8100-10809-TM Rev A0 PX-prod TechMan

PX Products Technical Manual Proprietary Information 8100-10809-TM, Rev.
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PX Products
Technical Manual
September 2006
If this technical data is being exported from the United States, it is being exported in accordance with Export Administration
Regulations (EAR) as follows:
ECCN - EAR99 - No License Required to PAN TECH ELECTRONICS ABU DHABI, UNITED ARAB EMIRATES.
Department of Commerce License Number ____________________ to Entity and Country of End-Use.
License Exception 740.13(a)1 to Entity and Country of End-Use.
Diversion contrary to U.S. law is prohibited. In accordance with U.S. Law (Title 15 CFR Part 746 and Supplement No. 1 to
part 774, and Title 31 CFR) resale/re-export or transfer to certain designated countries is prohibited without the prior written
consent of the U.S. Department of Commerce. If further transfer is required, contact your L-3 Communications representative
for authorization.
Number: 8100-10809-TM
© 2005-6 L-3 Communications, Security & Detection Systems
This technical data must be exported from the United States in accordance with Export Administration Regulations. Diversion
contrary to U.S. law is prohibited. In accordance with U.S. law, resale/re-export or transfer to certain designated countries is
prohibited without the prior written consent of the U.S. Department of Commerce
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PX Products Technical Manual Proprietary Information 8100-10809-TM, Rev. A0
Preface ROLL
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Disclaimer
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L-3 Communications, Security & Detection Systems has made all reasonable efforts to ensure the information in this manual is
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accurate and complete. L-3 Communications, Security & Detection Systems shall not be held liable for any technical O N Bor
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errors or omissions contained herein, or for incidental, special or consequential damages concerning the furnishing or use of this
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manual. The information contained in this manual is subject to change without notice. Any comments or proposed changes
should be submitted, in writing, to L-3 Communications, Security & Detection Systems to the attention of Documentation
Control, Document Comments.
Proprietary Information Notice

This manual contains proprietary information that is protected by copyright, and all rights are reserved. No portion of this
document may be copied, photocopied, reproduced by any means, or translated into another language without the prior written
consent of L-3 Communications, Security & Detection Systems.
Classified Information Notice

For security reasons, the U.S. Federal Aviation Administration (FAA) and the U.K. Department for Transport (DfT) have
classified much of the information and data pertaining to the performance criteria, test results and technical aspects of Explosive
Detection Systems. If additional information is required that is not part of L-3 Communications, Security & Detection Systems
proprietary documentation packages, qualified representatives of foreign governments and aviation agencies should specifically
request the information on letterhead. L-3 Communications, Security & Detection Systems will make every effort to provide
qualified individuals with detailed information in a manner consistent with the Classifications Guide for FAA Explosive Detection
Systems Information and Data in effect at the time of the request. Contact L-3 Communications, Security & Detection Systems
Customer Support for additional information.
Software License Agreement (Embedded Products)

You have acquired a device (“DEVICE”) that includes software licensed by L-3 Communications Security & Detection Systems
from Microsoft Licensing Inc. or its affiliates (“MS”). Those installed software products of MS origin, as well as associated
media, printed materials, and “online” or electronic documentation (“SOFTWARE”) are protected by international intellectual
property laws and treaties. The SOFTWARE is licensed, not sold. All rights reserved.
IF YOU DO NOT AGREE TO THIS END USER LICENSE AGREEMENT (“EULA”), DO NOT USE THIS DEVICE OR
COPY THE SOFTWARE. INSTEAD, PROMPTLY CONTACT L-3 Communications Security & Detection Systems FOR
INSTRUCTIONS ON RETURN OF THE UNUSED DEVICE(S) FOR A REFUND. ANY USE OF THE SOFTWARE,
INCLUDING BUT NOT LIMITED TO USE ON THE DEVICE, WILL CONSTITUTE YOUR AGREEMENT TO THIS
EULA (OR RATIFICATION OF ANY PREVIOUS CONSENT).
GRANT OF SOFTWARE LICENSE: This EULA grants you the following license:
¾ You may use the SOFTWARE only on the DEVICE.

¾ NOT FAULT TOLERANT. THE SOFTWARE IS NOT FAULT TOLERANT.
¾ NO WARRANTIES FOR THE SOFTWARE. THE SOFTWARE is provided “AS IS” and with all faults. THE
ENTIRE RISK AS TO SATISFACTORY QUALITY, PERFORMANCE, ACCURACY, AND EFFORT
(INCLUDING LACK OF NEGLIGENCE) IS WITH YOU. ALSO, THERE IS NO WARRANTY AGAINST
INTERFERENCE WITH YOUR ENJOYMENT OF THE SOFTWARE OR AGAINST INFRINGEMENT. IF
YOU HAVE RECEIVED ANY WARRANTIES REGARDING THE DEVICE OR THE SOFTWARE, THOSE
WARRANTIES DO NOT ORIGINATE FROM, AND ARE NOT BINDING ON, MS.
¾ Note on Java Support. The SOFTWARE may contain support for programs written in Java. Java technology is not
fault tolerant and is not designed, manufactured, or intended for use or resale as online control equipment in hazardous
environments requiring fail-safe performance, such as in the operation of nuclear facilities, aircraft navigation or
communication systems, air traffic control, direct life support machines, or weapons systems, in which the failure of Java
technology could lead directly to death, personal injury, or severe physical or environmental damage. Sun Microsystems,
Inc. has contractually obligated MS to make this disclaimer.
© 2005-6 L-3 Communications, Security & Detection Systems iii

¾ No Liability for Certain Damages. EXCEPT AS PROHIBITED BY LAW, MS SHALL HAVE NO LIABILITY
FOR ANY INDIRECT, SPECIAL, CONSEQUENTIAL OR INCIDENTAL DAMAGES ARISING FROM OR IN
CONNECTION WITH THE USE OR PERFORMANCE OF THE SOFTWARE. THIS LIMITATION SHALL
APPLY EVEN IF ANY REMEDY FAILS OF ITS ESSENTIAL PURPOSE. IN NO EVENT SHALL MSN
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LIABLE FOR ANY AMOUNT IN EXCESS OF U.S. TWO HUNDRED FIFTY DOLLARS (U.S. $250.00).
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¾ Limitations on Reverse Engineering, Decompilation, and Disassembly. You may not reverse engineer, decompile, or
disassemble the SOFTWARE, except and only to the extent that such activity is expressly permitted by applicable law
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¾ SOFTWARE TRANSFER ALLOWED BUT WITH RESTRICTIONS. You may permanently transfer rights under
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this EULA only as part of a permanent sale or transfer of the Device, and only if the recipient agrees to this EULA. If the
SOFTWARE is an upgrade, any transfer must also include all prior versions of the SOFTWARE.
¾ EXPORT RESTRICTIONS. You acknowledge that the SOFTWARE is of US-origin. You agree to comply with all
applicable international and national laws that apply to the SOFTWARE, including the U.S. Export Administration
Regulations, as well as end-user, end-use and country destination restrictions issued by U.S. and other governments. For
additional information on exporting the SOFTWARE, see http://www.microsoft.com/exporting/.
Regulations and Safety

This equipment produces ionizing X-radiation when energized. Do not operate the system without reading and understanding
this manual in its entirety.
This system complies with the following U.S. Federal Regulations applicable at the time of manufacture:
The Radiation Control for Health and Safety Act of 1968, as amended
FAA 14 CFR 108.17 Use of X-ray System
FAA 14 CFR 108.20 Use of Explosives Detection Systems
FAA 14 CFR 129.26 Use of X-ray System
CDRH 21 CFR 1020.40 Cabinet X-ray Systems
This system also meets the U.K. DfT User Requirements for X-ray Screening Equipment, Version 1 and all U.K. health and safety
regulations. Being a Certified Cabinet X-ray System, various country, state and local regulations may apply to its use. Different
regulations may apply depending on the operational location of the system. Local licensing may be required. It is the
responsibility of the user to adhere to all applicable regulations and licensing requirements. It is L-3 Communications, Security &
Detection Systems’ responsibility to manufacture and maintain the system within applicable regulatory requirements.
This system has been designed to meet CSA 114/UL 187 and applicable European CE directives.
The U.S. Federal Aviation Administration requires an annual radiation survey of all cabinet X-ray Systems in use at U.S. airports.
It is the responsibility of the user to obtain an approved radiation survey. If desired, you may contact L-3 Communications,
Security & Detection Systems Customer Support for assistance.
Due to certification requirements, the system must be installed, maintained and relocated only by L-3 Communications, Security
& Detection Systems-trained and L-3 Communications, Security & Detection Systems-certified Field Service/Customer Support
Representatives. There are no user-serviceable parts inside. There are potentially dangerous high voltages inside. Do not attempt
to gain access to the subassemblies inside the Mainframe or Operator Console.
Never allow anyone to ride the Conveyor Belt. Be aware of the normal mechanical hazards of moving conveyor components
at both ends of the Conveyor System.
Do not allow placement of any part of the body through the lead curtains located at the ends of the Conveyor System Tunnel
with the X-rays energized. An X-ray hazard could result.
Do not operate the system with torn or missing tunnel lead curtain strips. An X-ray hazard could result.
If you have any questions concerning regulatory or safety issues, contact your L-3 Communications, Security & Detection
Systems Customer Support Representative.
iv © 2005-6 L-3 Communications, Security & Detection Systems

Business Offices
L-3 Communications, Security & Detection Systems L-3 Communications, Security & DetectionROLL
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Telephone: 781-939-3800 Telephone: 727-556-0270
Fax: 781-939-3996 Fax: 727-556-0271
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© 2005-6 L-3 Communications, Security & Detection Systems v

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01 J.S. N/A JRP PRELIMINARY
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vi © 2005-6 L-3 Communications, Security & Detection Systems

Table of Contents ROLL

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1. INTRODUCTION ............................................................................................................................................. 1
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1.1 DEFINITION OF TERMS ..................................................................................................................................... 1
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1.2 RELATED DOCUMENTATION ............................................................................................................................
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1.3 MINIMUM TECHNICAL QUALIFICATIONS .........................................................................................................
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1.4 HOW TO USE THIS MANUAL ............................................................................................................................ 4
1.5 CONTACTING CUSTOMER SUPPORT ................................................................................................................. 5
2. SYSTEMS OVERVIEW ................................................................................................................................... 7
2.1 GENERAL SYSTEM DESCRIPTION ..................................................................................................................... 8
2.2 TECHNICAL HIGHLIGHTS ................................................................................................................................. 9
2.2.1 Mainframe Components ............................................................................................................................. 9
2.2.2 Operator Console Configuration ............................................................................................................. 17
2.2.3 Display Monitor Configuration................................................................................................................ 18
3. SAFETY PRECAUTIONS.............................................................................................................................. 19
3.1 ELECTRICAL SAFETY PRECAUTIONS .............................................................................................................. 19
3.2 MECHANICAL SAFETY PRECAUTIONS ............................................................................................................ 20
3.2.1 Fans.......................................................................................................................................................... 20
3.2.2 Conveyor .................................................................................................................................................. 20
3.2.3 Panels....................................................................................................................................................... 20
3.2.4 Top Panel Cable Entry............................................................................................................................. 20
3.2.5 Interlocks/Emergency Stops ..................................................................................................................... 20
3.2.6 X-ray On/Systems On Lights .................................................................................................................... 20
3.3 RADIATION SAFETY PRECAUTIONS ................................................................................................................ 21
3.3.1 Scattered Radiation.................................................................................................................................. 21
3.3.2 Radiation Dose to the Item Under Inspection .......................................................................................... 21
4. GENERAL MAINTENANCE AND SERVICE INFORMATION ............................................................. 23
4.1 SERVICE PHILOSOPHY .................................................................................................................................... 23
4.2 RECOMMENDED TOOLS AND TEST EQUIPMENT ............................................................................................. 23
4.3 ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ....................................................................................... 23
4.4 NO COMPONENT SUBSTITUTION OR SOFTWARE/HARDWARE MODIFICATION ................................................ 24
4.5 REGULATIONS................................................................................................................................................ 24
4.5.1 Radiation Survey after Servicing the System............................................................................................ 24
4.5.2 Annual Radiation Survey.......................................................................................................................... 24
4.5.3 CTP/STP Compliance .............................................................................................................................. 24
4.6 CUSTOMER’S MAINTENANCE RESPONSIBILITIES ........................................................................................... 24
4.7 RETURNED MATERIALS AUTHORIZATION ...................................................................................................... 25
4.8 INSTALLATION GUIDELINES ........................................................................................................................... 25
4.8.1 Site Inspection .......................................................................................................................................... 25
4.8.2 Shipment Exterior Inspection ................................................................................................................... 26
4.8.3 Recommended Tools and Test Equipment................................................................................................ 26
4.8.4 Installation ............................................................................................................................................... 26
5. SERVICE PROCEDURES ............................................................................................................................. 29
5.1 PREVENTIVE MAINTENANCE ......................................................................................................................... 29
5.2 SYSTEM CONFIGURATION .............................................................................................................................. 29
5.3 SERVICE REQUIREMENTS ............................................................................................................................... 30
5.4 GENERIC SERVICE AND MAINTENANCE ......................................................................................................... 37
5.4.1 Operator Console Subsystem ................................................................................................................... 37
5.4.2 Console Calibration ................................................................................................................................. 38
© 2005-6 L-3 Communications, Security & Detection Systems vii

5.4.3 Replacing the Message Center................................................................................................................. 39

5.4.4 Replacing the Leaded Curtains................................................................................................................ 39
5.4.5 TR40
Replacing the Conveyor Belt.................................................................................................................... OLL
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5.5 TENSION AND ALIGNMENT ............................................................................................................................ 44
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5.5.1 PX231 ...................................................................................................................................................... 44
5.5.2 Remove and Replace the X-ray Tank ....................................................................................................... 47
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5.5.3 Up Shooter X-ray Tank Replacement....................................................................................................... S I 49 O
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5.5.4 Down Shooter X-ray Tank Replacement .................................................................................................. 52 NT
5.5.5 X-ray Tank Season ................................................................................................................................... 54
5.5.6 Preliminary Radiation Survey (Refer to procedure 8101-10028-00)....................................................... 54
5.5.7 X-ray Alignment....................................................................................................................................... 55
5.5.8 Collimation .............................................................................................................................................. 57
5.5.9 X-ray Diagnostics Verification ................................................................................................................ 60
5.5.10 X-ray Tank Alignment ......................................................................................................................... 61
5.6 PX-208 COVER PANEL AND GUARD REMOVAL ............................................................................................. 63
5.6.1 Radiation Survey...................................................................................................................................... 66
6. SUBSYSTEMS................................................................................................................................................. 67
6.1 MAINFRAME SUBSYSTEMS ............................................................................................................................ 67
6.1.1 Power Distribution .................................................................................................................................. 67
7. SYSTEM SOFTWARE................................................................................................................................... 79
7.1 DIAGNOSTIC SOFTWARE ................................................................................................................................ 79
7.2 RE INSTALLATION OF SOFTWARE .................................................................................................................. 79
7.3 SELECTED SOFTWARE SYSTEM FILES ............................................................................................................ 79
7.4 KEYBOARD COMMANDS ................................................................................................................................ 80
8. TROUBLESHOOTING GUIDE.................................................................................................................... 81
8.1 POWER-UP PROBLEMS .................................................................................................................................. 81
8.2 DIAGNOSTICS ................................................................................................................................................ 83
8.3 APPLICATION ERROR MESSAGES ................................................................................................................... 84
9. INDEX .............................................................................................................................................................. 86
viii © 2005-6 L-3 Communications, Security & Detection Systems

List of Figures ROLL

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FIGURE 1: REAR VIEW OF PX COMPUTER.......................................................................................................... 10
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FIGURE 2: POWER DISTRIBUTION (PX208)......................................................................................................... 10
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FIGURE 3: LOW VOLTAGE POWER SUPPLY....................................................................................................... 11
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FIGURE 4: POWER ENTRY PANEL ........................................................................................................................
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FIGURE 5: REAR VIEW OF UPS.............................................................................................................................. 12
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FIGURE 6: SPELLMAN X-RAY TANK.................................................................................................................... 13
FIGURE 7: IXDA DETECTOR BOARD.................................................................................................................... 14
FIGURE 8: PXDA DETECTOR BOARD................................................................................................................... 15
FIGURE 9: DETECTOR ARRAY (PX208)................................................................................................................ 15
FIGURE 10: FOLD DOWN OPERATOR CONSOLE ............................................................................................... 17
FIGURE 11: REMOTE OPERATOR CONSOLE....................................................................................................... 17
FIGURE 12: TRANSFORMER WIRING ................................................................................................................... 27
FIGURE 13: COMPUTER CABLING ........................................................................................................................ 28
FIGURE 14: PX107 FRONT VIEW............................................................................................................................ 31
FIGURE 15: PX107 REAR VIEW .............................................................................................................................. 32
FIGURE 16: PX160P FRONT VIEW.......................................................................................................................... 33
FIGURE 17: PX160P REAR VIEW ............................................................................................................................ 33
FIGURE 22: PXM FRONT.......................................................................................................................................... 36
FIGURE 23: PXM REAR VIEW................................................................................................................................. 36
FIGURE 24: FOLD DOWN CONSOLE ..................................................................................................................... 37
FIGURE 25: FOLD DOWN & REMOTE CONSOLE................................................................................................ 38
FIGURE 26: TOUCHPAD CALIBRATION............................................................................................................... 38
FIGURE 27: CALIBRATION COMPLETE BOX ...................................................................................................... 39
FIGURE 28: BELT TENSION ADJUSTMENT (TANK SIDE SHOWN) ................................................................. 40
FIGURE 29: POWER ROLLER (DETECTOR SIDE SHOWN) ................................................................................ 40
FIGURE 30: POWER ROLLER (TANK SIDE SHOWN) .......................................................................................... 41
FIGURE 31: TENSION PULLEY AND TENSION PULLEY ADJUSTMENT ASSEMBLY .................................. 41
FIGURE 32: DRIVE PULLEY AND TRACKING PULLEY ASSEMBLY .............................................................. 42
FIGURE 33: COVER PLATE AND TRACKING PULLEY BRACKET................................................................... 43
FIGURE 34: INSTALLED CONVEYOR BELT ........................................................................................................ 45
FIGURE 35: SET-UP FOR BELT TENSION ADJUSTMENT .................................................................................. 45
FIGURE 36: TRACKING BOLT ................................................................................................................................ 46
FIGURE 37: TANK SIDE CLOSE-UP ....................................................................................................................... 47
FIGURE 38: TANK CLOSE-UP WITH LEAD COVER SET ASIDE ....................................................................... 47
FIGURE 39: DETECTOR SIDE EQUIPMENT TRAY – PULLED OUT.................................................................. 48
FIGURE 40: X-RAY TANK REAR CONNECTIONS ............................................................................................... 48
FIGURE 41: SYSTEM ASSEMBLY .......................................................................................................................... 49
FIGURE 42: X-RAY TANK HARDWARE................................................................................................................ 50
FIGURE 43: X-RAY TANK CABLING ..................................................................................................................... 50
FIGURE 44: X-RAY TANK SIDE ADJUSTMENT SCREWS.................................................................................. 51
FIGURE 45: X-RAY TANK INSTALLATION.......................................................................................................... 52
FIGURE 46 X-RAY TANK IN SYSTEM................................................................................................................... 53
FIGURE 47 REAR OF X-RAY TANK WITH CABLES ATTACHED ..................................................................... 53
FIGURE 48: DIAGNOSTICS...................................................................................................................................... 55
FIGURE 49: ALIGNMENT TOOL SCREEN............................................................................................................. 56
FIGURE 50: HI AND LO SIGNALS WITHOUT X-RAYS ....................................................................................... 56
FIGURE 51: HI AND LO SIGNALS WITH X-RAYS ON......................................................................................... 57
FIGURE 52: PX-M COLLIMATOR ADJUSTMENT SCREWS ............................................................................... 59
© 2005-6 L-3 Communications, Security & Detection Systems ix

FIGURE 53: PX-208 COLLIMATOR ADJUSTMENT SCREW................................................................................59

FIGURE 54: PX-107 COLLIMATOR ADJUSTMENT SCREW................................................................................60
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FIGURE 55: SCENARIO WINDOW...........................................................................................................................61
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FIGURE 57: MONITOR SET ASIDE & TOP COVER REMOVED ..........................................................................64
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FIGURE 58: CONVEYOR COVERS & BELT GUARDS SET ASIDE .....................................................................65
FIGURE 59: CONVEYOR SHROUD AND MOUNTING PLATES..........................................................................65
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FIGURE 60: TUNNEL OPENING WITH ALL COVERS REMOVED .....................................................................66 ME
FIGURE 61: POWER UP/DOWN PLC DIN RAIL.....................................................................................................67 NT
FIGURE 62: POWER SEQUENCER...........................................................................................................................70
FIGURE 63: POWER DIN RAIL.................................................................................................................................71
FIGURE 64: SIGNAL DIN RAIL ................................................................................................................................72
FIGURE 65: POWER DISTRIBUTION BOARD (PDB) ............................................................................................74
FIGURE 66: POWER DISTRIBUTION BOARD (PDB) JACKS ...............................................................................77
FIGURE 67: PXDA JUMPER LOCATIONS ..............................................................................................................78
x © 2005-6 L-3 Communications, Security & Detection Systems

List of Tables ROLL

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TABLE 1: TECHNICAL HIGHLIGHTS ...................................................................................................................... 7
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TABLE 2: COMPUTER REPLACEMENT PART NUMBER ..................................................................................... 9
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TABLE 3: SUMMARY OF DETECTORS/BOARDS ................................................................................................ 14
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TABLE 4: SUMMARY OF PXDA DETECTOR PART NUMBERS ........................................................................ SI 16
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TABLE 5: OPERATOR CONSOLE CONTROLS AND INDICATORS ...................................................................
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TABLE 6: DIN RAIL JUMPER WIRES..................................................................................................................... 68
TABLE 7: DIN RAIL CABLE CONNECTIONS ....................................................................................................... 69
TABLE 8: PDB CIRCUIT BREAKERS ..................................................................................................................... 73
TABLE 9: PDB FUSES ............................................................................................................................................... 73
TABLE 10: PDB LEDS ............................................................................................................................................... 73
TABLE 11: PDB TEST POINTS................................................................................................................................. 73
TABLE 12: PDB MANUAL SWITCHES................................................................................................................... 73
TABLE 13: PBD JACKS ............................................................................................................................................. 75
TABLE 14: CABLING BLOCK DIAGRAMS LIST .................................................................................................. 78
TABLE 15: SEASONING VALUES........................................................................................................................... 80
TABLE 16: KEYBOARD COMMANDS ................................................................................................................... 80
TABLE 17: TROUBLESHOOTING: NO ERROR MESSAGE.................................................................................. 81
TABLE 18: PX ERROR CODES ............................................................................................................................... 84
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1. Introduction
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Detection Systems. It also contains technical information and detailed instructions for system
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maintenance, service, and repair.
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• Definition of Terms
• Related Documentation
• Minimum Technical Qualification
• How to Use This Manual
• Contacting Customer Support
1.1 Definition of Terms

This document refers to the PX-M as the complete detection system.
The term Mainframe refers to the cabinet X-ray machine with conveyor belt assembly. The
Mainframe collects data by scanning a bag or package with X-rays. The computer simultaneously
analyzes and images the item being inspected. The resulting data is then analyzed and an image of the
bag with any target materials highlighted is displayed on the Display Monitor.
The term Operator Console refers to the console that receives the image of the item being inspected
from the Mainframe. The Console allows the Operator to control the Mainframe and manipulate the
way the image and threat information is viewed on the monitor.
© 2005-6 L-3 Communications, Security & Detection Systems 1

1.2 Related Documentation

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regulatory compliance, and the Windows operating system. Qualified individuals may obtain these
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documents by contacting Customer Support.
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Document Reference Number SI
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PX Products Operator Manual 8100-10809-OM
PX Products Configuration Manual 8100-10809-CM
PX Installation Commissioning Verification Procedure 8100-10544-00
PX/LS Diagnostic Manual 8100-10443-00
Radiation Survey Procedure 8101-10028-00
Preventive Maintenance Procedure 8601-10011-00
Document for Options
Accessory Table Installation Procedure 8100-10440-AP
Fold Down Console Field Installation Procedure 8100-10450-00
Message Center 8100-10544-00
Network Supervisor Workstation Installation Procedure 8100-10579-IP
2 © 2005-6 L-3 Communications, Security & Detection Systems

1.3 Minimum Technical Qualifications

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Communications Security & Detection Systems Customer Support personnel in the installation,
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operation, maintenance and repair of the PX Systems and possesses the following minimum technical
qualifications:
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• An Associates Degree in Electronics, or 5 years of related job experience NT
• A full working knowledge of PC AT-type computer systems and Microsoft Windows NT 4.0
Operating System
• A good working knowledge of complex digital and analog circuitry
• General knowledge of complex mechanical systems
• Is thoroughly familiar with the use of test equipment, especially a DVM
• Some experience with high voltage and X-ray producing equipment

1.4 How to Use This Manual

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material necessary to successfully maintain and service PX Systems after the training course has been
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completed, and a qualifying Certificate issued.
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This manual is divided into the following: SI
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• The Preface provides general information including a document Disclaimer, a Proprietary
Information Notice, a Classified Information Notice, a Software License Agreement,
Regulations & Safety Precautions and Business Information.
• The Introduction (Chapter 1) provides Related Documentation that might be required during
normal operation or servicing PX Systems, Minimum Technical Qualifications, and information
about Contacting Customer Support.
• The Systems Overview (Chapter 2) presents a General System Description and Technical
Highlights.
• The Safety Precautions (Chapter 3) contains important information about possible Electrical,
Mechanical and Radiation hazards.
• General Maintenance and Service Information (Chapter 4) presents the L-3 Communications
Security & Detection Systems’ Service Philosophy, a list of Recommended Tools and Test
Equipment, Electrostatic Discharge (ESD) Precautions, a section that covers No Component
Substitution or Software/Hardware Modification, Regulations, the Customer’s Maintenance
Responsibilities and our Returned Materials Authorization process.
• Installation Guidelines (Chapter 4.8)
• Service Procedures (Chapter 5) contains information about the actual servicing of the product.
It includes common servicing sections, such as Preventive Maintenance, and Generic Service
and Maintenance, as well as model-specific procedures.
• Subsystems(Chapter 6) details major subsystems of the Mainframe providing theory of
operation for the subsystems This provides information for service personnel to gain an
understanding of system function down to the board or subassembly level.
• System Software (Chapter 7) provides information on and Software Installation and Keyboard
Commands.
• The Troubleshooting Guide (Chapter 8) lists most common errors or problems that may be
encountered and how to resolve them.
• The Index is included for quick reference to features and terminology used throughout the
manual.

1.5 Contacting Customer Support

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Detection Systems Customer Support if you have any technical questions or require any additional
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information. It is L-3 Communications, Security & Detection Systems’ responsibility to help you solve
our customer’s problems as professionally, efficiently and safely as possible.
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Do not spend a long time troubleshooting unusually difficult or previously unknown problems. If after
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a few hours of professional, systematic troubleshooting techniques, you still cannot locate the cause of
the problem, contact L-3 Communications, Security & Detection Systems Customer Support. Be sure
to have your specific problem and the troubleshooting methods you have employed documented and
the installation site information available, especially the system location and serial number.
The L-3 Communications, Security & Detection Systems Customer Support staff in the U.S. can be
reached Monday through Friday, excluding company holidays, from 9:00 AM to 5:00 PM EST/EDT
(14:00 to 22:00 UT). Refer to Business Information in the Preface of this manual for more
information. After normal business hours, a voicemail system will automatically answer. After the
announcement, leave your name, return telephone or FAX number and a brief message. A Customer
Support representative will return your call as soon as possible.
Our U.K.-based support staff can be reached Monday through Friday, excluding company holidays,
from 9:00 AM to 5:00 PM UT. Refer to Business Information in the Preface of this manual for more
information. After normal business hours, a voicemail system will automatically answer. After the
announcement, leave your name, return telephone or FAX number and a brief message. A Customer
Support representative will return your call as soon as possible.
Customer Service Locations

To reach Customer Support Services in any location, call toll free at 800-776-3031.
North America
United States
L-3 Communications, Security & Detection Systems
10 Commerce Way
Woburn, MA 01801-1028 USA
Telephone: 781-939-3800
Fax: 781-939-3996
URL http://www.dsxray.com

2005 Gandy Boulevard North, Suite 600
St. Petersburg, FL 33702-2166 USA
Telephone: 727-556-0270
Fax: 727-556-0271
Latin America
10 Commerce Way
Woburn, MA 01801-1028 USA
Telephone: 781-939-3800
Fax: 781-939-3996

Asia/Pacific
Australia ROLL
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Europe/Middle East/Africa (EMEA)

United Kingdom
L-3 Security and Detection Systems
Unit 2 Astro House
Brants Bridge
Bracknell, Berkshire
RG129HW, England
Tel: 44 (0) 1344.477900
Fax: 44 (0) 1344.477901

2. Systems Overview ROLL

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• Technical Highlights
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Table 1: Technical Highlights
System Name PX107 PX160P PX208 PX231 PXM
Number of 1600 1280 1600 1536 1536
Detectors
Tunnel Size (mm) 1011 x 1011 1500 x 1650 825 x 654 1000 x 800 606 x 506
Wire Gauge 36 30 38 36 38
Penetration 27 25 29 27 29
Belt Speed (cm/s) 23 13.7 23 23 26
60Hz
Conveyor 200kg 3,000kg 150kg 135kg 100kg
Capacity 440lb 6,600lb 330lb 300lb 220lb
mA (F/B N/A 1 N/A N/A 0.5
Detector)
mA (Stacked 0.8 1 mA 0.8 0.8 0.8
Detector)
KeV 150 160 150 150 150
F/B Detector Size 2.7 5.25 2 2.7 1.5
Beam Orientation Up Shooter Side Shooter Up Shooter Down Up Shooter
Shooter

2.1 General System Description

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the capabilities of image analysis with an enhanced X-ray inspection system. PX Products support a
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freestanding inspection environment as well as networked installations.
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Standard Software Features
y Mark Threat (Enabled/Disabled by Supervisor)
y Print (Enabled/Disabled by Supervisor)
y Zoom
Direct – 1x, 2x, 4x, 8x, and 16x Magnification, or
Continuous – up to 64x Magnification
y Trimat
y Organic Stripping
y Inorganic Stripping
y Gray Scale
y PseudoColor (Enabled/Disabled by Supervisor)
y Contrast
y Contrast Windowing
y Edge Enhancement
y Reverse Video
Purchasable Options
Operator Assist (OA)
Threat Alert
Density Alert
Image Archiving (IA)
Threat Image Projection (TIP)
Network Supervisor Workstation (NSW)
Network TIP Server (NTS)

2.2 Technical Highlights

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Operator Console (or Remote Console) and Display Monitor.
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The Operator Console allows the Operator to control the Mainframe and to view, manipulate and
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analyze the image and any displayed threat information. It is also available in a remote Sversion.
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The Display Monitor is a color monitor used to view images.
2.2.1 Mainframe Components

The Mainframe contains the
• Computer
• Power Distribution System
• Inspection Tunnel
• Detector Array
• Conveyor
• X-ray Generation
Computer
The PX Computer analyzes X-ray information, and projects and stores images. It also runs the
software options Threat Image Projection (TIP), Operator Assist (OA), and Image Archiving (IA).
The PX107/PX160P/PX208 and PX231 all use a 32-bit computer. The replacement part numbers are
shown in Table 2.
Table 2: Computer Replacement Part Number

System Computer Part Number
PX107 1600-10423-00
PX160P 1600-10423-03
PX208 1600-10423-01
PX231 1600-10423-02
PXMs may have an 8-bit computer or a 32-bit computer. Be sure to replace with the correct
component. For example, a customer with an 8-bit computer should receive, if necessary, an 8-bit
computer as a replacement.
The replacement part number for a computer running 8-bit software is 1600-10424-01. The
replacement part number for a computer running 32-bit software is 1600-10426-01.

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Figure 1: Rear View of PX Computer
Power Distribution System

The computer and display monitor receive AC Power from the Mainframe’s power distribution system.
A Uninterruptible Power Supply (UPS) is connected between the Power Distribution Board (PDB and
computer. A system circuit breaker is located on the mainframe, below the conveyor.
POWER
DISTRIBUTION
BOARD (PDB)
UNINTERRUPTIBLE
POWER SUPPLY
(UPS)
Figure 2: Power Distribution (PX208)

Low Voltage Power Supply (LPVS)

The Low Voltage Power Supply provides ±5 VDC and ±12 VDC for the detector array and OLADC.
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Pin 1 +12V
Pin 2 GND
Pin 4 GND
Pin 5 +12V
Pin 6 -12V
Pin 1 +5V
Pin 2 GND
Pin 4 -5V
Figure 3: Low Voltage Power Supply

Meters
Three Electro-mechanical meters with LCD-readout are mounted on an external panel (except forTROLL
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• BAG COUNT: resettable; - counts the number of bags that have gone through the system.
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Figure 4: Power Entry Panel
Uninterruptible Power Supply

The Uninterruptible Power Supply (UPS) provides backup power to the PC in the event of a power
failure. This allows the PC to shutdown properly.
Figure 5: Rear View of UPS

Inspection Tunnel
The systems uses photocells mounted in the entrance and exit tunnel walls to determine whenTROaLbagL
enters the inspection tunnel. The state of these photocells signals the system to turn onNthe X-rays
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when a bag enters the tunnel. When the feedback voltage from the X-ray tank indicates that X-rays are
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being generated, LEDs located on the Console and the X-ray On lights at both ends of the Mainframe
are lit. The lights at both ends of the Mainframe are driven directly by the X-ray hardware on the
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X-ray Generation
The X-ray Source consists only of the X-ray Tank mounted to the Mainframe. The X-ray Generator
generates X-rays. The X-rays are shaped and projected through the object being scanned to the
Detector Boards.
Figure 6: Spellman X-ray Tank

The X-ray tank includes two pulse-width modulators for controlling the X-ray tube voltage and current.
Input line voltage range to X-ray tank ranges from 100VAC to 264VAC, 50Hz/60Hz, and 4 Amps
RMS max. PX X-ray generators are programmed to operate at 220VAC.
Output voltage performance for the X-ray tube operational range is programmed to be within 80 to 160
kV (±40kV to ±80kV) and is measured at the tube to within ±2% of the selected value. Voltage
regulation is <0.05% for ±10% of the nominal input line change and <0.05% for 0.1mA to 1.2mA load
change. The mA/kV ramp time is less than 200 mS from 10% – 90% of the output voltage and current.
The kV overshoot returns to within 5% of full output voltage in less than 10ms.
The X-ray tube generates a fan-beam of X-rays that penetrate the item under inspection as it passes
through the Inspection Tunnel. The X-ray fan beam is approximately 60 degrees by 0.1 inch wide.
X-ray Detectors
The detector subsystem consists of two arrays of detectors that are positioned around the X-ray focal
point. The detectors are mounted in a right-angled ‘L-shaped’ configuration that utilizes proprietary
detector circuitry. Every second, 240 lines of data are generated. Each line of data contains high and
low detector values. The digitized detector data is then sent to the computer for analysis.
The Detector Array consists of 18 to 25 Detector Boards. Each detector board is comprised of a
High-energy side and a Low-energy side. Each board has 32 High and 32 Low. The detectors on the
Low-energy side are made of an intensifying screen mounted to a silicon photodiode array. The
detectors on the High-energy Amp Boards are made of a laddered arrangement of scintillators mounted
to silicon photodiodes. A ribbon cable runs from the detector box assembly to the A/D Converter

Board next to the detector box assembly. The boards receive power and addressing information
through the cables and return analog signals to the A/D Converter Board through the cables. The A/D
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Interface Board located inside the computer.
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Every vertical sync pulse of the Video Board is transmitted from the System Interface Board to the A/D
Converter Board. A Complex Programmable Logic Device (CPLD) on the A/D Converter BoardS
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read all high and all low channels in 4.1 milliseconds. This reading process occurs 4 times, which
yields four lines of data. After receiving all four lines of data, the A/D Converter Board waits to
receive the next vertical sync pulse, which occurs every 16.667 milliseconds. This results in a rate of
240 lines of data each second.
The L-shaped Detector Array is mounted opposite the X-ray Source. The array consists of several
Detector Boards.
Table 3: Summary of Detectors/Boards

System Detectors Boards (Detectors/64)
PX107 1600 25
PX160P 1280 20
PX208 1600 25
PX231 1536 24
PXM 1536 24
IXDA Detectors
PXMs with serial numbers up to 2163 have IXDA detector boards. IXDAs are only used on PXM
assemblies.
Figure 7: IXDA Detector Board

The replacement part number for an IXDA is 1000-10452-00.

PXDA Detectors
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Figure 8: PXDA Detector Board
NOTE:
IXDAs and PXDAs are NOT interchangeable.
DETECTOR ARRAY
Figure 9: Detector Array (PX208)

Side-By-Side (SBS) Detectors

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with stacked detectors. The replacement part number for a PXDA with SBS Detectors is 1600-10208-
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PXMs with serial numbers of 4000 and higher have stacked detectors. All
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PX107/PX160P/PX208/PX231 assemblies have stacked detectors. Stacked detectors are not
interchangeable with side-by-side detectors (SBS) detectors.
Table 4: Summary of PXDA Detector Part Numbers

System PXDA Detectors Part Numbers
PX208 1600-10620-00
PX107 1600-10621-00
PX231 1600-10622-00
PX160P 1600-10623-00
PXM 1600-10208-00
NOTE:
SBS Detectors are NOT interchangeable with Stacked
Detectors.
Inspection Tunnel and Conveyor

The Inspection Tunnel is a lead-lined metal enclosure in which the bag or package is X-rayed. Lead
curtains at both ends of the tunnel provide shielding from X-ray scatter.
The Conveyor moves items to be inspected through the Inspection Tunnel. The Conveyor Assembly
consists of a supporting frame at each end, a belt, and a power roller assembly. The Operator, through
controls on the Console, controls the conveyor.

2.2.2 Operator Console Configuration

ROsystem.
The Operator Console (Figure 10) is the main control interface between the Operator andTthe LL It
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POWER ON INDICATOR INDICATOR X-RAY ON INDICATOR
POWER ON/OFF
KEYSWITCH
TOUCHPAD
CONVEYOR
CONTROL
BUTTONS
Figure 10: Fold Down Operator Console

Emergency Stop
Power ON/OFF
Keyswitch
Photocell
Indicator
Touchpad
Conveyor Control &

Decision Buttons
Figure 11: Remote Operator Console

Power On/Power Off Switch: Initiates start-up/shut-down sequences and allows power to be
distributed to all system components.
FORWARD, STOP and REVERSE buttons: These buttons control the conveyor movement of items
through the Tunnel.
Touchpad: A large touch-sensitive glass panel is provided as the primary image control mechanism
during operation. By moving a finger across the surface, an on-screen indicator can be directed to
select various image tools, represented as icons. Sliding a finger across the bottom portion of the
Touchpad will ‘activate’ the respective icon on the display; the upper portion is used for other features,
such as image zooming and contrast windowing.

Table 5: Operator Console Controls and Indicators

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Power On Indicator This indicator is illuminated when the Power On/Power Off Keyswitch is in the
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Photo sensor inspection tunnel and indicate that an item has entered the tunnel. When
Indicator illuminated (which one depends on the configuration), an object has entered
the inspection tunnel to be X-rayed, or is reversing out of the tunnel.
X-ray On Indicator This indicator is illuminated whenever the PX is producing

X-radiation.
FORWARD and The pushbuttons associated with these symbols move the conveyor in a
REVERSE forward or reverse direction. The forward direction is determined by the
(Configurable) ‘Standard’ or ‘Alternate’ console configuration selected in the Configuration
menu. Items moving through the inspection tunnel in either direction are
◁▷ scanned by the system. The system is designed to continuously operate in the
forward direction. However, provision has been made to intermittently reverse
the belt for re-inspection of a bag, if required. Operationally, it may be more
desirable to bring the bag around to the tunnel entrance for re-inspection.
CONVEYOR STOP Pressing the pushbutton below this symbol (Remote Workstation) stops the
conveyor. (Pressing the Left or Right Pushbutton will restart the conveyor).
○
Operator Sensor – Floor Mat
An optional Operator Sensor is also available. This sensor can determine whether the Operator is
standing in front of the console. If this option is part of the PX Product at the specified location, the
operator must be standing in front of the console for the system to operate. There are two different
means by which an Operator’s presence may be determined: one is an infrared sensor, and the other
is a footmat.
2.2.3 Display Monitor Configuration

The Display Monitor is a 17" SVGA high resolution display capable of 1280x1024 24-bit image
resolution.

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• Electrical Safety Precautions
• Mechanical Safety Precautions
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3.1 Electrical Safety Precautions
Be sure the system is properly wired and grounded. Be sure the system’s Isolation Transformer,
primary and secondary, are wired properly for the given line input voltage and that the system has a
fail-safe ground. Verify that the Conveyor Motor and the system Mainframe are at the same ground
potential.
Service personnel must check the size and rating of fuses before replacing. Replace fuses with
the same size and rating. Disconnect power before replacing.
Before replacing any High Voltage sub-assemblies of the mainframe be sure to secure power to
machine and unplug from power source.
Line Voltages
The systems can be configured to operate on line voltages from 100 to 240 VAC at 50 or 60 Hz.
Caution should be exercised when working at the main power inlet, the circuit breaker or the primary
of the system Isolation Transformer. Always be sure the system is properly grounded and de-energized
prior to commencing work on these components.

3.2 Mechanical Safety Precautions

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3.2.1 Fans
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220 VAC. Caution should always be exercised when working on or near any open fan or fan assembly. NT
Be especially careful of loose or bulky clothing, neckties, long hair and jewelry that may be caught in
the mechanisms, possibly drawing you in.
3.2.2 Conveyor
The Conveyor Subassembly contains various moving mechanical components. Be very

careful if the conveyor assembly must be operated for servicing reasons, with the stainless steel tunnel
extensions and conveyor shrouds removed. Be especially careful of your fingers, loose or bulky
clothing, neckties, long hair and jewelry that may be caught in the mechanisms, possibly drawing you
in. The systems should never be turned over to normal operating personnel without all protective
panels and covers securely replaced.
Additional safety measures may be required if optional conveyor accessories are being used. Please
consult local health and safety regulations.
3.2.3 Panels
Removal of panels for servicing equipment requires a factory-trained individual. Be sure to

reconnect any Ground strapping connections between any panel and the system frame that may be
removed for interior access during servicing.
3.2.4 Top Panel Cable Entry
The provided cable plug must be installed if the access hole is not used.
3.2.5 Interlocks/Emergency Stops

All PX products are equipped with Panel Interlocks to prevent system operation with panels open.
When activated Emergency Stops prevent X-rays from being produced and the conveyor belt from
moving. Technicians should ensure that these devices are functioning properly after servicing the
machine.
3.2.6 X-ray On/Systems On Lights

All PX products have X-ray On indicator lights at the entrance and exit of the inspection tunnel. In
addition, these indicator lights are also located on the Operator Console. The X-ray On lamp should be
illuminated when X-rays are being produced. The system on lamp should be illuminated whenever the
keyswitch is in the On position and power is on. Technicians should ensure that these devices are
functioning properly after servicing the machine.

3.3 Radiation Safety Precautions

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All L-3 Communications, Security & Detection Systems emit ionizing X-radiation when
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in operation. Operation of this system should only be performed by individuals qualified to use X-ray
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Do not insert, or allow anyone else to insert, any part of the body into the inspection tunnel when
the system is in operation.
Do not operate the system with torn or missing tunnel curtain strips.
You may be required to wear a radiation-monitoring device. Please check your local regulations
for compliance.
Do not operate the system with X-ray Source Scatter Shields removed.
3.3.1 Scattered Radiation
The systems emits a small amount of scattered radiation during normal operation. This amount is
less than 0.1 mR per hour (< 1 μSv/Hr) when measured anywhere about the Mainframe.
3.3.2 Radiation Dose to the Item Under Inspection
The standard systems operating at a factory set conveyor belt speed exposes the item under
inspection to an X-ray dose of less than 0.4 mR (< 4.0 μSv) per inspection.
PX107: dose limit is 0.25 mR per Inspection for 60Hz units and 0.30 mR per Inspection for 50Hz units
PX160P: dose limit is 0.2 mR per Inspection
PX208: dose limit is 0.1 mR per Inspection
PX231: dose limit is 0.25 mR per Inspection for 60Hz units and 0.30 mR per Inspection for 50Hz units
PXM: dose limit is 0.40 mR per Inspection for 60Hz units and 0.48 mR per Inspection for 50Hz units
The systems are not harmful to ISO 1600/33 DIN high speed photographic film, electronic items,
medicines, foods, or magnetically recorded media, even after multiple inspections.

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4. General Maintenance and Service Information ROLL

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• Service Philosophy
• Recommended Tools and Test Equipment
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• No Component Substitution or Software/Hardware Modification
• Regulations
• Customer’s Maintenance Responsibilities
• Returned Materials Authorization
4.1 Service Philosophy

Due to electronic complexity, systems have been designed for service to the board or subassembly level
only, not to the component level. Multi-layer PC boards, many employing dense surface-mount
technology, are used throughout the systems. This makes component level repair in the field difficult,
usually resulting in the destruction of the suspected PC board. Repairs made to boards in the field will
void the L-3 Communications, Security & Detection Systems warranty for the affected assembly.
If PC board repair is required, obtain a Return Materials Authorization (RMA) (refer to section 4.7) and
return your suspect or defective PC board(s) to L-3 Communications, Security & Detection Systems for
repair or replacement. Contact Customer Support for assistance.
4.2 Recommended Tools and Test Equipment

L-3 Communications, Security & Detection Systems recommends that as a minimum, the following
tools and test equipment be available for the general servicing of any PX Detection Systems:
• Jensen JTK-5 tool kit – or equivalent
• Standard Metric tool kit
• Digital Voltmeter (DVM) for quick voltage monitoring
• Scatted Radiation Meter
• A variable-speed, battery-operated cordless drill/driver
The above list defines specific vendors to establish a minimum requirement. Equivalent products may
be used.
4.3 Electrostatic Discharge (ESD) Precautions

When handling PC boards, ensure proper ESD procedures are observed. ESD damage may occur when
a charged surface contacts electronic devices. ESD damage may not cause instant failure; however,
latent device degradation may occur. Such damage may adversely affect the quality and reliability of
the product.
Refer to L-3 Communications, Security & Detection Systems’ ESD Control Operating Procedures,
8301-10005-00.

4.4 No Component Substitution or Software/Hardware Modification

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express written consent of L-3 Communications, Security & Detection Systems. Such substitutions, if
made, may void the product warranty and cause L-3 Communications, Security & Detection Systems to
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violation of U.S. HHS CDRH or U.K. DfT regulations.
No additions or modifications to the computer system, the disk operating system or any part of the
system software may be made without the express written consent of L-3 Communications, Security &
Detection Systems. Additions or modifications may constitute a violation of U.S.HHS CDRH or U.K.
DfT regulations and could adversely affect measurement accuracy, detection, and overall system
performance or system safety. If made, they may void the product warranty and cause L-3
Communications, Security & Detection Systems to refuse to support the equipment even if it is within
the warranty period. Contact Customer Support for the availability of computer accessories such as
video printers and mass storage devices and their L-3 Communications, Security & Detection Systems-
compatible and L-3 Communications, Security & Detection Systems supported software drivers.
4.5 Regulations
4.5.1 Radiation Survey after Servicing the System

The U.S. Department of Health and Human Services (HHS), Food and Drug Administration (FDA),
and the Center for Devices and Radiological Health (CDRH), require that a radiation survey be
performed whenever servicing may have affected the certification of the system.
The US Code of Federal Regulations (CFR) and U.K. Healthy and Safety Regulations require the
performance and documentation of a scattered radiation survey whenever the X-ray Source, X-ray
Controller, Collimator, Scatter Shields, Detector Array or Lead Curtains are moved, adjusted, or
replaced. Check with other state and local authorities that may require a radiation survey after
servicing as well.
4.5.2 Annual Radiation Survey

The U.S. Federal Aviation Administration (FAA) and U.K. Healthy and Safety Regulations require all
security X-ray inspection systems in use by U.S. air carriers and U.K. Department for Transport (DfT)
worldwide undergo annual radiation survey and certification compliance verification. The customer
should contact Customer Support for information regarding the current requirements.
4.5.3 CTP/STP Compliance

Starting May 1, 2006 U.K. Department for Transport (DfT) may require CTP/STP compliance after
servicing a machine. Check with local authorities.
4.6 Customer’s Maintenance Responsibilities

It is the customer’s responsibility to inform Customer Support or our local Representative or Reseller,
of any malfunction observed in the normal operation of these systems. L-3 Communications, Security
& Detection Systems should also be informed if whenever a system is relocated.

Most internal malfunctions will result in the automatic generation of an error message visible to the
Operator with specific information regarding the problem detected. Most external malfunctions will be
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as possible about a system malfunction to facilitate the proper diagnosis and timely repair.
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If the system has been relocated, a radiation survey and a general system check should be performed to
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Qualified service technicians are encouraged to contact Customer Support if there are any technical NT
questions or if additional information is required. See section 1.5 Contacting Customer Support.
4.7 Returned Materials Authorization

All defective and suspect boards and subassemblies should be returned to L-3 Communications,
Security & Detection Systems for warranty consideration and replacement or repair. A Returned
Material Authorization (RMA) number, issued by Customer Support, must be clearly marked on the
outside of the shipping container. Contact Customer Support (see section 1.5 Contacting Customer
Support) for details. Goods arriving at L-3 Communications, Security & Detection Systems without
the proper RMA number will be returned to the sender, unopened, freight collect.
4.8 Installation Guidelines

These installation guidelines detail the procedures required to install a PX system and the requirements
on others to provide services where appropriate. The order of events can be modified to suit particular
installations, but only with the prior approval of the Customer and L-3 Communications Security &
Detection Systems.
The installer must be trained and certified by L-3 Communications Security & Detection Systems, and
be familiar with both the system and the interface specifications.
4.8.1 Site Inspection

Before the machine is uncrated, refer to the appropriate System Information Sheet:
PX107 Information Sheet 8101-10022-P3
PX231 Information Sheet 8101-10022-P4
PXM Information Sheet 8101-10022-P2
The site should be inspected by L-3 Communications Security & Detection Systems personnel and a
Customer representative to ensure:

• Crated system has been delivered to site.

• The method of achieving the power supply requirements is demonstrable ROLL
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• Mounting platform/staging area (where appropriate) is installed to ensure correct physical
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alignment
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• Any lifting devices that may be required for installation are available for use by others. S IO O
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4.8.2 Shipment Exterior Inspection

Visually inspect for damage and notify shipping company where necessary. Crates contain shock
indicators that will indicate whether the crate may have been damaged during shipment.
Inspect the crate and note any shipping damage. If damage is found, make a note detailing the nature
of the damage. Photograph the affected area, as required. Also, document any damage to the contents
of the crate once the system is unpacked and the various components can be inspected.
4.8.3 Recommended Tools and Test Equipment

L-3 Communications Security & Detection Systems recommends that, as a minimum, the following
tools and test equipment are available for the installation and general servicing of the System:
Jensen JTK-5 tool kit;
DVM for quick voltage monitoring;
Fluke/Philips Model 97, 2-channel, 50-MHz Digital Oscilloscope/DVM;
Eberline ASP-1 Geiger type Radiation Meter with a HP-270 probe;
Keithley 36150 Integrating Ion Chamber Radiation Meter; and
variable-speed, battery-operated cordless drill/driver.
The above defines specific vendors to establish a minimum requirement. Equivalent products may be
used.
4.8.4 Installation
NOTE:
Both a Customer Representative and an L-3
Communications Security & Detection Systems
Representative must be present during the entire process
of moving the system into its final position.
The Customer is responsible for:
• Terminating Main system power to the System in accordance with the PX Product Power Site
Wiring requirements
• Leveling and aligning the system
• Discarding the packing crate and shipping material
• Contacting appropriate Regulatory Agencies to obtain any required inspections

Both the Customer and L-3 Communications Security & Detection Systems are responsible for:
• Either rolling the system directly into position without lifting, or
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L-3 Communications Security & Detection Systems is responsible for:
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• Uncrating the system operating console and any other components
• Requesting that power is made available to the system
• Assembling the operator console
• Attaching VGA, RGB, and Power Cables
• Installing all system accessories
• Powering up the system to verify that it functions properly, including verifying of alignment
and performing diagnostic testing
• Ensuring that Operator/Maintenance training and manuals are provided in accordance with the
contract
Power Installation:
• Connect power to the primary side as shown in drawing (Figure 12) below.
• Verify that connections match drawing for appropriate voltage.
Figure 12: Transformer Wiring

Incoming Voltage Transformer Tapping

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105 – 115 VAC 110 VAC
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115 – 125 VAC 120 VAC
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205 – 215 VAC 210 VAC NT
215 – 225 VAC 220 VAC
Computer Cabling Connections:

• Connect all cables to the computer according to the diagram (Figure 13) below:
1000-10386-00
1000-10286-01
KEYBOARD
0120-10143-00
MOUSE DISPLAY SETTINGS:
TO DIN RAIL 256 COLORS
1280 x 1024 RESOLUTION
1100-10097-01 1000-10211-06
(REMOTE) TO DIN RAIL
OR
1000-10426-00
(ATTACHED)
Figure 13: Computer Cabling

The system is now ready for Commissioning Verification in accordance with the appropriate
procedure. This procedure requires the attendance of L-3 Communications Security & Detection
Systems and Customer Representatives.

5. Service Procedures ROLL

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For procedures requiring the use of a keyboard, connect a
PC/AT Enhanced Keyboard (101/102-key) to the
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This chapter contains information about the following topics:
• Preventive Maintenance
• System Configuration
• Service Requirements
• Generic Service and Maintenance
• Tension and Alignment
5.1 Preventive Maintenance

L-3 Communications, Security & Detection Systems recommends that all systems undergo a full
Preventive Maintenance inspection by factory-trained service personnel on an annual basis. The
inspection consists of verifying that the system is operating within specifications and that it fully
complies with all applicable safety regulations. Using the Installation Procedure as a general guide,
perform all tests that would normally be required for the initial system installation, including verifying
the proper line voltages and performing scattered radiation surveys.
The systems will have undergone a nominal amount of wear since its initial installation. Be especially
aware of any of the following:
y unusual noises or odors
y a mistracking or damaged Conveyor Belt
y worn conveyor snub roller bearings
y torn or missing Inspection Tunnel curtain strip
y damaged or missing system labeling
y missing, broken or sticking pushbutton switches
y burned-out illuminating indicators
y any missing or loose hardware
In addition, the systems should be vacuumed internally, especially around the fan assemblies.
Internally, the systems mechanics should be inspected for any excessive component wear and be sure
the systems-cooling fans are operating properly.
All preventive maintenance and procedures should be done in accordance with the Preventive
Maintenance Procedure, 8601-10011-00.
5.2 System Configuration

The systems must be configured during initial setup. System Configurations may also be done after the
unit has been in operation for a period of time.
Refer to PX Family Configuration Manual, 8100-10809-CM for complete instructions.

5.3 Service Requirements

Various procedures are required to service and maintain PX family products in proper operating TROLL
condition. Contact L-3 Communications and Detection Systems Customer Service to obtain theNmost
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up-to-date part list.
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The following abbreviations are used on the following illustrations. These illustrations are included to
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ADC – Analog-to-Digital Converter converts analog signal from PXDAs to digital signal.
DIN Rail – The DIN Rail shuts down circuit for PC.
TANK – Generates X-rays.
IT – Isolation Transformer converts 110 VAC to 220 VAC.
I/O Extension Board – translates digital data from ADC Board into a format the PC understands.
LVPS – Low Voltage Power Supply supplies ±5 and ±12 VDC to PX Family components.
PC – PC analyzes X-ray data and displays images on monitor.
PDB – Power Distribution Board distributes AC and DC power to components, monitors E-Stops and
interlocks and controls conveyor.
PXDA – PX Family Detector Array contains up to 24 PXDA boards to detect X-rays.
UPS – Uninterruptible Power Supply shuts down the PC properly.

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Detector
Box
Photocell Photocell
DIN Rail
PDB I/O
Extension
PC
UPS
Transformer
Figure 14: PX107 Front View

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Photocell Photocell
LVPS
Tank
Figure 15: PX107 Rear View

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Detector
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Box
Motor Controller
Photocell Photocell
Figure 16: PX160P Front View
PC LVPS
Motor
Controller
Tank
PDB
UPS IT
Figure 17: PX160P Rear View

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Detector
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Box
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Photocell Photocell
LVPS
PC Tank
Transformer
Photocell Photocell
LVPS
Tank PC
Transformer

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DIN Rail
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Main
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Transformer
Extension
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Detector
Box
ADC
Photocell Photocell
LVPS
Tank
Power Distribution Board
UPS
Power Sequencer Board
Photocell Photocell

ADC
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I/O Extension
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Detector Interlock NT
Box
Photocells
Interlock
PC PDB
Transformer
LVPS DIN Rail
L
Tank UPS
Figure 22: PXM Front
Detector
Box
Transformer
PC
Tank
PDB
LVPS
Figure 23: PXM Rear View

5.4 Generic Service and Maintenance

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Security & Detection Systems’ Technical Training courses and is not provided in this manual. Parts
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involved are: Emergency Stop Buttons, System On and X-ray On Lamps, Photocells, Conveyor
Shrouds, Casters and like items.
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5.4.1 Operator Console Subsystem
NOTE:
The Console LEDs are software/computer driven.
The Console Subsystem is the main interface with the host control computer. It contains the
FORWARD, STOP and REVERSE controls, a Touchpad, and several indicator lamps.
The Console receives input from, and provides output to the Mainframe computer via an ISA Board
located in the computer. A Console Interface located in the console provides circuitry for processing
information. The controller processes signals from the Touchpad and sends information to the
Operator Console and Operator Footmat or I/R Operator Present Sensor (if installed and configured).
Physical Overview
CONSOLE
Electronics within the console. INTERFACE BOARD
POWER
SWITCH
TOUCH PANEL &

T.P. CONTROLLER BOARD
Figure 24: Fold Down Console

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Figure 25: Fold Down & Remote Console
5.4.2 Console Calibration

This procedure is to be followed whenever a Console is replaced.
Necessary Tools:
y Touch Screen Calibration Tool (P/N 3000-10345-00)
1. From Windows NT, press START > PROGRAMS > MICROTOUCH > TOUCHWARE CONTROL
PANEL. The following window will appear:
Figure 26: Touchpad Calibration

2. Place the Calibration Tool over the Console Touchpad
3. Click on the CALIBRATE button.

4. Follow the onscreen instructions when the subsequent screens appear: (Note: Use the Console
Touchpad, not the Monitor screen.)
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Figure 27: Calibration Complete Box

6. Remove the Touch Screen Calibration Tool.
5.4.3 Replacing the Message Center

1. Slide the Message Center into the System Frame.
2. Secure it using the four Socket Head Cap Screws that were retained during removal.
3. Route the Message Center Power Cable down through slot in System Frame.
4. Connect the Message Center Power Cable to the Message Center Power Supply:
• The two black leads connect to the V- ports on both sides of the Power Supply,
• The white lead connects to one of the V+ ports on the Power Supply, and the red lead
connects to the second V+ port.
5. Reinstall the Dress Panels to the system.
NOTE:
For instructions for programming the Message Center,
see PX-M Message Center Programming Instructions,
8100-10394-00.
5.4.4 Replacing the Leaded Curtains

Proceed as follows after removing the necessary panels (see section 5.6):
1. Remove the four fasteners from the top of the tunnel opening frame and allow the Leaded
Curtain Assembly to drop. Make note of which side of the assembly faces inward.
2. To install a replacement Leaded Curtain Assembly, place the assembly at the tunnel opening
frame and secure with the four fasteners previously removed.
Be sure to install the assembly with the proper side facing inward.
Before completely tightening the four fasteners, be sure to adjust the curtain height so that
there is a slight drag on the conveyor belt.
3. Perform a radiation survey in accordance with the regulations described in section 4.5.1,
Radiation Survey after Servicing the System.

5.4.5 Replacing the Conveyor Belt

Proceed as follows after removing the necessary panels (see section 5.6): ROLL
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2. Loosen the Belt Tension Adjustment Screws - both sides.
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3. Unzip the old conveyor belt. SI
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Figure 28: Belt Tension Adjustment (Tank Side shown)

Snub
Roller
Power
Roller
Figure 29: Power Roller (Detector Side shown)

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Figure 30: Power Roller (Tank Side shown)

4. Mate one end of the new conveyor belt with the old belt and zip it closed at the seam.
5. Manually (by hand) run the new belt through the conveyor system, using the old belt as a
leader.
6. After the new belt has traveled through the system, unzip the old belt from the new one and
zip the new one closed.
5.4.5.1 Belt Tensioning and Tracking

Tools Required:
Metric Socket Set
Tape Measure
Metric Allen Key Set
Tension Adjustment Bolt
Tension Pulley Bracket
Figure 31: Tension Pulley and Tension Pulley Adjustment Assembly

Tension Adjustment
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1. Remove the upper side panels of the machine so that the tension bolt and bracket is exposed
on both sides. NT RIF Y L
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2. Place an object weighing at least 30Kg (±2Kg) (66 lbs.) onto the belt.
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3. Using a socket set, tighten the Tension Adjustment Bolt until the 30Kg object does not stop
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4. Tighten the Tension Adjustment Bolt equally on BOTH sides of the machine so that the
Tension Pulley Brackets are at the same height.
Tip – The approximate position for this bracket is just below center.
5. Remove the Object from the belt and refit the upper side panels to the machine.
6. Ensure the belt runs correctly in both forward and reverse without slipping or losing track.
Tracking Snub Pulley Bracket

Powered Drive Pulley
Tracking Snub Pulley
Figure 32: Drive Pulley and Tracking Pulley Assembly

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Bracket Slots and

Nuts, 4 off Cover Plate
Snub Pulley Bracket
Figure 33: Cover Plate and Tracking Pulley Bracket
Belt Tracking
Perform the following steps from the entrance location of the machine.
Note: The entrance changes with respect to the belt direction:
1. With the cover plate removed, loosen the snub pulley bracket nuts and adjust the position of
the Snub Pulley Bracket until its four slots are centered. Repeat this for all four brackets.
Retighten the bracket nuts.
2. Ensure the Tensioning Brackets are at the same height on both sides of the machine. Adjust
if necessary.
3. Press the FORWARD button on the Operator’s Console. The belt should begin moving
through the inspection tunnel from the Entrance pulley to the Exit pulley.
4. When viewing the tunnel opening (Entrance Conveyor end), make sure the conveyor belt is
evenly spaced and that no undesirable tracking (movement) occurs toward the left or right
sides.
Tip - Center the belt at the start of observation by pushing it with the palms of your hands
towards a central position when the belt is moving. This enables you to see which way the
belt moves out of track without causing any damage to the edge of the conveyor belt. Take
care when carrying out this step.
5. Observe whether the conveyor belt moves toward the left or right side, or puckers (lifting of
the belt because of excess tracking). If neither occurs, proceed to step 7.

6. If poor tracking or puckering should occur, adjust the position of the snub pulleys as follows:
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Tip - Make small adjustments to the bracket position, tightening the nuts each time and
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bracket. The action of moving the snub towards the pulley drives the conveyor belt onto theB NT
pulley and pushes it away to the right.
If the left hand side of the machine is inaccessible, perform the procedure from the right
hand side of the machine. Move the snub pulley bracket away from the entrance pulley
toward the tunnel as necessary until no further poor tracking occurs.
Make small adjustments as above and observe the belt for several minutes.
Right side poor tracking/puckering: Loosen the nuts and adjust the position of the right
hand side snub pulley bracket toward the entrance pulley as necessary until no further poor
tracking occurs.
Tip - Make small adjustments to the bracket position as mentioned above and observe the
belt for several minutes.
If the right side of the machine is inaccessible, perform the procedure from the left side of
the machine. Move the Snub Pulley bracket away from the entrance pulley toward the tunnel
as necessary until no further poor tracking occurs.
Make small adjustments as above and observe the belt for several minutes.
7. Press the REVERSE button on the Operator’s Console for reverse belt movement to verify
that no poor tracking occurs. Repeat steps 5 and 6 if necessary and remember that the
entrance end has changed now that the belt is in reverse.
8. Press the FORWARD button on the Operator’s Console for forward belt movement to
verify that no poor tracking occurs.
9. Press the STOP button on the Operator’s Console.
10. Ensure all the bracket nuts are tight, the cover plates are refitted and any panels that have
been removed are refitted.
11. Press the FORWARD button on the Operator’s Console. Observe the belt for at least 5
minutes to ensure it remains in track.
5.5 Tension and Alignment
5.5.1 PX231
Tools Required:
Metric Ruler or Tape Measure
Four Post-It Stickers
½" Wrench
1. Verify that the conveyor belt has been installed properly per Figure 34.

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Figure 34: Installed Conveyor Belt

2. Place a Post-It Sticker on Entry side on top of conveyor belt in corner on right side.
Figure 35: Set-up for Belt Tension Adjustment

3. Place another Post-It 1000mm (1-meter) along the right side from the beginning of the post-
it in the right corner. See Figure 35.
4. Place a Post-It Sticker on Entry side on top of conveyor belt in corner on left side.
5. Place another Post-It 1000mm (1-meter) along the right side from the beginning of the post-
it in the left corner. See Figure 35.
6. Adjust the Entry tracking bolts to approximately the same location with respect to each other
and tighten in place using a ½ " wrench.

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Figure 36: Tracking Bolt

7. Adjust the exit tracking bolts using a ½ " wrench so that the belt stretches and the distance
between the post-its on the left and the right Entrance side is the same and between 1004mm
and 1007mm.
8. Using a Tape Measure or Ruler, measure the distance on the left Exit side between the
bracket and tracking bolt (shown as dimension X in the figure) , then measure the distance
on the right Exit side between the bracket and the tracking bolt. Verify that the distance on
both sides is approximately the same. If they are not, make adjustment to the tracking bolts
to make the distance the same. Tighten to lock in place.
9. Measure and make similar adjustments, if necessary, to the Entrance side tracking bolts as
you did in step 8.
10. Verify that the distance measured in step 7 is still between 1004mm and 1007mm.
11. Run belt for a minimum of four minutes to ensure the belt tracks true. Readjust if necessary.

5.5.2 Remove and Replace the X-ray Tank

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1. Remove both the Tank Side and Detector Side Lower Access Panels by first removing
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the cover straight out.
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Tank
Cover
M5 Hex
Bolts (4x)
Figure 37: Tank Side Close-up
Tank Cover
Tank
Figure 38: Tank Close-up with Lead Cover set aside

3. At the Detector Side, pull out the Equipment Tray to access the back of the X-ray Tank.
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Figure 39: Detector Side Equipment Tray – pulled out

4. Disconnect the following cables and retain hardware:
y DB-9 w/Thumb 10ft.
y Power Din Rail (TB9) to X-ray Tank (retain Gnd Nut)
y X-ray Enable
y Ground Wire
X-ray Enable
DB-9
Power Din Rail to

X-ray Tank
Figure 40: X-ray Tank Rear Connections

Tools Required
Scatter Radiation Meter
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Center Alpha Tool 1500-10021-00
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Cut Off Test Object 1004-10126-00
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ASTM Step Wedge 0700-10003-00
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Commission Bag 1004-10095-00 NT
Keyboard 0120-10023-00
Mouse 0120-10148-00
ESD Wrist strap 0290-10021-00
Various screwdrivers as required
Metric/standard Socket set with ratchet as required
Metric/Standard Allan head set with ratchet as required
5.5.3 Up Shooter X-ray Tank Replacement

PX-Ms, PX-107s and PX-208s are Up Shooter Systems.
CAUTION:
Shut down system and disconnect power.
1. Remove System front and rear panels from System Assembly to gain access to tank.
2. Remove ground and AC Power connectors from cooling fan.
3. Remove X-ray tank Shield from System Assembly and retain hardware.
4. Remove collimator mounting hardware (¼”-20 X .75” HHS, ¼” FW, & ¼” SLW) and retain.
X-RAY
TANK
Figure 41: System Assembly

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COLLIMATOR MOUNTING
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Figure 42: X-ray Tank Hardware

5. Disconnect AC Input to tank, including ground lead from ground stud and retain the hardware.
6. Disconnect X-ray Enable Cable, from X-ray Tank Assembly-J1.
X-RAY TANK
7. Disconnect DB-9 MF cable from X-ray Tank Assembly-J5. REAR
ADJUSTMENT
SCREWS (2X)
X-RAY TANK-J5 X-RAY TANK -J1 X-RAY TANK AC INPUT
Figure 43: X-ray Tank Cabling

8. Loosen (2) two of the (6) six tank adjustment screws on one side of X-ray Tank tray. This will
allow for ease of alignment during re-installation.
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X-RAY TANK SIDE

ADJUSTMENT
SCREWS LOOSEN
ONE SIDE ONLY (2X
PER SIDE)
Figure 44: X-ray Tank Side Adjustment Screws

9. Slide old X-ray Tank out and slide replacement tank (controller end first) all the way back, into
X-ray Tank tray.
10. Verify X-ray Tank jumper settings.
11. Tighten two tank adjustment screws to secure tank to tank tray.
12. Align collimator flush on top of X-ray.
13. Secure collimator to tank using retained hardware.
14. Install X-ray Tank Shield and secure using retained hardware.
15. Reconnect ground and AC Power connectors to cooling fan on X-ray tank shield.
16. Attach AC Input to X-ray Tank Assembly.
17. Attach ground lead to ground stud using the retained hardware.
18. Attach X-ray Enable Cable to X-ray Tank Assembly-J1.
19. Attach DB-9 MF cable to X-ray Tank Assembly-J5.

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Figure 45: X-ray Tank Installation
5.5.4 Down Shooter X-ray Tank Replacement

PX231s are Down Shooter Systems.
CAUTION:
Shut down system and disconnect power.
The tank is heavy and should be removed and installed by
two people.
1. Remove System top middle panel and middle side panel on X-ray side. Retain hardware.
2. Remove bracket from top middle of tank, one bolt per side, that holds lead shield in place.
Retain hardware.

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Retaining
Bracket
Figure 46 X-ray Tank In System

3. Remove top lead shield from X-ray tank.
4. Disconnect AC Input to tank.
5. Remove ground lead from ground stud and retain the hardware.
Figure 47 Rear of X-ray Tank with Cables Attached
6. Disconnect X-ray Enable Cable, from X-ray Tank Assembly-J1.

7. Disconnect DB-9 MF cable from X-ray Tank Assembly-J5.
8. Loosen X-ray Tank side adjustment screws on one side only.

9. With one person holding the tank remove front retaining bracket. See Figure 46.
10. With one person on either side of the X-ray Tank slide old out X-ray Tank. ROLL
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11. Verify X-ray Tank jumper settings.
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12. With one person on either side, lift and slide new X-ray tank all the way back, into X-ray Tank
tray.
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13. With one person holding the tank install front retaining bracket. See Figure 46. NT
14. Place lead shield on top of tank.
15. Install bracket on top of tank, in the middle, over the lead shield to hold it in place.
16. Attach D-Sub-9 MF cable to X-ray Tank Assembly-J5.
17. Attach X-ray Enable Cable, from X-ray Tank Assembly-J1.
18. Attach AC Input to X-ray Tank Assembly.
5.5.5 X-ray Tank Season

1. Connect Power to system and turn system on. While the system is starting hold down the c
key to prevent the operating software from starting
2. Use Windows explore (StartÆExplore) and navigate to C:\mfiles.
3. Delete the file TIMESTAMP.DAT.
4. Restart the computer. Note, when the operating software starts it will perform an auto
seasoning of the X-ray tank. This should take about an hour.
5.5.6 Preliminary Radiation Survey (Refer to procedure 8101-10028-00)

1. Place the Commissioning Bag (1004-10095-00) over the X-ray slot inside the tunnel. Verify
that X-rays are OFF and System is at Windows NT Desktop before entering the tunnel.
2. At Windows NT Desktop screen, click on SHORTCUT TO DIAG Icon.
3. When the Help screen appears, press ESC to bypass the screen.
4. When the Process screen appears, press CTRL T, to open the Tool Window menu.
5. When the Tool Window menu appears, press CTRL T again to open the Alignment Tool.
6. When the Alignment Tool Screen appears, press CTRL S to start running tool.
7. Press CTRL X at Alignment Tool Screen to toggle the X-rays ON.
8. Using a Scatter meter, perform a preliminary External Radiation Emissions Survey Check
around System exterior.
9. If the survey results are Ok, press CTRL X at Alignment Tool Screen to toggle the X-rays OFF.
10. Press F10 to return to the Windows NT Desktop screen.
11. Verify that it is safe to enter the tunnel (X-rays are OFF and System is at Windows NT
Desktop), then remove the Commissioning Bag (1004-10095-00) from inside the tunnel.

5.5.7 X-ray Alignment

1. After tank replacement verify all X-ray shields are in place. ROLL
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2. At “Windows NT” desktop screen, click on “Shortcut to DIAG” Icon.
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3. At “Help” screen press Esc to bypass screen.
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5. At “Tool Window” Menu screen, press Ctrl T again to open “Align Tool”.
TOOL WINDOW MENU SCREEN

Figure 48: Diagnostics
6. At Alignment Tool window, press Ctrl S to start Tool (Tool Status changes from idle to
running).
NOTE:
Screen shots may not reflect all hardware configurations.

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Figure 49: Alignment Tool Screen

7. Press Ctrl D to toggle display until both the “HI” (red) and “LO” (blue) signal appears.
Figure 50: Hi and Lo Signals Without X-rays

8. Press Ctrl Z to zero/clear the current quality output numbers.

9. At Alignment Tool window, press Ctrl X to toggle “ON” X-rays. (X-ray Status changes from
Off to ON.)
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Figure 51: Hi and Lo Signals With X-rays On

5.5.8 Collimation
1. At Alignment Tool window, press Ctrl X to toggle “OFF” X-rays, then press Ctrl Z to reset all
the Quality & Actual Output Numbers, then press Ctrl X to toggle “ON” X-rays.
2. Observe Detector PCB #1 Actual Output Number, turn System front Collimator Adjustment
Screw ¼ to ½ turn clockwise. If Detector PCB #1 Actual Output number decreases, turn
adjustment screw in opposite direction until Detector PCB #1 Actual Output number begins to
increase.
3. Continue adjustment until Detector PCB #1 Actual Output number stops increasing and begins
to decrease, then stop. The Detector PCB #1 Quality Output Number is now set.
4. Turn adjustment screw in the opposite direction until Detector PCB #1 Actual Output number
closely matches Detector PCB #1 Quality Output number. This is depicted by the Detector
PCB #1 changing colors from white to green.
5. At Alignment Tool window, press Ctrl X to toggle “OFF” X-rays, then press Ctrl Z to reset all
the Quality & Actual Output Numbers, then press Ctrl X to toggle “ON” X-rays.
6. Observe Detector PCB #22 Actual Output Number, turn System rear Collimator Adjustment
Screw ¼ to ½ turn clockwise. If Detector PCB #22 Actual Output number decreases, turn
adjustment screw in opposite direction, until Detector PCB #22 Actual Output number begins to
increase.
7. Continue adjustment until Detector PCB #22 Output number stops increasing and begins to
decrease, then stop. The Detector PCB #22 Quality Output Number is now set.

8. Turn adjustment screw in the opposite direction until Detector PCB #22 Actual Output number
closely matches Detector PCB #22 Quality Output number. This is depicted by the Detector
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9. Repeat Tank Alignment process for final adjustment to maximize Detector PCB #12 output.
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Then repeat Collimator Alignment process for final adjustment to maximize Detector PCB #1 &
#22 output, depicted by all Detector PCB Output numbers remaining green without resetting.
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10. It may be necessary to repeat Tank & Collimator Alignment process a few times to maximize NT
the X-ray output which is depicted by all Detector PCB Output numbers remaining green
without resetting. If “OK”, press Ctrl X to toggle X-rays “OFF”.
11. The “Actual=” value of the board with the highest output should be as close as possible to 3000,
but not over 3050 nor below 2900. The overall “Actual=” value for all detector boards should
be greater than 2100. Verify this on both the Hi and Lo side. Press Ctrl D to toggle between
the Hi and Lo side views. If “OK,” press Ctrl X to toggle the X-rays off.
FRONT FRONT
COLLIMATOR COLLIMATOR
ADJUSTMENT ADJUSTMENT
SCREW SCREW LOCKNUT
X-RAY TANK
SHIELD

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COLLIMATOR
TO TANK
MOUNTING
SCREWS (4X)
Figure 52: PX-M Collimator Adjustment Screws
PX-208
COLLIMATOR
ADJUSTMENT
SCREW
(NO TANK
ADJUSTMENT
SCREW FOR
PX-208)
Figure 53: PX-208 Collimator Adjustment Screw

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PX-107
COLLIMATOR
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Figure 54: PX-107 Collimator Adjustment Screw
5.5.9 X-ray Diagnostics Verification

X-ray Diagnostic Verification should always be done after performing an X-ray Alignment.
1. At Windows NT Desktop Screen, click on “Shortcut to DIAG” Icon.
2. Press Esc at “Help” screen to bypass.
3. Press Ctrl + S at “Process” screen to open “Scenario Window” menu.
4. Press Ctrl + O to open Option Pop-up menu.
5. Press Tab to select “loop count” and enter 10.
6. Press Tab to select “OK” and press Enter.
7. Press Ctrl + S at “Scenario Window” to start running Non Interactive Checkers and Tests.
8. Upon completion of all tests, observe the “Test Output” window and verify that there are not
more than 60 bad detectors and no more than five consecutive bad detectors.
9. Rectify any discrepancies before continuing and perform this entire Alignment procedure again.
10. If no discrepancies occur, press F10 to return to Windows NT desktop.

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Figure 55: Scenario Window
5.5.10 X-ray Tank Alignment

Perform PX-Family X-ray Tank Alignment Procedure 8100-10402-00.
IMPORTANT!
Generate a new AIRREF.DAT file if any failures require
the X-ray Tank to be realigned or if a detector board has
been replaced.
Create the AIRREF.DAT file

4. When the Tool Window menu appears, press TAB to select Tools menu, then use the arrow key
to select GENERATE AIRREF.DAT FILE.
5. Press CTRL T to open the Tool.
6. Press CTRL S to start the Tool.
7. Follow the directions onscreen to start the belt.
8. If the test is OK, tab to select YES to write the AIRREF.DAT file to C:\MFILES and press ENTER,
the proceed.

9. If the test fails, press CTRL Q to return to the Tool Window and rerun the test. If the test still
fails, determine the problem and correct it before proceeding. Please note that software may
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10. Press CTRL Q to quit the program. Select OK and press ENTER to return to the Tool Window.
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11. Press F10, select YES and press ENTER to return to the Windows NT Desktop.
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Create the machine.dat file ME
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4. When the Tool Window menu appears, press TAB to select Tools menu, then use the arrow key
to select MACHINE ALPHA TOOL.
5. Press CTRL T to open the Tool.
6. Press CTRL S to start the Tool.
7. Follow the directions onscreen to start the belt.
8. Follow the instructions that appear on the Monitor to start the ALPHA TEST (System will bounce
the Alpha Tool three times).
9. If the test is OK, select YES and press ENTER to update the file.
10. If the test fails, press CTRL Q to return to the Tool Window and rerun the test. If the test still
fails, determine the problem and correct it before proceeding (check the X-ray Tank and/or
Detector Board 0).
11. Press CTRL Q to quit the program. Select OK and press ENTER to return to the Tool Window.
12. Press F10, select YES and press ENTER to return to the Windows NT Desktop.

5.6 PX-208 Cover Panel and Guard Removal

1. The Upper Side Panels are removed by first unscrewing two Screws and lifting R Opanels
the LL
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DETECTOR SIDE TANK SIDE

Figure 56: Upper & Lower Side Panels Removed

3. The Top Cover is removed by first setting aside the Display Monitor, then removing the four
screws and lifting off the cover.
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Figure 57: Monitor Set Aside & Top Cover Removed

4. To remove the Conveyor Covers and Belt Guards, first remove the eight countersunk screws
and the two Hex Pan Head screws from the underside of both Conveyor Covers. The panels
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will drop, but the covers need to be slid off the ends of the conveyor frame. NTR L
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Figure 58: Conveyor Covers & Belt Guards set aside
Figure 59: Conveyor Shroud and Mounting Plates

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Figure 60: Tunnel Opening with all covers removed
5.6.1 Radiation Survey

Refer to Radiation Survey Sheet and Procedure 8101-10028-00.

6. Subsystems
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The Mainframe contains several subsystems that control the overall operation of the PX.
6.1.1 Power Distribution

The Mainframe houses a universal Isolation Transformer that accepts 100 to 240 Volts of single-phase
AC current at either 50 or 60 Hz with 1.5 kVA maximum – manual tapping must be performed.
Typical draw at 100—120 VAC is 12 amps. Typical draw at 220—240 VAC is 6 amps.
The Power Distribution system consists of Power Up/Down PLC DIN Rail (PXM only), Power
Sequencer Board and Power Distribution Board (PDB).
Power Up/Down PLC DIN Rail (PXM only)

The DIN Rail (Figure 61) contains the following:
• Jumper Wires (Table 6)
• Cable Connections (Table 7)
Figure 61: Power Up/Down PLC Din Rail

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Signal Source Voltage Destination Comments
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24 VDC PS2 +V 10 24 VDC TB2 24 VDC Power Supply
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KEY IN TB1 24VDC PLC l2 From Operator Console Key-Switch
24 VDC-1 TB3 24 VDC PLC +24 Power for PLC
24 RTN-1 TB5 COM PLC-COM Power for PLC
DELAY-2 TB12 12 VDC PLC-Q2-2
JMP1 PLC-Q3-2 12 VDC TB14
JMP2 PLC-Q4-1 12 VDC TB13
JMP3 TB11 12 VDC TDR-11 TDR-11 paired with TDR-12: open when coil is energized.
JMP7 TDR-12 12 VDC TB6 TDR-12 paired with TDR-11: open when coil is energized.
JMP4 TB3 24 VDC K2-14 K2 Coil
JMP5 TB4 COM K2-13 K2 Coil

TDR-A1 coil paired with TDR-A2
JMP6 TDR-A1 230 VAC K2-4
K2-4 paired with K2-12: open when coil is energized.
JMP10 K2-12 230 VAC TB7 K2-12 paired with K2-4: open when coil is energized.
JMP8 K2-1 12 VDC TB6 K2-1 paired with K2-9: open when coil is energized.
JMP9 K2-9 12 VDC TB9 K2-9 paired with K2-1: open when coil is energized.
12 VDC-1 TB10 12 VDC TB21
JMP11 TB11 12 VDC TB23
12 RTN PLC-Q2-1 12 VDC TB18

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Signal Source Voltage Destination Comments
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NEUTRAL 230 VAC PS2 N
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GROUND PS2 G
UPS KILL PIN 7 12 VDC TB23

SIGNAL
PIN 9 12 VDC TB18
24 VDC PIN 1 24 VDC PLC l1

SENSE
PIN 2 24 VDC PLC COM
PIN 1 TB7 Line

FAN POWER PIN 2 230 VAC TB8 Ground
PIN 3 TDR-A2 Neutral – TDR-A2 coil paired with TDR-A1
TANK PIN 2 12 VDC TB16

CONTROL
PIN 1 COM TB24 X-ray tank and X-ray hours meter share this ground
X-RAY HRS
+ TERM 12 VDC TB17
METER
PIN 3 COM TB19
INTERFACE
BOARD PIN 8 12 VDC TB22
PIN 5 12 VDC TB24
ARRAY PWR PIN 5 12VDC TB16

SUPPLY
PIN 6 12 VDC TB20
PIN 4 12 VDC PLC-Q3-1

COMPUTER
(COM 3) PIN 7 12 VDC PLC-Q4-2
PIN 8 12 VDC TB15
PIN 4 COM TB1
CONSOLE PIN 5 24 VDC TB2

KEY-SWITCH

Power Sequencer Board

The Power Sequencer Board replaces the Power Up/Down PLC DIN Rail on the TROLL
PX107/PX160P/PX208/PX231 . The Power Sequencer Board interfaces between the PC systemN
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controls and the power supply for the system. It monitors the external power source and control signals.
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The Power Sequencer Board regulates the system power up and power down sequence.
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Key switch
from PDB
System
Shutdown
LED
Shutdown
PC
Start Up/
Shutdown
UPS
220 VAC
220 VAC
from Power
from UPS
DIN Rail
Figure 62: Power Sequencer

Power DIN Rail

The PX107/PX160P/PX208 and PX231 all have a Power DIN Rail. This assembly is used TRtoOconnect
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main AC source power from the isolation transformer secondary windings to the PowerNSequencer
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Board, to distribute power to the Power Distribution Board, and to route power from the Power
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Distribution Board to the X-ray Generator.
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GRN/YEL
GRN/YEL
BRN
BRN
BRN
BLU
BLU
BLU
BRN
BRN
BLU
BLU
GRN/YEL
GRN/YEL
Figure 63: Power DIN Rail

Signal DIN Rail

The PX107/PX160P/PX208 and PX231 all have a Signal DIN Rail. This assembly is used to distribute ROLL
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on meter and enable detector box safety switches.
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WHT
WHT
BLK
BLK
GRN
WHT
WHT
RED
BLK
BLK
Figure 64: Signal DIN Rail

Power Distribution Board (PDB)

The Power Distribution Board (Figure 65 and Figure 66) contains the following: ROLL
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• LEDs (Table 10),
• Test Points (Table 11),
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• Manual forward and reverse override switches (Table 12),
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• Power connections for the system’s electrical components (Table 13).
Table 8: PDB Circuit Breakers
Circuit Breaker Rating Description
CB1 3.15A/250 VAC Motor 220VAC
CB2 6.30A/250 VAC X-ray 220 VAC & Post E-Stop 220VAC
CB3 4.50A/250 VAC Panel Fan
CB4 4.50A/250 VAC Computer 220 VAC
CB5 4.50A/250 VAC Array 220 VAC & Post Power-up 220 VAC
CB6 6.30A/250 VAC Power In
Table 9: PDB Fuses

Fuses Rated (in mA) at 250 V Description
F1 200 Primary side of T1 (post K3 – 220V)
F2 100 Primary side of T2 (from 220V)
F3 100 Secondary side of T2 (to keyswitch)
F4 200 External E-Stop
Table 10: PDB LEDs

Status LEDs Description Status LEDs Description
D32 + 12 VDC D40 Photo Right
D33 + 24 VDC D41 Photo Left
D37 Motor Current D42 Panel Interlock
D38 Line Frequency D43 E-Stop Coil
D39 Line Ok D44 E-Stop Chain
Table 11: PDB Test Points

Test Points Description
TP1 Line Monitor
TP2 Low Line Reference
TP3 High Line Reference
TP4 + 12 VDC
TP5 GRND
TP6 + 24 VDC (Power ON)
Table 12: PDB Manual Switches

Manual Switches Description
S1 Manual Belt Forward
S2 Manual Belt Reverse

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CIRCUIT
BREAKER 1
SWITCHES 1 and 2
LEDs 35 – 44
CIRCUIT
BREAKER 2
K2
CIRCUIT
BREAKER 3
TEST POINTS
1, 2, and 3
FUSE 1
CIRCUIT
BREAKER 4
LED 32 CIRCUIT
BREAKER 5
SPARE 1 & 2
K3
FUSE 4 FUSE 2
D16
D18
LED 33
TEST POINTS 4, 5 & 6 CIRCUIT BREAKER 6

FUSE 3
Figure 65: Power Distribution Board (PDB)

Table 13: PBD Jacks

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1 Motor Cable 1. 220 VAC 1. Main 1 - Power is initialized by system software.
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(8 pos.) 2. not used 2. n/u
3. 220 VAC 3. Phase 1 – Conveyor direction
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5. 220 VAC 5. Phase 2 – Conveyor direction ME
6. n/u 6. n/u
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7. 220 VAC 7. Main 2
8. n/u 8. n/u
2 Motor Capacitor 1. 220 VAC 1. To Capacitor
Cable 2. n/u 2. n/u
3. 220 VAC 3. Capacitor To Motor Main 1 on J1
4. n/u 4. n/u
3 Motor Cable 1. 220 VAC 1. Motor Thermal 1
(6 pos.) 2. n/u 2. n/u
3. 220 VAC 3. Motor Thermal 2
4. n/u 4. n/u
5. n/u 5. n/u
6. 0 VAC 6. Ground
4 X-ray Tank Power 1. 220 VAC 1. Line - Power is initialized by system software.
2. n/u 2. n/u
3. 220 VAC 3. Neutral
4. n/u 4. n/u
5. 0 VAC 5. Ground
5 Spare/Fan Power 1. 220 VAC 1. Line
2. n/u 2. n/u
4. 0 VAC 4. Ground
6 Monitor Power 1. 220 VAC 1. Line
2. n/u 2. n/u
4. 0 VAC 4. Ground
7 Computer Power 1. 220 VAC 1. Line
2. n/u 2. n/u
4. 0 VAC 4. Ground
8 Array LVPS 1. 220 VAC 1. Line
Assembly 2. n/u 2. n/u
4. 0 VAC 4. Ground
9 Ground Conductor 1. 0 VAC 1. Ground to System Frame
2. 0 VAC 2. Spare
10 Transformer To PDB 1. 220 VAC 1. Line
2. n/u 2. n/u
3. 0 VAC 3. Neutral
11 Photo Cells Receive 1. 12 VDC 1. Power
2. 12 VDC 2. Signal Photo L – Normally on, turns off when
3. 0 VDC beam is broken by parcel.
3. Ground
2. 12 VDC 2. Signal Photo L – Normally on, turns off when
3. Ground
13 Photo Cells Transmit 1. 12 VDC 1. Power
2. 0 VDC 2. Ground
2. 0 VDC 2. Ground

Jack Cable Name Pin #s with Voltages Description

15 Hour / Counter 1. 12 VDC 1. Power
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4. 12 VDC 4. Bag Counter
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5. 12 VDC 5. System Hours
16 Panel Interlock 1. n/u 1. n/u
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3. 12 VDC 3. Paired with #2. NT
4. 12 VDC 4. Normally Closed during operation.
5. 12 VDC 5. Paired with #4.
17 Panel Interlock 1. n/u 1. n/u
18 Jumper Panel 1. n/u 1. n/u
Interlock 2. 12 VDC 2. Normally Closed during operation.
19 Jumper Panel 1. n/u 1. n/u
Interlock 2. 12 VDC 2. Normally Closed during operation.
20 Not Used
21 Computer Interface 12 VDC and 24 VDC This is not a field serviceable connection.
(25 pin) connections
22 Power On Lights 1. 24 VDC 1. Power
2. n/u 2. n/u
3. 0 VDC 3. Ground
23 Not Used
24 Emergency Stop 1. 12 VDC 1. Normally Closed during operation.
25 Emergency Stop 1. 12 VDC 1. Normally Closed during operation.
26 Current Sensor 1. 24 VDC 1. Power – Normally on when there is power to PDB.
2. 0 VDC 2. Ground
27 Customer 2 Not Currently Used
2. 0 VDC 2. Ground
2. 0 VDC 2. Ground
2. 12 VDC 2. Signal Photo R – Normally on, turns off when
3. Ground
2. 12 VDC 2. Signal Photo R – Normally on, turns off when
3. Ground

JACK 13 JACK 12
JACK 14 JACK 11
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JACK 16
JACK 2
JACK 17
JACK 3
JACK 18
JACK 19
JACK 4
JACK 20
JACK 5
JACK 21
JACK 6
JACK 22
JACK 7
JACK 23
JACK 24 JACK 8
JACK 25
JACK 26
JACK 9
JACK 27
JACK 10
JACK 28 JACK 31
JACK 29 JACK 30
Figure 66: Power Distribution Board (PDB) Jacks

Table 14: Cabling Block Diagrams List

System Part Number ROLL
PXM 8100-10358-00 NT
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PX-107 8100-11012-00
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PX-160P 8100-10974-00
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PX-231 8100-10961-00
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Jumpers
Figure 67: PXDA Jumper Locations

7. System Software ROLL

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• Software Installation
• Keyboard Commands
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7.1 Diagnostic Software
Refer to PX/LS Diagnostic Manual, 8100-10443-00.
7.2 Re Installation of Software

For disk crashes or other situations that require re-installation in the field, refer to the Software
Installation Procedure, 8000-10673-AP for detailed information on installing system software.
Contact Customer Support for assistance. It is important to save the machine dependent files in the
c:\mfiles directory.
The c:\mfiles directory contains the following files:
AIRRDEF.DAT
TIMESTMP.DAT
BADDET.DAT
MACHINE.DAT
Re-install the software and then re-install mfiles.
7.3 Selected Software System Files

AIRREF.DAT
This file contains the Air Reference data for generated during System Verification. This file should
not be edited or deleted and must be updated after X-ray alignment or tank replacement.
BADDET.DAT
This file contains the detector mapping data required to eliminate data from bad detectors. This file is
generated during System Verification and should not be edited or deleted.
ERROR.LOG
This file is a circular file that holds any posted errors. Deleting this file would not affect the operation
of the system software.
MACHINE.DAT
This file contains the Alpha data generated by the Alpha Tool in the Diagnostics. This file should not
be edited or deleted and must be updated if the X-ray tank is replaced.
SYSTEM.CFG
This file is installed by manufacturing before the system is shipped. It contains software and hardware
configuration information for System Software.

TIMESTMP.DAT
This file is used to season the X-ray Tank: ROLL
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Table 15: Seasoning Values
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Idle Time Time at each stage
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3 < hours No reseasoning ME
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3 < days 5 seconds
< 7 days 15 seconds
< 30 days 30 seconds
< 90 days 60 seconds
> 90 days 300 seconds
7.4 Keyboard Commands

Keyboard commands are shown in Table 16.
Table 16: Keyboard Commands

Keypress Name Description
Moves the conveyor belt back and forth for a specific number
aB Bag Bounce of iterations, thus ‘bouncing’ an item under inspection on the
machine.
aP Save PXE Saves a PXE file screenshot.
cB Saves the screen (with or without the toolbar) as a .BMP
Save BMP
(bitmap) image file.
cQor ) Exit Exits the application.
! or @ Status Panel Displays ! or hides @ the status panel
space Clear Screen Clears the screen and all scrolling buffers.
$ Configuration
Menu

8. Troubleshooting Guide
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This chapter provides information for troubleshooting and resolving most common problems. A
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• Power-Up Problems
• Diagnostics
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• Error Messages ME
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8.1 Power-Up Problems
If the techniques defined in Table 17 do not resolve the problem encountered, contact Customer
Support for further assistance.
Table 17: Troubleshooting: No Error Message

Problem Possible Cause Remedy
No power (Power On/Power Off 1. Power not connected or 1. Verify power cord on is
Keyswitch turned clockwise to ON turned on. plugged in and power is
position) 2. Circuit breaker/switch at supplied to receptacle
AC power connector for power cord.
tripped or turned off. 2. Turn breaker/switch on;
3. Blown slow-blow fuse in if breaker trips again,
AC power connector. contact L-3
Communications for
4. Loose or incorrect
assistance.
Transformer
connections. 3. Replace fuse; if fuse
blows again, contact L-3
5. Faulty Transformer.
Communications for
6. Faulty Power assistance.
Distribution Board
4. Verify all Transformer
(usually indicated by a
connections.
burnt trace on the PDB).
5. Replace Transformer.
6. Replace the PDB.
No image on monitor. 1. Loose monitor cable. 1. Secure all monitor cable
2. Blown fuse on monitor. connections.
3. Monitor not turned on. 2. Replace monitor.
4. Faulty monitor. 3. Turn on monitor.
5. Faulty Power 4. If another monitor is
Distribution Board (if no available, connect that
power is supplied to monitor to PX; if that
monitor). monitor works but
original one doesn't,
6. Faulty video card (if
repair original monitor or
monitor has power but
replace it permanently.
no image).
5. Replace the PDB.


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System starts but does not complete 1. Non-bootable diskette in 1. Open panel and removeRIF Y L
start-up process the floppy drive. diskette from drive. VE
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2. AIRREF.DAT file is 2. Run Diagnostics to
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different from previous generate new
run. AIRREF.DAT file.
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3. Replace F1 fuse. O N B E F
3. Fuse F1 blown on Power
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Distribution Board.
Conveyor does not move. 1. Operator not standing on 1. Stand on Footmat during
Footmat during unit unit operation.
operation. 2. Replace access panel.
2. Interlock violation due to 3. Clear object(s) jamming
open access panel. conveyor; also check
3. Conveyor jam. conveyor circuit breaker
4. Tripped conveyor circuit since jams will trip the
breaker with no breaker.
conveyor jam. 4. Verify there are no
5. Faulty PDBFaulty power objects jamming the
roller. conveyor, then reset
breaker CB6; if it trips
6. Emergency Stop
again, contact Detection
activated
Systems for assistance.
5. Replace the PDB.
6. Replace the power
roller.
Conveyor belt moves to edge of roller. Conveyor belt tracking out of Adjust conveyor belt
adjustment. tracking.
X-ray stays on when nothing is in tunnel. 1. Dirty or blocked 1. Remove any objects
Photosensor Transmitter blocking Transmitters
or Receiver and Receivers, and
2. Faulty Photosensor clean Transmitters and
Transmitter and/or Receivers.
Receiver, Gain 2. Test and replace
adjustment too low on Photosensors.
Photosensor Receiver. 3. Adjust the position of the
3. Photosensor out of mounting brackets for
alignment. the Transmitter and
Receiver until Receiver
detects Transmitter.


Horizontal black line in image. 1. Foreign object in slot TROLL
1. Remove object.
N RIF Y L
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where X-rays enter the
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This may also appear as one of the 2. Use Diagnostics to
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following symptoms: tunnel. check whether X-rays
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y A blank green or gray screen. 2. No X-rays generated are being generated; if
due to faulty PDB X-ray X-rays are not being
RE
y A green or gray section on the S O the
generated,I Oexamine
I
monitor. Controller, or X-ray N BEFME
Generator.
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PDB, X-ray Controller,
y The line may appear as the image is and X-ray Generator to
scrolled. 3. Faulty X-ray Detector
Array board. determine which is
y Color bands may appear in the defective.
image. 3. Use Diagnostics to
determine which X-ray
Detector Array board is
faulty, then replace
board.
Jumbled or distorted image. Faulty ADC board in X-ray Replace the ADC board.
Detector Array assembly.
Image compressed or expanded 1. Conveyor and PDB not 1. Remove any objects
horizontally. synchronised due to preventing conveyor
partial conveyor jam. from moving freely.
2. Conveyor and PDB not 2. Adjust conveyor belt
synchronised due to tension
improper conveyor belt 3. Replace drive roller
tension adjustment.
4. Replace the PDB.
3. Conveyor and PDB not
synchronised due to
faulty drive roller.
4. Conveyor and PDB not
synchronised due to
faulty PDB.
8.2 Diagnostics
If there are no problems encountered as in section 8.1 above, diagnostics are performed at each system
start-up. Onscreen messages display any error condition and what steps should be taken to correct the
problem.
Follow the instructions according to the message received. If these do not solve the problem, contact
Customer Support.

8.3 Application Error Messages

TROLL
The following table contains various system application error messages that may be encounteredNby the
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customer, and either instructions for remedy or a description of what caused the error condition (in the
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left column). In the right column are suggested ‘Next Step(s)’ that the technician may undertake.
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Table 18:PX Error Codes ME
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# Error Message Resolved by:
"No Error", N/A
0 NO_HOST_ERROR "This message should never appear!"
1: "Emergency Stop Condition", Operator
1 EMERGENCY_STOP "Waiting for Emergency Stop Condition to be cleared"
2: "Panel Interlock Condition", Service
2 PANEL_INTERLOCKS_OPEN "Close panels to restore operation"
3: "Temperature Monitor Condition" Service
3 TEMPERATURE_HIGH "System temperature has exceeded limits"
4: "X-ray Source Fault" Service
4 XRAY_SOURCE_DEAD "X-ray subsystem is malfunctioning"
5: "Photocell Timeout" Operator
5 PHOTOCELL_TIMEOUT "Press a conveyor button to continue. Check for bags stuck
at tunnel entrance"
6: "A/D Cable Disconnected" Service
6 AD_CABLE_DISCONNECTED "Power down system and reconnect cable"
7: "Watchdog Timeout" Service
7 WATCHDOG_TIMEOUT "The system has shut down due to computer malfunction"
8: "System Failed Verification" Service
8 FAILED_VERIFICATION "Press a conveyor button to continue. If problem persists
contact service personnel."
9: "Tube Voltage-Differential Exceeds Allowable Range" Service
9 TANK_VOLT_DIFF_HIGH "Turn off system and contact service personnel"
10: "Tube Current-Differential Exceeds Allowable Range" Service
10 TANK_AMP_DIFF_HIGH "Turn off system and contact service personnel"
11: "Tube Voltage Exceeds Allowable Range" Service
11 TANK_VOLTAGE_HIGH "Turn off system and contact service personnel"
12: "Tube Current Exceeds Allowable Range" Service
12 TANK_AMPERAGE_HIGH "Turn off system and contact service personnel"
13: "X-ray Controller Cable is Disconnected Service
13 MAINFRAME_DISCONNECTED "Power down system and reconnect cable"
14: "Operator Sensor Interlock" Operator
14 OPERATOR_NOT_ON_MAT "Please return to the normal operating position"
15: "AC Voltage Out of Range" Operator
15 BAD_AC_VOLTAGE_TO_PDB "Power cycle the system"
16: "A/D Board Temperature Exceeds Allowable Range" Service
16 AD_TEMP_OUTSIDE_RANGE "Turn off system and contact service personnel"
Service
101- SYSTEM_ERROR
106
NOTE:
Whenever a Tank is replaced, an X-ray Alignment must
be performed.

The following is a list of Non-Fatal errors

• Timing off Data Collection ROLL
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•
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Timing off Data Collection: DC Manager
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• Timing off Data Collection: Header
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• Timing off Data Collection: Block SI
ON BEFO
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• The Last Bag Was Not Saved
• There Are No Workstations Online
• The Bag Queue On All Workstations are Full
• Fail to Send the Image to NSW, Check the connection or NSW Disk
Although Non-Fatal errors do not hinder the operation of the machine, if they persist, please contact
technical support.

9. Index
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A/D converter board ..........................................................14 Image Archiving.............................................................. 8, 9
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AC power ..........................................................................81 Inorganic Stripping..............................................................
S 8
Inspection Tunnel.......................9, 13, 16, 18, 20, 21,I O O
I
ADC board ............................................................11, 30, 83 29,
N 43BEF
ME
AIRREF.DAT........................................................61, 79, 82 Installation......................................... 2, 4, 25, 26, 29, 52, 79
NT
interlocks
violation ....................................................................... 82
B Interlocks ......................................................................... 20
BADDET.DAT.................................................................79 IXDA detector boards ....................................................... 14
Bag Count..........................................................................12
Belt Tension........................................ 29, 40, 41, 42, 44, 45
Belt Tracking .............................................................41, 43
K
Keyboard commands......................................................... 80
Keyswitch, ........................................................................ 17
C
Cabling Block Diagrams ...................................................78
circuit breaker..............................................................81, 82
L
Collimation.......................................................................57 Leaded Curtains
Collimator...................................... 24, 49, 51, 57, 58, 59, 60 replacement ................................................................ 39
Computer Cabling .............................................................28 Line Voltages ................................................................... 19
Console Calibration ...........................................................38 Low Voltage Power Supply ............................................ 11
Contrast ...............................................................................8
Contrast Windowing............................................................8
Conveyor .....................................................................16, 20 M
conveyor belt 1, 20, 21, 29, 39, 40, 41, 43, 44, 45, 80, 82, 83 MACHINE.DAT.............................................................. 79
replacement.................................................................40 Mainframe..........................1, 4, 9, 10, 13, 19, 20, 21, 37, 67
Customer Support................................................................3 Mark Threat......................................................................... 8
Mechanical Safety ..................................................... 19, 20
D message center
replacement ................................................................ 39
detector array.........................................................11, 14, 83 meters................................................................................ 12
DIN rail .............................................................................67
cable connections .........................................................69
jumper wires................................................................68 N
display monitor ............................................ 1, 9, 10, 18, 64 Network Supervisor Workstation ........................................ 8
drive roller .........................................................................83
O
E
operator
Edge Enhancement ..............................................................8 footmat................................................................... 18, 37
Electrical Safety ...............................................................19 I/R present sensor......................................................... 37
Emergency Stops .............................................................20 present sensor......................................................... 18, 37
Error Codes......................................................................84 Operator Assist................................................................ 8, 9
ERROR.LOG...................................................................79 Operator Console ............................ 1, 9, 17, 18, 20, 37, 68
Organic Stripping................................................................ 8
F
footmat ..............................................................................82 P
PBD Jacks ......................................................................... 75
G PDB..............................10, 30, 67, 71, 72, 73, 74, 81, 82, 83
fuses ............................................................................. 73
Gray Scale ...........................................................................8 Jacks............................................................................. 77
LEDs ............................................................................ 73
test points ..................................................................... 73
PDB Circuit Breakers........................................................ 73

PDB Manual Switches ...................................................... 73

photosensors................................................................ 18, 82
T
Power Distribution System...................................... 9, 10, 67 ROLL 42, 45
NT
Tension Adjustment...............................................40,
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Power Installation ............................................................. 27 Test Equipment........................................................... VE 23, 26
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power roller....................................................................... 82
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Threat Image Projection.................................................. 8, 9
ST REV
Power Sequencer Board.................................................. 70
DOCU
TIMESTMP.DAT ........................................................... 80
Power Up/Down PLC DIN Rail........................................ 67 TIP ...................................................................................... 9
RE
Preventive Maintenance ................................................ 2, 29 TIP Server...........................................................................
S 8
O
Tools .................................... 4, 23, 26, 38,I O
I
Print..................................................................................... 8 B E F49, 61, 62
41,ME
N 44,
PseudoColor........................................................................ 8 NT
transformer wiring ............................................................ 28
PX Computer ...................................................................... 9 Trimat ................................................................................. 8
PX107 7, 9, 14, 15, 16, 21, 25, 31, 32, 49, 60, 70, 71, 72, 78
PX160P ......................7, 9, 12, 14, 15, 16, 21, 70, 71, 72, 78
PX208 7, 9, 10, 14, 15, 16, 21, 34, 49, 59, 63, 70, 71, 72, 78 U
PX231 ...... 7, 9, 14, 15, 16, 21, 25, 35, 44, 52, 70, 71, 72, 78 uninterruptible Power Supply ........................................... 12
PXDA detector boards ...................................................... 15 UPS................................................................................... 10
PXM...............1, 7, 14, 15, 16, 21, 25, 36, 39, 49, 59, 67, 78
R X
X-ray
Radiation Safety ........................................................ 19, 21 controller ..................................................................... 83
Radiation Survey......................................... 2, 24, 39, 54, 66 generator................................................................ 13, 83
Returned Materials Authorization ................................ 25 source .......................................................................... 13
Reverse Video..................................................................... 8 tank .............................................................................. 13
X-ray Alignment ..................................................55, 60, 84
S X-ray Detectors ............................................................... 13
X-ray Diagnostics Verification....................................... 60
Safety Precautions........................................................... 19 X-ray Hours ...................................................................... 12
Scattered Radiation......................................................... 21 X-ray On indicator............................................................ 20
Service Requirements ..................................................... 30 X-ray Tank Alignment ................................................... 61
Side-By-Side (SBS) Detectors ......................................... 16 X-ray Tank Replacement ....................................47, 49, 52
Software Features ............................................................... 8 X-ray Tank Season.......................................................... 54
Stacked Detectors ............................................................ 16
System Configuration ..................................................... 29
System Files ...................................................................... 79 Z
System Hours .................................................................... 12 Zoom................................................................................... 8
SYSTEM.CFG................................................................. 79

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PX Products Technical Manual Proprietary Information 8100-10809-TM, Rev.

Department of Commerce License Number ____________________ to Entity and Country of End-Use.

License Exception 740.13(a)1 to Entity and Country of End-Use.

Proprietary Information Notice

Classified Information Notice

Software License Agreement (Embedded Products)

¾ You may use the SOFTWARE only on the DEVICE.

© 2005-6 L-3 Communications, Security & Detection Systems iii

Regulations and Safety

iv © 2005-6 L-3 Communications, Security & Detection Systems

© 2005-6 L-3 Communications, Security & Detection Systems v

Revision History ROLL

vi © 2005-6 L-3 Communications, Security & Detection Systems

Table of Contents ROLL

© 2005-6 L-3 Communications, Security & Detection Systems vii

5.4.3 Replacing the Message Center................................................................................................................. 39

viii © 2005-6 L-3 Communications, Security & Detection Systems

List of Figures ROLL

© 2005-6 L-3 Communications, Security & Detection Systems ix

FIGURE 53: PX-208 COLLIMATOR ADJUSTMENT SCREW................................................................................59

x © 2005-6 L-3 Communications, Security & Detection Systems

List of Tables ROLL

© 2005-6 L-3 Communications, Security & Detection Systems xi

1.1 Definition of Terms

© 2005-6 L-3 Communications, Security & Detection Systems 1

1.2 Related Documentation

2 © 2005-6 L-3 Communications, Security & Detection Systems

1.3 Minimum Technical Qualifications

© 2005-6 L-3 Communications, Security & Detection Systems 3

1.4 How to Use This Manual

4 © 2005-6 L-3 Communications, Security & Detection Systems

1.5 Contacting Customer Support

Customer Service Locations

L-3 Communications, Security & Detection Systems

© 2005-6 L-3 Communications, Security & Detection Systems 5

Europe/Middle East/Africa (EMEA)

6 © 2005-6 L-3 Communications, Security & Detection Systems

2. Systems Overview ROLL

© 2005-6 L-3 Communications, Security & Detection Systems 7

2.1 General System Description

8 © 2005-6 L-3 Communications, Security & Detection Systems

2.2 Technical Highlights

2.2.1 Mainframe Components

Table 2: Computer Replacement Part Number

© 2005-6 L-3 Communications, Security & Detection Systems 9

Figure 1: Rear View of PX Computer

Power Distribution System

Figure 2: Power Distribution (PX208)

10 © 2005-6 L-3 Communications, Security & Detection Systems

Low Voltage Power Supply (LPVS)

Figure 3: Low Voltage Power Supply

© 2005-6 L-3 Communications, Security & Detection Systems 11

Figure 4: Power Entry Panel

Uninterruptible Power Supply

Figure 5: Rear View of UPS

12 © 2005-6 L-3 Communications, Security & Detection Systems

Figure 6: Spellman X-ray Tank

© 2005-6 L-3 Communications, Security & Detection Systems 13

Table 3: Summary of Detectors/Boards

Figure 7: IXDA Detector Board

14 © 2005-6 L-3 Communications, Security & Detection Systems

Figure 8: PXDA Detector Board

Figure 9: Detector Array (PX208)

© 2005-6 L-3 Communications, Security & Detection Systems 15