D22 counts
synchronously
with the
gantry (during
ac tive
rotation) but
doesn"t count
during manual
rotation
(rotation
switch is
OFF).
11 Does the LED ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
counter on
D22 count
only at certain
rotation
speeds, i.e.
only 0.5 sec
or 1.5 sec or
during gantry
ac celeration
or braking?
12 Is the ground ......................................................................................................................................................................
cable part no.
71 09 999
installed?
13 Does the LED ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
counter on
D22 count
also when the
rotation switch
is OFF, no
X-ray and the
errors are
randomly
distributed in
time?
14 How did you .........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
solve the
problem?
Please
provide
details.

Troubleshooting data transfer GI card (Backplane) -> RCOM (Assignment test)

· Selec t Local Ser vice -> Test Tools -> Stat-Modes.
· Selec t -> static01 as predefined mode and click Show (to activ ate the static01 parameters).
· Selec t mode parameter: Tubepos. -> 270 deg for the other values, use default settings.
· Click Go .
· Press Start button (starts a sc an without radiation).
· Click Cancel after the scan is finished to exit the Static Mode mask.
· Click Home .
· Selec t Analyze from the Home platform.
· Selec t Load -> ICS Filesystem -> Raw Data (default setting).
· Click Go to open the c ommon load frame.
· Selec t the last raw data set measured: rotstatic.raw.
· Click Go (the region platform opens).
· In the region selection platform, select:
Row/Reading -> Low Bound = 1000 Upper Bound = 1000 Step = 1
Column/Channel -> Low Bound = 1 Upper Bound = 672 Step = 1
Selec t all 4 detector lines
· Click Go .
· Click Plot .
Fig. 41 Example of Analyze image

The plot (Fig. 41) shows one reading across all channels and all 4 detector lines. The lines must progress in a zig-zag pattern.
If the test results of the curve above indicate a problem, the module is not defective! Proceed with troubleshooting as follows:
1. Swap/replace the respective GI card (refer to plot (Fig. 41) to find the correct channel; use the Channel/Slot table in this document to find the correct slot).
2. Replace the RCOM.
3. In cas e of a backplane problem, contact CS HSC22.

Troubleshooting data transfer Gantry -> IRS

The disc test checks the data transfer from the RCOM to the IRS. An image reconstruction is performed using a data file in the form of a disc. The checksum can be calculated at different stages during the image reconstruction.
Before starting the test, the user has to choose whether to tes t with or without rotation.
Error mess ages are displayed in the event log.
· Selec t Local Ser vice -> Test Tools -> IRS/ICS -> IRS Disk Test .
· Selec t transmitter tes t with rotation .
· Click Go .
· Press the Star t button (starts a scan without radiation).
Test is finished when "IRS Disc Test succeeded" is returned. A disc m ust be displayed on the monitor (Fig. 42) .

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If not, trouble s hoot the RCOM -> IRS data path.

Fig. 42 Example of disk test

Uncontrolled document if printed or copied to another location!

Disclaimer and Copyright © Siemens AG 2001

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