Ingenuity CT Service Manual

Ingenuity CT, Ingenuity
Core, Ingenuity Core128

CT Scanner
Gantry Repair & Replacement
4598 000 72481

Revision L
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and Philips customers who have purchased a valid service agreement for use by the customer's designated in-house service employee on
equipment located at the customer's designated site. Use of this document or digital media by unauthorized persons is strictly prohibited. This
document or digital media must be returned to Philips when the user is no longer licensed and in any event upon Philips' first written request.
© 2016 Koninklijke Philips N.V. All Rights Reserved. CSIP-1

Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement
Safety and Legal Information

To the User of This Manual
The user of this manual is directed to read and carefully review the instructions, warnings and cautions contained herein
prior to beginning installation or service activities. While you may have previously installed or serviced equipment similar
to that described in this manual, changes in design, manufacture or procedure may have occurred which significantly
affect the present installation or service.
Legal Manufacturer
Philips Medical Systems (Cleveland), Inc.
A Philips Healthcare Company
595 Miner Road
Cleveland, OH 44143
USA
Warranty Disclaimer
Philips provides this document without warranty of any kind, implied or expressed, including, but not limited to, the
implied warranties of merchantability and fitness for a particular purpose.
Limitation of Liability
Philips has taken care to ensure the accuracy of this document. However, Philips assumes no liability for errors or
omissions and reserves the right to make changes without further notice to any products herein to improve reliability,
function, or design. Philips may make improvements or changes in the product(s) or program(s) described in this
document at any time.
Password Notice
The PASSWORD is the property of Philips Healthcare and is provided for the exclusive purpose of providing access to
selected service utilities which are described in this service manual as being associated with the password. Use of this
password for any purpose other than for the access to the selected services utilities is strictly prohibited.
4598 000 72481 Rev L CSIP‐1 ATTENTION: THIS PAGE CONTAINS COPYRIGHTED MATERIALS THAT ARE CONFIDENTIAL AND/OR PROPRIETARY. ANY RELEASE OR DISTRIBUTION OF THIS MATERIAL, WITHOUT PERMISSION, IS A VIOLATION OF LAW. 2
Safety
WARNING: In addition to the warnings listed below, follow all safety guidelines as described in the
Safety Manual. Failure to do so can result in severe personal injury.
Installation and Environment

Except for installations requiring certification by the manufacturer, see that a radiation protection survey is made by a qualified expert
in accordance with NCRP 102, section 7, as revised. Perform a survey after every change in equipment, workload, or operating
conditions which might significantly increase the probability of persons receiving more than the maximum permissible dose
equivalent.
Diagnostic Imaging Systems - Mechanical-electrical Warning
WARNING: Before initiating a movement of the patient table or gantry, ensure that the area is free of
obstructions such as tools, boxes, chairs, and step stools. Physical injury or damage can
occur.
All of the moveable assemblies and parts of this equipment should be operated with care and routinely inspected in accordance with
the manufacturer’s recommendations contained in the equipment manuals.
Only properly trained and qualified personnel should be permitted access to any internal parts. Live electrical terminals are deadly; be
sure line disconnects are opened and other appropriate precautions are taken before opening access doors, removing enclosure
panels, or attaching accessories.
Prior to any service and maintenance activities inside components:
• Switch off the system at the main power supply, and the uninterruptible power supply (UPS).
• Use lockout/tagout (LOTO) procedures to safeguard against the release of hazardous energy during installation,
maintenance or service work on the system.
• Always use an ESD protection wrist strap when servicing any component in the system.
Electrical-grounding Instructions
The equipment must be grounded to an earth ground by a separate conductor. The neutral side of the line is not to be considered the
earth ground. On equipment provided with a line cord, the equipment must be connected to a properly grounded, three‐pin
receptacle. Do not use a three‐to‐two pin adapter.
Diagnostic Imaging Systems - Radiation Warning

X‐ray and Gamma‐rays are dangerous to both operator and others in the vicinity unless established safe exposure procedures are
strictly observed.
Gamma radiation presents exposure risk to the operator and others in the vicinity of a radioactive source. Radiopharmaceutical‐filled
phantoms present the greatest risk, while sealed sources present lesser risk. Exposure mitigation procedures described in the GSS NA
radiation safety documents can reduce this risk. Operators should use a combination of time, distance, and shielding techniques to
reduce the exposure to themselves and others from sealed sources and injected phantoms. Philips employees are obligated to comply
with the conditions in Philips GSS NA’s Radioactive Materials License, out of state license reciprocity agreements, and the customers’
radioactive materials licenses.
The useful and scattered beams can produce serious or fatal bodily injuries to any persons in the surrounding area if used by an
unskilled operator. Adequate precautions must always be taken to avoid exposure to the useful beam, as well as to leakage radiation
from within the source housing or to scattered radiation resulting from the passage of radiation through matter.
Those authorized to operate, participate in or supervise the operation of the equipment must be thoroughly familiar and comply
completely with the current established safe exposure factors and procedures described in publications, such as: Subchapter J of Title
21 of the Code of Federal Regulations, ʺDiagnostic X‐ray Systems and Their Major Componentsʺ, and the national council on radiation
protection (NCRP) no. 102, ʺMedical X‐ray And Gamma‐ray Protection For Energies Up To 10 Mev‐equipment Design and Useʺ.
Those responsible for planning of x‐ray and gamma‐ray equipment installations must be thoroughly familiar and comply completely
with NCRP no. 49, ʺStructural Shielding Design and Evaluation for Medical of X‐rays and Gamma‐rays of Energies Up to 10 Mevʺ.
Failure to observe these warnings may cause serious or fatal bodily injuries to the operator or those in the area.
Symbol Descriptions
Warning symbol Radiation warning symbol
Laser warning symbol Biohazard warning symbol
Magnetism warning symbol Projectile warning symbol
Electrical warning symbol Do not touch
Recycle Label
Dispose of in accordance with your country’s
requirements. This label indicates that there is
Crush warning symbol material in the system that you must separately
collect and recycle in accordance with the
requirements of the European Waste Electrical
Equipment (WEEE) Directive.
Revision History
ECO # Revision Date Comments
2022885 A Sept. 15, 2010 Original release
Added rotor drive motor brake check and adjust procedure. Revised XRT
2023227 B Feb. 28, 2011
replacement procedure.
2023806 C July 25, 2011 Revised the MRC880 XRT replacement procedure for a revised shipping box.
Added Emerson motor controller replacement procedure. Updated FRC section
2023915 D Sept. 23, 2011 for new filter.
Added Ingenuity Core & Core128 to front cover title.
Added information about SpindleBlok 1.5 to SpindleBlok motor controller
2024476 E Jan. 20, 2012
section.
Added replacement procedure for the CPM control board to the RHost section.
Added reference to new RoHS power brushes.
2025926 F May 21, 2013 Added an adjustment procedure for the new 12V power supply in the FRC.
Added a replacement procedure for new front cover lasers. Added new front
cover lasers to the front cover replacement procedure.
ECO # Revision Date Comments
Added photos for new power components to the power‐up/down section (see
System Power Down/Power Up on page 22).
Added section for new front display panels (see Later Model RH or LH Front
Display/Control Panel Replacement on page 104).
Updated for systems without rear gantry control panels (see Replacing the Gantry
Rear Cover on page 112).
Added a replacement procedure for the MRC600
X‐ray tube (see MRC 600 X‐ray Tube Assembly Replacement on page 254).
E‐036318 G Dec. 12, 2013 Added a replacement procedure for the MRC600
X‐ray tube cooling unit (see MRC 600 Cooling Unit Replacement on page 333).
Added procedures for 16‐slice optical slip rings (see 16‐Slice Rotor Optical Slip
Ring Fiber Optic Cable Replacement on page 758) (see 16‐Slice Stator Optics
Assembly Replacement on page 775) (see 16‐Slice Invisible Laser Optical
Transmitter Replacement on page 789) (see 16‐Slice Invisible Laser Optical
Receiver Replacement on page 792).
Updated for systems without console transformers (see Utility & Console
Contactor (UTK & CTK) Replacement (Systems without Console Transformers)
on page 809).
Converted to new format.
E‐042431 H July 28, 2014 Added procedure to replace the M200 motor controller (see M200 Rotor Drive
Motor Controller Replacement on page 644). Made Emerson CSK or M200 Motor
Controller Commissioning a separate section.
The quick release procedure was added as appendix A and cross‐referenced in
the manual. Updated pages 245‐249 with instructions on properly securing
E‐047006 J 26‐MAY‐2015 cooling hose during XRT replacement. Updated Memory Stick procedure for
MRC880/MRC600 XRT replacement. Added PPE instruction for handling XRT
when in a heated state. Updated bolt torque specifications.
Updated OTR Tool section due to McAfee Whitelisting restrictions in 3.6.7+
E‐049424 K 22‐DEC‐2015
software. Corrected torque values in M200 motor controller section.
E‐079831 L 30 Oct 2016 Updating to resolve CTUDT00589960 and Formatting Documentation
This document was prepared by CT/AMI Service Innovations.
For any additions, corrections, or suggestions, contact your next level of support.
Contents
Section 1 System Power Down/Power Up: ...................................................... 22
1.1 System Shutdown and Power Down ........................................................................ 22
1.1.1 Shutting Down the CIRS Server .................................................................... 23
1.1.2 Shutting Down the Host ............................................................................... 25
1.1.3 Removing Power to the CIRS and Host........................................................... 25
1.1.4 Gantry Power Down (Except for the Host and CIRS)......................................... 27
1.1.5 Removing Gantry Rotor Power ...................................................................... 28
1.1.6 Removing Stator Power................................................................................ 30
1.1.7 Removing Table Power................................................................................. 33
1.2 System Power Up ................................................................................................. 34
1.2.1 Gantry Power Up......................................................................................... 34
CIRS and Host Power-Up ............................................................................ 38
Section 2 Ingenuity CT Gantry Front Cover Opening /Closing: .......................... 40

2.1 Opening the Ingenuity CT Gantry Front Cover .......................................................... 40
2.2 Closing the Ingenuity CT Gantry Front Cover............................................................ 45
2.3 Removing/Replacing the Ingenuity CT Gantry Lower Front Cover ................................ 46
2.3.1 Removing Ingenuity CT Gantry Lower Front Cover ........................................... 46
2.3.2 Installing the Ingenuity CT Gantry Lower Front Cover ...................................... 47
Section 3 Ingenuity CT Gantry Front Cover Replacement: ................................ 48

3.1 Special Tools and Equipment Required .................................................................... 48
3.2 Front Cover Removal ............................................................................................ 48
3.2.1 Removing Needed Parts from The Old Front Cover........................................... 50
3.2.2 Removing the Gantry Front Cover ................................................................. 60
3.3 Installing the Gantry Front Cover............................................................................ 61
3.3.1 Installing Parts onto the New Front Cover....................................................... 64
3.4 Ingenuity CT Front Cover Position Adjustments ........................................................ 71

3.4.1 Preparation for Cover Adjustments ................................................................ 71
3.4.2 Side to Side Adjustment............................................................................... 71
3.4.3 Front to Back Adjustment............................................................................. 73
3.4.4 Vertical Adjustment ..................................................................................... 74
Section 4 Gantry Front Cover Gas Spring Replacement: ................................... 76

4.2 Gas Spring Removal ............................................................................................. 76
4.3 Gas Spring Installation .......................................................................................... 79
Section 5 Original Style Front Cover Laser Module Replacement: ..................... 81

5.1 Front Cover Laser Module Removal ......................................................................... 82
5.2 Front Cover Laser Module Installation...................................................................... 84
Section 6 Newer Style Front Cover Laser Module Replacement: ....................... 86

6.1 Front Cover Laser Module Removal ......................................................................... 87
6.2 Front Cover Laser Module Installation...................................................................... 89
Section 7 Rotor Laser Module Replacement: ................................................... 92

7.1 Rotor Laser Module Removal .................................................................................. 92
7.2 Rotor Laser Modules Installation ............................................................................. 94
Section 8 Early Model RH or LH Front Display/Control Panel Replacement: ...... 95

8.0.1 Special Tools and Equipment Required ........................................................... 95
8.1 Removing the Ingenuity CT Front Control Panel ........................................................ 97
8.2 Installing an Ingenuity CT Front Control Panel .......................................................... 100
Section 9 Later Model RH or LH Front Display/Control Panel Replacement: ...... 104

9.2 Removing a Front Control Panel.............................................................................. 106
9.3 Installing a Front Control Panel .............................................................................. 109
Section 10 Replacing the Gantry Rear Cover: .................................................. 112

10.1 Special Tools and Equipment Required................................................................... 112
10.2 Removing the Gantry Rear Cover .......................................................................... 112
10.2.1 Invisible Laser Safety Precaution ................................................................. 112
10.2.2 Ingenuity CT Gantry Rear Cover Removal ..................................................... 115
10.2.3 On Systems with Rear Control Panels - Removing Parts from the Removed Cover118
10.2.4 Installing Parts onto the New Rear Cover - Systems with Rear Control Panels .... 119
10.2.5 Ingenuity CT Gantry Rear Cover Installation ................................................. 120
Section 11 Replacing the Ingenuity CT Gantry Rear Control Panels: ................. 122
11.2 Replacing the Right Rear Control Panel .................................................................. 122
11.2.1 Removing the Right Rear Control Panel ........................................................ 122
11.2.2 Installing the Right Rear Control Panel ......................................................... 124
11.3 Replacing the Left Rear Control Panel .................................................................... 125
11.3.1 Removing the Left Rear Control Panel .......................................................... 125
11.3.2 Installing the Left Rear Control Panel ........................................................... 127
Section 12 Ingenuity CT Gantry Rear Cone Replacement: ................................ 128

12.2 Removing the Ingenuity CT Gantry Rear Cone ........................................................ 128
12.2.1 Transferring Parts from the Removed Gantry Rear Cone to the New Rear Cone .. 132
12.3 Installing the Ingenuity CT Gantry Rear Cone ......................................................... 133
Section 13 Ingenuity CT Side Covers Replacement: ......................................... 135

13.1 Gantry RH/LH Upper Side Cover Removal .............................................................. 135
13.1.1 Gantry RH/LH Upper Side Cover Installation.................................................. 138
13.1.2 Upper Side Cover Adjustments .................................................................... 140
13.1.3 Gantry RH/LH Lower Side Cover Removal ..................................................... 142
13.1.4 Ingenuity CT Gantry RH/LH Lower Side Cover Installation ............................... 145
13.1.5 Lower Side Cover Adjustments .................................................................... 146
Side-to-Side Adjustment - Bottom of Lower Side Cover .................................. 146
Front to Back Adjustment - Bottom of Lower Side Cover ................................. 147
Lower Side Cover Upper Adjustments........................................................... 148
Section 14 Gantry Display/Switch Control Board Replacement: ....................... 150

14.1 Removal............................................................................................................ 150
14.1.1 Installation ............................................................................................... 151
Section 15 Front Cover Interlock Switch Replacement: ................................... 152

15.1 Front Cover Interlock Switch Removal ................................................................... 152
15.2 Front Cover Interlock Switch Installation................................................................ 153
Section 16 Ingenuity CT Gantry Exhaust Fans Replacement: ........................... 154

16.1 Removal............................................................................................................ 154
16.1.1 Installation ............................................................................................... 155
Section 17 Intake Air Filters Removal/Replacement: ...................................... 156

17.0.1 Air Filter Removal...................................................................................... 156
17.0.2 Air Filter Installation .................................................................................. 159
Section 18 Gantry Intake Fans Removal/Replacement: .................................. 160
18.1 Removal............................................................................................................ 160

18.2 Installation ........................................................................................................ 163
Section 19 MRC 880 X-ray Tube Assembly Replacement: ................................. 164

19.1 OTR Tool ........................................................................................................... 165
19.1.1 OTR Tool on Systems with McAfee Application Control (Whitelisting) ................ 165
19.1.2 OTR Tool on Systems without McAfee Application Control (Whitelisting) ............ 168
19.1.3 View OTR Tool Data ................................................................................... 170
19.1.4 Report OTR Tool Issues .............................................................................. 173
19.2 X-ray Tube Removal ........................................................................................... 174
19.3 X-ray Tube Installation ........................................................................................ 222
19.3.1 X-ray Tube Adjustment .............................................................................. 235
19.3.2 Connecting the X-ray Tube ......................................................................... 242
19.3.3 Restoring the System to Operation .............................................................. 252
Section 20 MRC 600 X-ray Tube Assembly Replacement: ................................. 254

20.1 OTR Tool ........................................................................................................... 255
20.1.1 OTR Tool (3.6.7 Software and Later)............................................................ 255
20.1.2 OTR Tool (3.6.6 Software and Earlier) .......................................................... 258
20.1.3 View OTR Tool Data ................................................................................... 260
20.1.4 Report OTR Tool Issues .............................................................................. 263
20.2 X-ray Tube Removal ........................................................................................... 264
20.3 Tube Installation ................................................................................................ 302
X-Adjustment Block ................................................................................... 318
Z-Adjustment Block ................................................................................... 321
Section 21 MRC 600 Cooling Unit Replacement: .............................................. 333

21.1 Removal............................................................................................................ 333
21.2 Installation ........................................................................................................ 348
Section 22 Heat Exchanger Fans Removal/Replacement: ................................. 356

22.1 Removal............................................................................................................ 356
22.2 Installation ........................................................................................................ 358
Section 23 A-Plane Collimator Removal/Replacement: .................................... 361

23.1 A-Plane Collimator Removal ................................................................................. 361
23.2 A-Plane Collimator Installation.............................................................................. 367
23.3 Loading A-Plane Calibration Constants (all software versions) ................................... 372
23.4 A-Plane Slice-Width Operation Test Procedure ........................................................ 376
23.4.1 Test 1: Test for 'Phase Angle' problem ....................................................... 376
23.4.2 Test 2: Test for 'Set' problem.................................................................... 384
23.5 Collimator Verification Procedure .......................................................................... 388
23.6 Calibrating and Returning the System to Normal ..................................................... 394
23.7 Returning the Old Collimator ................................................................................ 395
23.8 Procedures to Un-jam Collimator Blades or Z-carriage ............................................. 395
23.8.1 Procedure 1: Un-jamming Collimator Using DMC Utility ................................. 396
23.8.2 Procedure 2: Un-jamming Collimator Using DMC Service Switches ................... 398
23.8.3 Procedure 3: Un-jamming Collimator Using Existing Vicor Power Supply ........... 404
Section 24 Reference Converter Board Removal/Replacement: ........................ 410

24.0.1 Removal .................................................................................................. 410
24.0.2 Installation ............................................................................................... 412
Section 25 FRC Assembly Replacement: ......................................................... 413

25.1 Removing the FRC Assembly ................................................................................ 414
25.2 Installing the FRC Assembly ................................................................................. 419

25.2.1 Checking the 12V Power Supply .................................................................. 423
25.2.2 Adjusting the 12V Power Supply .................................................................. 424
Adjusting the Older Style 12 Volt Power Supply ............................................. 426
Adjusting the Newer Style 12 Volt Power Supply............................................ 427
Section 26 Cathode Power Module Assembly Removal/Replacement: ............... 436

26.1 Saving X-ray Power Module Log Data to a Memory Stick .......................................... 437
26.1.1 Introduction ............................................................................................. 437
26.2 Cathode Module Removal..................................................................................... 439
26.3 Cathode Module Installation ................................................................................. 460
Section 27 Anode Power Module Assembly Removal/Replacement: .................. 475

27.1 Saving X-ray Power Module Log Data to a Memory Stick .......................................... 476
27.1.1 Introduction ............................................................................................. 476
27.2 Anode Module Removal ....................................................................................... 478
27.3 Anode Module Installation .................................................................................... 498
Section 28 RHost or CPM Control Board Assembly Replacement: ...................... 512

28.1 Removing the RHost ........................................................................................... 512
28.2 Removing the Control Board................................................................................. 518
28.3 Installing the Control Board ................................................................................. 520
28.4 Installing the RHost Board ................................................................................... 522
Section 29 High Speed Starter Removal/Replacement: ................................... 527

29.0.1 High Speed Starter Removal ....................................................................... 528
29.0.2 High Speed Starter Installation ................................................................... 531
Section 30 GHost Board Removal/Replacement: ............................................. 533

30.1 Removal............................................................................................................ 533
30.2 Installation ........................................................................................................ 535
Section 31 Gantry Motion Processor Board Removal/Replacement: ................. 536

31.1 Removal............................................................................................................ 536
31.1.1 Installation ............................................................................................... 538
Section 32 Gantry Motion Power Board Removal / Replacement: ..................... 539

32.1 Removal............................................................................................................ 539
32.2 Installation ........................................................................................................ 540
Section 33 5 Volt Power Supply Removal/Replacement: .................................. 541

33.0.1 Removal .................................................................................................. 541
33.0.2 Installation ............................................................................................... 543
Section 34 Switching 12 Volt Power Supply Removal/Replacement: ................ 544

34.0.1 Removal .................................................................................................. 544
34.0.2 Installation ............................................................................................... 546
Section 35 R2D Board Removal/Replacement: ................................................ 547

35.1 R2D Board Removal ............................................................................................ 547
35.2 R2D Board Installation ........................................................................................ 549
Section 36 Replacing 5V/24 V DMS Power Supply: .......................................... 550

36.1 Removing the Supply .......................................................................................... 550
36.2 Installing the Supply ........................................................................................... 552
Section 37 Ingenuity CT DMS Triple 5V Power Supplies Replacement: .............. 553

37.1 Removal............................................................................................................ 553
37.1.1 Installation ............................................................................................... 556
Section 38 TDMS 48V Power Supply: .............................................................. 557

38.1 Introduction....................................................................................................... 557
38.2.1 Removing the 48 V Supply ......................................................................... 559
38.2.2 Installing the 48V Power Supply .................................................................. 562
Section 39 Replacing 5V Reference Converter Power Supply: .......................... 568

39.2 Installing the Supply ........................................................................................... 571
Section 40 Main Drive Motor Replacement: ..................................................... 572

40.1 Process Overview for Rotor Main Drive Motor Removal and Replacement .................... 572
40.2 Motor Removal ................................................................................................... 573
40.3 Motor Installation ............................................................................................... 576
Replacement Motor Identification................................................................. 576
Section 41 Rotor Drive Motor Brake Check and Adjustment: ............................ 582
41.1 Checking and Adjusting the Rotor Drive Motor Brake Air Gap .................................... 582
41.2 Checking the Rotor Stopping Time ........................................................................ 587
41.3 Adjusting the Stopping Time (Brake Torque) .......................................................... 591
Section 42 Main Drive Belt Replacement: ....................................................... 593
42.1 Process Overview for Rotor Main Drive Belt Replacement ......................................... 593
42.2 Belt Removal ..................................................................................................... 594
42.3 Belt Installation .................................................................................................. 596
Section 43 SpindleBlok Motor Controller Replacement: .................................. 601

43.1 Removing the Controller ...................................................................................... 602
43.2 Installing the New Controller ................................................................................ 605
43.3 SpindleBlok Motor Controller Commissioning .......................................................... 608
43.3.1 Checking/Setting the Motor Controller H Parameter ....................................... 613
Checking the Motor Controller H Parameter................................................... 613
Setting the Motor Controller H Parameter ..................................................... 616
Section 44 Commander SK Rotor Drive Motor Controller Replacement: ............ 620

44.3 Restoring the System to Operation........................................................................ 643
Section 45 M200 Rotor Drive Motor Controller Replacement: ........................... 644

Section 46 Emerson CSK or M200 Motor Controller Commissioning: ................. 663

46.1 Upload Drive Parameters ..................................................................................... 673
46.2 Restoring the System to Operation........................................................................ 676
Section 47 Three-Phase Filter Removal/Replacement: .................................... 677
47.0.1 Removal .................................................................................................. 677

47.0.2 Installation ............................................................................................... 680
Section 48 Motor Braking Resistor Removal/Replacement: ............................. 681

48.0.1 Removal .................................................................................................. 681
48.0.2 Installation ............................................................................................... 684
Section 49 Tilt Actuator Replacement: ........................................................... 685

Notes for Determining the Defective Actuator ................................................ 685
49.1 Determining Actuator Loading .............................................................................. 686
49.1.1 Relieving Downward Pressure on the Actuator Using Gantry Power: ................. 688
49.1.2 Relieving Downward Pressure By Manually Retracting the Actuator: ................. 690
49.1.3 Relieving Either Stretching or Compression of the Actuator Using Jogging Buttons692
49.2 Removing the Tilt Actuator................................................................................... 695
49.2.1 System Preparation ................................................................................... 695
49.3 Tilt Actuator Installation ...................................................................................... 700
Reinstall the Lift Switches ........................................................................... 704
Section 50 Tilt Limit Switches Replacement: .................................................. 706

50.1 Removal............................................................................................................ 706
50.1.1 Installation ............................................................................................... 708
Section 51 Tilt Lift Switches Removal/Replacement: ....................................... 709

51.0.1 Removal .................................................................................................. 709
51.1 Installation ........................................................................................................ 711
Section 52 Dual Tilt Pot Assembly Replacement: ............................................. 712

52.1 Removal............................................................................................................ 712
52.1.1 Installation ............................................................................................... 713
Section 53 Power Brush Block Replacement: .................................................. 714

53.1 Brush Block Removal .......................................................................................... 714
53.2 Installation ........................................................................................................ 717
Section 54 Signal Brush Block Assembly Replacement: ................................... 720

54.1 Removal............................................................................................................ 720
54.2 Installation ........................................................................................................ 723
Section 55 64-Slice Stator Optical Slip Ring Assembly Replacement: ............... 724
55.1 Removing the Stator Optics Assembly ................................................................... 726
55.2 Installing the Stator Optics Assembly .................................................................... 729
Section 56 64-Slice Rotor Optical Slip Ring Fiber Optic Cable Replacement: ..... 739
56.1 Removing the Rotor Fiber Optics Cable .................................................................. 740
56.2 Installing the Rotor Fiber Optics Cable ................................................................... 744
Section 57 64-Slice Invisible Laser Optical Transmitter Replacement: ............. 752

57.1 Removing the Optical Transmitter (Tx) .................................................................. 752
57.2 Installing the Transmitter .................................................................................... 754
Section 58 64-Slice Invisible Laser Optical Receiver Replacement: .................. 755

58.1 Removing the Optical Receiver (Rx) ...................................................................... 755
58.2 Installing the Receiver......................................................................................... 757
Section 59 16-Slice Rotor Optical Slip Ring Fiber Optic Cable Replacement: ..... 758
59.1 Removing the Rotor Fiber Optics Cable .................................................................. 759
59.2 Installing the Rotor Fiber Optics Cable ................................................................... 765
Section 60 16-Slice Stator Optics Assembly Replacement: ............................... 775

60.1 Removing the Stator Optics Assembly ................................................................... 776
60.2 Installing the Stator Optics Assembly .................................................................... 779
Section 61 16-Slice Invisible Laser Optical Transmitter Replacement: ............. 789

61.1 Removing the Optical Transmitter (Tx) .................................................................. 789
61.2 Installing the Transmitter .................................................................................... 791
Section 62 16-Slice Invisible Laser Optical Receiver Replacement: .................. 792

62.1 Removing the Optical Receiver (Rx) ...................................................................... 792
62.2 Installing the Receiver......................................................................................... 794
Section 63 Gantry Audio Board Removal/Replacement: ................................... 795

63.1 Removal............................................................................................................ 795
63.1.1 Installation ............................................................................................... 796
Section 64 I-Box Board Removal/Replacement: .............................................. 797

64.1 Removal............................................................................................................ 798
64.2 Installation ........................................................................................................ 799
Section 65 Revolution Counter Replacement: .................................................. 800

65.1 Removal............................................................................................................ 801
65.1.1 Installation ............................................................................................... 802
Section 66 AC Control Unit Board Replacement: .............................................. 803
66.1 Removal............................................................................................................ 804

66.2 Installation ........................................................................................................ 805
Section 67 Main Contactor (MKD) And Soft Start (S/S) Contactor

Replacement: ................................................................................................ 806
67.1 Removal............................................................................................................ 806
67.1.1 Installation ............................................................................................... 808
Section 68 Utility & Console Contactor (UTK & CTK) Replacement

(Systems without Console Transformers): ...................................................... 809
68.0.1 Removal .................................................................................................. 809
68.0.2 Installation ............................................................................................... 810
Section 69 Utility and Console Transformer Contactors (UTK & CTK)

(Systems with Console Transformers): ........................................................... 811
69.1 Removal............................................................................................................ 811
69.2 Installation ........................................................................................................ 812
Section 70 Main Drive Contactor (MDK) Replacement: .................................... 813

70.1 Removal............................................................................................................ 814
70.2 Installation ........................................................................................................ 815
Section 71 Entire Gantry Replacement: .......................................................... 816
Appendix A Patient Support Subframe Quick Release: ..................................... 817

A.1 Releasing the Patient Support Subframe Quick Release ............................................. 817
A.2 Engaging the Patient Support Subframe Quick Release .............................................. 819
A.3 Testing the Patient Support Subframe Quick Release................................................. 820
Section 1
Section 1 System Power Down/Power Up
1.1 System Shutdown and Power Down
!
CAUTION: Wait at least 30 seconds after the system is turned off before turning it back on. Turning the
system supply switch off and on too quickly can cause damage to system components.
This section provides instructions for shutting down and powering down the entire system. However,
turning the site system supply switch (wallbox) off and on too quickly can cause some fuses to blow and
can potentially cause damage to the system.
For servicing purposes it is usually not necessary to turn power off to the entire system using the system
supply switch (wallbox). Normally it will only be necessary to turn off power to the items being serviced.
It is not necessary to power down the host or the CIRS unless those are the items to be serviced. For that
reason this section contains procedures for removing power from individual subsystems in addition to
complete system power down.
To power down the complete system:
1. Shutdown the CIRS according to the following Shutting Down the CIRS Server on page 23
procedure.
2. Shutdown the host according to the following Shutting Down the Host on page 25 procedure.
3. If the system has a CIRS UPS, turn it OFF.
4. To remove power from the entire system, turn off the system supply breaker (wallbox).
5. When working inside the lower left column cover, be sure to turn off the 120/240 VAC to the room
annunciator (X‐ray) indicator light. Power to this light comes from a separate 120/240 VAC supply
and must be turned off by a site wall shut‐off switch.
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement System Power Down/Power Up
1.1.1 Shutting Down the CIRS Server

Use the following steps to power down the CIRS Server.
1. Shutdown the CIRS server as follows:
a. At the host, Log off from the Scanner Figure 1-1: Windows Security
Application (if running).
b. Log on as philips_service.
c. On the Host Windows desktop, double‐click
on the CIRS Folder.
d. In the CIRS folder window, double‐click on
the Recon‐S1 icon.
e. Log in as philips_service.
f. On the Server Windows Desktop,
Click on the Start button
g. Select Windows Security from the
menu (see Figure 1‐1).
The Windows Security screen appears (see
Figure 1‐2).
h. In the lower right corner of the Windows Security screen, click the Power icon and select Shutdown
(see Figure 1‐2).
i. Click Yes on the message that appears.
The connection to the server will automatically terminate and the Host desktop will be returned to the
display.
Figure 1-2: Vista Shut Down
1.1.2 Shutting Down the Host
Note: If the CIRS is also to be shut down, perform the preceding procedure Shutting Down the CIRS Server on

page 23 before shutting down the host.
To shut down the host:
1. Ensure that the keyswitch on the scan control box is OFF.
2. If the scanner application is running:
a) Bring up the scanner application Home menu by clicking on the Home tab along the top of the
window.
b) On the scanner application Home menu left panel, click on the Logout button.
3. From the pull‐down menu, select Shutdown, then click on OK. The computer will then turn off in
approximately one minute.
4. If the entire system is to be powered down:
a) If the system has a CIRS UPS, turn it OFF.
b) Turn OFF the system supply switch (wallbox), otherwise go to the shutdown procedure for the
subsystem to be powered down.
1.1.3 Removing Power to the CIRS and Host

The following procedure is for turning OFF power to the host and CIRS without turning power off to the
gantry components or the table. To only turn power off to the host and the CIRS:
1. On systems with horizontal servers:
a) Shutdown the CIRS according to the procedure “Shutting Down the CIRS Server” on page 23.
b) Shutdown the host according to the procedure “Shutting Down the Host” on page 25.
2. If the system has a CIRS UPS, turn it OFF.
WARNING: Avoid contact with live connections while servicing. Hazardous voltages are present in the
gantry support. Failure to do so will result in serious injury or death.
3. Remove the left upper gantry support cover according to “Gantry RH/LH Upper Side Cover
Removal” on page 135 of this manual.
4. Remove fuses F360 and F361as indicated in Figure 1‐3 on page 26.
Figure 1-3: Host and CIRS Fuses
HOST AND CIRS FUSES

F360 & F361
Early Systems
HOST AND CIRS FUSES
F360 & F361
Later Systems
1.1.4 Gantry Power Down (Except for the Host and CIRS)
This procedure will shut down all gantry power except for incoming power and will leave power on to
the host and the CIRS.
2. If the scanner application is running:
a) Bring up the scanner application Home menu by clicking on the Home tab along the top of the
window.
b) On the scanner application Home menu left panel, click on the Logout button.
3. Remove the left upper gantry support cover. See “Gantry RH/LH Upper Side Cover Removal” on
page 135.
4. Momentarily press and release the gantry power (blue) button on the side of the gantry switch panel
as shown in Figure 1‐4 on page 27. This will deenergize the utility contactor (UTK)
Figure 1-4: Gantry Power Toggle Button
..
Early Systems Blue Button Later Systems
!
CAUTION: Wait at least 30 seconds after toggling the blue button off before turning it back on. The blue
button is a toggle switch. Pressing it once toggles it off; pressing it again toggles it on.
Failure to wait at least 30 seconds after toggling the blue button can cause some fuses to
blow.
annunciator (X‐ray) indicators light. Power to this light comes from a separate 120/240 VAC supply
and must be turned off by a site wall shut‐off switch.
1.1.5 Removing Gantry Rotor Power
gantry. Failure to do so will result in serious injury or death.
To only remove power the components mounted on the gantry rotor without removing power to the
entire gantry:
2. If the scanner application is running, bring up the application Home menu by clicking on the Home
tab along the top of the window.
3. On the application Home menu left panel, click on the Logout button.
4. Remove the left upper gantry support cover according to “Gantry RH/LH Upper Side Cover
Removal” on page 135 of this manual.
5. Open fuseholders F351, F352, and F353 shown in Figure 1‐5 on page 29. This removes 480 VAC from

the brush blocks.
6. Open rotor power fuseholder F303. This removes 120 VAC from the rotor components.
Figure 1-5: Gantry Fuse and Contactor Assembly

(later model gantry shown ‐ early model is similar)
SLIP RING FUSES

F351, F352, F353
ROTOR POWER
FUSE F303
1.1.6 Removing Stator Power
To only remove power to the components mounted on the gantry stator without removing power to the
entire gantry:
4. Remove the left upper gantry support cover according to the procedureGantry RH/LH Upper Side
Cover Removal on page 135 of this manual.
5. On the switch panel turn OFF circuit breakers CB301 (Stator Power Supply) and CB302 (Stator
Electronics) shown in Figure 1‐6 on page 30.
Figure 1-6: Gantry Switch Panel

STATOR POWER
CB301
STATOR ELECTRONICS
CB302
annunciator (X‐ray) indicator light. Power to this light comes in to TB20 from a separate 120/240 VAC
supply and must be turned off by a site wall shut‐off switch (see Figure 1‐7 for early models and
Figure 1‐8 on page 32 for later models).
Figure 1-7: Location of Power Connection for Room Annunciator (X‐ray) Light

(Early Model LH Gantry Pedestal Shown)
ROOM ANNUNCIATOR
LIGHT POWER CONNECTION
TO TB20

(Later Model LH Gantry Pedestal Shown)
ROOM ANNUNCIATOR
TO TB20
1.1.7 Removing Table Power
To only remove power to the patient table without removing power to the entire gantry:
1. Ensure that the keyswitch on the scan control box to OFF.
4. Remove the left upper gantry support cover according to the Gantry RH/LH Upper Side Cover
Removal procedure in this manual.
5. On the switch panel turn OFF circuit breakers CB303 (Patient Table and Tilt Power) and CB304
(Patient Table Drive) shown in Figure 1‐6 on page 30.
P/T & TILT PWR SUP

CB303
P/T DRIVE
CB304
1.2 System Power Up

1.2.1 Gantry Power Up
1. If the Rotor has been powered down:
a) Insert the fuses and close fuseholders F351, F352, and F353 shown in Figure 1-10 on page 34.
These supply 480 VAC to the brush blocks.
b) Insert the fuse and close rotor power fuseholder F303. This supplies 120 VAC to the rotor
components.
(later model gantry shown ‐ early model is similar)
SLIP RING FUSES

F351, F352, F353
ROTOR POWER
FUSE F303
2. If the stator has been powered down:
a) On the switch panel turn ON circuit breakers CB301 (Stator Power Supply) and CB302 (Stator
Electronics) shown in Figure 1-11 on page 35.
Figure 1-11: .Gantry Switch Panel
STATOR POWER
CB301
STATOR ELECTRONICS
CB302
3. If the table has been powered down:
a) On the switch panel turn ON circuit breakers CB303 (Patient Table and Tilt Power) and CB304
(Patient Table Drive) shown in Figure 1-12 on page 36.
P/T & TILT PWR SUP

CB303
P/T DRIVE
CB304
4. If the gantry has been powered down, momentarily press and release the blue button on the side of
the gantry switch panel as shown in Figure 1‐13 on page 37.:
!
CAUTION: Wait at least 30 seconds after toggling the blue button off before turning it back on. The blue
button is a toggle switch. Pressing it once toggles it off; pressing it again toggles it on.
Failure to wait at least 30 seconds between toggling of the blue button can cause some fuses
to blow.
5. Turn ON the site wall switch to restore 120/240 VAC to the room annunciator (X‐ray) indicator light.

.
Early Systems BLUE BUTTON Later Systems
CIRS and Host Power-Up

1. If they were removed, insert and close host and CIRS cabinet power fuses F360 and F361as indicated
in Figure 1‐14 on page 38 .
Figure 1-14: Host and CIRS Fuses
HOST AND CIRS FUSES

F360 & F361
Early Systems HOST AND CIRS FUSES

F360 & F361
Later Systems
2. If the system has a CIRS UPS, turn it ON.
3. On the vertIcal server, momentarily press the power button.
4. Turn on power to the Host PC by momentarily pressing the power button.
5. Turn the monitor on.
6. Wait for the host PC to boot up (approximately 90 seconds). The PC will display a login prompt when
ready.
7. At the keyboard, press <Ctrl><Alt><Del> when prompted.
At this point there are two login options ‐ either for service or for normal operations.
If maintenance has been performed on the system, always check the operation of the system before
turning the system over to the customer.
8. To login for service:
a) In the User Name box, select “philips_service”.
b) In the password box, enter the service password.
c) Click the OK button, or press Enter.
9. To perform a normal login:
a) In the User Name box, select “CT”.
b) Leave the password box blank and click the OK button, or press Enter.
10. When the desktop is displayed, right‐click on the Scanner Application icon on the desktop. (Note:
Double‐clicking on the Scanner Application icon may inadvertently open multiple instances of the
application which may cause conflicts in operation.)
11. Select Open from the drop‐down selection box.
12. When the scanner application opens and the CLOSE ESTOP dialog box appears, on the scan control
box momentarily turn the keyswitch to the START position and the release it to allow it to return to
the ON position.
Section 2
Section 2 Ingenuity CT Gantry Front Cover Opening/Closing
This procedure is only for opening and closing the front cover. The procedure for replacing the front cover
is in the section “Ingenuity CT Gantry Front Cover Replacement” on page 48.
2.1 Opening the Ingenuity CT Gantry Front Cover
Note: The Gantry front cover is hinged at the top. Do not attempt to remove the hinge.
1. Make sure that the patient support top is as far away from the gantry as it will go.
2. Disengage the couch subframe and move it to the foot end as follows:
a. If installed, remove the access cover (not shown in Figure 4).
b. To disengage the patient support subframe quick release, see “Releasing the Patient Support
Subframe Quick Release” on page 817.
3. If it is not already on, turn ON power to the gantry (see Gantry Power Up on page 34).
4. Using the gantry front panel controls, lower the patient support as low as it will go.
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Ingenuity CT Gantry Front Cover Opening/Closing
5 At the rear of the gantry remove flat head screw securing lexan ring and slide the lexan ring toward
the rear of the gantry as far as it will go (see Figure 2‐1).
Figure 2-1: Lexan Ring Moved to Rear

SLIDE LEXAN
REMOVE SCREW RING TO REAR
6. Shut down power to the gantry components to be serviced (see System Power Down/Power Up on
page 22).
WARNING: Hazardous voltages are present inside the gantry front cover. Turn gantry power off before
working with the front cover open or removed.
7. Using a 3/16” hex key, turn the 2 latches 1/4 turn to release the latches. Refer to Figure 2‐2.
Figure 2-2: Gantry Front Cover Latches
Socket Head
Latch Releases
(One in Each Corner)
8. Firmly grasp the front cover at the center of the bore as shown in Figure 2‐3 and pull forward.
Maintain a firm grip on the front cover because it’s opening is assisted by air‐pressurized struts.
Figure 2-3: Gantry Front Cover Opening
Grasp cover at
center of bore and
pull forward
!
WARNING: Make sure to insert the hinge locking pins to prevent the cover from falling anytime it is
open. Failure of a front cover support gas spring may allow the front cover to fall quickly and
cause injury to personnel.
9. Lock the front cover open by moving the locking pins on both hinges from the rear hole to the front
hole to hold the front cover open (see Figure 2‐4).
Figure 2-4: Ingenuity CT Gantry LH Front Cover Hinge Locking Pin (RH is similar)

LOCKING PIN IN BOTTOM HOLE LOCKING PIN IN TOP HOLE TO
FOR CLOSING FRONT COVER HOLD FRONT COVER OPEN
2.2 Closing the Ingenuity CT Gantry Front Cover
WARNING: Hazardous voltages are present in the gantry. Avoid contact with live connections while
servicing. Failure to do so may result in serious injury or death.
1. Apply power to the gantry (see Gantry Power Up on page 34).
2. Make sure that the patient support top subframe is still all the way back away from the gantry.
3. Using the gantry front panel controls lower the patient support as far as it will go.
4. Move the locking pins on both front cover hinges to the lower holes to allow the front cover to close
(Figure 2‐4).
5. Grasp the side of the front cover and pull it down to close the cover.
6. Using a 3/16” hex key, turn the latches 1/4 turn to latch them.
7 At the rear of the gantry slide the lexan ring toward the front of the gantry into position and install the
flat‐head screw to secure the lexan ring (Figure 2‐1).
8. Raise the patient support to gain access to the subframe quick‐release.
9. Move the patient support subframe toward the gantry as far as it will go.
•On older style releases, engage the latch rod with the bracket and tighten the nut.
•On newer style releases install the nut and tighten it to 23 ft-lb (31 Nm).
10. If a cover was present over the subframe latch, reinstall the cover.
2.3 Removing/Replacing the Ingenuity CT Gantry

Lower Front Cover
2.3.1 Removing Ingenuity CT Gantry Lower Front Cover

1. Open the gantry front cover according to the procedure “Ingenuity CT Gantry Front Cover Opening/
Closing” on page 40.
2. Mark the position of the two socket‐head cap screws on the mounting bracket as indicated in
Figure 2‐5 and remove the two socket‐head cap screws securing the lower front cover mounting
bracket.
Figure 2-5: Gantry Lower Front Cover Mounting Details
Mark position and remove two

socket head cap screws
Lower Front Cover ‐ Front View Lower Front Cover Mounting ‐ Top View
2.3.2 Installing the Ingenuity CT Gantry Lower Front Cover

1. Obtain Loctite #242 and ensure the expiration date has not been reached.
2. Apply Loctite #242 to the 2 cover SHCS.
3. Place the lower front cover and bracket into position on the gantry (see Figure 2‐5) and loosely install
the two SHCS with 1/4” flat washers.
4. Position the screws to the marks made when the cover was removed and tighten the 2 SHCS. Torque
them to 10.5 ft‐lb (14.2 Nm).
5. Close the front cover according to the procedure “Closing the Ingenuity CT Gantry Front Cover” on
page 45 and check the alignment with the lower front cover. Adjust the lower cover as necessary to
align with the gantry front cover.
Section 3
Section 3 Ingenuity CT Gantry Front Cover Replacement
Note: Two people will be required to perform the front cover replacement procedure.
3.1 Special Tools and Equipment Required

• Standard FSE tool kit
• Loctite #425
• Cable ties
3.2 Front Cover Removal
WARNING: Hazardous voltages are present inside the gantry front cover. Turn rotor and stator power off
before working with the front cover open or removed.
1. Turn off gantry power according to the procedure “Gantry Power Down (Except for the Host and
CIRS)” on page 27.
2. Open the front cover according to the procedure “Ingenuity CT Gantry Front Cover Opening/
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Ingenuity CT Gantry Front Cover Replacement
3. Lock the front cover open by moving the locking pins on both hinges from the closing hole to the hole
to hold the front cover open (see Figure 3‐1).
Figure 3-1: Ingenuity CT Gantry LH Front Cover Hinge Locking Pin (RH is similar)

3.2.1 Removing Needed Parts from The Old Front Cover

1. Remove the RH front control panel according to the procedure “Removing the Ingenuity CT Front
Control Panel” on page 97.
2. Remove the LH front control panel according to the procedure “Removing the Ingenuity CT Front
3 Disconnect the cables from the display/switch control board (see Figure 3‐2).
4 Remove the four screws securing the display/switch control board to the front cover, and remove the
board.
Figure 3-2: Gantry Display/Switch Control Board

5. Disconnect the right and left E‐stop buttons, remove the two attaching SHCS and remove the buttons
(see Figure 3‐3).
Figure 3-3: E‐stop Button
6. Disconnect the microphone assembly and remove it (see Figure 3‐4).
Figure 3-4: Microphone
7. There are 2 styles of laser assemblies that have been installed on Ingenuity systems. Refer to Figure 3‐
5 and identify the type of lasers your system has.
For removing original style lasers, proceed to Step 8 on page 54.
For removing newer style lasers skip to Step 10 on page 56.
Figure 3-5: Side Laser Styles
Original Style Side Laser Newer Style Side Laser
8. To remove original style side lasers disconnect them, remove the 2 screws, and remove the lasers (see
Figure 3‐6).
Figure 3-6: Original Side Laser
REMOVE 2 SCREWS
9. Disconnect the top laser assembly, remove the 2 screws, and remove the laser (see Figure 3‐7).
Figure 3-7: Older Style Top Laser

10. To remove newer style side lasers:
a. From the back of the front cover cut the cable ties as required and disconnect the 2 side lasers and
the top laser (see Figure 3‐8).
Figure 3-8: Newer Style Laser Connections
CUT CABLE TIES AND CUT CABLE TIES AND

DISCONNECT DISCONNECT
Newer Style Side Laser Newer Style Top Laser
b. From the front of the front cover remove the screw from the lens cover (see Figure 3‐9) and remove
the laser lens cover.
Figure 3-9: Newer Style Laser Lens Cover
REMOVE
COVER SCREW
c. While supporting a laser assembly at the back of the front cover, from the front of the front cover
remove the 2 screws attaching it and remove it (see Figure 3‐10).
d. Repeat this for the remaining 2 laser assemblies.
Figure 3-10: Newer Style Laser Mounting Screws
REMOVE 2 SCREWS
11. Cut all the cable ties to free the cables from the front cover.
12. Remove the 2 cover latches by removing the outer and inner nuts as shown in Figure 3‐11.
Figure 3-11: Front Cover Latch

2 INNER NUTS
FRONT COVER LATCH
2 OUTER NUT
3.2.2 Removing the Gantry Front Cover

1. While another person supports the cover, remove the nuts attaching the cover to the right and left
hinges ‐ 4 nuts on each hinge (see Figure 3‐12).
2. Remove the cover and stand it in a convenient spot.
Figure 3-12: Front Cover Mounting to RH Hinge (LH is Similar)
REMOVE 4 MOUNTING NUTS
3.3 Installing the Gantry Front Cover

1. Raise the cover into position so that the cover studs engage the holes in the hinges (see Figure 3‐13).
2. While another person supports the cover, install the nuts attaching the cover to the right and left
hinges ‐ 4 nuts on each hinge (see Figure 3‐13).
Figure 3-13: Front Cover Mounting to RH Hinge (LH is Similar)
INSTALL 4 MOUNTING NUTS
4. Apply Loctite #425 to about the first 1/2” (13 mm) of the threads past the unthreaded parts of the 4
cover latch screws and assemble the parts onto the 4 latch screws as shown in Figure 3‐14.
Figure 3-14: Front Cover Latch Screw Assembly
SPRING
FLAT WASHER
LATCH SCREW
5. Install a cover latch screw assembly into one of the front cover latch counterbores.
a. While using a hex key to compress the latch spring, install the inner nut all the way to the end of
the threads.
b. Thread the second inner nut all the way and tighten it against the first (see Figure 3‐15).
c. Thread the latch onto the screw until it is against the inner nut as shown in Figure 3‐15.
d. Install the outer nylock nut.
e. While holding the inner nut with a wrench, tighten the outer nut.
f. Repeat Step 5 on page 63 to install the other 3 cover screw assemblies
Figure 3-15: Front Cover Latch Installation

2 INNER NUTS
FRONT COVER LATCH
2 OUTER NUT
3.3.1 Installing Parts onto the New Front Cover

1. Install and connect the RH front control panel according to the procedure “Installing an Ingenuity CT
Front Control Panel” on page 100.
2. Install the LH front control panel according to the procedure “Installing an Ingenuity CT Front
3 Place the display/switch control board in position and attach it to the front cover with 4 screws with
lock washers (see Figure 3‐16).
4 Connect cables to the display/switch control board (see Figure 3‐16).
5. Install and connect the right and left E‐stop buttons (see Figure 3‐17).
Figure 3-17: E‐stop Button

6. Install and connect the microphone assembly (see Figure 3‐18).
Figure 3-18: Microphone

7. For systems with original style lasers:
a. Install and connect the 2 side laser assemblies (see Figure 3‐19).

REMOVE 2 SCREWS
b. Install and connect the top laser assembly (see Figure 3‐20).
8. To install newer style side lasers:
a. While supporting a laser assembly at the back of the front cover, from the front of the front cover
install the 2 screws to attach it (see Figure 3‐21).
b. Repeat this for the remaining 2 laser assemblies.

INSTALL 2 SCREWS
c. From the back of the front cover connect the 2 side lasers and the top laser and tie the cables in
place (see Figure 3‐8).
d. Leave the lens cover off until the front cover is aligned and the laser alignment procedure is
completed.
9. Properly arrange all the cables on the front cover and tie them in place as they were originally.
10. Once the front cover is in position and adjusted, the locating lasers need to be aligned according to the
procedure in the Ingenuity Calibration Manual.

CONNECT AND CONNECT AND
TIE IN PLACE TIE IN PLACE
3.4 Ingenuity CT Front Cover Position Adjustments

3.4.1 Preparation for Cover Adjustments
1. Power down the system according to the procedure “Gantry Power Down (Except for the Host and
CIRS)” on page 27 and observe all safety precautions listed there.
2. Open the front cover according to the procedure “Opening the Ingenuity CT Gantry Front Cover” on
page 40 and observe the safety precautions listed there.
3.4.2 Side to Side Adjustment

1. To align the front cover from side to side, turn the adjustment screw on the right cover hinge shown in
Figure 3‐23 on page 72 in the required direction (turning the screw CW adjusts the cover to the right
and turning the screw CCW adjusts the cover to the left). Only the right side front cover hinge has a
side‐to‐side adjustment screw.
2. When the adjustment is complete, close the front cover according to the procedure “Closing the
Ingenuity CT Gantry Front Cover” on page 45.
Figure 3-23: Front Cover Side‐to‐Side Adjustment (Right Side of Gantry)

SIDE-TO-SIDE
ADJUSTMENT
3.4.3 Front to Back Adjustment

1. If not already done, prepare the gantry for front cover adjustments according to “Preparation for
Cover Adjustments” on page 71.
2. To adjust the position of the front cover toward the front, loosen the bolt shown in Figure 3‐24 on
page 73 on the side to be adjusted, loosen the adjustment screw, move the cover as required, and
retighten the bolt.
3. To adjust the position of the front cover toward the rear, loosen the bolt shown in Figure 3‐24 on
page 73 on the side to be adjusted, tighten the adjustment screw to move the cover as required, and
retighten the bolt.
4. When the adjustments are complete, close the front cover according to the procedure “Closing the
Figure 3-24: Front Cover Front‐to‐back Adjustment Screws (right side ‐ left side is similar)
FRONT-TO-BACK FRONT-TO-BACK
ADJUSTMENT BOLT ADJUSTMENT SCREW
3.4.4 Vertical Adjustment

To adjust the front cover up‐and‐down position:
1. If not already done, prepare the gantry for front cover adjustments according to “Preparation for
Cover Adjustments” on page 71.
2. To adjust the vertical position of the front cover, loosen the hinge mounting bolts shown in Figure 3‐
25 on the side to be adjusted, turn the adjustment bolt in or out to move the cover as required, and
retighten the bolts.
3. When the adjustments are complete, close the front cover according to the procedure “Closing the
4. Align the locating lasers according to the procedure in the Ingenuity Calibration Manual.
Figure 3-25: Light Gantry Front Cover Vertical Adjustment (right side shown, left side is similar)

HINGE MOUNTING BOLT
VERTICAL POSITION
ADJUSTMENT BOLT
5. From the front of the front cover place the lens cover in place and attach it with the screw (see
Figure 3‐26).
INSTALL LENS
COVER SCREW
Section 4
Section 4 Gantry Front Cover Gas Spring Replacement

Note: On each hinge there are 2‐120# gas springs and 1‐130# gas spring. Make sure to check the label on the gas
spring being replaced and replace it with the correct one.
4.2 Gas Spring Removal

1. Shut down power to the gantry components to be serviced (see System Power Down/Power Up on
page 22).
WARNING: hazardous voltages are present inside the gantry front cover. turn gantry power off before
working with the FRONT cover open or removed.
2. Remove the rear cover according to the procedure “Ingenuity CT Gantry Rear Cover Removal” on
page 115.
3. Open the front cover according to the procedure “Opening the Ingenuity CT Gantry Front Cover” on
page 40.
4. Push the front cover up as far as it will go to fully extend the gas springs and support it in that
position.
5. Remove the nut from the gas spring mounting screw (see Figure 4‐1).
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Gantry Front Cover Gas Spring Replacement
6. Move the front cover up or down as required to relieve the pressure from the gas springs mounting
pin until the pin can be pulled out (see Figure 4‐1).
Figure 4-1: Front Cover Gas Spring Attaching Screw

(right hinge shown ‐ left is similar)
GAS SPRING MOUNTING PIN

REMOVE NUT
7. Unscrew the gas spring to be replaced from its mounting eye located at the rear of the gantry (see
Figure 4‐2).
Figure 4-2: Front Cover Gas Spring Rear Mounting

UNSCREW GAS SPRING

FROM MOUNTING EYE
4.3 Gas Spring Installation
Note: On each hinge there are 2‐120# gas springs and 1‐130# gas spring. Make sure to check the label on the gas
spring being replaced and replace it with the correct one.
1. Screw the gas spring(s) to be replaced into its mounting eye located at the rear of the gantry (see
Figure 4‐3).
Figure 4-3: Front Cover Gas Spring Rear Mounting

SCREW GAS SPRING INTO

MOUNTING EYE
2. Move the front cover up or down as required to until the gas spring mounting pin can be inserted (see
Figure 4‐4).
3. Install the nut onto the mounting pin (see Figure 4‐4).
4. Install the rear cover according to the procedure “Ingenuity CT Gantry Rear Cover Installation” on
page 120.
5. Close the front cover according to the procedure “Closing the Ingenuity CT Gantry Front Cover” on
page 45.
Figure 4-4: Front Cover Gas Spring Attaching Screw


INSERT GAS SPRING
INSTALL NUT
MOUNTING PIN
Section 5
Section 5 Original Style Front Cover Laser Module Replacement
There are 2 styles of laser assemblies that have been installed on Ingenuity systems. Refer to Figure 5‐1
and identify the type of lasers your system has.
This section contains removal and replacement procedures for the original style gantry laser modules.
For replacing newer style laser modules refer to the section Newer Style Front Cover Laser Module
Replacement on page 86.
Original Style Side Laser Newer Style Side Laser
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement PublicationSort Original Style Front Cover Laser
5.1 Front Cover Laser Module Removal

1. Remove power from gantry Gantry Power Down (Except for the Host and CIRS) on page 27.
2. Open gantry front cover Opening the Ingenuity CT Gantry Front Cover on page 40.
3. To remove original style side lasers disconnect them, remove the 2 screws, and remove the lasers (see
Figure ).

REMOVE 2 SCREWS
4) To remove an original style top laser assembly, disconnect it, remove the 2 screws, and remove the
laser (see Figure 5‐3).
5.2 Front Cover Laser Module Installation

1. To install the side lasers, position the lasers into the front cover and attach them with 2 screws (see
Figure 5‐4).

REMOVE 2 SCREWS
2. Install top laser assembly, attach it with 2 screws, and connect it (see Figure 5‐5).
3. Close the front cover (see Closing the Ingenuity CT Gantry Front Cover on page 45).
4. Power up the system (see System Power Up on page 34).
5) Align the locating lasers according to the procedure in the Ingenuity Calibration Manual.

Section 6
Section 6 Newer Style Front Cover Laser Module Replacement
There are 2 styles of laser assemblies that have been installed on Ingenuity systems. Refer to Figure 6‐1
and identify the type of lasers your system has.
This section contains removal and replacement procedures for the newer style gantry laser modules.
For replacing earlier style laser modules refer to the section Original Style Front Cover Laser Module
Replacement on page 81.
Early Style Side Laser Newer Style Side Laser
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Newer Style Front Cover Laser Module Replacement
6.1 Front Cover Laser Module Removal

1. Remove power from gantry (see Gantry Power Down (Except for the Host and CIRS) on page 27).
2. Open gantry front cover (see Opening the Ingenuity CT Gantry Front Cover on page 40).
3. From the front of the front cover remove the screw from the lens cover from the laser to be replaced
(see Figure 6‐2) and remove the laser lens cover.

REMOVE
COVER SCREW
4. While supporting the laser assembly at the back of the front cover, from the front of the front cover
remove the 2 screws attaching it and remove it (see Figure 6‐3).

REMOVE 2 SCREWS
6.2 Front Cover Laser Module Installation

1. While supporting a laser assembly at the back of the front cover, from the front of the front cover
install the 2 screws to attach it (see Figure 6‐4).
INSTALL 2 SCREWS
2. From the back of the front cover connect the laser and tie the cables in place (see Figure 6‐5).
3) Properly arrange all the cables on the front cover and tie them in place as they were originally.
4) Align the lasers according to the procedure in the Ingenuity Calibration Manual.
CONNECT AND CONNECT AND

TIE IN PLACE TIE IN PLACE
5. When the laser alignment procedure is completed position the lens cover on the laser and attach it
with the screw (see Figure 6‐6).
INSTALL
COVER SCREW
Section 7
Section 7 Rotor Laser Module Replacement
This paragraph contains removal and replacement procedures for the two laser modules located on the
rotor at the 3 o’clock and 11 o’clock positions (with X‐ray tube at 12 o’clock position).
7.1 Rotor Laser Module Removal

1. Remove power from gantry (see Gantry Power Down (Except for the Host and CIRS) on page 27).
2. Open gantry front cover (see Opening the Ingenuity CT Gantry Front Cover on page 40).
3. Cut the cable tie securing the wires and disconnect the laser wires (Figure 7‐1).
4. Remove two screws securing the laser to be replaced, and remove laser (Figure 7‐1).
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Rotor Laser Module Replacement
Figure 7-1: Laser Positions On Rotor with XRT at Top

Remove 2 Screws Disconnect Wires Remove 2 Screws
Disconnect Wires
10 O’Clock Position Laser 3 O’Clock Position Laser
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Rotor Laser Module Replacement
7.2 Rotor Laser Modules Installation

2. Put Loctite #222 onto the 2 laser mounting screws, attach the laser (see Figure 7‐1 on page 93) and
tighten the screws.
3. Connect the laser wires and secure them with a cable tie (see Figure 7‐1 on page 93).
4. Remove two screws securing the laser to be replaced, and remove laser.
7. Calibrate the lasers. Refer to laser calibration procedure in the applicable Brilliance Calibration
Manual.
Section 8
Section 8 Early Model RH or LH Front Display/Control Panel
Replacement
8.0.1 Special Tools and Equipment Required
• Loctite #425
• Cable ties
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Early Model RH or LH Front Display/Control Panel
Figure 8-1: Ingenuity CT LH Front Cover Hinge Locking Pin (RH is similar)

8.1 Removing the Ingenuity CT Front Control Panel
Note: The pictures in this section show a right‐hand front control panel; however the procedure is similar for
the left‐hand display/control panel.
1. Remove the 6 screws mounting the control panel to the front cover (see Figure 8‐2).
2. Disconnect the ground wire (see Figure 8‐2).
3. Disconnect the one signal cable that is accessible (see Figure 8‐2).
4. Note which button terminals the wires are connected to and disconnect the wires from the E‐stop
button (see Figure 8‐2).
Figure 8-2: LH Front Control Panel Mounting Screws (RH is similar)
REMOVE 6 MOUNTING DISCONNECT GROUND DISCONNECT SIGNAL

SCREWS CABLE
DISCONNECT ESTOP
5. Gently lower the front cover so that the control panel is suspended by the remaining attached cable
(or leave the control panel lying on the cover and use a ladder to perform the remaining procedure).
6. Remove the 6 control panel rear cover screws (see Figure 8‐3) and pull the rear cover off far enough to
allow access to the remaining signal cable.
Figure 8-3: LH Front Control Panel Rear Cover Screws (RH is similar)
REMOVE 6 REAR COVER

SCREWS
7. Disconnect the remaining cables (see Figure 8‐4).
Figure 8-4: Disconnecting Cable from LH Front Control Panel (RH is similar)
DISCONNECT CABLES
8.2 Installing an Ingenuity CT Front Control Panel

1. Remove the 6 control panel rear cover screws from the new control panel (see Figure 8‐5) and remove
the rear cover.

REMOVE 6 REAR COVER

SCREWS
2. Thread the signal cable through the control panel rear cover opening and connect it as shown in
Figure 8‐6.
Figure 8-6: Connecting Cables to LH Front Control Panel (RH is similar)
CONNECT CABLES
3. Attach the control panel rear cover with 6 screws (see Figure 8‐7). If the front cover was lowered,
gently lower the control panel so that it is suspended by the attached cable and raise the gantry front
cover.

INSTALL 6 REAR COVER

SCREWS
4. Install the 6 screws to mount the control panel to the front cover (see Figure 8‐8).
5. Connect the ground wire (see Figure 8‐8).
6. Connect the signal cable (see Figure 8‐8).
7. Connect the wires to the E‐stop button (see Figure 8‐8).
Figure 8-8: LH Front Control Panel Mounting Screws (RH is similar)

INSTALL 6 MOUNTING CONNECT GROUND CONNECT SIGNAL
SCREWS CABLE
CONNECT ESTOP
Section 9
Section 9 Later Model RH or LH Front Display/Control Panel
Replacement

• Loctite #425
• Cable ties
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Later Model RH or LH Front Display/Control Panel
Figure 9-1: LH Front Cover Hinge Locking Pin (RH is similar)

9.2 Removing a Front Control Panel
Note: The pictures in this section show a right‐hand front control panel; however the procedure is similar for
the left‐hand display/control panel.
1. Remove the 6 screws mounting the control panel to the front cover (see Figure 9‐2).
2. Disconnect the ground wire (see Figure 9‐2).
3. Disconnect the one signal cable that is accessible (see Figure 9‐2).
4. Note which button terminals the wires are connected to and disconnect the wires from the E‐stop
button (see Figure 9‐2).
Figure 9-2: RH Front Control Panel Mounting Screws (LH is similar)
REMOVE 6 MOUNTING DISCONNECT DISCONNECT DISCONNECT

SCREWS ESTOP SIGNAL CABLE GROUND
5. Gently lower the front cover so that the control panel is suspended by the remaining attached cable
(or leave the control panel lying on the cover and use a ladder to perform the remaining procedure).
6. Remove the 6 control panel rear cover screws (see Figure 9‐3) and pull the rear cover off far enough to
allow access to the remaining signal cable.
Figure 9-3: Front Control Panel Rear Cover Screws
REMOVE 6 REAR COVER

SCREWS
7. Disconnect the remaining cables (see Figure 9‐4).
Figure 9-4: Disconnect Cables from Front Control Panel
DISCONNECT CABLE
9.3 Installing a Front Control Panel

1. Remove the 6 control panel rear cover screws from the new control panel (see Figure 9‐5) and remove
the rear cover.

REMOVE 6 REAR COVER
SCREWS
2. Thread the signal cable through the control panel rear cover opening and connect it to the display
board.
3. Attach the control panel rear cover with 6 screws (see Figure 9‐6). If the front cover was lowered,
gently lower the control panel so that it is suspended by the attached cable and raise the gantry front
cover.

INSTALL 6 REAR COVER

SCREWS
4. Install the 6 screws to mount the control panel to the front cover (see Figure 9‐7).
5. Connect the ground wire (see Figure 9‐7).
6. Connect the signal cable (see Figure 9‐7).
7. Connect the wires to the E‐stop button (see Figure 9‐7).
Figure 9-7: RH Front Control Panel Mounting Screws (LH is similar)

INSTALL 6 MOUNTING CONNECT CONNECT CONNECT
SCREWS ESTOP SIGNAL CABLE GROUND
Section 10
Section 10 Replacing the Gantry Rear Cover

• Philips Standard FSE tool kit
• Cable ties
Note: There are 2 types of replacement rear cover assemblies: one for Flex systems without rear control panels,
and one for other systems with rear control panels. This procedure is for replacing either type of rear
cover.
10.2 Removing the Gantry Rear Cover

The rear cover hangs on two upper mounting brackets, and is secured to mounting brackets in the lower
left and right corners on the rear of the gantry.
10.2.1 Invisible Laser Safety Precaution

Ingenuity CT gantries contain an optical data path system that uses lasers that emit Class 3B invisible
laser radiation. Personnel are cautioned about the presence of invisible lasers by a label on the back of the
gantry as shown in Figure 10‐1 on page 113. To protect service personnel an interlock is built into the
Gantry Rear Cover. When the Gantry Rear Cover is removed, internal Gantry Power is turned off. This
removes power from the optical data path system (Figure 10‐2 on page 114).
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Replacing the Gantry Rear Cover
Figure 10-1: Laser Warning Label on Systems with Invisible Lasers

Invisible Laser Warning Label
WARNING: Ingenuity CT systems contain Class 3B Invisible Lasers for the Optical Data Path. Class 3B
Invisible laser radiation is present when the Gantry rear cover is removed and the interlock
is defeated. Avoid exposure to the beam and use laser safety glasses, P/N 453567543401.
WARNING: DO NOT use a mirror or any other tool to attempt to view the laser beam to determine if it is
on or off.
Figure 10-2: Rear Cover Interlock Switch
REAR COVER INTERLOCK

REMOVES LASER POWER.
10.2.2 Ingenuity CT Gantry Rear Cover Removal
WARNING: Hazardous voltages are present inside the gantry rear cover. Turn gantry power off before
working with the rear cover removed.
1. Power down the gantry. Refer to the procedure “Gantry Power Down (Except for the Host and CIRS)”
on page 27.
2. Remove 4 screws securing the rear cover around the cone (see Figure 10‐3).
3. Turn the 2 bottom corner latches one‐quarter turn to release them (see Figure 10‐3).
Figure 10-3: Gantry Rear Cover Attachment
SCREWS (4)
SOCKET-HEAD LATCHES
4. Remove the upper right gantry side cover according to the procedure “Gantry RH/LH Upper Side
Cover Removal” on page 135.
Note: Flex systems may not have rear control panels. Rear control panels are optional on Flex systems.
5. On systems with rear control panels disconnect the gantry LH and RH rear switch panel data cables
(J11 and J12), rear e‐stop cable (J13), and ground lugs from rear bracket connections (see Figure 10‐4).
Figure 10-4: Gantry Rear Cover Cables and Rear Bracket Connections

(only on systems with rear control panels)

4 GROUND WIRES J11 J12
ESTOP CONNECTOR
6. Pull the cover out enough to allow it to be grasped inside the top center (see Figure 10‐5).
7. Lift the rear cover up to clear upper mounting brackets and remove rear cover from the gantry.
8. On systems with rear control panels where the rear gantry cover is being replaced, proceed to the next
section “On Systems with Rear Control Panels ‐ Removing Parts from the Removed Cover” on
page 118.
9. On systems that do not have rear control panels or to reinstall the same rear cover, skip to the section
“Ingenuity CT Gantry Rear Cover Installation” on page 120.
Figure 10-5: Removing the Rear Cover
10.2.3 On Systems with Rear Control Panels - Removing Parts

from the Removed Cover
1. Remove the rear control panels according to the section “Replacing the Ingenuity CT Gantry Rear
Control Panels” on page 122.
2. Remove the E‐stop buttons from the rear cover.
3. Cut the cable ties and remove the cabling from the rear cover (see Figure 10‐6).
Figure 10-6: Rear Gantry Cover Cabling (systems with rear control panels)
CUT CABLE TIES
10.2.4 Installing Parts onto the New Rear Cover - Systems with
Rear Control Panels
1. Install the rear control panels according to the section “Replacing the Ingenuity CT Gantry Rear
Control Panels” on page 122.
2. Install the E‐stop buttons from the rear cover.
3. Tie the cabling to the rear cover (see Figure 10‐7).
Figure 10-7: Rear Gantry Cover Cabling

(systems with rear control panels)
TIE CABLES TO COVER
10.2.5 Ingenuity CT Gantry Rear Cover Installation

1. While being careful not to pinch the rear cover cables, lift the rear cover up and set the rear cover
brackets onto the rear gantry mounting bracket. Position the rear cover from side‐to‐side until the rear
cover brackets drop into the slots in the gantry bracket.
2. Check the alignment of the rear cover. If needed, remove the rear cover and reposition the rear cover
mounting brackets on the gantry as required to obtain proper alignment of the rear cover (see
Figure 10‐8).
To reposition the upper rear cover mounting bracket, loosen the 7 mounting bracket nuts, reposition
the bracket, and retighten the nuts (see Figure 10‐8).
Figure 10-8: Gantry Rear Cover Upper Mounting Bracket Adjustments

SLOT FOR REAR COVER BRACKET
(ONE EACH SIDE)
LOOSEN NUTS TO
REPOSITION BRACKET
REAR COVER MOUNTING BRACKET
3. On systems with rear control panels, connect gantry LH and RH rear switch panel data cables, rear e‐
stop cable, and ground lugs to rear bracket connections (see Figure 10‐4).
4. Secure rear cover with 4 socket head cap screws around the cone (see Figure 10‐3).
5. Turn the 2 bottom corner latches one‐quarter turn to latch them (see Figure 10‐3).
6. Install the upper right gantry side cover according to the procedure “Gantry RH/LH Upper Side
Cover Installation” on page 138.
Section 11
Section 11 Replacing the Ingenuity CT Gantry Rear Control Panels

• Philips Standard FSE tool kit
• Cable ties
11.2 Replacing the Right Rear Control Panel

11.2.1 Removing the Right Rear Control Panel
1. Power down the gantry according to the procedure “Gantry Power Down (Except for the Host and
2. Remove the gantry rear cover according to the procedure “Ingenuity CT Gantry Rear Cover
Removal” on page 115.
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Replacing the Ingenuity CT Gantry Rear Control
3. Disconnect the signal, ground, and E‐stop cables from the RH rear control panel (see Figure 11‐1).
4. Remove the 6 RH rear control panel mounting screws (see Figure 11‐1) and remove the control panel.
Figure 11-1: RH Rear Control Panel

DISCONNECT E-STOP
DISCONNECT SIGNAL CABLE
DISCONNECT GROUND
CONTROL PANEL
MOUNTING SCREWS (6)
11.2.2 Installing the Right Rear Control Panel

1. Place the RH rear control panel in place and Install the 6 LH rear control panel mounting screws (see
Figure 11‐2).
2. Connect the signal, ground, and E‐stop cables to the RH rear control panel (see Figure 11‐2).
3. Install the gantry rear cover according to the procedure “Ingenuity CT Gantry Rear Cover
Installation” on page 120.
4. Power up and test the system.
Figure 11-2: Right Rear Control Panel Installed
CONNECT E-STOP
CONNECT SIGNAL CABLE
CONNECT GROUND
CONTROL PANEL
MOUNTING SCREWS (6)
11.3 Replacing the Left Rear Control Panel

11.3.1 Removing the Left Rear Control Panel
2. Remove the gantry rear cover according to the procedure “Ingenuity CT Gantry Rear Cover
3. Disconnect the signal, ground, and E‐stop cables from the LH rear control panel (see Figure 11‐3).
4. Remove the 6 LH rear control panel mounting screws (see Figure 11‐3) and remove the control panel.
Figure 11-3: LH Rear Control Panel

DISCONNECT E-STOP
DISCONNECT SIGNAL CABLE
DISCONNECT GROUND
CONTROL PANEL
MOUNTING SCREWS (6)
11.3.2 Installing the Left Rear Control Panel

1. Position the LH rear control panel on the rear cover (see Figure 11‐4) and attach it with the 6 LH rear
control panel mounting screws,
2. Connect the signal, ground, and E‐stop cables to the LH rear control panel (see Figure 11‐4).
4. Power up and test the system.
Figure 11-4: Left Rear Control Panel Installed

CONNECT E-STOP
CONNECT SIGNAL CABLE
CONNECT GROUND
CONTROL PANEL
MOUNTING SCREWS (6)
Section 12
Section 12 Ingenuity CT Gantry Rear Cone Replacement

• Philips standard FSE tool set
• Cable ties
12.2 Removing the Ingenuity CT Gantry Rear Cone
working with the rear cover open or removed.
1. Power down the system according to the procedure “Gantry Power Down (Except for the Host and
2. Remove the rear cover according to the procedure “Ingenuity CT Gantry Rear Cover Removal” on
page 115 and observe the safety precautions listed there.
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Ingenuity CT Gantry Rear Cone Replacement
3 Remove flat head screw securing lexan ring and slide the lexan ring toward the rear of the gantry as
far as it will go (see Figure 12‐1).

REMOVE SCREW SLIDE LEXAN
RING TO REAR
4. Cut the cable ties as required and disconnect the 2 speaker and microphone connectors shown in
Figure 12‐2.
Figure 12-2: Rear Cone Speaker and Microphone Connectors
DISCONNECT
2 CONNECTORS
5. Remove the 2 bottom screws mounting the rear cone as indicated in Figure 12‐3.
6. Remove one of the remaining top cone mounting screws.
7. While supporting the cone, remove the other top cone mounting screw.
Figure 12-3: Rear Cone Fasteners
CONE MOUNTING
SCREWS (4)
12.2.1 Transferring Parts from the Removed Gantry Rear Cone to

the New Rear Cone
1. Remove the speaker and microphone assy (see Figure 12‐4) from the removed cone and install them
onto the new cone.
2. Tie the cables into position on the new cone.
Figure 12-4: Rear Cone Parts
SPEAKER
MICROPHONE
ASSY
12.3 Installing the Ingenuity CT Gantry Rear Cone

1. Raise the cone into position and install the 4 screws to mount the rear cone as indicated in Figure 12‐
5. Make sure cone is positioned to allow the rear cover mounting screws to be installed.
Figure 12-5: Rear Cone Fasteners
CONE MOUNTING
SCREWS (4)
2. Connect the 2 speaker and microphone connectors shown in Figure 12‐6 and tie them in place.
3. Install the rear cover according to the procedure “Ingenuity CT Gantry Rear Cover Installation” on
page 120.
4. Power up the system according to the procedure “System Power Up” on page 34 and verify that it is
operating properly.
Figure 12-6: Rear Cone Speaker and Microphone Connectors
CONNECT
2 CONNECTORS
Section 13
Section 13 Ingenuity CT Side Covers Replacement
13.1 Gantry RH/LH Upper Side Cover Removal
Note: Due to the location of the lower side cover mounting screw, the upper side cover must be removed before
the lower side cover is removed. Before installing the upper side cover, the lower side cover must first be
installed.
The procedure is the same for removing and replacing either the gantry right‐hand or the left‐hand upper
side covers. Each cover hangs on mounting hooks and is held by a single socket head cap screw into a
mounting bracket.
WARNING: Turn off power to the gantry before servicing. Hazardous voltages are inside the gantry side
covers. Failure to do so may result in serious injury or death.
1. Power down the gantry according to the cover being removed:
For removing power inside the LH upper gantry cover perform the procedure “System Shutdown
and Power Down” on page 22.
For removing power inside the RH upper gantry cover, perform either the full system shutdown
procedure “System Shutdown and Power Down” on page 22 or the gantry power down procedure
“Gantry Power Down (Except for the Host and CIRS)” on page 27.
2. From the rear of the gantry, remove the single socket head cap screw securing the RH/LH upper side
cover(s) to the mounting bracket (see Figure 13‐1).
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Ingenuity CT Side Covers Replacement
Figure 13-1: Gantry Upper Side Cover Mounting Screw Location

(RH cover shown ‐ left is similar)
COVER SCREW
3. Lift the cover up and off the mounting hooks on the gantry column (see Figure 13‐2).
Figure 13-2: Lifting Upper Side Cover Up Off Upper Mounting Hooks

13.1.1 Gantry RH/LH Upper Side Cover Installation

1. Ensure the lower side cover has been installed first.
WARNING: Hazardous voltages are inside the gantry side covers. Stay clear of all powered items. Failure
to do so may result in serious injury or death.
Note: Since the gantry power button will be inaccessible once the LH upper cover is installed, the blue power
button must be placed in the active position before the cover is installed.
2. If it is not desired for the gantry to be powered on at this time perform the following:
a) Power down the entire system according to the procedure “System Shutdown and Power Down” on
page 22 and open the site supply breaker.
b) Once the system has been shut down and the site supply breaker opened, activate the blue gantry
power button.
3. Hook the cover onto the mounting hooks on the gantry column (see Figure 13‐3).
!
CAUTION: Use caution when installing cover so as not to depress and deactivate the gantry power
switch during cover installation.
4. If necessary, adjust the position of the cover using the adjustments shown in “Upper Side Cover
Adjustments” on page 140.
5. Secure cover(s) with a single socket head cap screw to the mounting bracket (see Figure 13‐1 on
page 136).
Figure 13-3: Placing the Upper Side Cover On the Upper Mounting Hooks

13.1.2 Upper Side Cover Adjustments

Gantry RH/LH Upper Side Covers can be repositioned by loosening moving the upper mounting hooks
horizontally and/or vertically as shown in Figure 13‐4.
Figure 13-4: Upper Side Cover Mounting Hook Adjustments

(RH column shown ‐ left is similar)
LOOSEN FOR VERTICAL

ADJUSTMENT
LOOSEN FOR HORIZONTAL

ADJUSTMENT
6. The RH/LH upper side cover mounting screw receptacle located on each side of the rear cover can be
repositioned horizontally and/or vertically as shown in Figure 13‐5 on page 141.
Figure 13-5: Upper Side Cover Mounting Adjustments
LOOSEN FOR HORIZONTAL

ADJUSTMENT
LOOSEN FOR VERTICAL

ADJUSTMENT
13.1.3 Gantry RH/LH Lower Side Cover Removal
Note: Due to the location of the lower side cover mounting screw, the upper side cover must be removed before
the lower side cover is removed. Before installing the upper side cover, the lower side cover must first be
installed.
The procedure is the same for removing and replacing either the gantry right‐hand or the left‐hand upper
side covers.
Each cover hangs on mounting hooks and is held by a single socket head cap screw into a mounting
bracket at the top. Clips on the base of the lower side cover attach to magnetic brackets installed at the
base of the column.
WARNING: Hazardous voltages are inside the gantry side covers. Turn off power to the gantry before
servicing. Failure to do so may result in serious injury or death.
1. Power down the gantry according to the cover being removed:
For removing power inside the LH lower gantry cover perform the procedure “System Shutdown and
Power Down” on page 22 and open the site supply breaker.
For removing power inside the RH lower gantry cover, perform either the full system shutdown
procedure “System Shutdown and Power Down” on page 22 or the gantry power down procedure
“Gantry Power Down (Except for the Host and CIRS)” on page 27.
2. Remove the upper side cover according to the procedure “Gantry RH/LH Upper Side Cover
3) When working inside the lower left column cover, be sure to turn off the 120/240 VAC to the room
annunciator (X‐ray) indicator light. Power to this light comes in to TB20 from a separate 120/240 VAC
supply and must be turned off by a site wall shut‐off switch (see Figure 13‐6 for early models and
Figure 13‐7 on page 144 for later models).

(Early Model LH Gantry Pedestal Shown)
ROOM ANNUNCIATOR
TO TB20

(Later Model LH Gantry Pedestal Shown)

ROOM ANNUNCIATOR
TO TB20
3. At the top of the lower side cover, remove the socket head cap screw securing the RH/LH lower side
cover(s) to the column cover mounting bracket (see Figure 13‐8).
4. Lift the cover(s) up and off the gantry column.
Figure 13-8: Gantry Lower Side Cover Screw Location

(LH cover shown ‐ RH is similar)

LOWER SIDE COVER
MOUNTING SCREW
13.1.4 Ingenuity CT Gantry RH/LH Lower Side Cover Installation

1. Place the RH/LH lower side cover(s) on the column cover mounting bracket. Ensure magnetic clips
are engaged at the base of the column.
2. Make adjustments as necessary according to the section “Lower Side Cover Adjustments” on
page 146.
3. Secure cover(s) with a single socket head cap screw to the mounting bracket (see Figure 13‐8).
13.1.5 Lower Side Cover Adjustments

Gantry RH/LH Lower Side Cover adjustments are as follows:
Side-to-Side Adjustment - Bottom of Lower Side Cover

The bottom of the lower side cover can be moved toward or away from the gantry by loosening the
bracket screws shown in Figure 13‐9 and repositioning the brackets.
Figure 13-9: Lower Cover Bracket Adjustments
LOOSEN 4 MOUNTING SCREWS

TO ADJUST POSITION
Front to Back Adjustment - Bottom of Lower Side Cover

The lower cover magnetic brackets can be moved front to back to allow repositioning of the lower side
cover as shown in Figure 13‐10.
Figure 13-10: Gantry Lower Side Cover Magnetic Bracket Adjustments

LOOSEN MOUNTING NUTS
TO ADJUST POSITION FRONT-TO-BACK
Lower Side Cover Upper Adjustments

The top of the lower side cover can be moved toward or away from the gantry by loosening the screws
shown in Figure 13‐11 and moving the upper mounting bracket toward or away from the gantry.
Figure 13-11: Lower Cover Upper Bracket Adjustments
LOOSEN 4 MOUNTING SCREWS

TO ADJUST SIDE-TO-SIDE POSITION
LOOSEN 2 SCREWS
TO ADJUST VERTICAL POSITION
There are lower side cover hooks on the front and back of the side of the gantry shown in Figure 13‐12.
Figure 13-12: Lower Cover Hook Bracket Adjustments
LOOSEN MOUNTING SCREWS

TO ADJUST POSITION
Section 14
Section 14 Gantry Display/Switch Control Board Replacement
The gantry display/switch control board is located on the inside of the gantry front cover.
14.1 Removal
1. Ensure system is powered down. Refer to (see ‘Gantry Power Down (Except for the Host and CIRS)
on page 1‐27) procedure.
2. Open the gantry front cover (see ‘Opening the Ingenuity CT Gantry Front Cover on page 2‐40).
3. Note that the safety interlock door switch (gantry upper left hand corner) prohibits gantry rotation
while it is in the enabled or “cover opened” position.
4. Disconnect data/power cables from display/switch control board. Disconnect ground wires from
board. Refer to Figure 14‐1 on page 151.
5. Remove four screws and washers securing display/switch control board to front cover, and remove
board.
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Gantry Display/Switch Control Board Replacement
14.1.1 Installation
1. Install replacement display/switch control board to front cover, and secure with four screws and
washers.
2. Connect ground wire ring lugs to board and secure with screws. Connect data power cables to
display/switch control board.
3. Program the board according to the applicable Brilliance System JTAG Programming Manual.
4. Close the gantry front cover (see ‘Closing the Ingenuity CT Gantry Front Cover on page 2‐45).
Section 15
Section 15 Front Cover Interlock Switch Replacement
This procedure is used to remove and replace the Gantry Front Cover Interlock Switch.
Tools Required: Philips FSE Standard Tool Kit
Estimated Time: 20 Min.
15.1 Front Cover Interlock Switch Removal
WARNING: Turn Gantry power OFF. Dangerous voltages are exposed when the gantry front cover is
open. Failure to comply can cause serious personnel injury or death.
1. Ensure system is powered down (see System Power Down/Power Up on page 22).
2. Open the Gantry Front Cover (see Opening the Ingenuity CT Gantry Front Cover on page 40).
3. Mark the position of the 2 interlock switch bracket mounting screws and remove them (see Figure 15‐
1).
4. From the back of the switch depress the two latches ‐ one on each end of the switch ‐ and remove the
switch from its bracket.
5. Tag and remove the two wires connected to the Interlock Switch.
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Front Cover Interlock Switch Replacement
Figure 15-1: Interlock Switch Location
MARK POSITION AND

REMOVE
15.2 Front Cover Interlock Switch Installation

1. Using a DVM, check the continuity of the switch on all three positions.
2. Snap the switch into the mounting bracket.
3. Connect the wires to the switch.
4. Mount the switch in the position that was marked before removal.
6. Apply power to the gantry (see System Power Up on page 34).
Section 16
Section 16 Ingenuity CT Gantry Exhaust Fans Replacement
This procedure describes the removal of the gantry exhaust fans, located in the gantry rear top left and
top right corners. The procedure is the same for either fan.
16.1 Removal
1. Remove power from the system Gantry Power Down (Except for the Host and CIRS) on page 27.
WARNING: Hazardous voltages inside. Disconnect power suppLy before servicing. Failure to do so may
result in serious injury or death.
2. Remove the gantry rear cover Ingenuity CT Gantry Rear Cover Removal on page 115.
Note: It’s probably easier to disconnect the wires from the fan after it is removed.
3. Remove 4 nuts and flat washers securing fan and mounting plate assembly to the gantry inside top
panel.
4. Tag and remove fan connectors and ground (see Figure 16‐1).
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Ingenuity CT Gantry Exhaust Fans Replacement
Figure 16-1: Gantry Exhaust Fan Location (RH Fan Shown)
REMOVE 4 FAN MOUNTING NUTS

DISCONNECT WIRES
16.1.1 Installation
1. Connect the wires to the fan (see Figure 16‐1).
2. Position fan to gantry inside top panel and attach it with the 4 nuts.
3. Install the gantry rear cover (see Ingenuity CT Gantry Rear Cover Installation on page 120).
Section 17
Section 17 Intake Air Filters Removal/Replacement
This procedure is used to remove and replace the gantry intake air filters. There are two air filters located
at the bottom front of the gantry. This procedure is applicable for either filter.
Tools Required: Philips Standard FSE Toolkit
Materials Required: Two air filters
17.0.1 Air Filter Removal

2. Open the gantry front cover (see Opening the Ingenuity CT Gantry Front Cover on page 40).
3. Remove the gantry lower front cover (see Removing Ingenuity CT Gantry Lower Front Cover on
page 46).
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Intake Air Filters Removal/Replacement
4. Release the motor brake and rotate the rotor so the FRC is at the bottom to give more access room.
5. Reapply the motor brake.
6. Remove the nut and the screw indicated in Figure 17‐1 on page 157 and remove the service access
cover.
Figure 17-1: Rotor Positioned with FRC at bottom

(left side shown, right side is similar)
Remove screw and nut to remove

service access cover
7. Cut the cable ties as required to allow the filter to be removed as shown in Figure 17‐2.
Figure 17-2: Removing Gantry Air Filter

(LH side shown, RH is similar)
17.0.2 Air Filter Installation

1. Be sure that the air flow arrow points up (^) away from the floor before replacing the Air Filter and
slide the air filter into the fan enclosure (see Figure 17‐2 on page 158).
2. Install the service access cover and attach it with the nut and the screw as indicated in Figure 17‐1 on
page 157.
3. Tie the cable back in place.
4. Install the lower front cover (see Installing the Ingenuity CT Gantry Lower Front Cover on page 47).
Section 18
Section 18 Gantry Intake Fans Removal/Replacement
This procedure is used to remove and replace the gantry intake fans. There are three fans on the right
intake duct and two fans on the left intake duct, located at the lower front of the gantry.
Tools and Materials Required:
• Philips FSE Tool Kit (including Chapman hex driver set, 11/32 in. open‐end wrench)
• Loctite #222)
18.1 Removal
WARNING: Hazardous voltages are inside the gantry front cover. Turn power to the Gantry OFF before
opening the front cover. Failure to do so may result in serious injury or death.
2) Open the gantry front cover (see Opening the Ingenuity CT Gantry Front Cover on page 40).
3. To give room to access the fan, unlock the motor and rotate the rotor CW so the FRC (or the heat
exchanger) is over the fan to be replaced. Lock the motor.
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Gantry Intake Fans Removal/Replacement
4. Disconnect power cable(s) and remove ground cable(s) from fan(s) to be replaced. Refer to Figure 18‐
1 on page 161 and Figure 18‐2 on page 162.
5. Remove 2 SHCS, two flat washers, and 2 hex nuts securing the fan guard from fan(s) to be replaced
and remove the fan guard(s) (see Figure 18‐1 on page 161 or Figure 18‐2 on page 162).
6. Remove 2 SHCS and flat washers securing the fan(s) to be replaced to the intake duct and remove the
fan (see Figure 18‐1 on page 161 or Figure 18‐2 on page 162).
Figure 18-1: LH Intake Fans (2)

FAN MOUNTING SCREWS FAN GUARD SCREWS FAN LABEL MUST FACE UP
(2 EACH FAN)
POWER & GROUND CONNECTORS
Figure 18-2: RH Intake Fans (3)

FAN MOUNTING SCREWS FAN GUARD SCREWS FAN LABEL MUST FACE UP
(2 EACH FAN) (2 EACH FAN)
POWER & GROUND CONNECTORS

(EACH FAN)
18.2 Installation
1. Position replacement fan(s) on intake duct with label up (see Figure 18‐1 on page 161 or Figure 18‐2
on page 162).
3. Apply Loctite #222 to the 2 fan SHCS and install the fan(s) to intake duct with the 2 SHCS with 2 flat
washers per fan. Hand tighten the screws (see Figure 18‐1 on page 161 or Figure 18‐2 on page 162).
4. Apply Loctite #222 to the 2 fan guard SHCS and install the fan guards to fans with 2 the SHCS with 2
flat washers and 2 hex nuts for each fan guard. Hand tighten the screws (see Figure 18‐1 on page 161
or Figure 18‐2 on page 162).
5. Install ground cable(s) and power cable(s) to replacement fan(s) as required. Add cable ties to secure
cables as necessary (see Figure 18‐1 on page 161 or Figure 18‐2 on page 162).
6. Unlock motor brake, remove locking pin, and hand rotate the rotor CW several times to check that no
interferences exist.
WARNING: Hazardous voltages are inside the gantry front cover. Stay clear of powered items. Failure to
do so may result in serious injury or death.
7. Power up the gantry according to the procedure “Gantry Power Up” on page 34.
8. Check that the fans are operating properly.
9. Close the gantry front cover (see Closing the Ingenuity CT Gantry Front Cover on page 45).
Section 19
Section 19 MRC 880 X-ray Tube Assembly Replacement
Time estimate: Three hours for mechanical replacement and three hours for calibrations.
Tools required:
• FE Tool kit
• MRC 880 X‐ray tube lift tool (same as MX8000 Dual v.EXP)
• Strap pad assembly for the X‐ray tube lift tool
Supplies:
• Loctite #242 and #243 (make sure they are not past their expiration dates)
• General purpose cleaning cloth
• 99% Isopropyl alcohol (for service availability, 90% Isopropyl Alcohol can be substituted, do
not use rubbing alcohol)
• Silicon paste (provided with replacement X‐ray tube)
• Anode silicon washer (provided with replacement X‐ray tube)
• Cathode silicon washer (provided with replacement X‐ray tube)
• Cardboard tubes (provided with replacement X‐ray tube)
• MRC Tube Shipping Box (provided with replacement X‐ray tube).
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement MRC 880 X‐ray Tube Assembly Replacement
!
CAUTION: The XRT and the cooling unit must be replaced together as a unit and must not be
separated. The cooling hoses connecting the cooling unit to the XRT must not be
disconnected.
19.1 OTR Tool

The OTR (Online Tube Report) tool captures data and logs that must be included with the returned X‐ray
tube. The OTR tool comes preloaded on a USB memory stick that is attached to the service manual of the
replacement X‐ray tube.
Note: Credit on the returned X‐ray tube will be reduced if the required data is missing or incomplete.
Proceed to the section that applies to the software version installed on the system:
OTR Tool on Systems with McAfee Application Control (Whitelisting) on page 165
OTR Tool on Systems without McAfee Application Control (Whitelisting) on page 168
Other information available includes:
View OTR Tool Data on page 170
Report OTR Tool Issues on page 173
19.1.1 OTR Tool on Systems with McAfee Application Control

(Whitelisting)
1. On the host, log in as Philips Service.
2. Insert the USB media stick containing the OTR tool into the host computer.
3. Copy the D:\DATA_TUBEHISTORY folder to the root of the media containing the OTR tool.
4. Copy the D:\DATA_LOGGER folder to the root of the media containing the OTR tool.
Figure 19-1: Copy Folders
Copy
5. Remove the USB media stick containing the OTR tool from the host computer.
6. Insert the USB media stick containing the OTR tool into the FSE Laptop.
7. Navigate to the USB media stick containing the OTR tool.
8. Locate the folder named DATAPACKER1 and do the following:
a. Within the folder, right click on DATAPACKER.INI and select EDIT.
b. Locate the line beginning with SrcPath=
c. Change any occurrences of the drive letter from D:\ to the drive letter of the media inserted into the
FSE laptop.
For instance, if your drive letter on the FSE laptop is F:\, change:
SrcPath=ʺ1D:\Data_Logger\ʺ,ʺ1D:\Data_TubeHistory\ʺ
to:
SrcPath=ʺ1F:\Data_Logger\ʺ,ʺ1F:\Data_TubeHistory\ʺ
d. Close and save the file.
e. Repeat steps Step a through Step d for the DATAPACKER2, DATAPACKER3, and
DATAPACKER4 folders.
9. Launch the OTR program.
10. Populate all applicable fields.
11. Press START.
The form information is captured and a confirmation appears.
Figure 19-2: Completed
12. Click OK to accept the message.
13. The log files are automatically packed.
The data packer program completes and disappears without user input.
Note: Data packing can take as long as 10 minutes, depending on the amount of data.
Figure 19-3: Data Packer
14. Click CLOSE on the OTR tool.
15. Verify that a .ZIP file containing the collected logs has been created by the tool in the root drive of the
USB media stick containing the OTR tool.
Figure 19-4: ZIP File
16. Stow the USB media stick along with the X‐ray tube that is being returned.
17. OTR data capture is now complete.
19.1.2 OTR Tool on Systems without McAfee Application Control

(Whitelisting)
5. Press START.
19.1.3 View OTR Tool Data

All information of the X‐ray tube assembly form and the generator data are stored on the memory stick as
a database file *.mdb named with the serial number of the X‐ray tube assembly and the date of the former
installation.
The *.mdb files stored on the memory stick can be viewed by using the MDB Viewer.
To view the tube data file:
1. On the host, log in as philips_service.
2. Plug the memory stick into a USB port on the front of the host.
3. Open windows Explorer by right‐clicking on the Windows Start button and left‐clicking on Explore
in the drop‐down menu.
4. Select the memory stick Removable Disk folder in the left (Folder) pane of the Explorer Window.
5. Double left‐click on Start OTR.exe in the right pane of the Explorer window.
The dialog box shown in Figure 19‐8 on page 171 will be displayed.
6. Click on the MDB‐Viewer button. The MDB viewer shown in Figure 19‐9 on page 172 should be
displayed.
Figure 19-8: System Type Selection Dialog Box
7. The OTR_Data folder should be automatically selected. Select the desired *.mdb data file (the file
name is the serial number of the X‐ray tube assembly and the date of the former installation.
Figure 19-9: X‐ray Tube MDB Data File Viewer

19.1.4 Report OTR Tool Issues

If faults occur when trying to store tube data on the memory stick, send an e‐mail to:
ms.de.tubes.datalog@philips.com
Include the following information:
1. Common data
• Your name
• Your SSD and country
• Description of the problem
2. Data concerning the replacement of the X‐ray tube assembly
• Customer
• System description
• Generator type
• Type of defective X‐ray tube assembly
• Serial number of defective X‐ray tube assembly
• Failure description
• Installation date
• De‐installation date
19.2 X-ray Tube Removal

1. At console screen, select Service Tools > General Tools > Tube History. Record the exposure count.
2. Place the patient support subframe into the service position and open the gantry front cover
according to the procedure “Opening the Ingenuity CT Gantry Front Cover” on page 40.
!
WARNING: Make sure to insert the front cover hinge locking pins to prevent the cover from falling
anytime it is open. Failure of a front cover support gas spring may allow the front cover to
fall quickly and cause injury to personnel.
3. Place the patient support lower telescoping covers into the service position according to the Ingenuity
CT Patient Support Repair and Replacement Manual.
Note: It is necessary to place the patient support lower covers into the service position so that the upper
vertical limit switches will be visible. This will make it possible to avoid damaging the limit switches by
raising the support too high.
4. Remove gantry LH upper side cover “Gantry RH/LH Upper Side Cover Removal” on page 135.
5. Turn the gantry power OFF by momentarily pressing the gantry power (blue) button on the side of
the gantry switch panel as shown in Figure 19‐10.

BLUE BUTTON
6. Remove power from the rotor by opening rotor power fuse F303. Refer to Figure 19‐11.
7. Open the slip ring 480 VAC fuses F351, F352, and F353. Refer to Figure 19‐11.
8. Open the main drive fuses F357, F358, and F359. Refer to Figure 19‐11.
9. Place the Mode key switch into the “SERV” position. Refer to Figure 19‐11.
WARNING: Avoid contact with live connections while servicing. Hazardous voltages are still present in
the gantry support. Contact with hazardous voltages may result in serious injury or death.
Figure 19-11: Location of Fuses and Keyswitch
SLIP RING FUSES MAIN DRIVE FUSES

F351, F352, F353 F357, F358, F359
MODE KEYSWITCH
ROTOR POWER
FUSE F303
10. Release the main drive motor brake by turning the release knob CW (Figure 19‐12 on page 177).
Figure 19-12: .Main Drive Motor Brake Release Knob

RELEASE
APPLY
11. Rotate the rotor CW so the FRC is in the 6 o’clock position (Figure 19‐13 on page 178).
Figure 19-13: FRC at 6 O’clock Position
FRC AT 6 O’CLOCK
POSITION
12. Apply the main drive motor brake by turning the release knob CCW (Figure 19‐12 on page 177).

13. Mark the position of the 2 lower front cover mounting screws and remove them (see Figure 19‐14).
Figure 19-14: Lower Cover Mounting
MARK POSITION &

REMOVE 2 SCREWS
14. Release the main drive motor brake by turning the release knob CW (see Figure 19‐12 on page 177).

15. Rotate the rotor CW so the X‐ray tube is in the 12 o’clock position.
16. With the X‐ray tube at the 12 o’clock position, insert the rotor locking pin as shown in Figure 19‐15 on
page 180.
Figure 19-15: Rotor Pinned in 12 o’clock Position (Gantry Front Lower Right)
!
WARNING: Do not touch the XRT housing until you make sure that it is not hot enough to cause burns.
To ensure the housing has cooled, leave the system at rest for least 1 hour with cooling
system running prior to tube removal.
17. Refer to Figure 19‐16 on page 181 for the location of the Z and X adjustment assemblies to be removed
next.
Figure 19-16: Location of Z and X Adjustment Assemblies
Z-ADJUSTMENT X-ADJUSTMENT
18. Refer to Figure 19‐17 on page 182 and remove the Z‐adjustment:

• The Z‐adjustment straddle plate (2 bolts, 3/16” hex key) and
• The Z‐adjustment static block (2 bolts, 5/32” hex key),
• The Z‐adjustment baseplate (2 bolts, 3/16” hex key).
Make sure not to turn the Zadjustment screw.
Figure 19-17: Z‐Adjustment Assembly Details
Z-ADJUSTMENT Z-ADJUSTMENT Z-ADJUSTMENT SCREW Z-ADJUSTMENT

STRADDLE PLATE STATIC BLOCK (do not turn) BASEPLATE
19. Disconnect the overflow line quick‐disconnect (see Figure 19‐18 on page 183).

20. Remove the velcro straps and pull the overflow out of the tube holes, out to the front of the rotor.
Figure 19-18: Overflow Line and Anode HV Connector
REMOVE VELCRO STRAPS AND OVERFLOW LINE

PULL HOSE OUT OF TUBE HOLES QUICK-DISCONNECT
21. Tie the overflow line so it will not be damaged or become entangled when the rotor is rotated (see
Figure 19‐19).
Figure 19-19: Tie Overflow Line
TIE OVERFLOW LINE
22. Refer to Figure 19‐20 on page 185 and remove the X‐adjustment:

• The X‐adjustment straddle plate (2 bolts, 3/16” hex key) and
• The X‐adjustment static block (2 bolts, 5/32” hex key),
• The X‐adjustment baseplate (2 bolts, 3/16” hex key).
• Make sure not to turn the Xadjustment screw.
Figure 19-20: X‐Adjustment Assembly Details
X-ADJUSTMENT X-ADJUSTMENT X-ADJUSTMENT SCREW X-ADJUSTMENT

BASEPLATE STATIC BLOCK (do not turn) STRADDLE PLATE
23. Unscrew the anode HV connector retaining ring and pull out the connector (see Figure 19‐21 on

page 186).
24. Place a protective cover on the connector to keep it clean (see Figure 19‐22 on page 187).
25. Secure the connector to keep it from being damages when the rotor is rotated (see Figure 19‐22 on
page 187).
26. Disconnect the FRC cables that go to the XRT (see Figure 19‐21 on page 186)
Figure 19-21: Anode HV Connector and FRC Connectors

.
DISCONNECT ANODE DISCONNECT FRC
HV CABLE CONNECTORS
Figure 19-22: Anode HV Connector Covered and Tied
TIE ANODE HV CABLE COVER ON

CONNECTOR
27. Unscrew the retaining screws and remove the anode HV and power module cable clamps (see
Figure 19‐23).
Leave the cables in place for now.
Figure 19-23: Anode HV and Power Module Cable Clamps

REMOVE CABLE CLAMPS
28. Remove 6 of the 8 heat exchanger attaching nuts, leaving one in the back on the left and one on the
front on the right as shown in Figure 19‐24 on page 189.
Note: The right rear nuts will be hard to get to when the rotor is rotated to put the XRT at the bottom.
Figure 19-24: Heat Exchanger Attaching Nuts
LEAVE
REAR NUT REMOVE 3 REAR
NUTS
REMOVE 3
FRONT NUTS
LEAVE FRONT NUT
29. Unscrew the retaining screw and remove the left cathode HV cable clamp on the front of the FRC (see
Figure 19‐25).
30. Unscrew the retaining ring and disconnect the cathode HV cable from the XRT (see Figure 19‐25).
Figure 19-25: Cathode HV Cable
DISCONNECT HV CABLE
REMOVE HV CABLE CLAMP
31. Put a protective cover over the cathode HV connector to keep it clean (see Figure 19‐26).
32. Secure the cable to the rotor so it will not be damaged when the rotor is turned (see Figure 19‐26).

SECURE HV CABLE
COVER CONNECTOR
33. Refer to Figure 19‐27 on page 192. Using a 3/4” socket, “break” the torque on the right rear bolt

securing the X‐ray tube to the gantry rotor. Leave the bolt snugly installed.
Figure 19-27: Right Rear X‐ray Tube Mounting Bolt

LOOSEN RH REAR
XRT MOUNTING BOLT
34. Refer to Figure 19‐28. Using a 3/4” socket, remove the left rear bolt securing the X‐ray tube to the

gantry rotor.
Figure 19-28: Left Rear X‐ray Tube Mounting Bolt

REMOVE LH REAR
XRT MOUNTING BOLT
35. Make sure all loose cables and hoses are secured enough to hand‐rotate the rotor safely.
36. Release the motor brake (Figure 19‐12 on page 177) and remove the rotor locking pin (Figure 19‐15 on page 180).
37. Slowly rotate the rotor CW so the anode power module (APM) is at the 10 o’clock position (see Figure 19‐29). I
38. Apply the motor brake (Figure 19‐12 on page 177).
Figure 19-29: Rotor Anode Module at the 10 o’clock Position (Gantry Front Upper Left)
APM AT 10 O’CLOCK
39. Remove the fuse covers from the anode power module fuses (see Figure 19‐30).

40. Cut the cable ties securing the 3 white power cables (see Figure 19‐30) and disconnect them (the
cables are not specific to any terminal).
41. Disconnect the HSS signal cable at HSS connector JB4 (blue plug) (see Figure 19‐30).
Figure 19-30: Anode Power Module Connections
CUT CABLE TIES AND

DISCONNECT 3 CABLES
DISCONNECT HSS
SIGNAL CABLE
42. Refer to Figure 19‐31 on page 196 and disconnect the red‐colored XRT power cable at the side of the

anode module.
Leave the black cable connected and in place.
43. Cut the cable ties as necessary to free the red cable from the anode module.
Figure 19-31: Anode Power Module (APM) Cable
SQUEEZE LATCH TO RELEASE RED

WIRE & DISCONNECT
44. Remove the cable bracket and cut the cable ties as required to free the red APM power cable and the
HSS, signal cable from the bracket. Leave the bracket attached to the other cables (see Figure 19‐32).
45. Cut the cable ties along the rotor to free the red APM red power and HSS signal cable (see Figure 19‐
32).
46. Pull the APM red power cable and HSS signal cable through the rotor frame hole (see Figure 19‐32).
Figure 19-32: Anode Power Module Cable Routing

PULL CABLES UP
OUT OF ROTOR HOLE
CUT CABLE TIES

AS REQUIRED
TO FREE CABLES
REMOVE BRACKET
47. Secure the cables in place so they will not be damaged when the rotor is rotated.(see Figure 19‐33 on

page 198).
Figure 19-33: APM Cables Secured

APM CABLES SECURED
48. Ensure all loose cables and hoses are secured enough to hand rotate the rotor safely.
49. Release the motor brake (Figure 19‐12 on page 177).

50. Slowly rotate the rotor CW so the X‐ray tube is at the 6 o’clock position. Insert the rotor locking pin as
shown in Figure 19‐34 on page 199 and apply the motor brake.
!
WARNING: Make sure to install the rotor locking pin before removing the X-ray tube. The motor brake
will not hold the rotor in position with the x-ray tube removed. Failure to pin the rotor will
allow the rotor to rotate quickly and cause personnel injury or death.
Figure 19-34: Rotor Pinned with XRT in 6 o’clock Position (Gantry Front Upper Left)
51 Remove flat head screw securing lexan ring and slide the lexan ring toward the rear of the gantry as
far as it will go (see Figure 19‐35).
REMOVE SCREW SLIDE LEXAN

RING TO REAR
52. Turn the gantry power ON by momentarily pressing the gantry power (blue) button on the side of the
gantry switch panel (see Figure 19‐10 on page 175).
53. Turn ON the patient support service switch. (The service switch is a rocker switch right next to the
UP/DOWN service push buttons. The UP/DOWN service push buttons will light when the patient
support is in the Service Mode and the service switch is on.
54. Using the patient support service controls, position the top high enough for installing the lifting tool.
55. Slide the X‐ray tube lifting tool onto the patient support as shown in Figure 19‐36 on page 201 and
position it so that the strap pad is even with the end of the top all the way across.
Make sure the support subframe is all the way toward the foot end.
56. Mount the lifting tool to the lower strap pad holes (see Figure 19‐36).
Figure 19-36: Lift Tool On Table

STRAP PAD EVEN
WITH END OF TOP
SUB FRAME TO
FOOT END
MOUNT LIFT
TO LOWER HOLES
57. Unscrew the set screws in the lift rods until they protrude about 1/4 in. (6 mm) (see Figure 19‐37).
Figure 19-37: X‐ray Tube Lifting Tool Installation Into X‐ray Tube
ADJUST SET SCREWS TO

PROTRUDE ABOUT 1/4 IN. (6 mm)
58. Move the support top toward the gantry so that the tube lifting tool rods slide into the tube cradle
holes until the set screws in the lift rods are up against the rotor. Refer to Figure 19‐38 on page 203.
INSERT RODS SO SET SCREWS

ARE AGAINST THE XRT
59. Place the piece of bubble‐wrap included with the XRT (or another a suitable padding material) into
the bottom of the gantry for the heat exchanger to rest on(see Figure 19‐39).
60. Remove the remaining 2 nuts holding the heat exchanger in place and lower the heat exchanger onto
the padding (see Figure 19‐39).
Figure 19-39: Removing Heat Exchanger
BUBBLE WRAP
61. Raise the table slightly so that it is attempting to lift the tube assembly.
62. Remove the remaining rear XRT mounting bolt (3/4” socket) (see Figure 19‐40).
Figure 19-40: Removing Remaining XRT Rear Mounting Bolt
REMOVE REMAINING XRT REAR

MOUNTING BOLT
!
WARNING: Make sure to install the rotor locking pin before removing the X-ray tube (see Figure 19-34
on page 199). The motor brake will not hold the rotor in position with the X-ray tube
removed. Failure to pin the rotor will allow the rotor to rotate quickly and cause personnel
injury or death.
63. Remove the 2 front bolts (3/4” socket) securing the X‐ray tube cradle to the rotor (see Figure 19‐41).
You will notice the weight of the tube being transferred to the lifting tool. Adjust the patient support
height to compensate.
Figure 19-41: XRT Front Mounting Bolts
REMOVE 2 XRT FRONT

MOUNTING BOLTS
64. Using the support service control buttons lower the XRT just enough so that it clears the rotor.
Be careful not to lower the lift so that it strikes the collimator reference detector (Figure 19‐42).
Figure 19-42: Make Sure Lift Does Not Contact Reference Detector
MAKE SURE LIFT DOES NOT

CONTACT REFERENCE DETECTOR
65. Use the patient support service buttons to move the XRT low enough to clear the tube shelf stiffener
bolt heads (see Figure 19‐43).
Figure 19-43: XRT Must Clear Tube Shelf Stiffener Bolts
TUBE SHELF
STIFFENER BOLTS
66. While supporting the heat exchanger and making sure the cables do not become snagged, move the
XRT out of the gantry (see Figure 19‐44).
Figure 19-44: Removing the XRT
67. Place the piece of bubble‐wrap included with the XRT on top of the XRT to prevent damage to the
heat exchanger (see Figure 19‐45).
68. Place the heat exchanger on top of the XRT (see Figure 19‐45).
Figure 19-45: Heat Exchanger on X‐ray Tube
HEAT EXCHANGER ON
BUBBLE WRAP
69. Unlatch the top from the new XRT shipping box and get out the molded foam section that has the
velcro straps.
70. Raise the support top as required and place the foam block under the XRT and align it with the tube
(see Figure 19‐46).
71. Lower the XRT into the formed cavity in the foam (see Figure 19‐46).
Figure 19-46: XRT Tube Lowered into Foam
72. Move the heat exchanger from the top of the XRT into the foam cavity (see Figure 19‐47).
Figure 19-47: Heat Exchanger Into Foam Cavity
73. Strap the foam to the XRT using the velcro straps attached to the foam (see Figure 19‐48).
Figure 19-48: Foam Strapped to XRT
VELCRO STRAPS
74. Place the bubble‐wrap on top of the XRT and place the heat exchanger on the bubble‐wrap (see
Figure 19‐49).
Figure 19-49: Heat Exchanger Placed on XRT
75. Press the release latch, slide the shipping box caster out of it’s channel, and remove it (see Figure 19‐

50).
76. Remove each of the 2 feet by pressing its release latch and sliding the foot out of it’s channels (see
Figure 19‐50).
Figure 19-50: XRT Shipping Box Caster and Feet

TO REMOVE CASTER AND FEET
PRESS LATCH AND PULL UP
77. Place the plywood board with foam on one side into the shipping box top as shown in Figure 19‐51 on

page 216.
Figure 19-51: Shipping Box with Board
FEET AND CASTER SHOULD BE OFF
!
CAUTION: Do not drive the table into the limit switches. All patient support travel limits are disabled in
service mode. Driving the table too far will cause damage.
78. Lift the XRT in the foam block by raising the patient support until the switch actuator just touches the
upper vertical limit switch Figure 19‐52.
Figure 19-52: Patient Support Upper Limit Switches
ACTUATORS JUST CONTACT

VERTICAL LIMIT SWITCHES
79. Move the shipping box top with the board inside over the footswitch under the foam (see Figure 19‐

53).
80. Lift the end of the shipping box and slide the caster that was removed into its track until it latches (see
Figure 19‐53).
Figure 19-53: Shipping Box Under Foam
PLACE CASTER
UNDER BOX
81. Lower the patient support enough so that the XRT is resting on the box (see Figure 19‐54).

82. Move the heat exchanger from the top of the XRT and insert it into the cavity in the foam block (see
Figure 19‐54).
83. Lower the patient support enough so that the lift strap pad can be removed over the end of the
support top. Rest the strap on top of the XRT (see Figure 19‐54).
Figure 19-54: XRT, Lifting Tool and Shipping Box Ready for Removal
84. Screw the setscrews into the lift rods enough so that they will go through the holes in the XRT cradle
and slide the lifting rods into the tube cradle as far as they will go (see Figure 19‐55).
85. Move the support subframe all the way to the foot end.
Figure 19-55: XRT, Lifting Tool Fully Inserted into XRT Cradle

RODS INSERTED SO THE LIFT BAR IS
NEAR THE XRT CRADLE
!
CAUTION: Make sure not to tilt the shipping box so much that the XRT slides off the box.
86. Slide the handle out on shipping box, lift the right side of the shipping box up and over the
footswitch. Wheel the shipping box with the XRT on it out from between the support and the gantry
to a convenient location.
87. Remove the lifting tool from the XRT.
19.3 X-ray Tube Installation

1. With the new X‐ray tube still in the shipping box, remove the port protective cover.
2. Using the box’s handle lift the end of the box and remove the 2 feet (see Figure 19‐50 on page 215).
Leave the caster mounted to the box.
3. Install the X‐ray tube lifting tool rods into the holes in the new tube cradle. Slide the lifting rods as far
as they will go into the tube cradle holes so that the lifting rod bar is close to the tube cradle (see
Figure 19‐56).
Figure 19-56: Lifting Tool Installed in XRT for Installation
LIFT BAR
NEAR CRADLE
LIFT INSTALLED ON XRT
4. Being careful not to damage footswitch, position the XRT shipping box containing new XRT over
patient support footswitch as shown in Figure 19‐57 on page 223.
5. Adjust the patient support height so the lifting tool strap pad can be installed on the end of the patient
support top (see Figure 19‐57).
6. Move the lifting tool toward the patient support and install the 2 setscrews in the lift rods (see
Figure 19‐37 on page 202).
7. Push the lift into the XRT cradle until the setscrews are against the cradle (see Figure 19‐57).
8. Adjust the strap pad so that it is even with the end of the support top all the way across (see
Figure 19‐57).
Figure 19-57: Placement of X‐ray Tube in Shipping Box over Patient Support Footswitch
STRAP PAD EVEN WITH

END OF TOP
SET SCREWS IN RODS

AGAINST XRT CRADLE
9. Place the bubble‐wrap on top of the XRT and place the heat exchanger on the bubble‐wrap (see
Figure 19‐58).
Figure 19-58: Heat Exchanger Placed on XRT
REMOVE CASTER
!
CAUTION: Do not drive the table into the limit switches. All patient support travel limits are disabled in
service mode. Driving the table too far will cause damage.
10. Once the lift is installed onto the patient support, raise the patient support until the actuator just
touches the upper vertical limit switch (see Figure 19‐52 on page 217).
11. Remove the shipping box caster (see Figure 19‐58 on page 224).
12. Move the shipping box out from under the XRT foam container.
13. Lift the heat exchanger as required and release the velcro straps holding the foam to the XRT.
14. Remove the foam out from under the XRT.
15. Move the patient support top down and forward as required to position tube into gantry while
guiding the heat exchanger into position (see Figure 19‐59).
Figure 19-59: Installing the XRT
16. Raise the support top and position the XRT as necessary so that the XRT mounting holes align with
the mounting holes in the rotor and so that the tube is up against the rotor (see Figure 19‐60).
Figure 19-60: XRT Installed
17. Install the two front XRT mounting bolts (3/4” socket) with flatwashers (see Figure 19‐61).
INSTALL 2 XRT FRONT

MOUNTING BOLTS
18. Install the rear XRT mounting bolt (now on the left rear) (3/4” socket) with a flatwasher (see Figure 19‐

62).
Note: The other rear bolt will be installed later when it can be more easily accessed.
20. Snugly tighten all 3 tube mounting bolts. These bolts may need to be loosened later for X‐ray tube
mechanical alignment, but after alignment these bolts will need to have Loctite #242 applied and
torqued to 56 ft‐lb (75 Nm).
Figure 19-62: Installing XRT Rear Mounting Bolt
INSTALL XRT REAR MOUNTING

BOLT
21. Lower the patient support to take tension off the lifting tool and back the lifting tool away from the
gantry.
22. Remove lifting tool from patient support top and place it aside.
the gantry switch panel (see Figure 19‐10 on page 175).
24. Temporarily attach the heat exchanger with 2 nuts on one side and one on the other as shown in
Figure 19‐63 on page 229. Final installation of the heat exchanger will be done when it is in a more
convenient position on top.
INSTALL INSTALL 2 NUTS

FRONT NUT
25. Remove the rotor locking pin and release the motor brake.
26. While watching and holding cables to make sure none are damaged, rotate the gantry rotor CW so the
XRT is at the 12 o’clock position.
27. Install the rotor locking pin and apply the motor brake (see Figure 19‐15 on page 180).
28. Remove the nuts holding the heat exchanger in place and install the 2 reinforcement bars so that the
side of the bars with greater distance to the holes is toward the heat exchanger (see Figure 19‐64).
30. Apply Loctite #222 to all of the heat exchanger mounting studs, install the 8, 10‐32 hex flange nuts,
and torque them to 15 in‐lb (1.7 Nm).
INSTALL 4 NUTS
INSTALL 4 NUTS
INSTALL BAR
INSTALL BAR
31. Refer to Figure 19‐65 on page 231. Using a 3/4” socket, install the left rear bolt securing the X‐ray tube

to the gantry rotor with a thick washer. Leave the bolt loose enough to allow the XRT to move on the
rotor shelf.
32. Check that all 4 XRT mounting bolts are loose enough to allow the XRT to move.
33. Push the XRT as far toward the rear as it will go.
Cable Tie “A” will come pre-installed
Cable Tie “B” must be installed

during XRT replacement.
Install left-hand rear XRT

Mounting Bolt.
!
CAUTION: Damage to the cooling hose can occur if both cable ties are not properly installed.
34. Cable tie “A” will come pre‐installed on the x‐ray tube (Figure 19‐65).

35. Cable tie “B” will be provided as an accessory to the x‐ray tube kit (Figure 19‐65) and must be
installed as follows:
a. Use the provided cable tie (TY‐527MXR, 6.9mmx340mm, black) to secure the cooling hose to the
cable clamp, as shown in Figure 19‐66 and Figure 19‐67.
Figure 19-66: Securing the Cooling Hose
Figure 19-67: Securing the Cooling Hose
b. Trim the cable tie excess length. as shown in Figure 19‐68.
Figure 19-68: Trim Excess

19.3.1 X-ray Tube Adjustment

2. Refer to Figure 19‐69 on page 235. Install flatwashers and lockwashers onto to the 2, Z‐adjustment
baseplate SHCS and apply Loctite #242. Using a 3/16” hex key loosely install the 2, Z‐adjustment
baseplate SHCS with flatwashers, and lockwashers. Leave these loose until the other adjuster parts
are installed.
Figure 19-69: Z‐adjustment Baseplate Installation
Z-ADJUSTMENT PLATE SCREWS

TORQUE TO 10.5 ft-lb (14.2 Nm)
Z-ADJUSTMENT BASEPLATE
4. Refer to Figure 19‐70 on page 236. Apply Loctite #222 to the 2‐SHCS. Using a 5/32” hex key loosely

install the Z‐static adjustment block with 2 SHCS. Leave these loose until the other adjuster parts are
installed.
Figure 19-70: Z‐Adjustment Block Installation
Z-ADJUSTMENT BLOCK SCREWS

#10-32 X 1" SHCS - unexpired LOCTITE #222
TORQUE TO 15 in-lb (1.7 Nm)
5. Install the Z‐adjustment straddle plate with the side with the raised bosses down (see Figure 19‐71) so
that the head of the adjusting screw fits into the adjustment block and so that the raised bosses on the
underside of the straddle plate drop into the opening in the baseplate (see Figure 19‐72 on page 238).
If necessary, move the tube so that the X‐Adjustment block can be installed without turning the
adjustment screw.
Figure 19-71: Raised Bosses on Bottom of Z‐adjustment Straddle Plate
RAISED BOSSES ON BOTTOM OF

Z-ADJUSTMENT STRADDLE PLATE
7. Refer to Figure 19‐72 on page 238. Install lockwashers and flatwashers onto the 2, Z‐adjustment
straddle plates screws and apply Loctite #242. Using a 3/16” hex key loosely install the Z‐adjustment
straddle plate with 2 the 2 SHCS with lockwashers and flatwashers.
8. Torque the Z‐adjustment baseplate screws to 10.5 ft‐lb (14.2 Nm) (see Figure 19‐72).
9. Torque the Z‐adjustment block screws to 15 in‐lb (1.7 Nm) (see Figure 19‐70 on page 236).
10. Torque the Z‐adjustment straddle plates screws to 10.5 ft‐lb (14.2 Nm) (see Figure 19‐72). Tightening
the screws should pull the XRT up against the straddle plate.
Figure 19-72: Z‐adjustment Straddle Block Installation
Z-ADJUSTMENT BASEPLATE SCREWS

TORQUE TO 10.5 ft‐lb (14.2 Nm)
Z-ADJUSTMENT Z-ADJUSTMENT STRADDLE PLATE SCREWS

STRADDLE PLATE LOCTITE #242
11. Push the XRT as far to the left as it will go.
13. Refer to Figure 19‐73. Install flatwashers and lockwashers onto to the 2, X‐adjustment baseplate SHCS
and apply Loctite #242. Using a 3/16” hex key loosely install the 2, X‐adjustment baseplate SHCS with
flatwashers, and lockwashers. Leave these loose until the other adjuster parts are installed.
Figure 19-73: X‐adjustment Assembly Details
X-ADJUSTMENT BASEPLATE SHCS

X-ADJUSTMENT TORQUE TO 10.5 ft-lb (14.2 Nm)
BASEPLATE
15. Refer to Figure 19‐74 on page 240. Apply Loctite #222 to the X‐static adjustment block SHCS and
using a 5/32” hex key loosely install the X‐static adjustment block with 2 SHCS, flatwashers, and
lockwashers. Leave these loose until the other adjuster parts are installed.
X-ADJUSTMENT X-ADJUSTMENT BLOCK SHCS

BLOCK TORQUE TO 15 in-lb (1.7 Nm)
16. Install the X‐adjustment straddle plate so that the head of the adjusting screw fits into the adjustment
block and so that the raised bosses on the underside of the straddle plate drop into the opening in the
baseplate (see Figure 19‐75). If necessary, move the tube so that the X‐Adjustment block can be
installed without turning the adjustment screw (see Figure 19‐75).
18. Install lockwashers and flatwashers onto the 2, X‐adjustment straddle plate SHCS and apply Loctite
#242. Using a 3/16” hex key loosely install the 2 SHCS and flatwashers (see Figure 19‐75).
19. When all the adjuster parts are installed, torque the baseplate screws as indicated in Figure 19‐73 on
page 239.
20. Torque the adjusting block screws as indicated in Figure 19‐74 on page 240.
21. Torque the straddle plate screws as indicated in Figure 19‐75 on page 241.
22. Torque all 4 XRT mounting bolts to 56 ft‐lb (75 Nm).
Note: The XRT mounting bolts may need to be loosened later for X‐ray tube mechanical alignment, but after
alignment these bolts will need to have unexpired Loctite #242 applied and torqued to 56 ft‐lb (75 Nm).
Figure 19-75: X‐Adjustment Straddle Block Installation

X-ADJUSTMENT X-ADJUSTMENT STRADDLE PLATE SCREWS
STRADDLE PLATE TORQUE TO 10.5 ft-lb (14.2 Nm)
19.3.2 Connecting the X-ray Tube

1. Route the overflow tube through the holes in the XRT cradle as shown in Figure 19‐76 and connect it
to the overflow tank.
2. Connect the FRC cables and tie the connectors together as shown in Figure 19‐76.
Figure 19-76: Overflow Line Routing and FRC Connections

ROUTE & CONNECT CONNECT FRC CABLE
OVERFLOW LINE
3. Install the cathode HV connector into the X‐ray tube as follows:
a. Clean the HV connector with isopropyl alcohol and cleaning cloth. Do not touch the connector
pins.
b. Using silicon paste, put a small bead of paste in the center of the plug between the connector pins
as shown in Figure 19‐77 on page 243.
c. Install the new silicon washer over the pins of the plug. The connector pins must be free from
silicon paste.
d. Put a second small bead of paste in the center of the new silicon washer between the connector pins
e. Do not grease the sides of the connector plug.
Figure 19-77: Applying Grease to HV Connector
SMALL BEAD OF GREASE SILICON WASHER SMALL BEAD OF GREASE
4. Position the cathode HV cable and plug the HV connector into the tube (see Figure 19‐78). Tighten the
retaining ring.
5. Route the HV cable and clamp it in place as shown in Figure 19‐78 on page 244.
Figure 19-78: Cathode HV Cable Routing
INSTALL INSTALL
HV CONNECTOR CABLE CLAMP
6. Route the anode HV cable from the anode power module around the rear of the XRT as shown in
Figure 19‐79 on page 245.
7. Prepare and Install the anode HV cable connector into the XRT according to Step 3 on page 243.
8. Tie the overflow hose in place with the velcro straps as shown in Figure 19‐79 on page 245.
CONNECT ANODE HV
CABLE
TIE OVERFLOW LINE
9. Route the cables to the anode power module (APM) as shown in Figure 19‐80 on page 246.

10. Attach the cable bracket as shown in Figure 19‐80 on page 246. Leave the cables lose until they are
connected before tying them in place.
Figure 19-80: Typical Routing of Anode Power Module (APM) and High Speed Starter (HSS) Cables
ROUTE APM CABLES APM CABLES

ATTACH CABLE BRACKET
THROUGH ROTOR HOLE
11. Connect the HSS starter cable with the blue connector to the HSS as shown in Figure 19‐81 on

page 247.
12. Route the red APM cable under the white power cables to the side of the APM as shown in Figure 19‐
81 on page 247.
13. Unpin the rotor and release the motor brake.
14. Rotate the rotor until the anode power module is at the 10 o’clock position.
15. Apply the motor brake.
ROUTE APM
CABLES
CONNECT CABLE
TO HSS
16. Connect XRT power (red colored cable) and signal cable to the connectors at the side of the anode
generator as shown in Figure 19‐82 on page 248. Tie the cables in place.
Figure 19-82: Anode Power Module Cables
CONNECTCABLE
TIE CABLES
17. Connect the 3 white power cables (see Figure 19‐83 on page 249) and tie them in place. The white

cables are not specific to any of the 3 terminals.
18. Install the fuse covers onto the anode power module fuses.
Figure 19-83: Anode Power Module Power Cable Connections
CONNECT
POWER CABLES
TIE CABLES
19. Clamp the anode HV cable and APM cables in place as shown in Figure 19‐84 on page 250.
Figure 19-84: Anode HV Cable and APM Cable Routing
INSTALL HV CABLE CLAMPS
20. Tie the APM cables in place as shown in Figure 19‐85 on page 251.
Figure 19-85: APM Cable Routing
TIE CABLES
19.3.3 Restoring the System to Operation

1. Release the main drive motor brake.
2. Rotate the rotor clockwise by hand one complete rotation and check for loose cables, connections,
parts, etc.
3 Slide the lexan ring back into position and install the screw (see Figure 19‐35).
4. Reinstall the lower front cover as follows:
a. Rotate the gantry rotor CW so the FRC is in the 6 o’clock position (see Figure 19‐13 on page 178).
b. Apply the main drive motor brake.
c. Place the lower front cover into position on the gantry according to the marks made when it was
removed.
d. Attach the lower front cover with 2, 1/4” ‐ 20 socket head cap screws (see Figure 19‐14 on page 179).
e. Turn on gantry power.
f. Lower the patient support.
g. Grasp the side of the front cover and temporarily close the cover to check the alignment. You may
have to readjust the lower front cover to ensure proper alignment with the front cover.
5. Take the patient support lower telescoping covers out of the service position according to the
Ingenuity CT Patient Support Repair and Replacement Manual.
6. Raise the patient support to access the top sub‐frame quick‐release.
7. To re‐engage the patient support quick release, see “Engaging the Patient Support Subframe Quick
Release” on page 819.
8. To test the quick release after re‐engagement, see “Testing the Patient Support Subframe Quick
9. Switch the patient support service switch (next to the Up/Down service buttons) to the normal
position. The Up and Down button lights should extinguish.
10. Place the gantry service key switch into the “NORM” position.
11. Close the slip ring 480 VAC fuses (F351, F352, and F353).
12. close the main drive fuses (F357, F358, and F359).
13. Close the rotor power fuse F303.
The front cover will need to be open for balancing and X‐ray tube alignment.
14. Perform rotor balancing according to the Ingenuity CT Calibration Manual.
15. Refer to the Ingenuity CT Calibration Manual and run Automatic / Selective Calibration using the
automatic mode and the reason: Tube Replacement.
!
CAUTION: When the X-ray tube Z-mechanical calibration and X-mechanical calibrations have been
completed, make sure that the four x-ray tube mounting bolts in the tube cradle bracket
have been coated with unexpired loctite #242 and torqued to 56 ft-lb (75 Nm).
16. Verify Performance Results. Refer to the appropriate Ingenuity CT System Performance manual.
17. Perform backup of the system CPM’s NVRAM according to the applicable system software
installation manual.
18. Backup the Site Configuration according to the applicable system software installation manual.
19. Install the gantry LH upper side cover “Gantry RH/LH Upper Side Cover Removal” on page 135.
20. Close the front cover and latch it in place.
21. Box up the old X‐ray tube and return it. Ensure all paperwork on the tube is completed. Be sure to
include tube history file on the FlashLink USB drive in shipping box.
22. Submit an FDA 2579 form for the new X‐ray tube installed.
Section 20
Section 20 MRC 600 X-ray Tube Assembly Replacement
Note: Two persons are required for MRC X‐ray Tube (XRT) Assembly Removal / Installation. Time estimate:
Three hours for mechanical replacement and three hours for calibrations.
Tools required:
• FE Tool kit
• X‐ray tube lift tool
• X‐ray strap pad assembly
• High voltage connector pin seating tool (for older systems with HV connectors that have split
contact pins)
Specific tools used include 3/16” hex bit, 5/32” hex bit, 7/16“socket, 3/4” socket, 3” and 6” socket
extensions, 4mm hex bit, 6 mm hex bit, and 3 mm hex key
Supplies:
• Loctite #242 (make sure it is not past the expiration date)
• Loctite #243 (comes with XRT)
• 99% Isopropyl alcohol (for service availability, 90% Isopropyl Alcohol can be substituted, do not
use rubbing alcohol)
• Silicon paste (provided with replacement X‐ray tube)
• Anode silicon washer (provided with replacement X‐ray tube)
• Cathode silicon washer (provided with replacement X‐ray tube)
• Cardboard tubes for protecting HV connectors (provided with replacement X‐ray tube)
• MRC Tube Shipping Box (provided with replacement X‐ray tube)
!
CAUTION: The XRT and the cooling unit must be replaced together as a unit and must not be
separated. The cooling hoses connecting the cooling unit to the XRT must not be
disconnected.
20.1 OTR Tool

The OTR (Online Tube Report) tool captures data and logs that must be included with the returned X‐ray
tube. The OTR tool comes preloaded on a USB memory stick that is attached to the service manual of the
replacement X‐ray tube.
Note: Credit on the returned X‐ray tube will be reduced if the required data is missing or incomplete.
Proceed to the section that applies to the software version installed on the system:
OTR Tool (3.6.7 Software and Later) on page 255
OTR Tool (3.6.6 Software and Earlier) on page 258
Other information available includes:
View OTR Tool Data on page 260
Report OTR Tool Issues on page 263
20.1.1 OTR Tool (3.6.7 Software and Later)

1. On the host, log in as Philips Service.
3. Copy the D:\DATA_TUBEHISTORY folder to the root of the media containing the OTR tool.
4. Copy the D:\DATA_LOGGER folder to the root of the media containing the OTR tool.
Figure 20-1: Copy Folders
Copy
5. Remove the USB media stick containing the OTR tool from the host computer.
6. Insert the USB media stick containing the OTR tool into the FSE Laptop.
8. Locate the folder named DATAPACKER1 and do the following:
a. Within the folder, right click on DATAPACKER.INI and select EDIT.
b. Locate the line beginning with SrcPath=
c. Change any occurrences of the drive letter from D:\ to the drive letter of the media inserted into the
FSE laptop.
For instance, if your drive letter on the FSE laptop is F:\, change:
SrcPath=ʺ1D:\Data_Logger\ʺ,ʺ1D:\Data_TubeHistory\ʺ
to:
SrcPath=ʺ1F:\Data_Logger\ʺ,ʺ1F:\Data_TubeHistory\ʺ
d. Close and save the file.
e. Repeat steps Step a through Step d for the DATAPACKER2, DATAPACKER3, and
DATAPACKER4 folders.
11. Press START.
Note: Data packing can take as long as 10 minutes, depending on the amount of data.
20.1.2 OTR Tool (3.6.6 Software and Earlier)

5. Press START.
20.1.3 View OTR Tool Data

All information of the X‐ray tube assembly form and the generator data are stored on the memory stick as
a database file *.mdb named with the serial number of the X‐ray tube assembly and the date of the former
installation.
The *.mdb files stored on the memory stick can be viewed by using the MDB Viewer.
To view the tube data file:
1. On the host, log in as philips_service.
2. Plug the memory stick into a USB port on the front of the host.
3. Open windows Explorer by right‐clicking on the Windows Start button and left‐clicking on Explore
in the drop‐down menu.
4. Select the memory stick Removable Disk folder in the left (Folder) pane of the Explorer Window.
5. Double left‐click on Start OTR.exe in the right pane of the Explorer window.
6. Click on the MDB‐Viewer button. The MDB viewer shown in Figure 20‐9 on page 262 should be
displayed.
Figure 20-8: System Type Selection Dialog Box
7. The OTR_Data folder should be automatically selected. Select the desired *.mdb data file (the file
name is the serial number of the X‐ray tube assembly and the date of the former installation.
Figure 20-9: X‐ray Tube MDB Data File Viewer
20.1.4 Report OTR Tool Issues

If faults occur when trying to store tube data on the memory stick, send an e‐mail to:
ms.de.tubes.datalog@philips.com
Include the following information:
1. Common data
• Your name
• Your SSD and country
• Description of the problem
2. Data concerning the replacement of the X‐ray tube assembly
• Customer
• System description
• Generator type
• Type of defective X‐ray tube assembly
• Serial number of defective X‐ray tube assembly
• Failure description
• Installation date
• De‐installation date
20.2 X-ray Tube Removal

1. At console screen, select Service Tools > General Tools > Tube History. Record the exposure count.
gantry. Contact with hazardous voltages may cause serious injury or death.
!
WARNING: Make sure to insert the front cover hinge locking pins to prevent the cover from falling
anytime it is open. Failure of a front cover support gas spring may allow the front cover to
fall quickly and cause injury to personnel.
3. Turn OFF gantry power See “Gantry Power Down (Except for the Host and CIRS)” on page 27..
4. Remove the gantry LH upper side cover (see ‘Gantry RH/LH Upper Side Cover Removal on page 13‐
135).
5. Remove power from the rotor by opening rotor power fuse F303. Refer to Figure 20‐10 on page 265.
6. Open the slip ring 480 VAC fuses F351, F352, and F353. Refer to Figure 20‐10 on page 265.
7. From the rear of the gantry remove the screw securing the Lexan ring to the rear cone. Pull the Lexan
ring toward the rear until the front of the Lexan ring is flush with the front edge of the rear cone.

F351, F352, F353 F357, F358, F359
MODE KEYSWITCH
ROTOR POWER
FUSE F303
8. Release the main drive motor brake by turning the lock knob CW (see Figure 20‐11 on page 266).

9. Rotate the rotor CW so the heat exchanger is in the 6 o’clock position.
10. Apply the motor brake (see Figure 20‐11 on page 266).
Figure 20-11: Main Drive Motor Brake Release Knob

RELEASE
APPLY
11. Loosen four socket head cap screws securing the lower front cover to the mounting bracket (see
Figure 20‐12).
12. Remove three screws securing the bracket to the gantry, and remove the lower front cover and bracket
from gantry. Refer to Figure 20‐12 on page 267.
Figure 20-12: Lower Cover and Mounting Bracket

THREE SCREWS
FOUR SCREWS AND SECURING MOUNTING
FLAT WASHERS BRACKET TO GANTRY
SECURING LOWER
FRONT COVER TO
MOUNTING BRACKET
13. Release the main drive motor brake by turning the release knob CW (see Figure 20‐11 on page 266).

15. With the X‐ray tube at the 12 o’clock position, insert the rotor locking pin as shown in Figure 20‐14 on
page 269.
Figure 20-13: Rotor Pinned with the XRT at the 12 o’clock Position (Gantry Front Lower Right)
!
WARNING: Do not touch the XRT housing until you make sure that it is not hot enough to cause burns.
To ensure the housing has cooled, leave the system at rest for least 1 hour with cooling
system running prior to tube removal.

next.
X-ADJUSTMENT
Z-ADJUSTMENT ASSEMBLY
ASSEMBLY
17. Refer to Figure 20‐15 on page 270 and remove the Z‐adjustment:

• The Z‐adjustment straddle plate (2 bolts, 3/16” hex key)
• The Z‐adjustment static block (2 bolts, 5/32” hex key),
• The Z‐adjustment baseplate (2 bolts, 3/16” hex key).
Make sure not to turn the Zadjustment screw.
Z-ADJUSTMENT Z-ADJUSTMENT Z-ADJUSTMENT SCREW Z-ADJUSTMENT

STRADDLE PLATE STATIC BLOCK (do not turn) BASEPLATE
18. Refer to Figure 20‐16 on page 271 and remove the X‐adjustment:

• The X‐adjustment straddle plate (2 bolts, 3/16” hex key)
• The X‐adjustment static block (2 bolts, 5/32” hex key)
• The X‐adjustment baseplate (2 bolts, 3/16” hex key)
Make sure not to turn the Xadjustment screw.
X-ADJUSTMENT X-ADJUSTMENT X-ADJUSTMENT SCREW X-ADJUSTMENT

BASEPLATE STATIC BLOCK (do not turn) STRADDLE PLATE
19. Disconnect the overflow line quick‐disconnect (see Figure 20‐17 on page 272).

20. Remove the velcro straps and pull the overflow out of the tube holes, out to the front of the rotor.
OVERFLOW LINE
QUICK-DISCONNECT
21. Unscrew the retaining screw and remove the left cathode HV cable clamp on the front of the FRC (see
Figure 20‐18).
22. Unscrew the retaining ring and pull the cathode HV connector out of the XRT (see Figure 20‐18).
DISCONNECT HV CABLE REMOVE HV CABLE CLAMP
23. Put a protective cover over the cathode HV connector to keep it clean (see Figure 20‐19).

24. Secure the cable to the rotor so it will not be damaged when the rotor is turned (see Figure 20‐19).
Figure 20-19: Cathode HV Cable Secured

SECURE HV CABLE
COVER CONNECTOR
25. Refer to Figure 20‐20 on page 275. Using a 3/4” socket, slightly loosen the right rear bolt securing the

X‐ray tube to the gantry rotor. Leave the bolt snugly installed.
Figure 20-20: Right Rear X‐ray Tube Mounting Bolt
LOOSEN RH REAR
XRT MOUNTING BOLT
26. Refer to Figure 20‐21 on page 276. Using a 3/4” socket, remove the left rear bolt securing the X‐ray

tube to the gantry rotor.
REMOVE LH REAR
XRT MOUNTING BOLT
Note: The X‐ray tube cradle (see Figure 20‐22) is composed of two parts, an upper half (the cooling unit bracket)

and a lower half (the X‐ray tube port bracket).
27. Using a 3/4” socket, slightly loosen all four bolts holding the X‐ray tube cradle bracket together. Refer
to Figure 20‐22 on page 277. Leave all 4 bolts snugly installed.
Figure 20-22: Initial Loosening of X‐ray Tube Cradle Bracket Bolts

XRT CRADLE UPPER HALF
(COOLING UNIT BRACKET)
XRT CRADLE LOWER HALF

(XRT PORT BRACKET)
LH CRADLE BOLTS
RH CRADLE BOLTS
28. Cut the cable ties as required and disconnect the FRC cables that go to the XRT (see Figure 20‐23 on

page 278).
Figure 20-23: Anode HV Connector and FRC Connectors

CUT CABLE TIES DISCONNECT FRC

CONNECTORS
29. Slightly loosen the 2 front bolts securing the X‐ray tube cradle to the rotor (see Figure 20‐24) but leave

them snugly installed.
LOOSEN 2 XRT FRONT

MOUNTING BOLTS
30. Make sure all loose cables and hoses are secured enough to hand‐rotate the rotor safely.
31. Release the motor brake Figure 20‐11 on page 266 and remove the rotor locking pin Figure 20‐13 on
page 268.
32. Slowly rotate the rotor CW so the anode power module (APM) is at the 10 o’clock position (see
Figure 20‐25). I
33. Apply the motor brake Figure 20‐11 on page 266.
Figure 20-25: Rotor Anode Module at the 10 o’clock Position (Gantry Front Upper Left)

APM AT 10 O’CLOCK

35. Cut the cable ties securing the 3 white power cables (see Figure 20‐26) and disconnect them (the
cables are not specific to any terminal).
36. Disconnect the HSS signal cable at HSS connector JB4 (blue plug) (see Figure 20‐26).

CUT CABLE TIES AND

DISCONNECT 3 CABLES
DISCONNECT HSS
SIGNAL CABLE
37. Refer to Figure 20‐27 on page 282 and disconnect the red‐colored XRT power cable at the side of the

anode module.
Leave the black cable connected and in place.
38. Cut the cable ties as necessary to free the red cable from the anode module.
Figure 20-27: Anode Power Module (APM) Cable

WIRE & DISCONNECT
39. Remove the cable bracket and cut the cable ties as required to free the red APM power cable and the
HSS, signal cable from the bracket. Leave the bracket attached to the other cables (see Figure 20‐28).
40. Cut the cable ties along the rotor to free the red APM red power and HSS signal cable (see Figure 20‐
28).
41. Pull the APM red power cable and HSS signal cable through the rotor frame hole (see Figure 20‐28).
42. Secure the cables in place so they will not be damaged when the rotor is rotated.

PULL CABLES UP
OUT OF ROTOR HOLE
CUT CABLE TIES

AS REQUIRED
TO FREE CABLES
REMOVE BRACKET
43. Ensure all loose cables and hoses are secured enough to hand rotate the rotor safely.
44. Release the motor brake Figure 20‐11 on page 266.
45. Slowly rotate the rotor CW so the X‐ray tube is at the 6 o’clock position.
46. Insert the rotor locking pin as shown in Figure 20‐29 on page 284 and apply the motor brake.
!
WARNING: Make sure to install the rotor locking pin before removing the X-ray tube. The motor brake will not hold
the rotor in position with the x-ray tube removed. Failure to pin the rotor will allow the rotor to rotate
quickly and cause personnel injury or death.
Figure 20-29: Rotor Pinned with XRT in 6 o’clock Position (Gantry Front Upper Left)
47. Turn the gantry power ON See “Gantry Power Up” on page 34..

a) On systems that have a gantry power toggle button (blue button) momentarily press and release
the blue button on the side of the gantry switch panel (see Figure 1-13 on page 37).
b) On systems that don’t have the blue button, replace and close fuses F354, F355, and F356
Figure 20-30 on page 285.
48. Place the Mode key switch into the “SERV” position. Refer to Figure 20‐30 on page 285.
Figure 20-30: Location Mode Keyswitch
MODE KEYSWITCH UTILITY FUSES

F354, F355, F356
49. Remove the patient support service switch cover at the RH head end of the base trim cover as shown
in Figure 20‐31 on page 286.
50. Turn ON the patient support service switch (see Figure 20‐32). On older style units the UP/DOWN
service push buttons will light when the patient support is in the service mode and the service switch
is on. On newer units the indicator will light when the service switch is ON.
Figure 20-31: Removing Service Switch Cover Figure 20-32: Service Controls

OLDER STYLE CONTROLS
UP/DOWN BUTTONS ON/OFF
NEWER STYLE CONTROLS
!
CAUTION: Do not drive the table to the vertical mechanical limits. All patient support travel limits are
disabled in the service mode. Driving the table too far will cause damage to the limit
switches and/or mechanical damage.
51. Using the patient support service controls, position the top high enough for installing the lifting tool.
Make sure the support subframe is all the way toward the foot end.
52. Slide the X‐ray tube lifting tool onto the patient support as shown in Figure 20‐33 on page 287 and
position it so that the strap pad is even with the end of the top all the way across.
53. Attach the service tool to the strap by inserting bolts through the upper strap holes for standard
patient supports or the lower holes for extended supports (see Figure 20‐33).
Figure 20-33: Lift Tool On Table

STRAP PAD EVEN
WITH END OF TOP
SUB FRAME TO
FOOT END
MOUNT LIFT
TO UPPER HOLES FOR
STANDARD SUPPORTS
MOUNT LIFT
TO LOWER HOLES FOR
EXTENDED SUPPORTS
54. Raise or lower the support to align the lifting rods with the XRT holes. Refer to Figure 20‐34 on

page 288.
55. Insert the stop pins into the holes in the lift rods as shown in Figure 20‐34 on page 288.
56. Move the support top toward the gantry so that the tube lifting tool rods slide into the tube cradle
holes until the set stop pins in the lift rods are up against the rotor as shown in Figure 20‐34 on
page 288.

INSERT RODS SO PINS

ARE AGAINST THE XRT
57. Raise the table slightly so that it is attempting to lift the tube assembly.
58. Remove the remaining rear mounting bolt see (see Figure 20‐20 on page 275).
!
WARNING: Make sure to install the rotor locking pin before removing the X-ray tube. The motor brake
will not hold the rotor in position with the x-ray tube removed. Failure to pin the rotor will
59. Remove the 2 front bolts securing the X‐ray tube cradle to the rotor (see Figure 20‐35). You will notice
the weight of the tube being transferred to the lifting tool. Adjust the patient support height to
compensate.
REMOVE 2 XRT FRONT

MOUNTING BOLTS
60. Lower X‐ray tube assembly using patient support service controls until the XRT is resting on the
bottom of the gantry (see Figure 20‐36).
Figure 20-36: XRT Resting on the Bottom of the Gantry
61. Disconnect both oil lines from the tube by twisting the large knurled nuts on the quick disconnect
couplings. Refer to Figure 20‐37 on page 291.
Figure 20-37: Location of Oil Line Connections to XRT

DISCONNECT OIL LINES
(SHOWN DISCONNECTED)
62. Remove the four bolts holding the two halves of the cradle bracket together (see Figure 20‐38).



(XRT PORT BRACKET)
CRADLE BOLTS
CRADLE BOLTS
63. Using a 6 mm hex key, remove the two (M6 size) screws securing the small bracket of the cooling unit
bracket. Save hardware for installation. Refer toFigure 20‐39 on page 293.
64. Raise patient support and XRT so that the lower cradle assembly remains resting on the bottom of the
gantry. Refer to Figure 20‐42 on page 296.
Figure 20-39: Removing the Front X‐ray Tube Cooling Unit Bracket
REMOVE 2
BRACKET SCREWS
65. Remove the top from the new XRT shipping box.
66. Invert the top of the shipping box that was removed and position it over the patient support
footswitch with the “Gantry Side” arrow pointing to the gantry as shown in Figure 20‐40 on
page 294.
Figure 20-40: Shipping Box

GANTRY SIDE
67. While adjusting the XRT height using the patient support service buttons, carefully move the XRT out
of the gantry and over the shipping box (see Figure 20‐41) making sure that cables and other
components are not damaged.
The detached portion of the XRT cradle will remain in the gantry as shown in Figure 20‐42 on
page 296.
68. Remove the anode HV cable from the X‐ray tube. Place a cardboard tube over the connector to protect
the pins. Refer to Figure 20‐41 on page 295.
Figure 20-41: XRT Removed from Gantry
DISCONNECT
ANODE HV CABLE
Figure 20-42: XRT Cradle Assembly Left On Bottom Of Gantry

69. After anode HV cable is removed, continue removing tube from gantry until the tube is over the
shipping box bottom.
70. Slowly lower the tube into the shipping box, using the patient support service down button. Refer to
Figure 20-43: X‐ray Tube Lowered into Shipping Box

71. Lower the patient support enough to take tension off the lifting tool.
72. Move the table top away from the gantry until the lifting strap can be removed over the end of the
table as shown in Figure 20‐44 on page 298.
Figure 20-44: Lifting Tool Strap Removed from Table Top
73. Remove the clip release pins from lifting tool rods and slide the tool all the way forward. Refer to
Figure 20‐45 on page 299. This will give more room for moving the XRT box off the footswitch. Retain
clip release pins for use during installation.
74. Remove the shipping box from the footswitch:
a. Slide the handles out on the shipping box.
b. While making sure shipping box wheels do not damage the foot switch, lift the left side of the
shipping box up and over the footswitch.
c. Pull the box away from the table and wheel the entire unit out of the way.
75. Remove the lifting tool from tube cradle bracket.
Figure 20-45: Removing Clip Release Pins from Service Tool Lift Rods
REMOVE PINS
Note: Be sure to note the orientation of the X‐ray tube port bracket prior to removal. The notch in the port
window faces the cathode side of tube. Mark direction of cathode with marker, if necessary.
76. Refer to Figure 20‐46 on page 301. Using a 4 MM. hex key, remove the 4 screws and lock washers (M4
size) attaching the tube port bracket to the tube.
Discard the lock washers. The lock washers will not be used on the new tube since unexpired
Loctite will be applied to the screws when they are installed.
77. Using a 3mm hex key, remove the ground wire from the XRT bracket. Refer to Figure 20‐46 on
page 301.
78. Remove XRT port bracket. Retain the bracket for use on replacement XRT.
Figure 20-46: Port Bracket on XRT

NOTCHED AREA
OF TUBE BRACKET
CATHODE LABEL
REMOVE 4 SCREWS
ANODE LABEL
REMOVE GROUND
20.3 Tube Installation
!
CAUTION: The temperature at the surface of the X-ray tube housing assembly and at the surface of the
heat exchanger must be between 62 and 80 degrees F (17 to 27 degrees C) before the
cooling lines are connected or disconnected to avoid over- or under-pressure within the
cooling unit.
1. Check the tube oil temperature on the surface of the X‐ray tube housing assembly and on the surface
of the heat exchanger. The tube temperature must be between 62 and 80 degrees F (17 to 27 degrees C)
before removing oil expansion bottle. When the temperature is within this range, disconnect the oil
expansion bottle from the XRT.
2. With the new X‐ray tube still in crate, remove the port protective cover (see Figure 20‐47) from the
new XRT and place it on the XRT to be returned.
Figure 20-47: Tube Port Cover
!
CAUTION: Make sure that the X-ray tube port bracket is installed as shown in Figure 20-48 on
page 303. The port bracket is not keyed and can be installed with the wrong orientation.
3. Refer to Figure 20‐48 on page 303. With the new X‐ray tube still in crate, install the X‐ray tube port
bracket with the notch of the X‐ray tube port window facing the cathode side of tube (front of tube).
5. Apply Loctite #243 to the four M4 screws, install them, and hand tighten them.
6. Reconnect the XRT ground wire to the bracket.
Figure 20-48: Port Bracket Installed on XRT

NOTCHED AREA
OF TUBE BRACKET
CATHODE LABEL
INSTALL 4 SCREWS
ANODE LABEL
CONNECT GROUND
7. Install the X‐ray tube lifting tool rods into the holes in the new tube cradle (see Figure 20‐49).
8. Slide the lifting rods as far as they will go into the tube cradle (see Figure 20‐49).
Figure 20-49: XRT Lifting Tool Installed

9. Being careful not to damage the footswitch, position the X‐ray shipping box containing the new X‐ray
tube over patient support footswitch with the anode end of the XRT toward the gantry as shown in
10. Adjust the patient support height so the lifting tool support can be installed on the end of the patient
support top. Make sure that the strap pad is even with the end of the support top all the way across
11. Slide the service tool lift rods back and install pins on lift rods in the positions shown in Figure 20‐50
on page 305.
Figure 20-50: Placement of X‐ray Tube for Installation

STRAP PAD EVEN
WITH END OF
SUPPORT TOP
LIFTING ROD PINS
12. Once the service tool is installed into the tube and onto the patient support, raise the patient support
slightly to lift the tube up and off the box bottom.
13. Move the XRT close enough to the gantry so that the anode HV connector can be installed (see
Figure 20‐51).
Figure 20-51: Anode HV Connector

CONNECT
ANODE HV CABLE
14. Connect the anode HV cable to X‐ray tube by performing these steps:
a. If the HV connector has split pins as shown in Figure 20‐52 on page 307:
• Align the blade inside the HV connector pin spreading tool (p/n 9890 000 02841) with the slot in the
pin.
• Push the tool all the way onto the pin until the tool is against the end of the connector to spread the
pin.
• Repeat this for each pin.
• See Figure 20‐52 on page 307 for an illustration of correct and incorrect pin splits.
Figure 20-52: Spreading HV Connector Pins with Pin Spreading Tool
PIN WITH PUSH TOOL UP AGAINST PINS WITH

INCORRECT SPLIT CONNECTOR CORRECT SPLITS
b. Clean HV plug with isopropyl alcohol and cleaning cloth. Do not touch connector or pins with
your fingers.
c. Put a pea‐sized deposit of connector grease (supplied with the XRT) in the center of the connector
between the connector pins as shown in Figure 20‐53 on page 308.
d. Install a new silicon washer over the pins of the plug as shown in Figure 20‐53 on page 308.
Note: The connector pins must be free from silicon paste.
e. Put a pea‐sized deposit of connector grease in the center of the new silicon washer between the
connector pins as shown in Figure 20‐53 on page 308.
Note: Do not grease the sides of the connector plug.
f. Position the anode HV cable behind the heat exchanger hoses and plug the HV connector into the
XRT Figure 20‐51 on page 306.
g. Tighten the coupling ring.
Figure 20-53: Grease on the HV Connector

GREASE ON END OF GREASE ON TOP OF
CONNECTOR SILICONE WASHER
SILICONE WASHER
15. While being careful not to damage any cables or hoses, move the XRT into the gantry and align it with
to the part of the cradle on the bottom of the gantry. Adjust the patient support as necessary to get the
tube properly aligned to the cradle.
16. Remove shipping box from the patient support footswitch.
18. Apply Loctite #242 to the M6 bracket screws and install the bracket (see Figure 20‐54) onto the tube
cradle using a 6 mm hex key.
Figure 20-54: Installing Bracket onto the XRT Cradle
SCREWS ATTACHING SMALL

BRACKET TO TUBE CRADLE
20. Install the flatwashers onto the 4 cradle bolts, apply Loctite# 242, and bolt the 2, X‐ray tube cradle
halves together (3/4” socket) (Figure 20‐38 on page 292). Just install the bolts snugly for now can be
torqued later when the XRT is in a more convenient position.
Figure 20-55: X‐ray Tube Cradle Bracket Bolts


(XRT PORT BRACKET)
CRADLE BOLTS
CRADLE BOLTS
21. Move patient support up and forward to position the tube so that the tube cradle and gantry rotor
mounting holes are aligned.
Note: The front and rear XRT bolts are different lengths.
The 2 longer bolts (1/2”‐13 x 1‐3/4”) go to the rear.
The 2 shorter bolts (1/2”‐13 x 1‐1/2”) go to the front.
22. Select the 2, 1/2”‐13 x 1‐1/2” bolts. Install the flatwashers and start the 2 bolts through the front rotor
holes into XRT cradle to secure it to the rotor (3/4” socket). Refer to Figure 20‐56 on page 311.
INSTALL 2 XRT FRONT

MOUNTING BOLTS
23. Install one of the flatwashers onto a longer rear bolt (1/2”‐13 x 1‐3/4”). Install the bolt through the
hole on the left side of the tube (in this position) attach the cradle to the rotor (see Figure 20‐57).
The other bolt will be installed when the XRT is in a more convenient position.
24. Tighten the 3 XRT mounting bolts installed enough to hold the XRT securely to the rotor.
These bolts will need to be loosened later for mechanical alignment.
After the XRT alignment the bolts will need to have unexpired Loctite #242 applied and be torqued to
56 ft‐lb (75 Nm).
Figure 20-57: Rear XRT Cradle Mounting Bolt
FLAT WASHER
1/2-13 x 1-3/4 BOLT
25. Lower the patient support to take tension off the lifting tool and back the patient support and service
tool away from the gantry.
26. Remove lifting tool from patient support.
the gantry switch panel (see Figure 1‐4 on page 27).
28. Remove the locking pin from rotor and unlock the motor.
29. While watching and holding cables to make sure none are damaged, rotate the gantry rotor CW to the
12 o’clock position.
30. Install the rotor locking pin to lock the rotor in the 12 o’clock position and lock the motor.
31. Torque all 4 cradle bolts to 56 ft‐lb (75 Nm) (see Figure 20‐55 on page 310).
32. Install the other rear XRT cradle to rotor bolt (1/2”‐13 x 1‐3/4”)(3/4” socket) with a flatwasher
(Figure 20‐57 on page 312).
Leave the bolt loose enough to allow the XRT to move.
33. Install the cathode HV cable to the X‐ray tube following the same procedure contained in Step 14 on

page 307.
!
cooling unit.
34. Before connecting the oil lines, make sure that the X‐ray tube and the cooling unit are both at room
temperature (between 62 and 80 degrees F or 17 to 27 degrees C). The oil temperature can be checked
at the surface of the X‐ray tube housing and at the surface of the cooling unit heat exchanger.
35. When the temperature is within the allowed range, connect both front oil hose quick disconnects to
the X‐ray tube. Refer to Figure 20‐58 on page 314.
Figure 20-58: Installation of Cathode HV Cable and Cooling Hoses
CONNECT COOLING LINES
CONNECT CATHODE
HV CABLE
(ROUTE BETWEEN
COOLING LINES)
CONNECT COOLING LINES
36. Route the HV cable and clamp it in place as shown in Figure 20‐59 on page 315.
Figure 20-59: Cathode HV Cable Routing

INSTALL
CABLE CLAMP
37. Route the overflow hose through the XRT cradle as shown in Figure 20‐60 on page 316.

38. Connect the overflow line to the quick‐disconnect on the overflow tank (see Figure 20‐60 on
page 316).
Figure 20-60: Overflow Line

OVERFLOW LINE
QUICK-DISCONNECT
39. Loosen the 4 tube mounting bolts enough to allow the tube to move.
40. Push the XRT as far toward the back of the gantry that it will go.
41. Push the XRT as far toward the left of the gantry that it will go.
42. Locate the X‐adjustment baseplate (see Figure 20‐61).
44. Refer to Figure 20‐61 on page 317. Install flatwashers and lockwashers onto to the 2, X‐adjustment
baseplate SHCS and apply Loctite #242.
45. Using a 3/16” hex key, loosely install the 2, X‐adjustment baseplate SHCS with flatwashers, and
lockwashers. Leave these loose until the other adjuster parts are installed.
46. Leave the mounting screws finger‐tight until the rest of the assembly is installed.
Figure 20-61: X‐Adjustment Baseplate Installation
X-ADJUSTMENT BASEPLATE
¼” - 20 X 3/4” (3/16” HEX KEY)
X-ADJUSTMENT PLATE SCREWS WITH
FLATWASHERS & LOCKWASHERS
X-Adjustment Block
2. Refer to Figure 20‐62 on page 318. Apply Loctite #222 to the 2, X‐static adjustment block SHCS.
3. Using a 5/32” hex key loosely install the X‐static adjustment block (adjusting screw slot facing up)
with 2 SHCS, flatwashers, and lockwashers.
4. Torque the screws as indicated in Figure 20‐62 on page 318.
Figure 20-62: X‐Adjustment Block Installation

X-ADJUSTMENT BLOCK 10-32 x 1-1/2 (5/32” HEX KEY)

X-ADJUSTMENT BLOCK SCREWS
WITH FLATWASHERS & LOCKWASHERS
LOCTITE #222
5. Install the X‐adjustment straddle plate so that the head of the adjusting screw fits into the adjustment
block and so that the raised bosses on the underside of the straddle plate drop into the opening in the
baseplate (see Figure 20‐63).
Note: Avoid turning the adjusting screw. If the adjusting screw is left in the original position it may make the
XRT alignment procedure easier.
7. Install lockwashers and flatwashers onto the 2, X‐adjustment straddle plate SHCS and apply Loctite
#242. Using a 3/16” hex key loosely install the 2 SHCS and flatwashers (see Figure 20‐63).
8. Torque the straddle plate screws as indicated in Figure 20‐63 on page 319.
Figure 20-63: X‐Adjustment Straddle Block Installation
X-ADJUSTMENT STRADDLE PLATE SCREWS

¼ - 20 X 2-3/4 SHCS (3/16” HEX KEY)
WITH FLATWASHERS - APPLY unexpired LOCTITE #242
X-ADJUSTMENT
STRADDLE PLATE
X-ADJUSTMENT PLATE SCREWS

X-ADJUSTMENT BASEPLATE APPLY unexpired LOCTITE 242
9. Locate the Z‐adjustment baseplate (see Figure 20‐64).
11. Install flatwashers and lockwashers onto to the 2, Z‐adjustment baseplate SHCS and apply Loctite
#242.
12. Refer to Figure 20‐64 on page 320. Using a 3/16” hex key loosely install the 2, Z‐adjustment baseplate
SHCS with flatwashers, and lockwashers.
Leave these screws loose until the other adjuster parts are installed.
Figure 20-64: Z‐adjustment Baseplate Installation

Z-ADJUSTMENT BASEPLATE
¼” - 20 X 5/8” (3/16” HEX KEY)
Z-ADJUSTMENT PLATE SCREWS WITH
FLATWASHERS & LOCKWASHERS
Z-Adjustment Block
2. Apply Loctite #222 to the 2, #10‐32 X 1ʺ SHCS for the Z‐adjustment block.
3. Refer to Figure 20‐65 on page 321. Using a 5/32” hex key loosely install the Z‐static adjustment block
(adjusting screw slot facing up and to the front) with the 2 SHCS.
4. Torque the Z‐adjustment block screws to 15 in‐lb (1.7 Nm) (see Figure 20‐65).
Figure 20-65: Z‐adjustment Adjustment Block Installation
Z-ADJUSTMENT BLOCK SCREWS

#10-32 X 1" SHCS (5/32” HEX KEY)
LOCTITE #222
Z-ADJUSTMENT BLOCK (REAR VIEW)

WITH #10-32 X 1" SHCS
Note: Avoid turning the adjusting screw. If the adjusting screw is left in the original position it may make the
XRT alignment procedure easier.
5. Install the Z‐adjustment straddle plate with the side with the raised bosses down so that the head of
the adjusting screw fits into the adjustment block as shown in Figure 20‐66 on page 322.
Position the baseplate as necessary so that the raised boss on the underside of the straddle plate drops
into the opening in the baseplate.
Figure 20-66: Z‐adjustment Straddle Block Installation

Z-ADJUSTMENT BASEPLATE Z-ADJUSTMENT PLATE SCREWS
APPLY unexpired LOCTITE 242
Z-ADJUSTMENT STRADDLE PLATE SCREWS

Z-ADJUSTMENT ¼ - 20 X 2-3/4 SHCS WITH FLATWASHERS -
STRADDLE PLATE LOCTITE #242 - TORQUE TO 10.5 ft‐lb (14.2 Nm)
7. Install lockwashers and flatwashers onto the 2, Z‐adjustment straddle plates screws and apply Loctite
#242. Refer to Figure 20‐66 on page 322. Using a 3/16” hex key loosely install the Z‐adjustment
straddle plate with 2 the 2 SHCS with lockwashers and flatwashers.
8. Apply Loctite #242 to the Z‐adjustment baseplate screws and torque them to 10.5 ft‐lb (14.2 Nm)
9. Torque the Z‐adjustment straddle plates screws to 10.5 ft‐lb (14.2 Nm) (Figure 20‐66 on page 322).
Tightening the screws should pull the XRT up against the straddle plate.
10. Torque all 4 XRT mounting bolts to 56 ft‐lb (75 Nm).
Note: The XRT mounting bolts may need to be loosened later for X‐ray tube mechanical alignment, but after
alignment these bolts will need to have unexpired Loctite #242 applied and torqued to 56 ft‐lb (75 Nm).
11. Route the cables to the anode power module (APM) as shown in Figure 20‐67 on page 324.
Figure 20-67: Typical Routing of Anode Power Module (APM) and High Speed Starter (HSS) Cables
ROUTE APM CABLES APM CABLE ROUTING

THROUGH ROTOR HOLE
12. Connect the HSS starter cable with the blue connector to the HSS as shown in Figure 20‐68 on

page 325.
13. Route the red APM cable under the white power cables to the side of the APM as shown in Figure 20‐
68 on page 325.
14. Attach the cable bracket as shown in Figure 20‐68 on page 325. Leave the cables lose until they are
connected before tying them in place.
15. Unpin the rotor and release the motor brake.
16. Rotate the rotor until the anode power module is at the 10 o’clock position.

ATTACH CABLE BRACKET
ROUTE APM
CABLES
CONNECT CABLE
TO HSS
18. Connect XRT power (red colored cable) and signal cable to the connectors at the side of the anode
generator as shown in Figure 20‐69 on page 326. Tie the cables in place.
CONNECTCABLE
TIE CABLES
19. Connect the 3 white power cables (see Figure 20‐70) and tie them in place. The white cables are not

specific to any of the 3 terminals.
20. Install the fuse covers onto the anode power module fuses.
Figure 20-70: Anode Power Module Power Cable Connections
CONNECT
POWER CABLES
TIE CABLES
21. Clamp the anode HV cable and APM cables in place as shown in Figure 20‐71 on page 328.
Figure 20-71: Anode HV Cable and APM Cable Routing
INSTALL HV CABLE CLAMPS
22. Tie the APM cables in place as shown in Figure 20‐72 on page 329.
Figure 20-72: APM Cable Routing
TIE CABLES
23. Connect the FRC cables that go to the XRT (see Figure 20‐23 on page 278). Tie the connectors in place

Figure 20-73: FRC Connectors
INSTALL CABLE TIES CONNECT FRC

CONNECTORS
24. Unlock the main drive motor.
25. Rotate the rotor clockwise by hand one complete rotation and check for loose cables, connections,
parts, etc.
26. Raise the patient support to access the top sub‐frame quick‐release.
28. To test the patient support quick release after re‐engagement, see “Testing the Patient Support
29. Switch the patient support service switch (next to the Up/Down service buttons) to the normal
position. The Up and Down button lights should extinguish.
30. Place the gantry service key switch into the “NORM” position.
31. Close the slip ring 480 VAC fuses (F351, F352, and F353)
32. close the main drive fuses (F357, F358, and F359).
33. Close the rotor power fuse F303.
34. Save Tube History folder on Host PC to Flash‐Stick USB drive provided with replacement MRC tube.
35. Reinstall the small front lower cover as follows:
a. Release the main drive motor brake.
b. Rotate the gantry rotor CW so the FRC is in the 6 o’clock position.
c. Apply the main drive motor brake.
d. Place the lower front cover into position on the gantry according to the marks made when it was
removed.
e. Attach the lower front cover with 2, 1/4” ‐ 20 socket head cap screws (see Figure 20‐12 on page 267).
f. Turn on gantry power.
g. Lower the patient support.
h. Grasp the side of the front cover and temporarily close the cover to check the alignment. You may
have to readjust the lower front cover to ensure proper alignment with the front cover.
i. The front cover will need to be open for balancing and X‐ray tube alignment.
36. Refer to the appropriate Brilliance CT Calibration Manual and run Automatic / Selective Calibration
using the automatic mode and the reason: Tube Replacement.
!
completed, make sure that the four x-ray tube mounting bolts in the tube cradle bracket
have been coated with unexpired Loctite #242 and torqued to 56 ft-lb (75 Nm).
37. Verify Performance Results. Refer to the appropriate Brilliance CT System Performance manual.
38. Perform backup of the system CPM’s NVRAM according to the applicable system software
installation manual.
39. Backup the Site Configuration according to the applicable system software installation manual.
40. Box up the old X‐ray tube and return it. Make sure all paperwork on the tube is completed. Be sure to
include tube history file on the FlashLink USB drive in shipping box.
41. Close the front cover and latch it in place (see Closing the Ingenuity CT Gantry Front Cover on page
45).
42. From the rear of the gantry pull the Lexan ring back into position and secure it with the screw.
43. Submit an FDA 2579 form for the new X‐ray tube installed.
Section 21
Section 21 MRC 600 Cooling Unit Replacement
This procedure is used to remove and replace the CU 6100 cooling unit (heat exchanger).
Note: Two persons are required for Cooling Unit Removal / Installation. Time estimate: Three hours for
mechanical replacement and three hours for calibrations.
Tools required:
FE Tool Kit, X‐ray tube lift tool, and X‐ray strap pad assembly
Specific tools used include 3/16” hex bit, 5/32” hex bit, 7/16“socket, 3/4” socket, 3” and 6” socket
extensions, 4mm hex bit and key, 3mm hex bit and key, and 6mm hex bit
Supplies: unexpired Loctite 242
21.1 Removal
1. Remove gantry LH upper side cover (see gantry covers procedure).
2. Remove power from the rotor by opening rotor power fuse F303. Refer to Figure 21‐1 on page 334.
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement MRC 600 Cooling Unit Replacement
Figure 21-1: Rotor Power Fuse
ROTOR POWER FUSE F303
3. See “Releasing the Patient Support Subframe Quick Release” on page 817.
4. Open the slip ring 480 VAC fuses (F351, F352, and F353) and main drive fuses (F357, F358, and F359).
Place the Mode key switch into the “SERV” position.
!
CAUTION: All patient support safety mechanisms are disabled in service mode. Make sure not to
damage patient support components.
5. Use the patient support “SERV MODE” switch located at the bottom right front of the patient support
to put the patient support into service position. Patient support is in the Service Mode when the UP/
DOWN switches are lit. Use the DOWN switch to lower patient support to the lowest position
available.
6. Remove the two, 2‐1/4” socket head cap screws from the bottom left and right corners of the front
cover, and lift gantry front cover up.
7. Unlock the motor. Rotate the rotor CW so the heat exchanger is in the 6 o’clock position. Lock the
motor.
8. Loosen four 3/4” socket head cap screws and 1/4” flat washers securing the lower front cover to the
mounting bracket. Remove three screws securing the bracket to the gantry, and remove the lower
front cover and bracket from gantry. Refer to Figure 21‐2 on page 335.
Figure 21-2: Lower Cover and Mounting Bracket
THREE SCREWS
FOUR SCREWS AND SECURING MOUNTING
FLAT WASHERS BRACKET TO GANTRY
SECURING LOWER
FRONT COVER TO
MOUNTING BRACKET
9. Unlock the motor. Rotate the rotor CW so the X‐ray tube is in the 12 o’clock position. Lock the motor
and pin the rotor with rotor locking pin.
next.

X-ADJUSTMENT
ASSEMBLY
11. Remove the Z‐adjustment assembly from the front of the X‐ray tube and tube shelf using a Chapman
hex bit tool set and ratchet (3/16” and 5/32” hex bits used). Refer to Figure 21‐4 on page 337.
12. Remove the X‐adjustment assembly from the right‐hand side of the X‐ray tube and tube shelf using a
Chapman hex bit tool set and ratchet (3/16” and 5/32” hex bits used). Refer to Figure 21‐5 on
page 338.
13. Using a 7/16” socket, remove the two tube stiffener bolts and flat washers. Refer to Figure 21‐6 on

page 339. Cut ty‐wraps and adjust cables as needed to access bolts.
Figure 21-6: Location of Tube Shelf Stiffener Bolts
RH STIFFENER BOLT
LH STIFFENER BOLT
LH STIFFENER BOLT RH STIFFENER BOLT
14. The X‐ray tube cradle bracket is composed of two parts, an upper half (the cooling unit bracket) and a
lower half (the X‐ray tube port bracket). Using a 3/4” socket, “break” the torque on all four bolts
holding the X‐ray tube cradle bracket together. Refer to Figure 21‐7 on page 340. Remove RH rear and
LH front bolts on cradle. Ensure the remaining two bolts are snug tight.
CRADLE BRACKET UPPER HALF

CRADLE BRACKET LOWER HALF

(X-RAY TUBE PORT BRACKET)
FOUR BOLTS HOLD THE

TWO HALVES OF THE
X-RAY TUBE CRADLE
TOGETHER (ONLY THREE
BOLTS SHOWN IN PHOTOS)
15. Disconnect cables between X‐ray tube and cooling unit. Do not disconnect the anode and cathode
HV cables and the two X‐ray tube front oil hoses at quick disconnects. Cut ty‐wraps as necessary.
16. Disconnect hose at oil overflow tank. Refer to Figure 21‐7 on page 340 for location of hose. Secure all
loose cables.
17. Using a 3/4” socket, “break” the torque on the four bolts securing the X‐ray tube port bracket to the
rotor (two front and two rear). Refer to Figure 21‐8 on page 341. Remove rear RH and front LH bolts.
Note that rear bolts have square washers and the front bolts have round washers. Ensure the
remaining two bolts are snug tight.
18. Remove all but two nuts securing heat exchanger to rotor (leave one nut attached on each side).
Figure 21-8: Initial Loosening of X‐ray Tube Mounting Bolts
HOSE CONNECTION AT
OIL OVERFLOW TANK
FRONT BOLTS
FRONT BOLTS - VIEW FROM UNDERNEATH LOOKING UP REAR LH BOLT REAR RH BOLT
19. From rear of gantry, remove screw securing lexan ring to rear cone. Pull lexan ring back (pull evenly
on all sides) until front edge of lexan ring is flush with front edge of rear cone.
20. Ensure all loose cables and hoses are secured enough to hand rotate the rotor safely. Unlock the
motor and remove locking pin. Slowly rotate the rotor CW so the X‐ray tube is at the 6 o’clock
position. Pin the rotor and lock motor.
21. Slide the X‐ray tube service tool on the patient support. Raise patient support so the lift rods on the
service tool line up with the service lifting holes on the tube cradle bracket. Slide the service tool lift
rods into the service lifting holes. The lift rods should slide into the service lifting holes until the clip
release pins on the lift rods touch the cradle bracket. Refer to Figure 21‐9 on page 342.
Figure 21-9: X‐ray Tube Service Tool Installation into X‐ray Tube
22. Remove the two remaining bolts and flat washers securing the X‐ray tube port bracket to the rotor.
You will notice the weight of the tube being transferred to the service tool. Adjust patient support
height to compensate.
!
CAUTION: Be careful when removing X-ray tube assembly from gantry so that anode and cathode high
voltage cables are not stressed.
23. Using the patient support SERV MODE / DOWN switch, lower the X‐ray tube assembly enough to
clear rotor. Move patient support away from gantry, and slowly remove X‐ray tube assembly. Ensure
that tube and cooling unit are completely clear of the gantry. Refer to Figure 21‐10 on page 343. HV
cables will remain connected at both ends through entire cooling unit swap.
Figure 21-10: Using Service Tool to Remove X‐ray Tube and Cooling Unit from Gantry
LEFT SIDE VIEW RIGHT SIDE VIEW
24. Place pad provided with shipping box underneath X‐ray tube assembly.
25. Using the patient support SERV MODE / DOWN switch, lower the X‐ray tube assembly onto the pad.
Do not put full weight of tube on pad. Lower only until contact is made. Remove the two remaining
bolts holding the two halves of the cradle bracket together. Refer to Figure 21‐11 on page 344.
Figure 21-11: Lowering X‐ray Tube and Cooling Unit onto Pad
26. Disconnect both oil hose connections from X‐ray tube.
27. Using the patient support SERV MODE / UP switch, raise the X‐ray tube away from the cooling unit
to provide clearance for cooling unit to be removed. Note that the base of the X‐ray tube port bracket
will be above the tube stiffener shelf. Refer to Figure 21‐12 on page 345.
Figure 21-12: Tube Raised to Provide Clearance for Cooling Unit
NOTE THAT BASE OF X-RAY

TUBE PORT BRACKET IS
ABOVE TUBE STIFFENER
SHELF (SEE ARROW)
DISCONNECT BOTH OIL

HOSES BEFORE
SEPARATING X-RAY TUBE
FROM COOLING UNIT
28. Ensure that all cables are clear of heat exchanger hoses as shown in Figure 21‐13 on page 346.

29. Remove remaining two nuts securing heat exchanger and washer bars to rotor. Remove heat
exchanger, and place on pad. Save washer bars and nuts for installation.
Figure 21-13: Preparing for Heat Exchanger Removal
ONE NUT AND WASHER BAR

REMAINING ON EACH SIDE
OF HEAT EXCHANGER
30. Slide cooling unit and pad away from the gantry. Refer to Figure 21‐14 on page 347.

31. Slide cooling unit off pad so pad is ready to install new cooling unit.
Figure 21-14: Cooling Unit on Pad Ready for Removal
21.2 Installation
1. Remove new cooling unit from shipping box and place on pad. Record serial number of new cooling
unit. Refer to Figure 21‐15 on page 348.
Figure 21-15: Cooling Unit Packed in Shipping Box
2. Place old cooling unit into shipping box and package according to Figure 21‐5 on page 338. Be sure to

provide all required data on the return form (cooling unit technical report).
3. Position pad and cooling unit underneath X‐ray tube at front of gantry.
4. Lower X‐ray tube using patient support.
!
WARNING: Do not put full weight of tube on pad. Lower only until contact is made.
5. Install the two halves of the cradle bracket together with two cradle bolts removed earlier.
6. Hand‐tighten the bolts. The Bolts will be torqued with tube at 12:00 position.
!
cooling unit.
7. Before connecting the oil lines, make sure that the X‐ray tube and the cooling unit are both at room
temperature (between 62 and 80 degrees F or 17 to 27 degrees C). The oil temperature can be checked
at the surface of the X‐ray tube housing and at the surface of the cooling unit heat exchanger.
8. When the temperature is within the allowed range, connect both oil hoses to X‐ray tube. Refer to
Note: Be sure to route the black cooling hose down around the lower portion of the X‐ray tube as shown in
Figure 21‐6 on page 339. Routing the hose over top of the tube may allow it to scrape the gantry creating
a hole.
9. Move patient support forward and up as required to position X‐ray tube and cooling unit into gantry.
Adjust patient support as needed to get tube properly aligned.
11. Install heat exchanger over studs on heat exchanger mounting duct. Add washer bars and install two
nuts over studs (one on each side). Apply Loctite #222 to all nuts and torque to 15 in‐lb (170 Ncm).
Figure 21-16: Installation of Oil Hoses
NOTE ORIENTATION
OF OIL HOSES AND
CATHODE HV CABLE
13. Raise patient support and install three bolts (both front bolts and one rear bolt) with washers into X‐
ray tube port bracket securing tube to rotor. Install front bolts first in outer holes. Round washers go
on tube front, square washer goes on tube back. Hand torque bolts tight. Refer to Figure 21‐17 on
page 351. After the X‐ray tube Z‐mechanical calibration and X‐mechanical calibration procedures
have been completed, these bolts will be individually removed, unexpired Loctite #222 will be
applied, and the bolts will be torqued to specification.
Figure 21-17: Installing Front Bolts into X‐ray Tube Port Bracket
BOLTS INSTALLED
INTO OUTER HOLES
14. Lower the patient support to take tension off the service tool and back the patient support and service
tool away from the gantry.
15. Remove service tool from patient support.
16. Remove locking pin from rotor and unlock the motor. While watching and holding cables, rotate the
tube CW to the 12 o’clock position. Use care that no cables or hoses are damaged when rotating.
Install locking pin and lock the motor.
18. Install two remaining bolts and flat washers attaching X‐ray tube port bracket and cooling unit
bracket. Apply Loctite #242 to the bolts and torque all bolts to 56 ft‐lb (75 Nm).
19. Install remaining bolt and square washer into X‐ray tube port cradle bracket. Hand torque bolt tight.
21. Install remaining six nuts to heat exchanger. Apply Loctite #222 to all nuts and torque to 15 in‐lb (170
Ncm).
22. Install the X‐adjustment assembly removed earlier. Refer to Figure 21‐18 on page 352 and Figure 21‐5
on page 338 for detail. Torque screws as described in Figure 21‐5 on page 338.
23. Install the Z‐adjustment assembly removed earlier. Refer to Figure 21‐18 on page 352 and Figure 21‐4
on page 337 for detail. Torque screws as described in Figure 21‐4 on page 337.
X-ADJUSTMENT
ASSEMBLY
24. Install any cables previously removed. Be sure to tie wrap cables and hoses as they were before
removal. Refer to Figure 21‐19 on page 353.
Note: Be sure to route the black cooling hose down around the lower portion of the X‐ray tube as shown in
Figure 21‐19 on page 353. Routing the hose over top of the tube may allow it to scrape the gantry creating
a hole.
Figure 21-19: Typical Routing and Tying of X‐ray Tube Cables and Hoses

COOLING HOSE ROUTED
UNDER TUBE
LEFT SIDE OF X-RAY TUBE RIGHT SIDE OF X-RAY TUBE
25. Install the two tube stiffener bolts and flat washers. Torque to 9 ft‐lb (12.2 Nm). Refer to Figure 21‐20

on page 354.
Figure 21-20: Location of Tube Shelf Stiffener Bolts and Tungsten Shield LH Bolt
RH STIFFENER BOLT
LH STIFFENER BOLT
LH STIFFENER BOLT RH STIFFENER BOLT
26. Install lexan ring into the rear cone and secure using flat head screw.
27. Unlock motor and remove locking pin.
28. Make one complete rotation of the rotor by hand and check for loose cables, connections, etc.
29. Raise the patient support slightly to remove from service mode. Place the couch service switch in
normal mode.
31. To test the patient support quick release after re‐engagement, see “Testing the Patient Support
32. Close the slip ring 480 VAC fuses (F351, F352, and F353) and main drive fuses (F357, F358, and F359).
Close the rotor power fuse F303. Place the gantry service key switch into the “NORM” position.
33. Box up old cooling unit and return. Ensure all paperwork on cooling unit is completed.
34. Refer to System Calibration Manual for specific calibrations that need to be run.
!
completed, make sure that the four X-ray tube mounting bolts in the XRT cradle bracket
have unexpired Loctite #242 applied and are torqued to 56 ft-lb (75 Nm).
35. When calibrations are complete, rotate the rotor CW so the heat exchanger is in the 6 o’clock position.
Lock the motor.
36. Place the lower front cover into position on the gantry. Install bracket with three screws to the gantry.
Tighten the four 1/4” ‐ 20 socket head cap screws and 1/4” flat washers securing the lower front cover.
37. Lower the patient support. Grasp the side of the front cover and close the cover. You may have to
readjust the lower front cover to ensure proper alignment with the front cover.
38. Install the two 2 1/4” socket head cap screws from the bottom left and right corners on the front cover.
Section 22
Section 22 Heat Exchanger Fans Removal/Replacement
This procedure is used to remove and replace the heat exchanger fans. There are two heat exchanger fans
mounted underneath the heat exchanger. This procedure is identical for either fan.
22.1 Removal
WARNING: Hazardous voltages are inside the gantry front cover. Turn power to the Gantry OFF before
opening the front cover. Failure to do so may result in serious injury or death.
3. Release the main drive motor brake and rotate the rotor CW so the X‐ray tube is in the 12 o’clock
position. Pin the rotor with rotor locking pin and apply the motor brake.
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Heat Exchanger Fans Removal/Replacement
4. Remove eight nuts securing the heat exchanger to rotor, and set heat exchanger aside.
5. Disconnect the heat exchanger fan cable from the fan to be replaced.
6. Remove two screws, four flat washers, and two nuts securing fan guard to fan. Refer to Figure 22‐1 on
page 357.
7. Remove six screws securing the two tie wrap clamps to heat exchanger ducts.
8. Remove four screws and flat washers securing fan to heat exchanger duct, and remove fan.
Figure 22-1: Heat Exchanger And Fan Guards
22.2 Installation
1. Mount the fan to the heat exchanger duct with the UL and rating labels facing outwards. Refer to
3. Install four screws and flat washers securing fan to duct. Apply Loctite #222 and hand torque screws.
4. Assemble fan guard to fan with two screws, four flat washers, and two nuts. Apply Loctite #222 and
hand tighten screws.
Figure 22-2: Heat Exchanger And Fan Guards

5. Install heat exchanger fan cable to fan. Route cable as shown in Figure 22‐3 on page 359.

6. Apply spiral wrap to cable approximately four inches on either side of housing wall.
7. Install heat exchanger over studs on heat exchanger mounting duct. Add washer bars and install
eight nuts over studs.
8. Loctite and torque nuts to 15 in‐lb (170 Ncm).
9. Remove locking pin from rotor.
Figure 22-3: Heat Exchanger Cable And Plug Orientation
Note Plug Orientation Route Cable Down

Between Fan Housings
Note Plug
Orientation
WARNING: Hazardous voltages are inside the gantry front cover. Stay clear of powered items. Failure to
11. Check that the fans are operating properly.
12. Close the gantry front cover (see Closing the Ingenuity CT Gantry Front Cover on page 45).
Section 23
Section 23 A-Plane Collimator Removal/Replacement
Note: Reference Detector Replacement: The procedure for replacing the reference detector is in the applicable
Ingenuity CT DMS Repair and Replacement manual.
23.1 A-Plane Collimator Removal
Note: Do not disassemble the collimator because it is a certified component.
Tools Needed:
• Philips FSE tool set • Metric ruler
• 5/16 in., 3/8 in. drive hex key socket • Loctite #222
• 3/8 in. drive 3 in. extension • Metric hex keys: 1.5 mm, 2.5 mm, 5 mm, 6 mm,10 mm
• 3/8 in. drive ratchet
WARNING: Hazardous voltages inside. Turn power supply off before servicing. Failure to do so can result
in serious injury or death.
1. Turn OFF power to the gantry according to the section “Gantry Power Down (Except for the Host and
3. Remove the flat head screw securing lexan ring to the rear cone and slide the lexan ring into the rear
cone until it is out of the way.
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement A‐Plane Collimator Removal/Replacement
!
CAUTION: Always rotate the gantry rotor in a clockwise direction only (as viewed from gantry front).
4. Release the rotor drive motor brake and rotate the gantry rotor clockwise so the A‐Plane Collimator is
at the 6 o’clock position as shown in Figure 23‐1 on page 362. Lock the rotor with the locking pin at
upper left of rotor.
5. Loosen the connector retaining screws and unplug the two DMS cables on the left side. Refer to
Note: One way to access the bottom connector screws is by using a long, small‐diameter screwdriver as shown
in Figure 23‐2 on page 363 (if the rotor plate has the appropriate holes).
6. Loosen the connector retaining screws and disconnect the cable from the reference converter board on
the right side (see Figure 23‐1).
Figure 23-1: A‐Plane Collimator at 6 o’clock position
Disconnect reference
converter cable
Disconnect 2 cables
Figure 23-2: Accessing DMS Cable Connector Retaining Screws
Loosen screws,
remove both cables
Remove 2 Bolts -
1 On Each Side
7. The collimator bolts are recessed in areas at the bottom of the collimator near the rotor (see Figure 23‐
3). Using a socket wrench with a 3 in. extension and a 5/16 in. hex key socket, loosen and remove the
four SHCS that secure the collimator to the rotor (2 on each side) (Figure 23‐4 on page 365).
Figure 23-3: Collimator Bolt Location ‐ Left Side (right side is similar)
LH collimator mounting
SHCS (RH is similar)
8. Pull the collimator toward the front of the gantry enough to disengage it from the guide pins.
Note: The collimator weighs about 45 pounds (20.5 Kg).
9. Grab the collimator on each side and lift it up and out of the Gantry, being careful to not hold the area
around the DMC cables as seen in Figure 23‐1 on page 362.
Figure 23-4: Removing Collimator Mounting Bolts
10. Disconnect the cable from the reference converter, remove the 4 attaching screws and remove the
reference converter board from the removed collimator (see Figure 23‐5).
Figure 23-5: Reference Converter Board
Remove 4 screws to remove Disconnect cable

reference converter
23.2 A-Plane Collimator Installation

1. Remove the new collimator from its shipping container. Locate the A‐Plane manufacturing
documentation and the Calibration CD_ROM.
2. Verify that the A‐Plane serial number on the CD matches the serial number on the actual A‐Plane.
!
CAUTION: The A-Plane constants from the new CD-ROM must be installed prior to applying power to
the collimator. Possible damage to the collimator can occur if power is applied to the
collimator without installing the new constants.
3. Verify that the collimator rotor mounting surfaces are free of debris and the tube port is clean.
4. Attach the reference converter with the 4 screws and connect the cable (Figure 23‐5 on page 366).
5. Check the area around the collimator alignment pins and remove any shims that may be installed
there. (Shims should be installed on the collimator, not the gantry.)
6. Set the new collimator down on the rotor plate. Lift the collimator slightly to align the two holes in the
back with the alignment pins. The bottom of the collimator will be off of the rotor plate slightly when
set on the pins. The pins are shown in Figure 23‐6 on page 368. Make sure the collimator is pushed
back as far as it will go.
Figure 23-6: A‐Plane Collimator Alignment Pins

Alignment pins
8. Apply loctite #222 to the 4 SHCS and insert the four screws to secure the A‐Plane Collimator to the
rotor (Figure 23‐3 on page 364). One way to do this is to place the SHCS onto the hex key socket on the
3 in. extension (without the ratchet) and start the screw in using only your fingers.
9. Draw the collimator evenly onto the mounting pins by lightly tightening one of the SHCS on one side
of the collimator, then lightly tightening one of the SHCS on the other side. Alternate back an forth
tightening the SCHS until the collimator is all the way in place. Torque the SHCS to 22 ft‐lb (30 Nm).
!
CAUTION: Do not apply power to the collimator before loading new constants. The collimator may be
damaged if power is applied to the collimator before the new constants are installed.
10. Connect the cable to the reference converter board on the right side (Figure 23‐1). Tighten the
connector retaining screws.
11. Leave the power cable disconnected until the A‐plane constants are loaded (see Figure 23‐1), but
attach and secure the other DMC cable as indicated in Figure 23‐1.
Figure 23-7: Aplane cable connections

Leave Power Cable Disconnect-
ed Until A-Plane Calibration Install this cable
Constants Are Loaded
12. On the gantry switch panel turn OFF the DRIVES switch shown in Figure 23‐8 on page 371 to disable

the rotor drive.
WARNING: Hazardous voltages are inside the gantry when the power is on. Stay clear of all powered
items. Failure to do so can result in serious injury or death.
13. Power up the gantry according to the procedure “System Power Up” on page 34.
Note: In order to complete the tests in this section the DMP and the DMC PCBs must be fully booted up.
14. With the collimator power cable disconnected, load the A‐plane constants according to the following
procedure “Loading A‐Plane Calibration Constants (all software versions)” on page 372.
DRIVES
SWITCH
23.3 Loading A-Plane Calibration Constants (all

software versions)
1. Verify that the A‐Plane serial number on the CD Figure 23-9: Service Tools Selections

matches the serial number on the collimator.
2. Open Windows Explorer and create a new folder on
the D:\ drive named APLANE.
3. Copy the file with extension .clb from the CD to the
D:\APLANE\ folder just created.
Do not copy files with .jpg or .old extensions.
Do not use files downloaded from InCenter.
4. Right click on the file and select ”Properties” from
the drop‐down menu.
5. If the ”Read Only” box is checked, click on it to
unselect it, then click ”Apply” and ”Close”.
6. Close the application software if it is running.
7. Log in as philips_service.
8. Open Service Tools.
9. Start up the DMC Utility by clicking on Diagnostic
Tools > DMS Tools > DMS Utilities
The DMC Utility selection window shown in
Figure 23‐10 on page 373 should be displayed.
e A‐Plane serial number on the CD matches the serial number on the collimator.
10. Set the window to the tile mode so other windows can be displayed at the same time.
11. On the DMS Utility Selection window, click on the DMC Utility button (see Figure 23‐10).
The DMC Utility screen shown in Figure 23‐11 on page 374 should be displayed.
Figure 23-10: DMS Utilities Selection Window
!
CAUTION: Do not enter values from the .clb file manually into the DMC Utility. Doing so will cause the
A-plane to operate incorrectly.
12. On the DMC Utility screen Figure 23-11: DMC Utility Screen
(see Figure 23‐11) click on the
OpenJIGFile icon at the top (second icon
from the left as indicated in Figure 23‐11 “Open JIG File” icon
on page 374.
13. In the Open Folder window, navigate to
the D:\APLANE\ folder just created,
select the .clb file copied from the CD and
click on the Open button. This will upload
the .clb file and the values from the file
should be displayed.
14. With the A‐Plane Tab still selected and the
values displayed (see Figure 23‐11) click
on the”SetAC” button to save calibration
values to NVRAM.
15. Write down the values displayed. These
will be used for comparison to verify that
new values are loaded.
16. To verify the values were stored correctly,
click on the ”Clear” button and then on
the ”GetAC” button. (The GetAC button
displays the values stored in NVRAM.) If
the file is properly loaded to NVRAM, the
numbers displayed will match those
displayed in Step 15 on page 374 before
the clear button was selected.
17. Remove the CD from the Host drive and
place it in the system data book.
18. After the A‐Plane constants are loaded, connect the power cable to the collimator (see Figure 23‐2).
Note: The A‐plane collimator cannot be tested or calibrated with the power cable disconnected.
19. Perform “Test 1: Test for ʹPhase Angleʹ problem” on page 376 and “Test 2: Test for ʹSetʹ problem” on
page 384.
Note: If the collimator passes the “Test 1: Test for 'Phase Angle' problem” on page 376 and “Test 2: Test for
'Set' problem” on page 384 it is functioning properly and the collimator A-Plane Encoder Calibration
does not need to be performed; however, all other required image quality calibrations specified for
collimator replacement in the applicable Ingenuity CT Calibration manual will need to be
performed including the XRT Mechanical Alignment and A-plane Z-mechanical alignment as well
as Air, Phantom, and HCOR calibrations.
23.4 A-Plane Slice-Width Operation Test Procedure

The following tests must be performed when a collimator is replaced to verify that the A‐Plane Collimator
can provide proper slice width operation in all slice configurations.
23.4.1 Test 1: Test for 'Phase Angle' problem

1. If the DMS Utility Selection Screen shown in Figure is not still displayed, start up the DMS Utility by
clicking on Diagnostic Tools > DMS Tools > DMS Utilities.
The DMS Utility selection window shown in Figure should be displayed.
2. Set the DMS Utility Selection window to the tile mode so other windows can be displayed at the same
time.
3. On the DMS Utility Selection window, click on the DMC Utility button (see Figure ).
4. The DMC Utility window shown in Figure 23‐13 on page 377 should be displayed.
Figure 23-12: DMS Utilities

Figure 23-13: DMC Utility Window
5. On the DMC Utility Selection window click on the Aplane Reader button to open the Aplane reader
window (see Figure 23‐11).
6. Move the Aplane Reader window so that both the DMC Utility window and the Aplane reader are
visible at the same time.
7. On the Aplane reader, click on the “Reading” button so that it indicates “ON” (green) to start the
reader (see Figure 23‐11).
8. Select the “Go2Position” tab on the DMC Utility. The display should be as shown in Figure 23‐15.
Figure 23-14: A‐Plane Reader
CLICK READING BUTTON SO IT TURNS

GREEN (ON) TO START READER
Note: This note is to give you an overview of the process in the following procedure. In the following procedure,
while watching the Aplane Reader display you will command a collimator movement, and when the
movement is complete, click on the Reading button to turn it off and stop the display. The testing range is
1,000 to 15,000 microns.
9. In the A Plane Units box enter 15,000 (see Figure 23‐15).
10. While watching the Aplane Reader, click on the “Move” button on the DMC Utility Go2Position
screen (see Figure 23‐15).
11. When the collimator movement is complete, turn OFF the Aplane Reader by clicking on the Reading
button to turn it off and stop the display. The display should look similar to Figure 23‐16 on page 381.
Figure 23-15: DMC Utility Menu with Go2Position Tab Selected

Go2Position Tab
Enter slice width opening of

15,000 microns
Move Button
12. Check the slice width reading in the A‐plane reader to verify that the requested position 15,000) has
been reached (+/‐ 75 microns from requested value). Refer to Figure 23‐16.
13. On the A‐plane reader, start the reader again by clicking on the “Reading” button so that it displays
“ON”.
14. On the DMC Utility Menu, change the Go2 Position from 15,000 to 100 microns.
Figure 23-16: A‐Plane Reader Display (top part) for Going to a 15,000 Micron Slice Width
Slice width graph slope must be smooth

with no breakpoints or changes in angle Slice width should be
(this is an acceptable/good graph) 15,000 +/- 75 microns
15. While watching the Aplane Reader, click on the “Move” button on the DMC Utility and observe the
graph of the slice width position (the red line) as the opening changes (see Figure 23‐16). The blade
motion line should be smooth, not wiggly.
16. When the movement is complete in the A‐plane Reader, click on the “Reading” button to switch it to
“OFF” to stop the display.
In the reader displays for both the open and close commands, the plotted slope of the slice width
graph should be smooth with no interruptions or changes in slope as shown in Figure 23‐17.
Figure 23-17: A‐plane Reader Display for Slice Width Change from 15,000 to 100 Microns

(Step 16 on page 374)
Slice width graph slope must be smooth Spikes at end of transition

with no breakpoints or changes in angle. are normal
17. If a system displays breakpoints in the slope as shown in Figure 23‐18 on page 383 it has a “Phase

Angle” problem.
If a system displays breakpoints in the slope as shown in Figure 23‐18 on page 383 replace the A‐
plane Collimator.
Note: Collimators that exhibit the “Phase Angle” problem will give wrong slice openings (smaller or larger
than requested) over the range where the slope is incorrect.
Figure 23-18: A‐Plane Reader Display for a Collimator with a “Phase Angle” Problem
Breakpoint in the slope of slice width graph.

In this example, it is at approximately 5000uM.
(Note: There could be multiple breaks at any
point in the graph).
23.4.2 Test 2: Test for 'Set' problem

1. Return to the DMC utility and open the “Go2Position” tab (see Figure 23‐19).
2. Be sure that the A‐Plane Reader utility is open.
3. On the A‐plane reader, click on the “Reading” button so that it displays “ON” to start the reader.
4. On the DMC Utility window click on the “Go2Position” tab (see Figure 23‐19).
5. In the Aplane units box enter a slice width of 1000 microns (uM) (see Figure 23‐19).
6. Click on the Move button. The A‐plane Reader should show that the collimator blades moved to
1,000.
Figure 23-19: DMC Utility Screen ‐ G2Position Tab Selected
1000 Aplane Units
Move Button
7. On the DMC Utility Screen, click on the “A‐plane” tab to select it (see Figure 23‐20).
IMPORTANT: Check that the A-Plane values displayed are the values that were loaded from the .clb and
recorded in Step 15 on page 23-374. Wrong values will cause the collimator to malfunction.
If needed, obtain the current values from the DMC NVRAM by pressing the GetAC button.
8. While watching the Aplane reader, press the ʹSetACʹ button on the DMC Utility window.
9. On the A‐Plane reader observe the slice width displayed (the RED line and numeric value) as you
press the “SetAC” button. You may see a temporary spike but the graph should always return to the
current opening. Confirm the current opening value in the A‐plane read out.
Figure 23-20: DMC Utility Screen ‐ A‐Plane Tab Selected
Make Sure All Values Dis-

played are same as Step 15 on
page 23-374
Press SetAC
10. While watching the Aplane reader, press ʹSetACʹ button on the DMC Utility window at least five
times in succession. Ensure that neither the graph nor the numeric value changes from the current
displayed position.
11. Repeat Step 4 on page 384 to Step 10 on page 386 for openings: 2000, 5000, 8000, 10,000 11,000, 12,000
& 15,000.
12. If the value does jump, the results will look like Figure 23‐18 on page 383.
Note: Since the A‐Plane reader cannot display negative numbers, an error will be displayed as a large jump in
the position reading. In the example of Figure 23‐18 on page 383, note that the SW position has changed
from the original commanded 150uM to 61,688uM. The position trace has jumped off of the graph. The
change may occur in the other direction where a 1000 micron reading may suddenly jump to a 4000 or a
10000 uM opening to 14000 immediately after a set. If this occurs it must be corrected.
13. Repeat Step 4 on page 384 to Step 10 on page 386 for an opening of 150 uM and depress the “SetAC” a
total of 6 times. Verify that neither the line nor numeric value change from the current displayed
position. A temporary spike in the display is normal when the “SetAC” button is depressed.
Figure 23-21: A‐Plane Reader Display for Collimators with “Set” Problem
Position readout
has jumped
from 150uM to
61688uM
Red slice width

position graph
has jumped off
of the scale.
14. If the collimator exhibits the “Phase Angle” problem or the “Set” problem:
a) Complete the collimator A-plane Encoder Calibration from the Selective Calibration pull-down
menu according to the applicable Ingenuity CT System Calibration manual for the version of
software loaded on the system.
Note: If the A‐plane encoder calibration is not available in Selective Calibrations, it may also be found in
service tools.
b) After performing the A-Plane Encoder calibration procedure, repeat the “A-Plane Slice-Width
Operation Test Procedure” on page 376.
c) If the collimator passes the “Test 1: Test for 'Phase Angle' problem” on page 376 and “Test 2: Test
for 'Set' problem” on page 384, skip to calibration and final checks starting in Step 15 on page 388
below.
d) If the collimator still exhibits the “Phase Angle” problem or the “Set Problem” after the A-Plane
Encoder calibration has been performed, replace the collimator.
15. If the collimator passes the “Test 1: Test for ʹPhase Angleʹ problem” on page 376 and “Test 2: Test for

ʹSetʹ problem” on page 384, perform the following Collimator Verification Procedure on page 388.
23.5 Collimator Verification Procedure

This procedure is for verifying that the actual collimator blade opening tracks closely with the opening
indicated on the Aplane Readers and that the collimator does not exhibit a phase angle problem or have
an incorrect .clb file loaded. This verification must be done each time a collimator is replaced.
WARNING: Failure to confirm slice width may result in incorrect blade openings, thus potentially
exceeding radiation dose and causing overexposure.
!
CAUTION: Be very careful not to allow any debris to fall into the collimator opening.
16. Lift up one end of the plastic tape over the collimator opening (see Figure 23‐22). Pull it off the

opening, fold it back so the sticky side is toward the collimator, and stick it to the bracket as shown in
Figure 23-22: Removing The Tape from the Collimator Opening
Fold tape back and stick to bracket
Note: In order to complete the tests in this section the DMP and the DMC PCBs must be fully booted up.
17. If not already open, open Service Tools by selecting Diagnostic Tools > DMS Tools > DMS Utilities.
18. Set the DMS Utility Selection window to the tile mode so other windows can be displayed together
19. On the DMC Utility Selection window, click on the Aplane Reader button to open the Aplane reader
window (see Figure 23‐11).
20. Move the Aplane Reader window so that both the DMC Utility window and the Aplane reader are
visible same time.
21. On the Aplane reader, click on the “Reading” button so that it indicates “ON” (green) to start the
reader (see Figure 23‐11).
Figure 23-23: A‐Plane Reader

CLICK READING BUTTON SO IT TURNS CHECK OPENING READING HERE
22. On the DMS Utility Selection window, click on the DMC Utility button.
The DMC Utility window shown in Figure 23‐24 should be displayed.
23. Select the “Go2Position” tab on the DMC Utility. The display should be as shown in Figure 23‐24.
24. In the A Plane Units box enter a slice width opening of 1500 microns (1500 microns = 1.5 mm)
Figure 23‐24.
25. Click on the Move button (Figure 23‐24).
26. On the Aplane Reader, check that an opening of 1500 microns (+/‐ 75 microns) is indicated (Figure 23‐
11 on page 374).
Note: The maximum selectable collimator blade opening is 15 mm (15,000 microns) for Ingenuity systems.
Figure 23-24: DMC Utility Menu with Go2Position Tab Selected

Go2Position Tab
Enter slice width opening

of 1500 microns
(1500 microns = 1.5 mm)
1500
Move Button
!
CAUTION: The collimator blades are delicate. Be careful not to scratch, nick, or gouge blades when
checking blade openings.
27. Carefully attempt to insert a 1.5 mm hex key into the blade opening with the flat sides of the key next
to the blades as shown in Figure 23‐25 on page 392.
The 1.5 mm hex key should fit freely through the opening.
28. Carefully attempt to insert a 2 mm hex key into the blade opening as shown in Figure 23‐25 on
page 392.
The 2 mm hex key should NOT fit through the opening.
29. Repeat Step 23 on page 23‐391 through Step 28 on page 392 (above) to verify collimator openings of
5,000 and 10,000 microns using 5 mm and 6 mm hex keys to check the 5,000 micron opening and a 10
mm hex key for 10,000 microns. Use a ruler to check that the blade opening for the 10,000 micron
setting is not more than 11 mm.
Figure 23-25: Verifying Collimator Blade Opening with a Hex Key
INSERT HEX KEY INTO

BLADE OPENING
30. Repeat Step 23 on page 391 through Step 28 on page 392 (above) to verify a collimator opening of

15,000 microns except by using a metric ruler as shown in Figure 23‐26 to measure the blade opening.
The opening should not be less than 15 mm or more than 16 mm.
Figure 23-26: Checking Collimator Blade Opening Using a Ruler
31. If the collimator blade openings are not correct perform the following:
a) Reload the calibration file according to the procedure “Loading A-Plane Calibration Constants (all
software versions)” on page 372 and perform this verification procedure again.
b) If the collimator blade openings are still not correct, perform the encoder calibration according to
the according to the applicable Ingenuity CT Calibration manual and perform this verification
procedure again.
c) If the collimator blade openings are still not correct, reject the collimator and order a new collimator
assembly.
32. When it has been verified that the collimator blade openings correspond to the openings displayed in
the A‐plane Reader, reattach the clear plastic tape over the collimator opening to keep out debris.
33. Remove the rotor locking pin.
34. On the gantry switch panel turn ON the DRIVES switch shown in Figure 23‐9 on page 372 to enable
the rotor drive.
35. Proceed to the following section “Calibrating and Returning the System to Normal” on page 394.
23.6 Calibrating and Returning the System to Normal

1. If the collimator passes the “Test 1: Test for ʹPhase Angleʹ problem” on page 376, “Test 2: Test for ʹSetʹ
problem” on page 384, and the “Collimator Verification Procedure” on page 388, perform the
alignments and calibrations specified for collimator replacement except for A‐Plane Encoder
Calibration according to the applicable Ingenuity CT Calibration manual.
Note: If the collimator passes the “Test 1: Test for 'Phase Angle' problem” on page 376 and “Test 2: Test for
'Set' problem” on page 384 it is functioning properly and the collimator A-plane Encoder Calibration
does not need to be performed; however, all other required image quality calibrations specified for
collimator replacement in the applicable Ingenuity CT Calibration manual will need to be
performed including the XRT Mechanical Alignment and A-plane Z-mechanical alignment as well
as Air, Phantom, and HCOR calibrations.
2. When the collimator testing and the calibration is complete:
a) Check image performance.
b) Backup calibration files from DMC NVRAM.
c) Backup site configuration.
3. Close the gantry front cover (see “Closing the Ingenuity CT Gantry Front Cover” on page 45).
4. Slide the rear cone lexan ring forward into position and install the screw to secure it to the rear cone.
23.7 Returning the Old Collimator

Re‐package the “old” collimator in the “new” collimator shipping box so it will not be damaged
during transit. This expensive assembly can be repaired from all types of problems, and must not be
discarded.
Note: Make sure to complete and submit all the paperwork required by the key market. In the USA an
Assembler’s Report (form 2579) must be completed and submitted to the FDA.
Note: When returning a collimator, place a detailed written description of the symptoms in the shipping
container. This will help the repair facility to diagnose and repair the collimator and may help to
prevent future problems.
Note: The CD for the old collimator must be shipped back with the old collimator. The old .clb file on the hard
drive must also be deleted to prevent the wrong file from being loaded.
23.8 Procedures to Un-jam Collimator Blades or Z-

carriage
Calibration of the A-Plane Encoder can introduce a 'set problem' on the working/functional collimator
which may cause jamming of the collimator blades. This section contains three separate procedures that
can be used to un-jam the collimator blades or z-carriage while this issue is under investigation by CT
Engineering. These procedures should be attempted in the order they are listed. The procedures
are:
• Procedure 1: Un‐jamming Collimator Using DMC Utility on page 396
• Procedure 2: Un‐jamming Collimator Using DMC Service Switches on page 398
• Procedure 3: Un‐jamming Collimator Using Existing Vicor Power Supply on page 404
23.8.1 Procedure 1: Un-jamming Collimator Using DMC Utility

1. In Service Tools, select Diagnostic Tools > DMS Tools > DMS Utilities.
2. Close E‐stop.
3. Open the A‐plane Reader.
4. In A‐plane reader, turn Information Reading on (the red button turns green when enabled).
5. Under DMS Utilities, open DMC Utility.
6. Choose Go2Position tab.
7. Press Alt‐Tab to bring up A‐plane Units window on‐screen.
Note: Have the A‐Plane Units window and DMC Utility window open at the same time on the screen.
8. Enter 5000 into A‐plane Units box. (5000 μm equals 5 mm)
9. Ensure μm is selected and hit Move button.
10. Look at the A‐plane reader and ensure that the red position line (top graph) is close (+/‐ 100) to 5000
μm, and the position display reads approximately 5000 μm (5 mm) (Figure 23‐27 on page 397).
Note: The slice width can now be exercised. For collimators 4535 670 62391 allowable movements are from 0 to
16,000 μm (0 to 16 mm).
11. 1.Go to the “Collimator Verification Procedure” on page 388, and test the collimator for normal
operation.
12. If blades are still jammed, go to Procedure 2: Un‐jamming Collimator Using DMC Service
Switches on page 398.
Figure 23-27: A Plane Reader
Position Line
Position display
23.8.2 Procedure 2: Un-jamming Collimator Using DMC Service

Switches
!
CAUTION: Always keep a close visual watch on the collimator blades whenever moving them manually
using the DMC switches. Be aware when mechanical limits are reached.
1. From Scanner applications, select the Home button in the upper left of the screen to activate the
‘HOME’ window.
2. A menu appears on the left side consisting of light gray background and medium blue menu bars.
Select the medium blue menu bar labeled Calibration.
3. Select Calibration CAN Interface.
WARNING: Hazardous voltages are inside the gantry when covers are open. Exercise extreme caution
when servicing. Failure to do so may result in serious injury or death.
4. The best position to view the collimator blades is with the collimator at six o’clock, and the DMS at
the 12 o’clock position (see Figure 23‐28). Open the front cover of the gantry. Refer to “Opening the
Ingenuity CT Gantry Front Cover” on page 40. Use caution while enabling the front door interlock
switch and whenever the rotor is commanded to move.
Figure 23-28: A‐Plane Collimator at 6 o’clock position
5. From the CAN Utility, select Rotor_Position_180 and then send the command. Ensure the collimator
moves to the 6 o’clock position.
6. Use the keyswitch to open E‐stop.
7. Disable Front Door Interlock.
8. Open Service Tools, select Diagnostic Tools > Controller Utilities.
9. In Controller Utilities, Connect as Zone Specialist, then click Connect.
10. Click Service Mode.
Note: When in Service Mode, you will be unable to use the A‐Plane Reader tool to verify feedback and
positioning.
11. Click Connect to Controller from the Configuration Tool.
12. Click DMC.
13. Click Toolbox.
14. Click DMC Baseboard.
15. Click Move collimators using switches.
Enter a time‐out value (between 1 and 10) into Submit Parameters box (see Figure 23‐26) to keep the
program from timing out. For example: entering a 1 will time out in approximately one minute,
entering a 10 will time‐out in approximately ten minutes. The timing is done with loops and is
approximate. Select Submit Parameter. Note that the status: ’PP Pos = 800 Int. Status = 0’ will scroll
down right side, which is an indication the switches on the DMC are now enabled.
Note: If you want to interrupt the loop and stop the status from scrolling, you will need to log out and then log
back in.
Figure 23-29: Controller Utilities
Enter time-out value here
16. It is suggested to point a flashlight down at the collimator blades depending on available light in the
scan room. Be very careful during the next step. Do not run the blades of the collimator into each
other. Do not run the blades of the collimator away from each other into the outside limits (0 to 16
mm).
17. While keeping a close eye on the collimator blades, pulse the DMC switch labeled “Slice Width”
(see Figure 23‐30) once to get a feel for which direction the blades are moving. The switch can be
jogged in either direction.
Figure 23-30: Location of DMC Slice Width switch
Slice width switch
18. Using the “Slice Width” switch, move the blades as close to the center of the window (Z‐direction) as
possible. Note that the Slice Width switch controls the gap between the blades (use this to set gap
between blades to a few mm to better see how close to center the gap is). Note that the switch labeled
“Z Dir” controls the location of both blades (the Z‐carriage) in unison, in the Z direction. Center the
gap between the blades with respect to the collimator’s window (see Figure 23‐31).
Figure 23-31: Centering Gap between Blades in Window
19. From the Host, wait for the scrolling to stop in the User Information window (DMC switch enabling
times out based on the time‐out value entered from Step 15 on page 400).
20. Click Quit, then click Continue.
21. Click Return (4) times to back out.
22. Click Application Mode. Wait for the CT Box displays to stop flashing. The E‐stop window comes up
and the buttons will then become disabled. Click Exit.
23. Enable Front Door Interlock.
24. Go to the “Collimator Verification Procedure” on page 388. If blades are still jammed, go to
Procedure 3: Un‐jamming Collimator Using Existing Vicor Power Supply on page 404.
23.8.3 Procedure 3: Un-jamming Collimator Using Existing Vicor

Power Supply
Note: Shorting output of the Vicor power supply will cause a shutdown of the output without any harm to the
power supply. Removal of short will cause an automatic recovery of the power supply. The Vicor power
supply is rated 24 VDC 100 W (just over 4 Amps) where A‐plane requires up to 2 Amps to un‐jam.
Note: Before performing this procedure, confirm that the Vicor power supply to be used has 24 VDC output.
Some of the Vicors have more than one output. Measure the Vicor output voltage to confirm 24 VDC.
1. Rotate the rotor to place the collimator at the 6 o’clock position.
2. Using a flat head screwdriver, remove the two screws securing the 9‐pin A‐Plane cable connector
from the collimator, and disconnect the cable from the connector (see Figure 23‐32). Use the access
hole in the rotor frame to access the two screws.
Figure 23-32: Collimator Connector
Remove 9-pin Type D

A-plane cable connector
3. Use two wires (at least 2 amp size) approximately two feet in length and strip wire ends. Insert the
bare end of each wire into cable connector pinouts 1 and 6. Refer to Figure 23‐33 on page 406 below
and the schematic Figure 23‐34 on page 407.
Figure 23-33: Wires connected into connector pins 1 and 6
Connect one end of each wire to

connector pinouts 1 and 6
Note: Use the A‐plane motor cable schematic below as a reference to unplug the cable from the DMC and
connect the Vicor power supply to the respective motor on the A‐plane. All A‐plane motors are 24 VDC,
the same as the Vicor power supply.
Note: Reversal of leads will cause motor to drive in opposite direction.
Figure 23-34: Schematic
4. Touch the other bare end of both wires to the positive and negative terminals of the Vicor power
supply (see Figure 23‐35). Pin 1 wire to positive (red) terminal, pin 6 wire to negative (black) terminal.
Figure 23-35: Connections to Power Supply
Positive terminal Negative terminal
5. Listen for the sound of the collimator blades opening and closing. Visually confirm if blades are
opening and closing when voltage is applied. Reversing leads will cause motor to drive in opposite
direction.
6. If collimator blades are un‐jammed, remove the wires from the 9‐pin A‐plane cable connector. Re‐
install A‐plane cable to the 9‐pin connector, and secure connector with two screws.
7. If the collimator is unjammed, perform the section “Collimator Verification Procedure” on page 388.
8. If blades are still jammed, replace collimator. Refer to “A‐Plane Collimator Removal/Replacement” on
page 361.
Section 24
Section 24 Reference Converter Board Removal/Replacement
The reference converter board is located on the right‐hand side of the A‐plane collimator.
24.0.1 Removal
WARNING: Hazardous voltages are inside the gantry front cover. Turn gantry power supply off before
servicing. Failure to do so can result in serious injury or death.
1) Turn OFF power to the gantry (see Gantry Power Down (Except for the Host and CIRS) on page 27).
2) Open the gantry front cover (see Opening the Ingenuity CT Gantry Front Cover on page 40).
3) Remove the flat head screw securing lexan ring to the rear cone and slide the lexan ring into the rear
cone until it is out of the way.
!
CAUTION: Always rotate the gantry rotor in a clockwise direction only (as viewed from gantry front).
4) Release the rotor drive motor brake and rotate the gantry rotor clockwise so the A‐Plane Collimator is
at the 6 o’clock position.
5) Lock the rotor with the locking pin at upper left of rotor and apply the motor brake.
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Reference Converter Board Removal/Replacement
6. Remove the cable from the reference converter board on the right side of the collimator (Figure 24‐1).
7. Remove 4 screws and lock washers securing reference converter board cover, and remove the cover.
8. Remove the four cover standoffs and remove the reference converter board.
Figure 24-1: Reference Converter Board Location
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Reference Converter Board Removal/Replacement
24.0.2 Installation
1. Position the reference converter board on the right side of the collimator and install four standoffs
securing board to collimator. Refer to Figure 24‐1 on page 411.
2. Install the reference converter board cover with four screws and lock washers.
3. Install cable connection to reference converter board.
4. Remove locking pin from rotor.
5. Close the gantry front cover (see ‘Closing the Ingenuity CT Gantry Front Cover on page 2‐45).
6. Slide the rear cone lexan ring forward into position and install the screw to secure it to the rear cone.
7. Apply Gantry power (see ‘System Power Up on page 1‐34).
8. Verify that the system is operating properly.
Section 25
Section 25 FRC Assembly Replacement
Estimated Time: 30 minutes
Tools Required:
• FE Tool Kit
• Loctite #222 and #242
The FRC is located on the front of the Rotor as shown in Figure 25‐1.
Figure 25-1: FRC Location on the Front of the Rotor

(system with MRC 880 XRT shown ‐ systems with MRC 600 & 800 XRTs are similar)
FRC ASSEMBLY
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement FRC Assembly Replacement
25.1 Removing the FRC Assembly
WARNING: Hazardous voltages are inside the gantry. Turn power off before servicing. Failure to do so
may result in serious injury or death.
1. Turn power OFF to gantry according to the procedure “Gantry Power Down (Except for the Host and
2. Open the Gantry Front Cover (see “Opening the Ingenuity CT Gantry Front Cover” on page 40).
!
CAUTION: When rotating the gantry rotor by hand, always rotate in a clockwise direction (as viewed
from gantry front).
3. If the X‐ray tube is not at the 12 o’clock position, unlock the main rotor drive motor brake and rotate
the gantry rotor CW so the X‐ray tube is at the 12 o’clock position.
4. Pin the rotor with locking pin at upper left of rotor.
5. Apply the rotor drive motor brake.
!
CAUTION: Observe all anti-static precautions according to the Brilliance CT Safety Manual. Use an anti-
static wrist band according to the section (ESD‐Anti‐Static Field Service Kit in the Ingenuity Safety
Manual). Failure to comply may result in equipment damage.
6. Mark as necessary and remove the cables from both ends of the FRC (Figure 25‐2 on page 415).
Note: Be sure that cables are labeled because there are some connectors that will fit more that one place.
7. Cut the cable ties as required to free the cables from the FRC.
LEFT CONNECTORS
RIGHT CONNECTORS
NEWER STYLE COVER

WITH END COVERS
8. Remove the 7 cover screws and remove the cover from the FRC (see Figure 25‐3 on page 416).
Figure 25-3: FRC Cover Screws

9. Mark as necessary and disconnect the cables from the rear of the FRC (see Figure 25‐4 on page 417).

Be sure that the cables are marked with their connection locations because there are connectors that
will fit in more than one place.
Figure 25-4: FRC Rear Connectors
DISCONNECT REAR
CONNECTORS
10. Remove the 2 screws attaching the HV cable clamps to the front of the FRC (see Figure 25‐5 on

page 418).
11. Remove the 3 front and 3 rear FRC mounting screws (see Figure 25‐5 on page 418).
12. Remove the FRC assembly from the rotor.
Figure 25-5: FRC Mounting Screws
REMOVE HV CABLE
CLAMP SCREWS
REMOVE 3 FRONT MOUNTING SCREWS

AND 3 IN BACK
25.2 Installing the FRC Assembly

1. Remove the 7 cover screws and remove the cover from the new FRC (see Figure 25‐3 on page 416).
2. Place the FRC into position on the rotor.
4. Apply Loctite #242 to the 6 mounting screws and install the 3 front and 3 rear FRC mounting screws
(see Figure 25‐6 on page 420).
5. Torque the mounting screws to 10.5 ft‐lb (14.2 Nm).
7. Apply Loctite #222 to the 2 HV cable clamp screws and install them (see Figure 25‐6 on page 420).
Figure 25-6: FRC Mounting Screws
INSTALL HV CABLE
CLAMP SCREWS
INSTALL 3 FRONT MOUNTING SCREWS

AND 3 IN BACK
Note: The replacement FRC will come with a filter on the back (see Figure 25‐7 on page 421). The output of the

filter will come connected to J8 as shown.
8. When replacing an older style FRC with a newer style FRCs with a filter (see Figure 25‐7) connect the
plug that was connected to J8 on the older unit to the input connector on the filter on the newer FRC
Figure 25-7: Connections on FRC with Line Filter
CONNECT CONNECTOR THAT WAS CONNECTED

TO J8 ON OLD UNIT TO THIS FILTER CONNECTOR
Note: The output of the 12 V optical transmitter power supply inside the FRC must be checked with the power
supply loaded, and if necessary, adjusted.
The replacement FRC top cover also covers the 2 ends of the FRC and blocks access to the
12 V supply adjustment. So to make the 12 V supply output check, the cables will need to be connected to
the FRC and the power turned on. However, the cover needs to remain off to allow access for adjusting
the 12 V power supply.
9. To prepare for checking the 12 V power supply connect the remaining cables to the FRC as indicated
in Figure 25‐8 on page 422). Be sure the connectors are put back into their correct locations as there are
some connectors that will fit in more than one place.
10. Check and adjust the 12V power supply according to the procedure “Checking the 12V Power
Supply” on page 423.
LINE FILTER CONNECT REAR

CONNECTS HERE CONNECTOR
(see Figure 25-7)
CONNECT REAR
CONNECTOR
CONNECT RIGHT
CONNECTORS
CONNECT LEFT
CONNECTORS
25.2.1 Checking the 12V Power Supply

1. Remove the rotor locking pin and rotate the rotor CLOCKWISE ONLY to place the optical
transmitter in a convenient position of measuring the voltage.
2. Remove the gantry rear cover according to the procedure “Removing the Gantry Rear Cover” on
page 112.
3. Remove the gantry rear cone according to the procedure “Removing the Ingenuity CT Gantry Rear
Cone” on page 128.
4. Turn ON the gantry power by pressing the blue power toggle button (see “System Power Up” on
page 34.
Figure 25-9: Rotor Optical Transmitter Power Connector

INSERT METER PROBES INTO

POWER CONNECTOR TO
MEASURE VOLTAGE
25.2.2 Adjusting the 12V Power Supply

1. If the 12V power supply voltage is NOT between 10.8 VDC and 13.2 VDC turn OFF power to the FRC
by opening rotor power fuse holder F303 in the gantry left column (see Figure 25‐10 on page 424).
This removes 120 VAC from the rotor components.
ROTOR POWER
FUSE F303
2. Determine the type of 12V power supply that is in the FRC according to Figure 25‐11 on page 425.

• For older model power supplies proceed to “Adjusting the Older Style 12 Volt Power Supply”
on page 426.
• For newer model power supplies go to “Adjusting the Newer Style 12 Volt Power Supply” on
page 427.
Figure 25-11: Identifying Models of 12 V Power Supplies in the Right End View of the FRC
TERMINALS PARALLEL TO TERMINALS PERPENDICULAR TO

THE BACK OF THE FRC THE BACK OF THE FRC
OLDER STYLE POWER SUPPLY NEWER STYLE POWER SUPPLY
Adjusting the Older Style 12 Volt Power Supply
WARNING: Hazardous voltages are present in the FRC. Make sure the power is off when working inside
the FRC. Failure to do so may result in serious injury or death.
For older model 12V supplies:
1. Make sure the power to the FRC is turned off by opening rotor power fuse holder F303 in the gantry
left column (see Figure 25‐10 on page 424).
2. Adjust the pot shown in Figure 25‐12 on page 426.
3. Check the voltage according to the appropriate section:
• “Checking the 12V Power Supply” on page 423.
Figure 25-12: Voltage Adjustment Pot on Older 12 V Power Supplies in the FRC

RIGHT END VIEW OF FRC 12 V ADJUSTMENT POT
Adjusting the Newer Style 12 Volt Power Supply

For adjusting the newer model power supplies (see Figure 25‐11 on page 425) it will be necessary to
unmount and lift the FRC circuit board in order to gain access to the voltage adjustment pot.
WARNING: Hazardous voltages are present in the FRC. make sure the power is off when working inside
the FRC. failure to do so may result in serious injury or death.
1. Make sure the power to the FRC is turned off by opening rotor power fuse holder F303 in the gantry
left column (see Figure 25‐10 on page 424).
2. Disconnect the connectors from each side of the FRC board (see Figure 25‐13). The rear connectors
may be left connected but it may be necessary to cut some cable ties.
LEAVE REAR LEAVE REAR

CONNECTORS CONNECTORS
CONNECTED CONNECTED
DISCONNECT
CONNECTORS
DISCONNECT
CONNECTORS
3. Remove the 7 stand‐offs that mount the FRC circuit board (see Figure 25‐14).
Figure 25-14: FRC Board Mounting
REMOVE 7 STAND-OFFS

4. Lift the front side of the board (see Figure 25‐15).
5. Use some method to hold the board in the lifted position as shown in Figure 25‐15 on page 429.
Figure 25-15: Lifting the FRC Board to Access the 12V Adjustment

TAPE HOLDING BOARD UP
6. Using a small screwdriver with about a 1/16‐in. wide blade Slightly turn the adjustment pot shown in
7. Lower the circuit board into mounting position and loosely install one stand‐off to hold it in position.
8. Connect all the cables to the FRC board (see Figure 25‐8 on page 422).
9. Close rotor fuse F303 (see Figure 25‐10 on page 424).
10. Check the voltage according to the appropriate section:
Figure 25-16: Voltage Adjustment Pot on Newer 12 V Power Supplies in the FRC

12 V ADJUSTMENT POT
(BOTTOM POT)
RIGHT END VIEW OF FRC

1. Open the rotor power fuse holder F303 in the gantry left column (see Figure 25‐10 on page 424).
2. If the FRC circuit board was removed apply Loctite #222 to the 7 stand‐offs and attach the FRC board

INSTALL 7 STAND-OFFS
3. If the cable ties on the rear cables were removed, install new cable ties.
4. Disconnect the cables from the right and the left of the FRC so the top cover can be installed (see
Note: Leave the rear cables connected.

DISCONNECT
RIGHT
DISCONNECT CONNECTORS
LEFT
CONNECTORS
5. Place the top cover into place on the FRC.
7. Apply Loctite #222 to the 7 cover screws install them into the top cover (see Figure 25‐19 on page 433)
and hand tighten them.
Figure 25-19: FRC Cover Screws
8. Install the cables onto both sides of the FRC (see Figure 25‐20 on page 434).

9. Secure all cables into position with cable ties.

LEFT CONNECTORS
RIGHT CONNECTORS
NEWER STYLE COVER

WITH END COVERS
10. Release the rotor drive motor brake and slowly rotate the rotor CW to check that all of the cables have
clearance.
11. Apply the drive motor brake.
12. Install the gantry rear cone according to the procedure “Installing the Ingenuity CT Gantry Rear
Cone” on page 133.
14. Close the front cover and return the patient support to normal position (see “Closing the Ingenuity
CT Gantry Front Cover” on page 45).
15. Power up the system and test for proper operation. Refer to System Performance manual.
Section 26
Section 26 Cathode Power Module Assembly Removal/Replacement
Tools required:
• FE Tool kit
• Generator service (lift) tool and lift tool strap pad assembly
• Supplies:
• Silicon paste
• Cathode silicon washer
• HV Connector Cover
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Cathode Power Module Assembly Removal/
26.1 Saving X-ray Power Module Log Data to a Memory

Stick
26.1.1 Introduction
These instructions describe how to save CT X‐ray module log data to a memory stick to be returned with
a defective anode or cathode power module that has been replaced.
Note: The X‐ray module log data files must be copied from the host computer onto a memory stick before a
failed KPM or APM module is replaced.
1. Open the replacement Cathode Power Module (KPM) or Anode Power Module (APM) shipping
container.
2. Locate the memory stick. It will be in an envelope inside the shipping container. Keep the envelope
for returning it.
3. Insert the memory stick into a USB port on the host computer.
4. On the host computer monitor’s Windows desktop, double‐click on the My Computer icon.
Note: If the scanner application program is running, you can display the Windows desktop by simultaneously
pressing the <Windows> and <d> keys.
5. In the My Computer window, navigate to the memory stick and display the list of files on the stick.
6. Double‐click on the batch file named “PackAllGeneratorHistory.bat” located on the memory stick.
The Data Packer program should start and a progress box like the one in Figure 26‐1 on page 438
Note: Don’t remove the memory stick until the Data Packer progress box shown in Figure 26‐1 on page 438

automatically closes.
7. Wait until the Data Packer progress box automatically closes. This may take a few minutes after the
progress bar reaches completion. The number of zipped files created on this memory stick will
depend on the quantity of data saved.
Figure 26-1: Data Packer Progress Box

8. In the My Computer window look to see that zipped folders were created on the memory stick. The
number of zipped folders created will vary depending on the quantity of data stored.
9. After the Data Packer progress box closes, click on the drive removal icon at the right of the Windows
desktop bottom tool bar and click on the selection for safe removal of the memory stick.
10. Remove memory stick from the USB port.
11. Locate the repair form in the envelope the memory stick was in. Record FSE name, phone number,
date, site name, site S/N, module S/N, and Tube S/N on the repair form.
12. Place memory stick and the completed repair form into the envelope and place the envelope into the
shipping container along with the KPM or APM module being returned.
26.2 Cathode Module Removal

1. Power down the gantry See “Gantry Power Down (Except for the Host and CIRS)” on page 27..
3. Remove the rotor power fuse F303. Refer to Figure 26‐2 on page 439.
5. Open the main drive fuses F357, F358, and F359. Refer to Figure 26‐2 on page 439.

F351, F352, F353 F357, F358, F359
MODE KEYSWITCH
ROTOR POWER
FUSE F303
WARNING: Hazardous voltages are still present in the gantry support. Exercise proper precautions to
avoid contact with live connections while servicing. Failure to do so may result in serious
injury or death.
7. Remove the lower front cover (see ‘Removing/Replacing the Ingenuity CT Gantry Lower Front Cover
on page 2‐46).
8. Remove the rear cover (see Removing the Gantry Rear Cover on page 112).
9. Remove the rear cone (see Removing the Ingenuity CT Gantry Rear Cone on page 128).
12. From the rear of the gantry, remove one of the bolts from the cathode module that is visible (see
Figure 26‐3).
13. Rotate the rotor slightly CCW (as viewed from the rear) so the other bolt is visible and remove it (see
Figure 26‐3).
Figure 26-3: Removal of Two Rear Power Cathode Module Bolts

Rotate Rotor Slightly and Remove Second

Cathode Module Mounting Bolt
Remove Cathode Module Mounting Bolt
14. From the front of the gantry, rotate the rotor CW until the X‐ray tube is at the 6 o’clock position.
15. With the X‐ray tube at the 6 o’clock position, pin the rotor with rotor locking pin as shown in
Figure 26-4: Rotor Pinned with XRT at 6 o’clock Position (Gantry Front Upper Left)

16. Loosen the retaining ring and remove the HV connector from the cathode module (see Figure 26‐5).

17. Place a protective cover on the connector to keep it clean.
18. Tie the cable to the rotor so it will not be damaged when the rotor is turned.

LOOSEN RETAINING RING AND
REMOVE HV CONNECTOR
19. Remove the cathode power module fuse covers by pulling out on them (see Figure 26‐6).

20. Cut the cable ties securing the 3 white power cables (see Figure 26‐6) and disconnect them (the cables
are not specific to any terminal).
21. Disconnect the cables indicated in Figure 26‐6 on page 444 from the front and side of the RHost and
from the front of the control board.
Figure 26-6: Cathode Power Module Connections

DISCONNECT CABLES FROM
RHOST AND CONTROL BOARDS
DISCONNECT CABLES
FROM RHOST
CUT CABLE TIES AND

DISCONNECT CABLES
REMOVE FUSE COVERS
22. Refer to Figure 26‐7 on page 445 and disconnect the cable at the side of the cathode module.

23. Cut the cable ties as necessary to free the cables from the cathode module.
24. Tie the cables to the rotor so they will not be damaged when the rotor is rotated.
Figure 26-7: Cathode Power Module Cables

DISCONNECT CABLE
26. Release the motor brake.
27. From the front of the gantry, rotate the rotor CW until the cathode power module is at the 6 o’clock
position.
!
WARNING: Make sure to install the rotor locking pin before removing the power module. The motor
brake will not hold the rotor in position with the module removed. Failure to pin the rotor will
28. With the cathode power module at the 6 o’clock position, pin the rotor with rotor locking pin as
shown in Figure 26‐8 on page 446.
Figure 26-8: Ingenuity CT Rotor Pinned with Cathode Power Module at 6’oclock

(Gantry Front Upper Left)
30. Power up the gantry by pressing the blue power button on systems that have one or by replacing and
closing utility fuses F354, F355, and F356.
WARNING: Do not install the rotor power fuse (F303), the slip ring 480 VAC fuses (F351, F352, and
F353), and the main drive fuses (F357, F358, and F359). Refer to Figure 26-2 on page 439.
Danger of electrical shock. Installing the fuses may result in serious injury or death.
injury or death.
32. Pull out the plunger on the gantry front cover switch to put it in the service position.
33. On systems that have one, pull out the plunger on the gantry rear cover switch to put it in the service
position.
Note: The gantry optical slip ring lasers will not come on.
!
CAUTION: All patient support safety mechanisms are disabled in service mode. Take care not to

Note: There are 2 styles of power module shipping boxes being used ‐ an older version and a new version. The
photos in this procedure all show the newer style shipping box, but the procedure is similar for the older
style shipping box. The instructions describe differences when needed.
Figure 26-11: Old and New Styles of Shipping Boxes

New Style Shipping Box Older Style Shipping Box
35. Make sure all latches that hold the sections of the shipping box together are engaged and locked.
Gently and carefully turn the shipping box over as shown in Figure 26‐12 on page 450 so the bolts are
on top as shown in Figure 26‐13 on page 451.
Figure 26-12: Turning Power Module Shipping Box Over

Lift With Top Handles Retract Handles Tilt with Opposite Handles Lift With Top Handles
36. Remove the 4 shipping bolts from the box (see Figure 26‐13).
Note: Save the four shipping bolts and washers for repacking the removed module.
37. Remove the top from the box.
Figure 26-13: Location of Shipping Bolts on Shipping Container

Remove 4 Bolts
38. Position the module shipping box over the couch footswitch with the “notched” sides of the box front
and back and the side marked “CPM ‐ CONTROL BOARD THIS SIDE” toward the left of the gantry
Figure 26-14: Shipping Box in Place

“Notched” Areas of Box Front
and Back
Marked:
“CPM - CONTROL BOARD
THIS SIDE”
39. Install the two lift rods into the “C” positions on the service tool (see Figure 26‐15).

41. Position the table top as required and install the strap pad and service tool onto the very end of the
couch top.
Figure 26-15: Lifting Tool Mounted on Table

X-ray Strap Pad Assembly
Use upper hole for standard

Use lower hole for extended
Lift rods in the “C” positions

of lift bar
42. Raise or lower the couch and rotate the rotor as required until the lift rods line up with the service
holes on the module. Refer to Figure 26‐16 on page 454.
Figure 26-16: Service Tool on End of Couch Aligned with Module Holes

Lift rods aligned
to module holes
43. Move the couch top to move the lift tool as far as it will go into the module as shown in Figure 26‐17

on page 455.
44. Raise the couch until the service tool is supporting the Cathode assembly.
Figure 26-17: Lifting Tool Fully Inserted into Cathode Power Module

45. Remove the 4 module mounting bolts holding the module onto the rotor (see Figure 26‐18). You will

feel the weight transfer to the service tool and couch. Adjust the couch upward to compensate if
necessary.
Figure 26-18: Cathode Power Module Mounting Bolts

Remove 4 mounting bolts
46. Pull the couch top back until the module is clear of the gantry and above the shipping box. Adjust the
couch height as necessary.
47. Lower the couch while positioning the shipping box so that the rear bar of the lifting tool is centered
to the “notch” in the box side so that the lifting tool can be removed through the notch (see Figure 26‐
19).
48. Lower the couch until you can move the lifting tube cradle off the end of the couch top. Leave the
lifting tool inserted into the power module.
49. Carefully lift the shipping box with the module and lifting tool attached up and over the couch
footswitch and wheel out of the way.
Figure 26-19: Cathode Power Module on Shipping Box

Remove Tool From Table Top
Lifting Tool Bar Centered to

Box “Notch”
50. Loosen the 2 thumbscrews securing protective cover over RHost board, pull the cover toward the
front and remove the cover.
51. Remove the RHost board (see Figure 26‐20) by removing the 10 screws securing RHost board (see
Figure 26‐21).
52. Pull up on the RHost board to unplug it from the control board and remove it.
Figure 26-20: RHost on Cathode Power Module on Shipping Box

Remove RHost Board
Figure 26-21: RHost Attaching Screws

26.3 Cathode Module Installation

1. Unlatch and remove the sides from the shipping box.
2. Plug the RHost board into the control board.
4. Apply Loctite #222 to the 10 screws and install them to attach the RHost (see Figure 26‐21 on
page 459).
5. Slide the RHost board cover over the 2 pins on the cover in the back and secure the cover with the 2
thumbscrews.
6. Insert the module service tool all the way into the front of the module as shown in Figure 26‐22 on
page 461.
7. Position the shipping box with the new module on it over the footswitch with the correct orientation
Figure 26-22: Lift Tool Inserted Into New Module Positioned for Installation

8. Lower the couch until the lifting tool cradle can be placed onto the end of the couch.
9. Place the lifting tool cradle over the end of the table top flush with the end.
10. Move the module into position in the gantry being careful not to pinch any of the module cables and
position it to the rotor so that the bolt holes align (see Figure 26‐23).
Figure 26-23: Cathode Power Module In Position

12. Apply Loctite #242 to one of the 6 mounting bolts, install a flatwasher, and position the module so it
can be started in one of the four mounting holes on the front of the rotor (see Figure 26‐24). Screw it in
most of the way.
13. Use this bolt as a pivot point to move the module as required to align the remaining holes. Apply
Loctite #242 to and install the remaining 3 front rotor module mounting bolts with flatwashers.
14. Tighten the bolts enough to hold the module tightly to the rotor, but do not torque them (the rear
bolts still need to be installed).
Figure 26-24: Module Mounting Bolts at the Front of the Rotor

Install 4 module mounting bolts
16. Apply Loctite #242 to 1 of the 6 module mounting bolts, install a flatwasher at the back of the rotor
install it in the one hole that is accessible (see Figure 26‐25 on page 464).
Figure 26-25: Module Mounting Bolt at the Rear of the Rotor

Install module mounting bolt
17. Adjust the couch height so you can push the couch top and lifting tool back pulling the lifting rods
out of the power module.
18. After the lifting tool is clear of the module, lower the couch until the service tool rests on the shipping
box enough to slip the service tool off the end of the couch.
19. Lift the shipping box up and over the couch cable trough and wheel it out of the way.
20. Power down the gantry by pressing the blue power button on systems that have one or by opening
utility fuses F354, F355, and F356.
23. Rotate the rotor slightly so the other rear module mounting hole is accessible (see Figure 26‐25 on
page 464).
25. Apply Loctite #242 to the last of the 6 module mounting bolts, install a flatwasher, and install it in the
remaining hole at the back of the rotor.
26. Once all 6 module mounting bolts are installed, tighten all 6 bolts to 56 ft‐lb (76 Nm).
27. Rotate the rotor CW so the X‐ray tube is in the 6 o’clock position (the cathode power module will be at
the 3 o’clock position).
28. Insert the rotor locking pin.
29. Apply the main drive motor brake.
30. Refer to Figure 26‐26 on page 466 and connect the wire at the side of the cathode module.
Figure 26-26: Cathode Power Module Cable

CONNECT CABLE
31. Connect the cables to the front of the module as shown in Figure 26‐27 on page 467.

32. Connect the 3 white power cables (see Figure 26‐27) (the cables are not specific to any terminal) and
tie them in place.
33. Secure the cables with cable ties as they were originally tied.
34. Install the fuse covers over the cathode power module fuses.

CONNECT CABLES TO RHOST AND
CONTROL BOARDS
CONNECT CABLES TO
RHOST
CONNECT CABLES AND

INSTALL CABLE TIES
INSTALL FUSE COVERS
35. Clean and prepare the cathode HV connector as follows: (refer to Figure 26‐28 on page 468):

a. Clean HV plug with isopropyl alcohol and a cleaning cloth. Do not touch connector pins with your
fingers.
b. Using silicon paste, put a small dab of paste in the center of the plug between the connector pins as
silicon paste.
d. Put a second small dab of paste in the center of the new silicon washer between the connector pins
e. Do not apply paste to the sides of the connector plug.
Figure 26-28: Applying HV Connector Paste

Paste on Connector Before Washer Paste on Connector Washer
36. Install the HV connector into the cathode module (see Figure 26‐29) and hand‐tighten the retaining

ring.

INSTALL HV CONNECTOR AND
TIGHTEN RETAINING RING
38. Release the motor brake and rotate the rotor CW by hand while checking that there is proper cable
clearance.
40. Install the rear cone (see Installing the Ingenuity CT Gantry Rear Cone on page 133).
41. Install the rear cover (see Ingenuity CT Gantry Rear Cover Installation on page 120).
42. Install the lower front cover (see Removing/Replacing the Ingenuity CT Gantry Lower Front Cover
on page 46).
43. Install the patient support service switch cover at the RH head end of the base trim cover as shown in
44. Place the mode key switch into the “NORM” position. Refer to Figure 26‐2 on page 439.
45. Install the rotor power fuse F303. Refer to Figure 26‐2 on page 439.
46. Close the slip ring 480 VAC fuses F351, F352, and F353. Refer to Figure 26‐2 on page 439.
47. Close the main drive fuses F357, F358, and F359. Refer to Figure 26‐2 on page 439.
48. Install the upper left gantry support cover (see Gantry RH/LH Upper Side Cover Installation on page
138).
49. Close the Gantry Front Cover (see Closing the Ingenuity CT Gantry Front Cover on page 45).
50. Power up the gantry according to “Gantry Power Up” on page 34.
51. Run the required calibrations according to the applicable Ingenuity CT System Calibration manual.
52. Test the system to verify that it is operating properly.
53. Position the removed power module on the shipping box as required and install the sides of the box
with the thick and thin foam sides as shown in Figure 26‐30 on page 471.
Figure 26-30: Removed Cathode Module in Shipping Box
Thick Foam Thin Foam
54. Place the top of the shipping box in place.
55. On new style shipping boxes install the 4 shipping bolts with washers into the 4 holes marked “C” as
shown in Figure 26‐31 on page 472. If the module holes do not align, insert a large screwdriver into
one of the holes and pry the hole into alignment so the bolts can be inserted. Screw the bolts in until
they just contact the box, but do not tighten them.
Figure 26-31: Location of Shipping Bolts on Newer Style Shipping box

Install 4 Bolts
56. On older style shipping boxes, position the module in the shipping box as required so that the 4
shipping bolts can be installed when the remaining part of the shipping box is installed
57. Install the 4 shipping bolts with washers into the 4 holes as shown in Figure 26‐31 on page 472. If the
module holes do not align, insert a large screwdriver into one of the holes and pry the hole into
alignment so the bolts can be inserted.
58. Install the 4 shipping bolts with washers. Screw the bolts in until they just contact the box, but do not
tighten them.
Figure 26-32: Location of Shipping Bolts on Older Style Shipping Box

Install 4 Bolts
(one is missing in picture)
Gently and carefully turn the shipping box over (see Figure 26‐12 on page 450) so the bolts are on the
bottom.
60. Tighten the bolts snugly against the bottom of the box.
61. Return the removed module according to the key market’s procedure.
Figure 26-33: Tightening Shipping Bolts on Shipping Container Bottom
Tighten 4 Bolts
Section 27
Section 27 Anode Power Module Assembly Removal/Replacement
Tools required:
• FE Tool kit
• Generator service (lift) tool and lift tool strap pad assembly
Supplies:
• Silicon paste
• Anode silicon washer
• HV Connector Cover
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Anode Power Module Assembly Removal/
27.1 Saving X-ray Power Module Log Data to a Memory

Stick
27.1.1 Introduction
These instructions describe how to save CT X‐ray module log data to a memory stick to be returned with
a defective anode or cathode power module that has been replaced.
Note: The X‐ray module log data files must be copied from the host computer onto a memory stick before a
failed KPM or APM module is replaced.
1. Open the replacement Cathode Power Module (KPM) or Anode Power Module (APM) shipping
container.
2. Locate the memory stick. It will be in an envelope inside the shipping container. Keep the envelope
for returning it.
3. Insert the memory stick into a USB port on the host computer.
4. On the host computer monitor’s Windows desktop, double‐click on the My Computer icon.
Note: If the scanner application program is running, you can display the Windows desktop by simultaneously
pressing the <Windows> and <d> keys.
5. In the My Computer window, navigate to the memory stick and display the list of files on the stick.
6. Double‐click on the batch file named “PackAllGeneratorHistory.bat” located on the memory stick.
The Data Packer program should start and a progress box like the one in Figure 27‐1 on page 477
Note: Don’t remove the memory stick until the Data Packer progress box shown in Figure 27‐1 on page 477

automatically closes.
7. Wait until the Data Packer progress box automatically closes. This may take a few minutes after the
progress bar reaches completion. The number of zipped files created on this memory stick will
depend on the quantity of data saved.
Figure 27-1: Data Packer Progress Box

8. In the My Computer window look to see that zipped folders were created on the memory stick. The
number of zipped folders created will vary depending on the quantity of data stored.
9. After the Data Packer progress box closes, click on the drive removal icon at the right of the Windows
desktop bottom tool bar and click on the selection for safe removal of the memory stick.
10. Remove memory stick from the USB port.
11. Locate the repair form in the envelope the memory stick was in. Record FSE name, phone number,
date, site name, site S/N, module S/N, and Tube S/N on the repair form.
12. Place memory stick and the completed repair form into the envelope and place the envelope into the
shipping container along with the KPM or APM module being returned.
27.2 Anode Module Removal

1. Power down the gantry according to “Gantry Power Down (Except for the Host and CIRS)” on
page 27.
3. Remove the rotor power fuse F303. Refer to Figure 27‐2 on page 478.
5. Open the main drive fuses F357, F358, and F359. Refer to Figure 27‐2 on page 478.

F351, F352, F353 F357, F358, F359
MODE KEYSWITCH
ROTOR POWER
FUSE F303
injury or death.
7. Remove the lower front cover (see Removing/Replacing the Ingenuity CT Gantry Lower Front Cover
on page 46).
12. From the rear of the gantry, remove one of the bolts from the anode module that is visible (see
Figure 27‐3).
13. Rotate the rotor slightly CCW (as viewed from the rear) so the other bolt is visible and remove it (see
Figure 27‐3).
Figure 27-3: Removal of Two Rear Power Anode Module Bolts

Remove Anode Module Mounting Bolt
Rotate Rotor Slightly and Remove Second

Anode Module Mounting Bolt
14. From the front of the gantry, rotate the rotor CW until the X‐ray tube is at the 6 o’clock position.
15. With the X‐ray tube at the 6 o’clock position, pin the rotor with rotor locking pin as shown in
Figure 27-4: Rotor Pinned with XRT at 6 o’clock Position (Gantry Front Upper Left)

16. Loosen the retaining ring and remove the HV connector from the anode module (see Figure 27‐5).

17. Place a protective cover on the connector to keep it clean.
18. Tie the cable to the rotor so it will not be damaged when the rotor is turned.
Figure 27-5: Anode HV Cable

LOOSEN RETAINING RING AND
REMOVE HV CONNECTOR

20. Cut the cable ties securing the 3 white power cables (see Figure 27‐6) and disconnect them (the cables
21. Disconnect the blue connector, the signal cable, and the ground from the HSS (see Figure 27‐6).

DISCONNECT CABLES &
GROUND FROM HSS
CUT CABLE TIES AND

DISCONNECT CABLES
22. Refer to Figure 27‐7 on page 484 and disconnect the red power wire at the side of the anode module.

23. Disconnect the other cable shown in Figure 27‐7 on page 484 from the power module.
24. Cut the cable ties as necessary to free the cables from the anode module.
25. Tie the cables to the rotor so they will not be damaged when the rotor is rotated.

DISCONNECT CABLE

WIRE & DISCONNECT
28. From the front of the gantry, rotate the rotor CW until the anode power module is at the 6 o’clock
position.
!
WARNING: Make sure to install the rotor locking pin before removing the power module. The motor
brake will not hold the rotor in position with the power module removed. Failure to pin the
rotor will allow the rotor to rotate quickly and cause personnel injury or death.
29. With the anode power module at the 6 o’clock position, pin the rotor with rotor locking pin as shown
Figure 27-8: Ingenuity CT Rotor Pinned with Anode Power Module at 6’oclock
(Gantry Front Lower Right)

31. Power up the gantry by pressing the blue power button on systems that have one or by replacing and
closing utility fuses F354, F355, and F356.
WARNING: Do not install the rotor power fuse (F303), the slip ring 480 VAC fuses (F351, F352, and
F353), and the main drive fuses (F357, F358, and F359). Refer to Figure 27-2 on page 478.
Danger of electrical shock. Installing the fuses may result in serious injury or death.
injury or death.
33. Pull out the plunger on the gantry front cover switch to put it in the service position.
34. On systems that have one, pull out the plunger on the gantry rear cover switch to put it in the service
position.
Note: The gantry optical slip ring lasers will not come on.
!
CAUTION: All patient support safety mechanisms are disabled in service mode. Take care not to
Note: There are 2 styles of power module shipping boxes being used ‐ an older version and a new version. The
procedure is similar for both the old and new style shipping boxes. These instructions describe differences
when needed.
Figure 27-11: Old and New Styles of Shipping Boxes

New Style Shipping Box Older Style Shipping Box
Gently and carefully turn the shipping box over as shown in Figure 27‐12 on page 489 so the bolts are
on top as shown in Figure 27‐13 on page 490.
Figure 27-12: Turning Power Module Shipping Box Over
Lift With Top Handles Retract Handles Tilt with Opposite Handles Lift With Top Handles
37. Remove the 4 shipping bolts from the box (see Figure 27‐13).
Note: Save the four shipping bolts and washers for repacking the removed module.
38. Remove the top from the box.
Figure 27-13: Location of Shipping Bolts on Shipping Container

(bolts shown in cathode module holes (“C”) ‐ they will be in holes marked “A” for anode modules)

Remove 4 Bolts
(will be in holes marked “A”
for anode modules)
39. Position the module shipping box over the couch footswitch with the “notched” sides of the box front
and back and the side stenciled “APM ‐ STARTER THIS SIDE” toward the right of the gantry (see
Figure 27‐14).
Figure 27-14: Shipping Box in Place
“Notched” Areas of Box

Front and Back
Stencil:
“APM - STARTER
THIS SIDE”
40. Install the two lift rods into the “A” positions on the service tool (see Figure 27‐15).

42. Install the strap pad and service tool onto the very end of the couch top as shown in Figure 27‐15 on
page 492.
Figure 27-15: Lifting Tool Mounted on Table (shipping box not shown)

X‐ray Strap Pad Assembly
Use upper hole for standard
Use lower hole for extended
Lift rods in the “A” position
43. Raise or lower the couch and rotate the rotor as required until the lift rods line up with the service
holes on the module. Refer to Figure 27‐16 on page 493.
Figure 27-16: Service Tool on End of Couch with Lift Rods in “A” Position Aligned with Module Holes

(shipping box not shown)

Lift rods aligned to module holes
44. Move the couch top with the service tool as far as it will go into the module as shown in Figure 27‐17

on page 494.
45. Raise the couch until the service tool is supporting the Anode assembly.
Figure 27-17: Lifting Tool Fully Inserted into Anode Power Module (shipping box not shown)

46. Remove the 2 front module mounting bolts (see Figure 27‐18).
Figure 27-18: Anode Power Module Mounting Bolts
Remove 2 front bolts
47. Remove the last 2 bolts holding the module onto the rotor (see Figure 27‐19). You will feel the weight

transfer to the service tool and couch. Adjust the couch upward to compensate if necessary.
Figure 27-19: Removing Last 2 Bolts

Remove 2 rear bolts
48. Pull the couch top back until the module is clear of the gantry and above the shipping box. Adjust the
couch height as necessary.
49. Lower the couch so the power module assembly sets on the shipping box in approximately the same
position as the impressions in the foam from the previous module (see Figure 27‐20).
50. Lower the couch until you can move the lifting tube cradle off the end of the couch top. Leave the
lifting tool inserted into the power module.
51. Carefully lift the shipping box with the module and lifting tool attached up and over the couch
footswitch and wheel out of the way.
Figure 27-20: Anode Power Module on Shipping Box
27.3 Anode Module Installation

1. Unlatch and remove the sides from the shipping box (see Figure 27‐21).
2. Insert the module service tool all the way into the front of the module (see Figure 27‐21).
Figure 27-21: New Module on Shipping Box with Sides Removed

(old style shipping box shown ‐ new box is similar)
3. Position the shipping box with the new module on it over the footswitch with the correct orientation
4. Lower the couch until the lifting tool cradle can be placed onto the end of the couch.
5. Place the lifting tool cradle over the end of the table top flush with the end.
6. Move the module into position in the gantry being careful not to pinch any of the module cables and
position it to the rotor so that the bolt holes align (see Figure 27‐22).
7. Lift the shipping box up and over the couch cable trough and wheel it out of the way.
Figure 27-22: Anode Power Module in Installation Position
9. Apply Loctite #242 to one of the 6 mounting bolts, install a flatwasher, and position the module so it
can be started in one of the four mounting holes on the front of the rotor (see Figure 27‐23). Screw it in
most of the way.
10. Use this bolt as a pivot point to move the module as required to align the remaining holes. Apply
Loctite #242 to and install the remaining 3 front rotor module mounting bolts with flatwashers.
11. Tighten the bolts enough to hold the module tightly to the rotor, but do not torque them (the rear
bolts still need to be installed).
Figure 27-23: Module Mounting Bolts at the Front of the Rotor

Install 4 module mounting bolts
13. Apply Loctite #242 to 1 of the 6 module mounting bolts, install a flatwasher at the back of the rotor
install it in the one hole that is accessible (see Figure 27‐24 on page 501).
Figure 27-24: Module Mounting Bolt at the Rear of the Rotor

Install module mounting bolt
14. Adjust the couch height so you can push the couch top and lifting tool back pulling the lifting rods
out of the power module.
15. After the lifting tool is clear of the module, lower the couch until the service tool rests on the shipping
box enough to slip the service tool off the end of the couch.
16. Power down the gantry by pressing the blue power button on systems that have one or by opening
utility fuses F354, F355, and F356.
19. Rotate the rotor slightly so the other rear module mounting hole is accessible (see (see Figure 27‐24 on
page 501)).
21. Apply Loctite #242 to the last of the 6 module mounting bolts, install a flatwasher, and install it in the
remaining hole at the back of the rotor.
22. Once all 6 module mounting bolts are installed, tighten all 6 bolts to 56 ft‐lb (76 Nm).
23. Rotate the rotor CW so the X‐ray tube is in the 6 o’clock position (the anode power module will be at
the 9 o’clock position).
24. Insert the rotor locking pin.
26. Refer to Figure 27‐25 on page 503 and connect the red power wire at the side of the anode module.
27. Connect the other cable shown in Figure 27‐25 on page 503 from the power module.
28. Secure the cables with cable ties as they were originally tied.
CONNECT CABLE
CONNECT CABLE
29. Route the cables in front of the module as shown in Figure 27‐26 on page 504 and tie them in place.

30. Connect the blue connector, the signal cable, and the ground to the HSS (see Figure 27‐26).
31. Connect the 3 white power cables (see Figure 27‐26) (the cables are not specific to any terminal) and
tie them in place.
32. Install the fuse covers over the anode power module fuses.
CONNECT CABLES &

GROUND TO HSS
CONNECT CABLES AND

TIE IN PLACE
33. Clean and prepare the anode HV connector as follows: (refer to Figure 27‐27 on page 505):

a. Clean HV plug with isopropyl alcohol and a cleaning cloth. Do not touch connector pins with your
fingers.
b. Using silicon paste, put a small dab of paste in the center of the plug between the connector pins as
silicon paste.
d. Put a second small dab of paste in the center of the new silicon washer between the connector pins
e. Do not apply paste to the sides of the connector plug.
Figure 27-27: Applying HV Connector Paste

Paste on Connector Before Washer Paste on Connector Washer
34. Install the HV connector into the anode module (see Figure 27‐28) and hand‐tighten the retaining

ring.
Figure 27-28: Anode HV Cable
INSTALL HV CONNECTOR AND

HAND-TIGHTEN RETAINING RING
35. Release the motor brake and rotate the rotor CW by hand while checking that there is proper cable
clearance.
39. Install the lower front cover (see Removing/Replacing the Ingenuity CT Gantry Lower Front Cover
on page 46).
40. Install the patient support service switch cover at the RH head end of the base trim cover as shown in
41. Place the mode key switch into the “NORM” position. Refer to Figure 27‐2 on page 478.
42. Install the rotor power fuse F303. Refer to Figure 27‐2 on page 478.
43. Close the slip ring 480 VAC fuses F351, F352, and F353. Refer to Figure 27‐2 on page 478.
44. Close the main drive fuses F357, F358, and F359. Refer to Figure 27‐2 on page 478.
45. Install the upper left gantry support cover (see Gantry RH/LH Upper Side Cover Installation on page
138).
47. Power up the gantry according to “Gantry Power Up” on page 34.
48. Run the required calibrations according to the applicable Ingenuity CT System Calibration manual.
49. Test the system to verify that it is operating properly.
50. Position the removed power module on the shipping box as required and install the sides of the box
with the thick and thin foam sides as shown in Figure 27‐29 on page 508.
Figure 27-29: Removed Power Module in New Style Shipping Box

(cathode module shown ‐ anode module is similar)

Thick Foam Thin Foam
51. Place the top of the shipping box in place.
52. On new style shipping boxes install the 4 shipping bolts with washers into the 4 holes marked “A” as
indicated in Figure 27‐30 on page 509. If the module holes do not align, insert a large screwdriver into
one of the holes and pry the hole into alignment so the bolts can be inserted. Screw the bolts in until
they just contact the box, but do not tighten them.
Figure 27-30: Location of Shipping Bolts on Newer Style Shipping box

(bolts shown installed for cathode module)

Install 4 Bolts
In Holes Marked “A”
53. On older style shipping boxes, position the module in the shipping box as required so that the 4
shipping bolts can be installed when the remaining part of the shipping box is installed
54. Install the 4 shipping bolts with washers into the 4 holes as shown in Figure 27‐31 on page 510. If the
module holes do not align, insert a large screwdriver into one of the holes and pry the hole into
alignment so the bolts can be inserted.
55. Install the 4 shipping bolts with washers. Screw the bolts in until they just contact the box, but do not
tighten them.
Figure 27-31: Location of Shipping Bolts on Shipping Container Bottom

Install 4 Bolts
(one is missing in picture)
Gently and carefully turn the shipping box over (see Figure 27‐12 on page 489) so the bolts are on the
bottom.
57. Tighten the bolts snugly against the bottom of the box.
58. Return the removed module according to the key market’s procedure.
Figure 27-32: Tightening Shipping Bolts on Shipping Container Bottom
Tighten 4 Bolts
Section 28
Section 28 RHost or CPM Control Board Assembly Replacement
This procedure is for replacing the RHost and/or the CPM control board. The RHost and control boards
are mounted on the cathode generator assembly located on the rotor at the front of the gantry.
Note: Clear RTV Adhesive/Sealant P/N 4535 641 38261 is required when replacing the control board.
28.1 Removing the RHost
Note: The RHost will need to be removed in order to remove the control board.
1. Verify that there is a valid current backup of the NVRAM for the RHost before proceeding. If the
NVRAM backup is not valid and current, attempt to create one according to the procedure in the
applicable Brilliance CT System Software Installation manual. However, be aware that the backup of
the NVRAM from a failed board may be corrupt.
2. Open the Gantry Front Cover (see “Opening the Ingenuity CT Gantry Front Cover” on page 40).
3. If not already done, power down the gantry according to the “Gantry Power Down (Except for the
Host and CIRS)” on page 27.
injury or death.
4. Remove power to the rotor according to the procedure “Removing Gantry Rotor Power” on page 28.
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement RHost or CPM Control Board Assembly Replacement
5. Release the main drive motor brake by turning the brake release lever shown in Figure 28‐1 on
page 513 CW.
!
CAUTION: When rotating the gantry rotor by hand, always rotate in a clockwise direction (as viewed
from gantry front).
6. Rotate the rotor CW so the heat exchanger is in the 6 o’clock position.
7. Apply the motor brake (see Figure 28‐1 on page 513).
!
CAUTION: Observe all anti-static precautions according to the Brilliance CT Safety Manual. Failure to
comply may result in equipment damage.

.
RELEASE
APPLY
8. Disconnect the cables indicated in Figure 28‐2 on page 514 from the front and side of the RHost.
Figure 28-2: RHost Connections

DISCONNECT CABLES DISCONNECT CABLES FROM
FROM RHOST RHOST BOARD
9. If the controller is to be replaced, disconnect the 2 cables from the controller indicated in Figure 28‐3
on page 515.
Figure 28-3: Cathode Power Module Control Board Connections

DISCONNECT CABLES FROM
CONTROL BOARD
10. Loosen the 2 thumbscrews securing protective cover over RHost board (see Figure 28‐4), pull the

cover toward the front and remove the cover.
If the power cables hinder removing the cover or the RHost, disconnect them as follows:
a) Remove the cathode power module fuse covers by pulling out on them (see Figure 28-4).
b) Cut the cable ties securing the 3 power cables (see Figure 28-4) and disconnect them (the cables
COVER THUMBSCREWS CUT CABLE TIES AND

DISCONNECT CABLES
IF NEEDED
REMOVE FUSE COVERS

IF NEEDED
11. Remove 10 screws securing RHost board, and remove board (see Figure 28‐5). The screws on the rotor

side can be accessed using a philips bit in a Chapman ratchet or a stubby philips screwdriver. Note
the screw hidden behind the CPM module.
IMPORTANT: Make sure to work the RHost board up evenly on all sides so that it remains parallel to the
control board. If it is lifted on one side it may damage the connectors.
12. Work the RHost board up evenly on all sides to unplug it from the control board and remove it.
If only the RHost board is being replaced, proceed to the section “Installing the RHost Board” on
page 522. If the control board is to be replaced, proceed to the next section.
28.2 Removing the Control Board

1. Disconnect the cables from control board connectors JB6, JB9, JB3, JB13, JB4, and JB16 (see Figure 28‐
6).
2. Carefully remove the RTV around the fiber‐optic connectors and disconnect them (see Figure 28‐6).
Figure 28-6: Control Board Connectors

DISCONNECT CONNECTORS DISCONNECT CONNECTOR
FROM JB6 AND JB9 FROM JB3 &JB13
IF PRESENT DISCONNECT
DISCONNECT FIBER-OPTIC
CONNECTOR FROM JB4 & JB16
CONNECTORS JB10 & JB11
3. Remove the 10 stand‐offs that mount the control board (see Figure 28‐7).
4. Remove the 2 screws that mount the control board (see Figure 28‐7).
5. Lift the control board off of the power module.
Figure 28-7: Control Board Mounting

REMOVE 2 SCREWS REMOVE 10 STAND-OFFS
28.3 Installing the Control Board

1. Position the control board onto the power module.
2. Install the 10 stand‐offs that mount the control board (see Figure 28‐8).
3. Install the 2 screws that mount the control board (see Figure 28‐8).
4. Tighten all the fasteners to 5 in‐lb (57 N‐cm).
Figure 28-8: Control Board Mounting

INSTALL 2 SCREWS INSTALL 10 STAND-OFFS
5. Connect the cables to control board connectors JB6, JB9, JB3, and JB13 (see Figure 28‐9).
6. Connect the fiber‐optic cables to connectors JB10 and JB11 (see Figure 28‐9).
7. Apply a small bead of RTV Adhesive/Sealant P/N 4535 641 38261 to the top of the fiber‐optic
connectors as shown in Figure 28‐9 on page 521.
Figure 28-9: Control Board Connectors
CONNECT CONNECTORS CONNECT FIBER- CONNECT FIBER- CONNECT CONNECTOR

TO JB6 AND JB9 OPTIC CABLE OPTIC CABLE TO JB3 & JB13
JB11 JB10
PUT BEAD OF RTV ON FIBER-OPTIC

CONNECTORS JB10 & JB11
28.4 Installing the RHost Board
IMPORTANT: Make sure to press the RHost board down evenly on all sides so that it remains parallel to
the control board. If it is tilted one side it may damage the connectors.
1. Carefully correctly position the RHost board onto the control board and press it down evenly so that
it remains parallel to the control board.
2. Install the 10 screws to attach the RHost (see Figure 28‐10).
3. If the controller was replaced, connect the 2 cables from the controller indicated in Figure 28‐11 on
page 523.
4. Slide the metal CPM cover over the top of the RHost so that the holes in the back of the cover engage
with the pins on the back of the CPM and secure the cover with the 2 thumbscrews (see Figure 28‐13).
Figure 28-11: Cathode Power Module Control Board Connections

CONNECT CABLES TO
CONTROL BOARD
5. Connect the cables indicated in Figure 28‐12 on page 524 to the front and side of the RHost.
Figure 28-12: RHost Connections
CONNECT CABLES TO CONNECT CABLES TO RHOST

RHOST BOARD
6. If removed, connect the 3 power cables (see Figure 28‐13) and tie them in place (the cables are not
specific to any terminal). Install the cathode power module fuse covers (see Figure 28‐13).
COVER THUMBSCREWS IF DISCONNECTED,

CONNECT CABLES
AND INSTALL CABLE TIES
INSTALL FUSE COVERS

IF REMOVED
7. Reburn the CPM module boot and application flash and restore the NVRAM according to the
procedure “Reburning CPM Boot and Application Flash and Restoring NVRAM” in the Ingenuity
CT JTAG Programming Manual.
8. Program the RHost according to the procedure in the Ingenuity CT Hardware (JTAG) Programming
Manual.
10. Rotate the rotor CW and listen for any abnormal noises and check for cable clearance.
12. Close the Gantry Front Cover (see “Closing the Ingenuity CT Gantry Front Cover” on page 45).
13. Restore power to the gantry according to the procedure “Gantry Power Up” on page 34.
14. Perform filament calibration. Refer to the applicable calibration manual.
15. Run test scans on a water phantom to verify the system is operating correctly.
16. Cycle power to the gantry before turning the system over to the customer.
Section 29
Section 29 High Speed Starter Removal/Replacement
The high speed starter is mounted on the anode generator assembly located on the front of the gantry.
Note: Systems with Dunlee X‐ray tubes cannot use the P/N 4535 670 30531 high speed starter board. Systems
with Dunlee tubes must use the newer starter with dual tube firmware, currently P/N 4535 670 30532.
Refer to eSPF for the latest part number and to service note CT3470 for more information.
Tools required: See (see ‘Anode Power Module Assembly Removal/Replacement on page 27‐475)
Supplies: See (see ‘Anode Power Module Assembly Removal/Replacement on page 27‐475)
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement High Speed Starter Removal/Replacement
29.0.1 High Speed Starter Removal

1. Remove the Anode Power Module according to the procedure Anode Module Removal on page 478
up to the point where the Anode Power module is removed from the rotor, but still suspended on the
lifting tool as shown in Figure 29‐1 on page 528. The high speed starter (HSS) can be replaced with the
module in this position.
Figure 29-1: Anode Module Removed

!
WARNING: Exercise caution when working around the anode module while it is suspended on the lifting
tool. Failure to comply may result in personnel injury.
!
CAUTION: Observe all anti-static precautions according to the Ingenuity CT Safety Manual. Failure to
comply may result in equipment damage.
2. Remove the signal cable connector and the ground wire connector (see Figure 29‐2 on page 529).
3. Remove six screws and lock washers securing protective cover and remove cover (see Figure 29‐2 on
page 529).
Figure 29-2: HSS Cable Connections & Cover Screws (APM shown upright for clarity)

Disconnect Ground Disconnect Cable
Remove 6 Cover Screws (3 on other side)
4. Disconnect the wires from the HSS to the APM (see Figure 29‐3 on page 530).

5. Loosen the 2 screws at the rear of the HSS assembly (see Figure 29‐3 on page 530) or if the tray is not
slotted, remove them.
6. Remove the 2 screws at the front as shown in Figure 29‐3 on page 530 and remove the HSS assembly.
Figure 29-3: High Speed Starter Assembly Screws (APM shown upright for clarity)
Disconnect Wires
Remove 2 Screws
Loosen 2 Screws
(slotted tray)
29.0.2 High Speed Starter Installation

1. The new HSS will come with the cover installed. Remove the 6 cover screws and remove the cover.
2. Place the HSS into position and attach it with 2 front screws (and 2 rear, if removed) (see Figure 29‐4
on page 531).
3. Connect the wires from the HSS to the APM (see Figure 29‐4 on page 531).
Figure 29-4: High Speed Starter Assembly Screws (APM shown upright for clarity)

Connect Wires
Install Screws
Tighten 2 Screws
(slotted tray)
4. Place the protective cover in place and attach it with 6 screws with lock washers (see Figure 29‐5 on
page 532).
5. Connect the signal cable connector and the ground wire connector (see Figure 29‐5 on page 532).
6. Install the Anode Power Module according to the procedure Anode Module Installation on page 498.
7) Power up the gantry according to “Gantry Power Up” on page 34.
8) Run the rotor balance check according to the applicable Ingenuity CT System Calibration manual.
Note: No other calibrations should be necessary.
9) Test the system to verify that it is operating properly.
Figure 29-5: HSS Cable Connections & Cover Screws (APM shown upright for clarity)

Connect Ground Connect Cable
Install 6 Cover Screws

(3 on other side)
Section 30
Section 30 GHost Board Removal/Replacement
This section includes instructions for replacing a GHost board.The GHost board is located on the gantry
RH upper side column (see Figure 30‐1 on page 534).
30.1 Removal
1. Verify that there is a valid current backup of the NVRAM for the board before proceeding. If the
NVRAM backup is not valid and current, attempt to create one; however, be aware that the backup of
WARNING: Hazardous voltages are present inside the gantry. Turn off power before servicing. Failure to
2. Turn off gantry power Gantry Power Down (Except for the Host and CIRS) on page 27.
3. Remove the gantry RH upper side cover Gantry RH/LH Upper Side Cover Removal on page 135.
4. Tag and remove all GHost board cable connections. Cut ty‐wraps as required. Refer to Figure 30‐1 on
page 534.
5. Remove nine screws securing GHost board to mounting bracket, and remove GHost board.
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement GHost Board Removal/Replacement
Figure 30-1: GHost Board Location On Upper RH Side Column

Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement GHost Board Removal/Replacement
30.2 Installation
1. Position GHost board onto the gantry mounting plate, and secure it to the plate with nine screws.
2. Connect all the other cables to the GHost board and secure them with cable ties as required.
3. Program the GHost board according to the applicable Ingenuity CT System Hardware (JTAG)
Programming Manual.
4. Flash the CPM module and restore the NVRAM according to the procedures in the applicable
Ingenuity CT System Hardware (JTAG) Programming Manual.
5. Install the gantry RH upper side cover Gantry RH/LH Upper Side Cover Installation on page 138.
6. Test the system to verify that it is functioning properly.
Section 31
Section 31 Gantry Motion Processor Board Removal/Replacement
This procedure describes the removal of the gantry motion processor (GMP) board, located on the gantry
rear top left panel.
31.1 Removal
1. Verify that there is a valid current backup of the NVRAM for the board before proceeding. If the
NVRAM backup is not valid and current, attempt to create one; however, be aware that the backup of
WARNING: Hazardous voltages inside. Turn power off to the gantry before servicing. Failure to do so
2. Remove power from the system (see Gantry Power Down (Except for the Host and CIRS) on page
27).
3. Remove the gantry rear cover (see Ingenuity CT Gantry Rear Cover Removal on page 115).
4. Tag and remove all GMP board cable connections. Cut ty‐wraps as required.
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Gantry Motion Processor Board Removal/
5. Remove eight screws and lock washers securing GMP board to mounting studs at the top of the
gantry rear left panel. Refer to Figure 31‐1 on page 537.
Figure 31-1: Gantry Motion Processor Board Located at the Top of the Gantry Rear Left Panel

Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Gantry Motion Processor Board Removal/
31.1.1 Installation
1. Position GMP board to mounting studs on gantry rear top left panel, and secure with eight screws
and lock washers.
2. Install GMP board cable connections, and install ty‐wraps as required.
3. Reburn the CPM module boot and application flash and restore the NVRAM according to the
procedure “Reburning CPM Boot and Application Flash and Restoring NVRAM” in the Ingenuity
CT JTAG Programming Manual.
4. Program the GMP board according to the applicable Ingenuity CT System JTAG Programming
Manual.
5. Perform angulation calibration according to the applicable Ingenuity CT Calibration Manual.
7. Test the system to verify proper operation.
Section 32
Section 32 Gantry Motion Power Board Removal / Replacement
The gantry motion power board is located at the base of the gantry RH lower side column.
32.1 Removal
WARNING: Hazardous voltages are inside the gantry. Turn gantry power off before servicing. Failure to
1. Turn off gantry power (see Gantry Power Down (Except for the Host and CIRS) on page 27).
2. Remove the gantry RH upper and lower side covers (see Ingenuity CT Side Covers Replacement on
page 135).
3. Tag and remove all cable connections from the gantry motion power board. Refer to Figure 32‐1 on
page 540
4. Remove eight screws and lock washers securing gantry motion power board to mounting studs on
RH column.
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Gantry Motion Power Board Removal / Replacement
Figure 32-1: Gantry Motion Power Board Location on RH column base

32.2 Installation
1. Install gantry motion power board to mounting studs on RH column with eight screws and lock
washers. Refer to Figure 32‐1 on page 540.
2. Install all cable connections to the gantry motion power board.
3. Install the gantry RH side covers (see Ingenuity CT Side Covers Replacement on page 135).
Section 33
Section 33 5 Volt Power Supply Removal/Replacement
The 5 V power supply is located on the front upper right of the gantry.
33.0.1 Removal
1. Remove power from the system. Refer to “Gantry Power Down (Except for the Host and CIRS)” on
page 27.
2. Open the Gantry Front Cover Opening the Ingenuity CT Gantry Front Cover on page 40.
working with the FRONT cover open or removed.
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement 5 Volt Power Supply Removal/Replacement
3. Tag and disconnect cable connections to 5V power supply. Remove ground wire lug. Cut ty‐wraps as
needed.
4. Remove four socket head cap screws and flat washers securing 5V power supply and bracket to
gantry, and remove power supply and bracket (see Figure 33‐1).
5. Remove screws and flat washers securing 5V power supply to bracket. Retain bracket for installation.
Figure 33-1: Ingenuity CT Gantry 5V Power Supply and Bracket

DISCONNECT CABLES AND
GROUND
REMOVE 4 SCREWS
(2 ON TOP)
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement 5 Volt Power Supply Removal/Replacement
33.0.2 Installation
1. Install bracket to 5V power supply with four screws with flat washers.
2. Apply Loctite #222 to the 4 screws with flatwashers and install the 5V power supply and bracket to
3. Connect the cables and the ground to 5V power supply. Tie the cables as they were originally.
4. Close the Gantry Front Cover Closing the Ingenuity CT Gantry Front Cover on page 45.
Section 34
Section 34 Switching 12 Volt Power Supply Removal/Replacement
The switching 12 V power supply is located on the front upper right of the gantry.
34.0.1 Removal
1. Turn gantry power off Gantry Power Down (Except for the Host and CIRS) on page 27.
working with the front cover open or removed.
3. Tag and remove cable connections from switching 12V power supply.
4. Remove four socket head cap screws and flat washers securing switching 12V power supply to the
5. Remove four screws and flat washers securing switching 12V power supply brackets to the power
supply. Refer to Figure 34‐1 on page 545.
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Switching 12 Volt Power Supply Removal/
Figure 34-1: Switching 12V Power Supply Mounting

REMOVE MOUNTING SCREWS

(2 EACH SIDE)
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Switching 12 Volt Power Supply Removal/
Figure 34-2: Power Supply Mounting Bracket
REMOVE 2 BRACKET SCREWS

(2 ON OTHER SIDE ALSO)
34.0.2 Installation
1. Install flatwashers and apply Loctite #222 to the bracket mounting screws and attach the 2 mounting
brackets to the switching 12V power supply. Hand tighten the screws.
2. Install flatwashers and apply Loctite #222 to power supply mounting screws and attach the 2
mounting brackets to the supply. Hand tighten the screws.
3. Connect the cables to the supply.
Section 35
Section 35 R2D Board Removal/Replacement
This procedure is for replacing R2D boards. The R2D board is located on the rotor, adjacent to the anode
generator. Refer to Figure 35‐1 on page 548.
35.1 R2D Board Removal
WARNING: Hazardous voltages are inside the gantry. Turn off power before servicing. Failure to do so
1. Power down the gantry Gantry Power Down (Except for the Host and CIRS) on page 27.
3. For easier access remove the flat head screw securing lexan ring to the rear cone and slide the lexan
ring into the rear cone until it is out of the way.
4. Release the rotor drive motor brake and rotate the rotor to position the X‐ray tube at the 9 o’clock
position (so the R2D is at the bottom).
6. Tag and remove cable connections from R2D board (Figure 35‐1 on page 548).
7. Remove four socket head cap screws and flat washers securing R2D board to mounting plate, and
remove board. Refer to Figure 35‐1 on page 548.
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement R2D Board Removal/Replacement
Figure 35-1: R2D Board Location, Connectors, and Mounting

Disconnect Cables
Mounting Screws
Mounting Screws
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement R2D Board Removal/Replacement
35.2 R2D Board Installation

1. Install R2D board to mounting plate with 4 screws and flat washers. Apply Loctite #242 to screws and
hand tighten.
2. Install cable connections to R2D board.
3. Program the R2D board according to the applicable Ingenuity CT System JTAG Programming
Manual.
Note: The new R2D board requires a different FPGA programming file than the old R2D. Make sure to use file
number beginning with the board’s part number 4535 674 83621 where the revision is the one required by
the Software Installation Manual for the system’s version of software.
4. Perform angulation calibration according to the applicable Ingenuity CT Calibration Manual.
6. Slide the lexan ring back into position in the rear cone and secure it with the flat head screw.
Section 36
Section 36 Replacing 5V/24 V DMS Power Supply
WARNING: Hazardous voltages are present in the gantry. Exercise proper precautions to avoid contact
with live connections while servicing. Failure to do so may result in serious injury or death.
36.1 Removing the Supply

1. Turn off gantry power Gantry Power Down (Except for the Host and CIRS) on page 27.
The 24 V DMS power supply is located inside the front of the rotor as shown in Figure 36‐1 on
page 550.
Figure 36-1: 5V/24 V DMP Power Supply Location
5V/24 V DMS P/S
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Replacing 5V/24 V DMS Power Supply
3. Note where the input and output wires are connected and disconnect them from the supply. Refer to
4. Remove 5 screws securing the 5V / 24V Flatpac power supply to the rotor, and remove power supply.
Refer to Figure 36‐2 on page 551.
Figure 36-2: 5V / 24V Power Supply Attaching Screws

ATTACHING SCREWS (5)
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Replacing 5V/24 V DMS Power Supply
36.2 Installing the Supply

1. Make sure that the local sense jumpers shown in Figure 36‐3 on page 552 are installed on the new
supply. If they are not, remove the ones from the old supply and install them.
3. Apply Loctite #242 to the 5 attaching screws, include flat washers, and attach the 5V / 24V Flatpac
power supply to gantry. Hand‐tighten the screws
4. Connect the input and output wires to the supply.
6. Restore power to the gantry according to the procedure “System Power Up” on page 34.
7 Perform collimator A‐plane calibration according to the applicable Ingenuity CT Calibration Manual.
Note: Changes in the voltage level on the A-plane >0.1V may render existing calibration data on the gantry useless.
Therefore, as a good practice, the A-plane collimator should be recalibrated whenever the DMP or power supplies to
DMS are replaced.
8. Run several helical scans to verify that the system is functioning properly. Examine the images for any
artifacts.
Figure 36-3: 5 V/24 V Power Supply Local Sense Jumpers

LOCAL SENSE JUMPERS
Section 37
Section 37 Ingenuity CT DMS Triple 5V Power Supplies
Replacement
The Ingenuity CT gantries contain two triple 5V output flatpac DMS power supplies (PS1 and PS2)
located on the rear of the gantry rotor. With the x‐ray tube at the 12 o’clock position, the power supplies
are located on the lower left and lower right of the gantry rear. The procedure provided is applicable for
either flatpac power supply.
37.1 Removal
WARNING: Hazardous voltages are present in the gantry. Turn power off before servicing. Failure to do
so may result in serious injury or death.
1. Remove power from the system See “Gantry Power Down (Except for the Host and CIRS)” on
page 27..
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Ingenuity CT DMS Triple 5V Power Supplies
5. Release the main drive motor brake and rotate the rotor (clockwise only as viewed from the front of
the gantry) until the power supply to be replaced is accessible.
6. Tag and remove cable connections from power supply to be removed. Refer to Figure 37‐1 on
page 554 and Figure 37‐2 on page 555.
Figure 37-1: BR 40/64 Triple Output Flatpac Power Supplies (PS1 and PS2) Location

NOTE: X-ray tube is at the

12 o’clock position.
PS1 location PS2 location
7. Remove six socket head cap screws and flat washers securing power supply to mounting bracket, and
remove power supply. Refer to Figure on page 555.
Figure 37-2: BR 40/64 Triple Output Flatpac Power Supplies Close‐up

Flatpac Power Supply PS1 Flatpac Power Supply PS2
37.1.1 Installation
2. Apply Loctite #222 to the 6 power supply attaching screws and attach the replacement power supply
to the mounting bracket on rear of gantry rotor. Hand tighten the screws.
3. Connect the cables to the power supply.
5. Install the rear cone Installing the Ingenuity CT Gantry Rear Cone on page 133.
6. Install the rear cover Ingenuity CT Gantry Rear Cover Installation on page 120.
8. Restore power to the gantry System Power Down/Power Up on page 22.
9. Perform collimator A‐plane calibration according to the applicable Ingenuity CT Calibration Manual.
Note: Changes in the voltage level on the A‐plane >0.1V may render existing calibration data on the gantry
useless. Therefore, as a good practice, the A‐plane collimator should be recalibrated whenever the DMP
or power supplies to DMS are replaced.
10. Run a helical scan to verify that the system is functioning properly.
Section 38
Section 38 TDMS 48V Power Supply
38.1 Introduction
This procedure is for replacing the 48V power supply assembly, P/N 4535 674 88921.

1. Remove power from the gantry See “Gantry Power Down (Except for the Host and CIRS)” on
page 27..
3. Release the main drive motor brake and rotate the rotor clockwise so that the DMS is at the 6 o’clock
position as shown in.Figure 38‐1 on page 558.
4. Pin the rotor in that position and apply the motor brake.
4598 000 72481 Rev K#0.2 CSIP‐1 ATTENTION: THIS PAGE CONTAINS COPYRIGHTED MATERIALS THAT ARE CONFIDENTIAL AND/OR PROPRIETARY. ANY RELEASE OR DISTRIBUTION OF THIS MATERIAL, WITHOUT PERMISSION, IS A VIOLATION OF LAW. 557
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement TDMS 48V Power Supply
Figure 38-1: Location of 48V Power Supply

48V TDMS P/S
38.2.1 Removing the 48 V Supply

1. Disconnect the DC output cable from the 48V power supply (see Figure 38‐2).
2. Disconnect the ground wire from the 48V P/S bracket.
Figure 38-2: 48 V P/S Output Cable

DISCONNECT GROUND
WIRE FROM BRACKET
DISCONNECT 48V P/S

OUTPUT CABLE
3. Remove the two 48V power supply mounting bolts (see Figure 38‐3).
Figure 38-3: 48 V Power Supply Mounting Bolts

48 V POWER SUPPLY MOUNTING BOLTS

(SHOULD BE 5/16” x 1.5” HEX-HEAD)
WITH SPHERICAL SET WASHERS
4. Remove the attaching clamps and disconnect the shutdown cable and the AC power cable from the 48
V P/S (see Figure 38‐4).
Figure 38-4: Cable Connections to 48 V Power Supply
AC Power Cable
P/N 4550 123 09091
Shutdown Cable
P/N 4535 674 67161
38.2.2 Installing the 48V Power Supply

1. Connect the shutdown cable and the AC power cables to the 48V Power Supply before you install it
on the rotor (see Figure 38‐5).
2. Run the wire ties through the two black plastic clips and secure the cables with the wire ties.
Figure 38-5: Cable Connections to 48 V Power Supply

AC Power Cable
Shutdown Cable
P/N 4535 674 67161
3. If it is not already installed, install the rotor locking pin into the rotor and leave it in place throughout
the installation of the 48V power supply assembly. This is to ensure that the power supply does not
interfere with the locking pin when it is installed (see Figure 38‐6).
4. Align the front face of the aluminum mounting plate the front face of the rotor casting.
Figure 38-6: 48 V Power Supply Must Clear Rotor Locking Pin

ALIGN MOUNTING PLATE
TO FRONT OF ROTOR
48 V POWER SUPPLY
ROTOR LOCKING PIN
6. Apply Loctite #242 to the 2, 5/16” x 1.5” long hex head bolts and install them with 2 spherical set
washers to secure the 48V power supply assembly to the rotor as shown in Figure 38‐7 on page 564.
7. Torque the two (2) 5/16” x 1.5” long hex head bolts to 13 ft‐lb (17.6 Nm).
8. Verify that the rotor locking pin is able to move freely in and out of hole in the rotor. If the pin is not
free, loosen the mounting bolts, position the supply so that it does not contact the pin and is still flush
with the front of the rotor and retighten the screws. Recheck that the pin is free.
Figure 38-7: 48 V Power Supply Mounting Bolts
48 V POWER SUPPLY MOUNTING BOLTS

(SHOULD BE 5/16” x 1.5” HEX-HEAD)
WITH SPHERICAL SET WASHERS
9. Connect the DC output cable to the 48V power supply (see Figure 38‐8).
10. Connect the ground wire to the 48V P/S bracket (see Figure 38‐8).
Figure 38-8: 48 V P/S Output Cable

CONNECT GROUND WIRE

TO BRACKET
CONNECT 48V P/S

OUTPUT CABLE
11. Route the 48V P/S Shutdown Cable from the DMC16 to the 48V P/S as shown in Figure 38‐9 on

page 566 and secure it with cable ties.
Figure 38-9: Shutdown Cable

SHUTDOWN CABLE CONNECTED TO CONNECTOR CONNECT TO
DMC-16 J23
DISCONNECTED FROM DMC-16 J23 48 V P/S
AC CABLE TO
CAPACITOR HUB
12. Remove the rotor locking pin, release the motor brake and manually rotate the rotor to verify that all
the new cables are secure.
15. Install the gantry left column cover (see Ingenuity CT Side Covers Replacement on page 135).
16 Restore power to the gantry according to System Power Up on page 34.
17 Perform collimator A‐plane calibration according to the applicable Ingenuity CT Calibration Manual.
Note: Changes in the voltage level on the A‐plane >0.1V may render existing calibration data on the gantry
useless. Therefore, as a good practice, the A‐plane collimator should be recalibrated whenever the DMP
or power supplies to DMS are replaced.
18 Run a helical scan to verify that the system is functioning properly.
Section 39
Section 39 Replacing 5V Reference Converter Power Supply

1. Turn off gantry power (see Gantry Power Down (Except for the Host and CIRS) on page 27).
The 5 V reference converter power supply is located inside the front of the rotor as shown in
Figure 39-1: 5V Reference Converter Power Supply Location
5V Reference
Converter P-/S
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Replacing 5V Reference Converter Power Supply
3. Disconnect the two cables from the supply. Refer to Figure 39‐2 on page 569.

4. Loosen the 4 power supply cover screws (2.5 mm hex key) enough to allow the cover to be removed.
These are captive screws and can be left in the cover. Refer to Figure 39‐2 on page 569.
Figure 39-2: 5V Power Supply Connections and Cover Screws

DISCONNECT CABLE REMOVE COVER SCREWS (4)
DISCONNECT CABLE
5. Remove 4 screws securing the power supply and remove the supply. Refer to Figure 39‐3 on page 570.
Figure 39-3: 5V Power Supply Attaching Screws

ATTACHING SCREWS (5)
39.2 Installing the Supply

2. Apply Loctite #222 to the 4 attaching screws and attach the power supply to gantry (see Figure 39‐3
on page 570). Hand‐tighten the screws.
3. Apply Loctite #222 to the 4 cover screws and install the cover (see Figure 39‐2 on page 569). Hand‐
tighten the screws.
4. Connect the 2 cables to the supply.
6. Restore power to the gantry according to the procedure “System Power Up” on page 34.
7. Run several helical scans to verify that the system is functioning properly. Examine the images for any
artifacts.
Section 40
Section 40 Main Drive Motor Replacement
Tools Required: FE Tool Kit
40.1 Process Overview for Rotor Main Drive Motor

Removal and Replacement
Note: THIS IS NOT THE PROCEDURE. IT IS AN OVERVIEW OF THE PROCEDURE. The removal procedure
starts on page 40‐573.
This is a listing of the general steps required to remove and replace a rotor main drive motor. It is meant
as a quick overview for the experienced service person who does not need detailed procedures. Detailed
instructions for replacing a main drive motor are in the section following these overview steps.
1. Remove system power. Refer to System Power Down/Power Up on page 22 procedure.
2. Open the gantry front cover
3. Remove the gantry rear cover.
4. Remove the drive belt.
5. Mark the position of the motor and remove the drive motor.
6. Disconnect the wires from the motor.
7. Remove the poly‐vee sheave from the motor shaft.
8. Install the poly‐vee sheave on the new motor.
9. Connect the wires to the new motor.
10. Install the new motor.
11. Check motor rotation.
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Main Drive Motor Replacement
40.2 Motor Removal
WARNING: Exercise proper precautions to avoid contact with live connections while servicing.
Hazardous voltages are present in the gantry. Failure to do so will result in serious injury or
death.
1. Remove power to the gantry according to the Gantry Power Down (Except for the Host and CIRS) on
page 27 procedure in the System Power Down/Power Up on page 22 section of this manual.
3. Remove the gantry rear cover (see Removing the Gantry Rear Cover on page 112).
4. Refer to Figure 40‐1 on page 574. Using a large screwdriver or other suitable prying device, pry the

belt tensioner up to loosen the belt and slip the belt off the motor drive pulley. Slowly release the
tensioner.
Figure 40-1: Main Drive Motor and Tensioner
Note: The motor weighs 52 lb (23 kg). It takes two people to support the motor while removing and installing
it.
5. Mark the position of the motor mounting plate on the gantry rotor casting.
6. While supporting the motor, remove the four hex nuts that mount the motor to the stator casting and
remove the motor and rest it on the floor (the cable should be long enough to allow this).
7. Remove the motor connection box cover.
8. Mark all of the cables that lead to the motor.
9. Disconnect all of the leads from the motor.
10. Remove the three hex bolts on the front face of the sheave (see Figure 40‐1).
11. Thread two of the three bolts into the two threaded holes in the sheave as shown in Figure 40‐2 on
page 575.
12. Alternately tighten the bolts equal partial turns. If done correctly, the two pieces of the motor poly‐vee
sheave will separate and loosen, allowing the motor poly‐vee sheave to slide freely off the motor
shaft.
13. Remove the sheave and pulley from the motor shaft.
Figure 40-2: Bolts Installed to Remove the Sheave

40.3 Motor Installation
Replacement Motor Identification

The motor connections are determined by the type of motor. The original motors manufactured by
Reliance Electric are being replaced by motors from Baldor Electric when replacement is required. This
change was necessary because Baldor Electric acquired the motor division from Reliance Electric and the
plant where the original motors were produced has now been closed.
The original 2 HP Reliance motor (P/N 4535 670 25511 ‐ dark green in color) is being replaced by the
Baldor motor
(P/N 4535 674 87011 ‐ gray in color).
Since the normal shaft rotation is different for the two types of motors (clockwise vs. counterclockwise),
the wiring connections are different. Changing the shaft rotation direction requires swapping 2 of the 3
input phases to the motor in order to obtain the proper shaft rotation.
Note: The phase swapping must take place between the output of the Spindleblok (T1, T2, T3) and the drive
motor and not on the 3 input phases to the Spindleblok.
1. Determine the manufacturer of the motor being installed from the motor nameplate and connect the
motor according to Table 40‐1 on page 577 for Baldor motors and Table 40‐2 on page 578 for Reliance
motors.
Table 40-1: Connections for Baldor Motors (P/N 4535 674 87011 ‐ gray in color)
From Spindleblok
Cable Designator/Lead Number Connects to Baldor Motor Leads:
Terminal:
Lead 1 ‐ Black T1 1 & 7 (blue & pink)
Lead 2 ‐ Black T2 3 & 9 (orange & gray)
Lead 3 ‐ Black T3 2 & 8 (white & red)
B1 (red) & B3 (black)
Cable 4535 664 91741 Black lead L1
(to Stearns brake coil)
Cable 4535 664 91741 Red lead L2
Cable 4535 664 91731 Red lead ‐‐‐‐ 20ga BLUE (motor thermal switch)
Cable 4535 664 91731 Black lead ‐‐‐‐ 20ga BLUE (motor thermal switch)
NOTE: Motor leads 4, 5, & 6 are connected together and do not connect to an incoming wire.
Table 40-2: Connections for Reliance Motors (P/N 4535 670 25511‐ dark green in color)
From Spindleblok
Cable Designator/Lead Number Connects to Reliance Motor Leads:
Terminal:
Lead 1 ‐ Black T1 T1 & T7
Lead 2 ‐ Black T2 T2 &T8
Lead 3 ‐ Black T3 T3 & T9
Cable 4535 664 91741 ‐ Black lead L1
Cable 4535 664 91741 ‐ Red lead L2
Cable 4535 664 91731 ‐ Red lead ‐‐‐‐‐ P1 (motor thermal switch)
Cable 4535 664 91731 ‐ Black lead ‐‐‐‐‐ P2 (motor thermal switch)
NOTE: Motor leads 4, 5, & 6 are connected together and do not connect to an incoming wire.
2. Reinstall the cover on the motor connection box.
3. Install the motor. One way to install the motor is to insert the front of the motor through the hole in
the front plate of the gantry and rest the front of the motor on the plate. Then while one person
supports the motor at the back, another person can start the mounting bolts through the motor
mounting plate into the gantry stator casting.
4. Using the marks made before removing the old motor in Step 5 on page 40‐575, position the base of
the new motor in the same position as the previous motor and tighten the mounting bolts.
5. Make sure that the key is in the keyway on the motor shaft and slide the sheave and pulley onto the
motor shaft of the new motor.
6. Position the sheave so that the end of the motor shaft is recessed 1/8” from the outer surface of the
sheave (see Figure 40‐3). (This is factory alignment).
Figure 40-3: Main Drive Motor and Tensioner

MOTOR SHAFT
RECESSED 1/8” FROM
OUTER SHEAVE
SURFACE
7. While maintaining the position of the sheave on the motor shaft, progressively tighten each hex head
bolt, alternating frequently from each of the three bolts. Tighten each bolt 1 to 2 turns before moving
to the next, until all are tight. Torque each bolt to 13 ft‐lb (17.6 Nm).
8. Before installing the belt, power up the system according to the procedure “Gantry Power Up” on
page 34.
9. Go immediately to the back of the gantry and observe motor direction of rotation. The motor should
start to rotate a few seconds after power is applied, and should continue to rotate for 20‐45 sec. after
power is applied before it errors out.
The motor should rotate clockwise (as viewed from the front of the gantry; counterclockwise viewed
from the rear of the gantry).
If the motor is rotating the right direction, commissioning should not be necessary.
If the motor is rotating the wrong direction, check the wiring of the motor controller.
10. When the motor rotation is correct:
• For systems with SpindleBlok motor controllers, reinstall the belt and proceed to the next step.
• For systems with Emerson CSK or M200 motor controllers, perform the procedure “Emerson CSK
or M200 Motor Controller Commissioning” on page 663 (also contained in the applicable version of
Ingenuity CT Calibration Manual).
11. Test the gantry operation.
If gantry operation is correct, proceed to the following section Restoring the System to Operation on
page 581.
Note: The fan on the heat sink of the motor controller only runs when the temperature exceeds 50 degrees
centigrade.
12. If rotational problems are encountered on systems with SpindleBlok motor controllers, perform the
procedure “SpindleBlok Motor Controller Commissioning” on page 608 in the section “SpindleBlok
Motor Controller Replacement” on page 601 section (also contained in the applicable version of
Ingenuity CT Calibration Manual).
13. If problems persist, troubleshoot the gantry (motion systems).

1. After the motor controller is installed and the system is operating properly, install the rear cover (see
‘Ingenuity CT Gantry Rear Cover Installation on page 10‐120).
2. Close the Gantry Front Cover (see ‘Closing the Ingenuity CT Gantry Front Cover on page 2‐45).
3. Power up the system according to the procedure “System Power Up” on page 34.
4. Perform a helical scan to verify that the system is functioning properly.
Section 41
Section 41 Rotor Drive Motor Brake Check and Adjustment
This sections contains procedures for checking the time it takes the rotor drive motor brake to stop the
rotor after an
E‐stop command and for adjusting the brake as required.
The recommended sequence of these procedures is as follows:
1. Check and adjust if necessary the brake air gap.
2. Check the rotor stopping time.
3. Adjust the brake torque as required to achieve the correct rotor stopping time.
41.1 Checking and Adjusting the Rotor Drive Motor

Brake Air Gap
Adjusting the air gap will affect the brake torque which will affect the rotor stopping time. If the air gap is
adjusted the rotor stopping time must be checked (see “Checking the Rotor Stopping Time” on page 587)
and the brake torque adjusted as required (see “Adjusting the Stopping Time (Brake Torque)” on
page 591).
WARNING: Avoid contact with powered components. Hazardous voltages are present inside the front
cover. Contact with powered components may result in personnel injury or death.
1. If the front cover is not already open, open the gantry front cover (see Ingenuity CT Gantry Front
Cover Opening/Closing on page 40). Leave the system in the E‐stop mode.
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Rotor Drive Motor Brake Check and Adjustment
2. Remove the 2 nuts (3/8‐in. socket) and remove the brake cover (see Figure 41‐1).
Figure 41-1: Rotor Drive Motor Brake Cover

REMOVE 2 NUTS
3. Push gently up on the solenoid plunger until it begins to meet resistance. Do not push it so hard that
it begins to move the brake plate to release the brake (see Figure 41‐2).
4. When pushed up, the solenoid plunger lip should align within 0.03 in. of the SET edge of the air gap
gauge (see Figure 41‐2).
If the gage is not present, use a ruler to measure the air gap as (see Figure 41‐2 on page 584). The gap
should be 0.5 in. +/‐ 0.03 in.
Figure 41-2: Checking Brake Air Gap

AIR GAP GUAGE SOLENOID PLUNGER LIP
PUSH UP ON SHOULD ALIGN WITH THE SET
PLUNGER SIDE OF THE GUAGE
Figure 41-3: Measuring Solenoid Air Gap with a Ruler
5. If the solenoid plunger position is not 0.5 in. +/‐ 0.03 in as measured in Figure 41‐2 on page 584 or,

Figure 41‐3 on page 585 adjust the air gap using the 2 screws indicated in Figure 41‐4 on page 586.
• Adjust each screw the same amount about 1/4 turn at a time until the air gap is correct.
• Turn the screws clockwise to decrease the air gap or counterclockwise to increase the air gap.
6. If the air gap is adjusted, check the rotor stopping time (see “Checking the Rotor Stopping Time” on
page 587).
Figure 41-4: Air Gap Adjustment Screws

AIR GAP ADJUSTMENT SCREWS
41.2 Checking the Rotor Stopping Time
WARNING: Hazardous voltages are inside the front cover. Use proper precautions to avoid contact with
powered components. Failure to comply may result in personnel injury or death.
1. Open the gantry front cover (see Ingenuity CT Gantry Front Cover Opening/Closing on page 40).
2. Pull out the plunger on the front cover safety switch to allow the system to be operated with the front
cover opened.
3. If the application program is running, log out of it.
4. Log in as philips_service.
5. Open Service Tools.
6. From the General Tools list select the CAN Send utility (see Figure 41‐5).
Figure 41-5: Service Tools General Tools

GENERAL TOOLS
CAN Send
7. In the left Category column select ROTOR (see Figure 41‐6).
8. Select MsgName ROTOR_JOG_REQ (see Figure 41‐6).
Figure 41-6: CAN Send ROTOR_JOG_REQUEST

SELECT ROTOR
ROTOR_JOG_REQ
9. In the right Can Sender pane enter a value of 500 for VarName ushortParamM (see Figure 41‐7).
10. Enter a value of 1 for VarName boolParamM (see Figure 41‐7).
Figure 41-7: Values to Enter in Can Sender

ENTER VALUE 500

ENTER VALUE 1
!
WARNING: The next step will result in the Gantry rotor rotating at 120 rpm. Stay clear of the rotor.
Failure to comply may result in personnel injury or death.
11. Click on the Send to CAN button at the bottom of the left pane (see Figure 41‐6 on page 589).
12. Prepare to start a timing device that can measure in seconds the time it takes for the rotor to stop in
the next step.
13. When the Rotor is up to speed, press any of the system red E‐STOP buttons.
14. Measure the time it takes for the rotor to come to a complete stop.
The allowable time is 15 to 30 seconds for BRILLIANCE 6‐64 and 20 to 40 seconds for BRILLIANCE
Big Bore.
15. Close the E‐Stop loop as soon as the test is complete.
16. If the stopping time is not within specification adjust the brake according to the following procedure
“Adjusting the Stopping Time (Brake Torque)” on page 591.
17. If the stopping time is correct, install the brake cover and close the gantry front cover (see Closing the
Ingenuity CT Gantry Front Cover on page 45).
41.3 Adjusting the Stopping Time (Brake Torque)

Adjusting the air gap will affect the brake torque. Therefore it is recommended that the brake air gap be
checked and, if necessary, adjusted before adjusting the brake torque “Checking and Adjusting the Rotor
Drive Motor Brake Air Gap” on page 582.
If the brake torque or the air gap is adjusted the rotor stopping time must be checked (see “Checking the
Rotor Stopping Time” on page 587).
WARNING: Avoid contact with powered components. Hazardous voltages are present inside the front
cover. Contact with powered components may result in personnel injury or death.
1. If the front cover is not already open, open the gantry front cover (see Ingenuity CT Gantry Front
Cover Opening/Closing on page 40). Leave the system in the E‐stop mode.
2. If the brake cover is in place, remove the 2 nuts (3/8‐in. socket) and remove the brake cover (see
Figure 41‐8).
Figure 41-8: Rotor Drive Motor Brake Cover
REMOVE 2 NUTS
3. If not already done, check the brake solenoid air gap “Checking and Adjusting the Rotor Drive Motor
Brake Air Gap” on page 582.
4. Adjust the brake torque by equally adjusting the 2 adjustment nuts 2 turns each (see Figure 41‐9).
• To increase the braking torque (decrease stopping time) adjust both nuts 2 turns clockwise.
• To decrease the braking torque (increase stopping time) adjust both nuts 2 turns counterclockwise.
5. After adjusting the torque adjusting nuts 2 turns in the desired direction, recheck the rotor stopping
time “Checking the Rotor Stopping Time” on page 587.
Figure 41-9: Brake Torque Adjustment Nuts

BRAKE TORQUE
ADJUSTMENT NUTS
Section 42
Section 42 Main Drive Belt Replacement
The following procedure describes how to remove and replace the gantry rotor main drive motor belt.
Estimated Time: 1 hour Tools required: Standard FE tool kit
42.1 Process Overview for Rotor Main Drive Belt

Replacement
Note: THIS IS NOT THE PROCEDURE. IT IS AN OVERVIEW OF THE PROCEDURE. The removal procedure
starts on page 42‐594.
This is a listing of the general steps required to remove and replace a main drive belt. It is meant as a
quick overview for the experienced service person who does not need detailed procedures. Detailed
instructions for replacing a main drive belt are in the section following these overview steps.
1. Turn off power to the gantry according to the procedure (see ‘Gantry Power Down (Except for the
Host and CIRS) on page 1‐27) procedure.
2. Open the gantry front cover and remove the gantry rear cover.
3. Remove the heat shields.
4. Remove the drive belt.
5. Reinstall the drive belt.
6. Replace the heat shields.
7. Power up the gantry.
8. Check the tensioner position.
9. Check the belt tracking.
10. Replace the rear cover and close the front cover.
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Main Drive Belt Replacement
42.2 Belt Removal
1. Turn off power to the gantry according to the procedure (see ‘Gantry Power Down (Except for the
Host and CIRS) on page 1‐27).
5. Refer to Figure 42‐1 on page 594. Using a large screwdriver or other suitable prying device, pry the
belt tensioner up to loosen the belt and slip the belt off the motor drive pulley. Slowly release the
tensioner.
Figure 42-1: Main Drive Motor and Newer Style Tensioner and Bracket
6. The belt will come off through the front of the gantry. Remove the heat shields from the front of the
stator by removing the small bolts that hold them to the stator.
The upper left heat shield is shown in Figure 42‐2 on page 595 as an example. The other shields are
similarly attached. Rotate the rotor CW as required for easiest access to each shield.
7. Work the belt out of the front of the gantry through the opening made by removing the heat shields.
Figure 42-2: Left Upper Heat Shield Removal (others are similar)

HEAT SHIELD ATTACHING
SCREWS
HEAT SHIELDS
42.3 Belt Installation

1. Work the new belt over the rotor and into the groves on the rotor.
Note: There is one more groove in the rotor and in the motor pulley than there are ribs on the belt. Install the
belt toward the rear so that the open groove in both the rotor and in the motor pulley are toward the
front of the gantry as shown in Figure 42‐3 on page 596.
Figure 42-3: Belt Positioning on Motor Pulley and Rotor

OPEN GROOVE
AT FRONT
REAR OF FRONT OF
GANTRY GANTRY
MOTOR PULLEY ROTOR
2. Using a large screwdriver or other suitable prying device, pry the belt tensioner and slip the belt over
the motor drive pulley and under the tensioner (see Figure ). Slowly release the tensioner.
Note: If the new belt is a slightly different length than the original belt it may require that tensioner be
repositioned according to the following instructions. Tensioner repositioning is only possible with new
style tensioner brackets as shown in Figure 42‐4 on page 597.
3. Check the tensioner position. There should be less than a 3/4” (20 mm) gap at the place shown in
Figure 42‐4 on page 597 to ensure that the tensioner has adequate travel. It must have enough travel
up to allow installation of the belt.
Figure 42-4: Tensioner Positioning

LESS THAN 3/4” GAP (20 mm)
FOR REPOSITIONING, MARK

POSITION OF TENSIONER
ON BRACKET HERE
4. If the tensioner has more than a 3/4” gap as shown in Figure 42‐4 on page 597, the tensioner will need

to be repositioned.
Refer to Figure 42‐5 on page 599. If the tensioner mounting bracket has 3 pair of tensioner mounting
holes, proceed to Step 5 on page 42‐598.
If the tensioner mounting bracket does not have 3 pair of mounting holes as shown in Figure 42‐5 on
page 599, obtain a new tensioner mounting bracket (P/N 4535 671 78301) and install it as follows:
a) Remove the belt.
b) Measure and record the distance between the tensioner mounting bolts and the vertical part of the
mounting bracket as indicated in Figure 42-5 on page 599.
c) Remove the 2 tensioner mounting bolts (see Figure 42-5) and remove the tensioner.
d) Remove the 3 bolts that attach the tensioner mounting bracket to the motor (see Figure 42-5) and
remove the bracket.
e) Obtain Loctite #242 and ensure the expiration date has not been reached.
f) Apply Loctite #242 to the tensioner mounting bracket bolts and attach the new 4535 671 78301
mounting bracket to the motor.
g) Apply Loctite #242 to the tensioner mounting bolts and reattach the tensioner using the bracket
holes closest to the center of the gantry to decrease the gap shown in Figure 42-4 on page 597.
h) Position the tensioner front-to-back position so the distance from the tensioner mounting bolts to
the bracket is the same that was measured previously (see Figure 42-5).
5. If the tensioner gap is more than the 3/4” shown in Figure 42‐4 on page 597, and the tensioner
mounting bracket has 3 pair of tensioner mounting holes as shown in Figure 42‐5 on page 599,
reposition the tensioner as follows:
a) Remove the belt.
b) Mark the front-to-back position of the tensioner on the bracket as shown in Figure 42-4 on
page 597.
c) Unbolt the tensioner from the bracket (see Figure 42-5).
d) Apply Loctite #242 to the bolts and reattach the tensioner using the bracket holes closer to the
center of the gantry to decrease the gap shown in Figure 42-4 on page 597. Make sure to remount
the tensioner in the same front-to-back position according to the mark you made.
Figure 42-5: Tensioner Mounting Bolts

TENSIONER BRACKET WITH TENSIONER MOUNTING
3 PAIR OF TENSIONER BOLTS
MOUNTING HOLES
MEASURE DISTANCE BETWEEN

TENSIONER BRACKET &
MOUNTING BOLTS
TENSIONER BRACKET
MOUNTING BOLTS
6. Check that the belt tracks correctly as follows:
a) Release the rotor drive motor brake and slowly turn the rotor clockwise by hand (clockwise
direction only as viewed from the front of the gantry).
b) As the rotor turns, watch how the belt tracks on the motor pulley and the belt tensioner. The belt
should track straight and true and there should not be any front-to-back tracking movement or other
signs of misalignment. The belt should track centered on the tensioner.
If the belt does not track correctly on systems with new style tensioner brackets, the tensioner can
be repositioned front to back to obtain alignment.
On systems with earlier brackets, belt alignment is achieved by moving the position of the motor
pulley on the motor shaft. Refer to the procedure (see ‘Main Drive Motor Replacement on page 40‐
572) for instructions on how to loosen the pulley.
c) Apply the rotor drive motor brake.
7. Replace the heat shields that were removed earlier.
8. Install the rear (see Installing the Ingenuity CT Gantry Rear Cone on page 133).
11. Turn power on to the gantry according to the procedure (see Gantry Power Up on page 34).
Section 43
Section 43 SpindleBlok Motor Controller Replacement
Note: You may receive a SpindleBlok 1.5 as a replacement for a previous model (see Figure 43‐1). The

SpindleBlok 1.5 is different in appearance from the older model shown in the procedure pictures; however,
the installation procedure is the same.
Figure 43-1: SpindleBlok 1.5 Motor Controller

Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement SpindleBlok Motor Controller Replacement
43.1 Removing the Controller
1. Turn off power to the gantry according to the procedure “Gantry Power Down (Except for the Host
and CIRS)” on page 27.
2. Turn off power to the rotor according to the procedure “Removing Gantry Rotor Power” on page 28.
4. Looking at the rear of the gantry the controller is located at the lower right above the rotor drive
motor as shown in Figure 43‐2 on page 602.
Figure 43-2: Motor Controller Location on Gantry

MOTOR CONTROLLER
Note: This procedure calls for removing the controller from the gantry before disconnecting the wires because
the restrictive space may make it difficult to disconnect the wires while the controller is installed.
5. While supporting the controller, remove the four nuts that attach the controller heatsink to the gantry
side (see Figure 43‐3). The controller and heatsink are replaced as a unit.
6. Cut cable ties as required so that the controller can be pulled far enough out of the back of the gantry
to allow access to the wire terminals.
Figure 43-3: Controller Mounting
TOP 2 ATTACHING NUTS

(TWO MORE ON BOTTOM)
!
CAUTION: Set up to control static discharge to prevent damage to the controller by electrostatic
discharge (ESD).
7. Set up to control static discharge according to the section (ESD‐Anti‐Static Field Service Kit in the
Ingenuity Safety Manual) to prevent damage to the controller by electrostatic discharge (ESD). Make
sure that the wrist strap is properly grounded.
8. On the 20‐pin connector, only disconnect the black wire from terminal 17 and the red wire from
terminal 18 (fan wires) (see Figure 43‐4). Leave all the other wires connected to the connector.
9. Disconnect the 20‐pin connector and the 5‐pin connector from the controller.
10. Disconnect the RJ‐45 communication cable.
Figure 43-4: Controller Connections
DISCONNECT
RJ-45 CONNECTOR
DISCONNECT
5-PIN CONNECTOR
DISCONNECT BLACK WIRE

FROM TERMINAL 17 AND RED
WIRE FROM TERMINAL 18
DISCONNECT
20-PIN CONNECTOR
11. Check that each of the remaining wires connected to the controller have destination labels and label
any that do not have a label.
12. Remove the terminal cover (see Figure 43‐5).
13. Disconnect the remaining wires from the terminal strip.
Figure 43-5: Connection Cover Removed

43.2 Installing the New Controller

1. If the new controller has the red and black fan wires connected to the 20‐pin connector that comes
with the new controller, disconnect them from the connector (see Figure 43‐5).
2. Remove the connectors and the cover from the new controller (see Figure 43‐5).
3. Properly connect the wires to the controller terminals.
4. Install the controller cover.
5. Connect the 20‐pin, 5‐pin and RJ‐45 connectors (see Figure 43‐4).
6. On the 20‐pin connector, connect the black fan wire to terminal 17 and the red wire to terminal 18 (see
Figure 43‐4). Make sure the screw clamps are against the wire and not the insulation. Gently pull on
each wire to make sure it is clamped securely.
7. Secure the new motor controller to the side of the Gantry column with the four nuts removed earlier
8. Position all the wires as they were before and secure in place with cable ties as required.
9. Using a large screwdriver or other suitable prying device, pry the belt tensioner up to loosen the belt
and slip the belt off the motor drive pulley. Slowly release the tensioner.
10. Power up the system according to the procedure “Gantry Power Up” on page 34.
The motor should rotate clockwise (as viewed from the front of the gantry; counterclockwise viewed
from the rear of the gantry). If the motor is rotating the wrong direction, check the wiring of the motor
controller.
IMPORTANT: Determine if commissioning is necessary from the following conditions:

• SpindleBlok version 1.5 controllers are supplied already commissioned and should NOT be
commissioned in the system unless troubleshooting indicates that it is needed.
• For systems with version 3.5 software:
•Older models of controllers (prior to version 1.5) must be commissioned.
• SpindleBlok version 1.5 controllers should NOT be commissioned.
• For systems with software versions prior to 3.5 the factory commissioning of the
replacement SpindleBlok motor controllers (both models) is correct and they should NOT
be commissioned in the system unless troubleshooting indicates that it is needed.
• If the controller fails to operate, troubleshoot the gantry motion system.
12. When the motor rotation is correct, reinstall the belt.
13. Test the gantry operation.
If gantry operation is correct, proceed to the section “Restoring the System to Operation” on page 619.
Note: The fan on the heat sink of the motor controller only runs when the temperature exceeds 50 degrees
centigrade.
14. Only if rotational problems persist, run the following procedure “SpindleBlok Motor Controller
Commissioning” on page 608 (also contained in the applicable version of the Ingenuity CT
Calibration Manual).
43.3 SpindleBlok Motor Controller Commissioning

The following commissioning procedure will set the SpindleBlok motor controller to the electrical
operating characteristics of the motor. This procedure is also in the applicable Ingenuity CT System
Calibration Manual.
Note: There is a description of the motor commissioning procedure in the “Help” pages of Service Tools.
1. On the host, Login as philips_service.
2. From the desktop, open Service Tools.
3. In the left Service tools panel under the heading “Calibration Tools”, select “SpindleBlok
Commission”(see Figure 43‐6). The SpindleBlok Commissioning dialog box shown in Figure 43‐7 on
page 609 should be displayed.
Figure 43-6: Service Tools Menu

4. Remove power to the gantry according to the procedure “Gantry Power Down (Except for the Host
WARNING: Hazardous voltages are present in the gantry support. Exercise proper precautions to avoid
contact with live connections while servicing. Failure to do so may result in serious injury or
death.
Figure 43-7: SpindleBlok Commissioning Dialog Box
5. Pin the rotating scan frame in one of the two locking locations before removing the main drive belt.
Only move the scan frame in CW direction.
6. TAKE NOTE whether the belt is installed on the motor pulley so that there is an open pulley groove
toward the motor or toward the back so the belt can be reinstalled in the same grooves and maintain
the original alignment.
!
CAUTION: Be careful releasing the tensioner since it is under considerable spring force.
7. Pry the belt tensioner up with a suitable tool to relieve tension on the belt (see Figure 43‐8) and
remove the belt from the motor pulley. (For more detailed instructions see the drive belt removal /
replacement instructions in the applicable Gantry Repair / Replacement Manual).
8. Spin the tensioner pulley by hand to make sure it rotates smoothly and freely
Note: The motor will rotate during the commissioning procedure.
9. With the gantry power off, click the “Start” button to begin SpindleBlok commissioning.
10. A prompt will appear notifying the user to Pin the scan frame, (which is already done) click OK.
Figure 43-8: Belt Tensioner

PRY UP ON
TENSIONER
Figure 43-9: Power‐Up Dialog Box
11. If the front cover is open, make sure the front cover interlock switch is in the service position.
12. On systems that a have rear cover interlock switch, place it in the service position.
14. , When the gantry is powered up, click on the OK button in the “Power up Gantry “dialog box.
15. .After clicking the “OK” button, a prompt to close E‐Stop (switch box) should appear. When
prompted, turn the keyswitch to close the E‐Stop.
You should hear the sound of the main drive contactor closing and the green LED on the top of the
SpindleBlok controller should now be on, indicating that the main drives are on.
The Commissioning Program will automatically begin.
16. When the commissioning has ended, a service tools verification dialog box with instructions will
appear (see Figure 43‐10). DO NOT CLICK OK until instructed to do so in the following instructions.
Figure 43-10: Verification Dialog Box
17. Follow the instructions within the dialog box to:
a) Power down the gantry according to the procedure “Gantry Power Down (Except for the Host and
b) Install the belt.
Note: Make sure the belt is installed so the same groove on the motor drive sheave it was in before it was
removed and check all around rotor casting for proper alignment.
c) Unpin the gantry.
d) Rotate the rotor CLOCKWISE ONLY by hand 4 or 5 times to seat the belt and ensure that it is
centered on the belt tensioner wheel.
e) Also check that all cables and components are secure and there is no interference of rotor and
stator components during rotation.
18. When the preceding instructions in the Figure 43‐10 on page 612 verification dialog box are complete,

power up the system according to the procedure “Gantry Power Up” on page 34.
19. When the system has finished powering up, click the OK button (see Figure 43‐10).
20. On the next dialog box, select “Verify Rotation”
21. When instructed to in a dialog box close the E‐Stop.
22. When the warning that the rotor will rotate appears, click OK.
There will be a wait while the X‐Ray tube rotor spins up.
The rotor will begin to rotate.
23. While the rotor is rotating, check the belt to make sure it is tracking correctly centered to the tensioner
pulley and that it is not making noticeable noise.
24. After allowing the rotor to rotate for a couple minutes, click OK to stop the rotor and position it to
zero degrees. The verification is now complete.
43.3.1 Checking/Setting the Motor Controller H Parameter
Checking the Motor Controller H Parameter

Check the value of the motor controller H parameter as follows:
1. From Service Tools open CanSender and select Rotor Category (see Figure 43‐11).
2. Select ROTOR_SB_READ_REQ command (see Figure 43‐11).
3. Populate the following fields with the values listed: (see Figure 43‐11)
a) driveAddress = 1 (numeric 1)
b) paramType = H (the “H” must be Upper Case)
c) paramNum = 00 (00 is |zero|zero|)
4. Click on the Send to Can button to send the ROTOR_SB_READ_REQ command
Figure 43-11: CanSender Display for ROTOR_SB_READ_REQ
5. Using CanTrace, check the parameters of ROTOR_SB_READ_ANS.
ParamData should have the value 00AC.
• If ParamData has a 00AC value, proceed to the section “Restoring the System to Operation” on
page 619.
• If ParamData has a different value, proceed with the following section Setting the Motor Controller H
Parameter on page 616. to set the H parameter.
Figure 43-12: CanTrace Display

Setting the Motor Controller H Parameter

1. From Service Tools open CanSender and select Rotor category (see Figure 43‐13)
2. Select the ROTOR_SB_WRITE_REQ command (see Figure 43‐13)
3. Populate the following fields with the values listed: (see Figure 43‐13)
a) driveAddress = 1 (numeric one)
c) ParamNum = 00 (00 is |zero|zero|)
d) ParamData = 00AC (00AC is |Zero|Zero|Upper Case A|Upper Case C|)
4. Click on the Send to Can button to send the ROTOR_SB_WRITE_REQ command.
Figure 43-13: CanSender Display for ROTOR_SB_WRITE_REQ

5. Select ROTOR_SB_READ_REQ command
6. Populate the following fields with the values listed:
a) driveAddress = 1 (numeric 1)
c) paramNum = 00 (00 is |zero|zero|)
7. Click on the Send to Can button to send the ROTOR_SB_READ_REQ command.
Figure 43-14: CanSender Display for ROTOR_SB_READ_REQ

8. Using CanTrace, check the parameters of ROTOR_SB_READ_ANS.
ParamData should have the value 00AC. If ParamData has a different value, make sure that Main
Drive Contactor is closed (see note below) and repeat Step 2 on page 616 through Step 8 on page 618.
Note: Missing or Incorrect values entered by READ commands in Step 3 on page 614 or Step 6 on page 617 or the

WRITE command in Step 3 on page 616 can cause the Main Drive Contactor to open. Any attempts to re‐
enter data in Step 3 on page 616 will fail until Main Drive Contactor is closed. You can close Main Drive
Contactor by issuing a ROTOR_RESTART_REQ from CanSender and repeat Step 2 on page 616 through
Step 8 on page 618.
Figure 43-15: CanTrace Display


Section 44
Section 44 Commander SK Rotor Drive Motor Controller
Replacement
Note: The system must have software version 3.5 or higher in order for the Emerson motor controller to operate
properly.
gantry support. Failure to do so may result in serious injury or death.
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Commander SK Rotor Drive Motor Controller
motor as shown in Figure 44‐1 on page 621.
Figure 44-1: Motor Controller Location on Gantry

MOTOR CONTROLLER
5. Disconnect the motor thermal sensor connector (see Figure 44‐2).
Figure 44-2: Motor Thermal Sensor Connector

MOTOR THERMAL
SENSOR CONNECTOR
6. Loosen the controller cover screw (it’s a captive screw) and remove the cover (see Figure 44‐3).
Figure 44-3: Controller Cover Screw

COVER SCREW
7. Make sure that the wires are labeled with their destinations. Disconnect the wires from the large
terminal strips by loosening the terminal screw and pulling the wire out (see Figure 44‐4).

DISCONNECT WIRES FROM

LARGE TERMINAL STRIPS
8. Remove the 2 nuts that attach the controller mounting plate to the to the bracket on the side of the
gantry (see Figure 44‐5).

REMOVE 2 NUTS
Note: This procedure calls for removing the controller from the gantry before disconnecting the smaller wires
because the restrictive space may make it difficult to disconnect the wires while the controller is
installed.
Note: It is suggested that the motor controller be placed on a box or some other suitable item while the
remaining wires are disconnected (Figure 44‐8 on page 628).
9. Cut cable ties as required so that the controller can be pulled out of the back of the gantry.
10. Pull the motor controller toward the rear of the gantry until the mounting bracket is disengaged from
the mounting studs (see Figure 44‐6).
Figure 44-6: Removing the Motor Controller

PULL CONTROLLER TOWARD THE

REAR UNTIL THE BRACKET IS
DISENGAGED FROM THE STUDS
11. Lift the controller out of the gantry (see Figure 44‐7) and place it onto a suitable support (see

Figure 44‐8 on page 44‐628).
12. Disconnect the RJ‐45 communication cable (see Figure 44‐8).
Note: On the small terminal strips make sure to use a screwdriver with a blade narrow enough to fit into the
plastic terminal hole. Using too wide of a screwdriver may damage the terminal strip.
13. Make sure that the wries are labeled with their destinations and disconnect the wires from the small
terminal strips (see Figure 44‐8).
To release wires from the small terminals, push a small, flat‐bladed screwdriver into the slot above the
terminal as shown in Figure 44‐9 on page 44‐629 and push up on the screwdriver handle to release the
wire.

DISCONNECT
RJ-45 CONNECTOR

SMALL TERMINAL STRIPS
SUPPORT STOOL
Figure 44-9: Releasing Wires From Small Controller Connectors

PUSH SCREWDRIVER INTO

SLOT AND PUSH UP TO
14. Remove the 4 screws and remove the mounting bracket from the motor controller (see Figure 44‐10).
Figure 44-10: Controller Mounting Bracket

REMOVE 4 SCREWS
(2 ON OTHER END)

1. Attach the mounting bracket to the motor controller with 4 screws (see Figure 44‐11).

INSTALL 4 SCREWS
(2 ON OTHER END)
2. Connect the RJ‐45 communication cable (see Figure 44‐12).
Note: On the small terminal strips make sure to use a screwdriver with a blade narrow enough to fit into the
plastic terminal hole. Using too wide of a screwdriver may damage the terminal strip.
3. Connect the wires to the small terminal strips (see Figure 44‐12).
To connect wires to the small terminals, push a small, flat‐bladed screwdriver into the slot above the
terminal as shown in Figure 44‐13 on page 44‐633 and push up on the screwdriver handle until the
wire can be inserted into the connector.

CONNECT
RJ-45 CONNECTOR
CONNECT WIRES FROM

SUPPORT STOOL
Figure 44-13: Connecting Wires to the Small Controller Connectors

PUSH SCREWDRIVER INTO

SLOT AND PUSH UP TO
CONNECT WIRES TO THE
4. Place the controller onto the mounting bracket. Slide the controller toward the front of the gantry
until the mounting bracket engages with the mounting studs (see Figure 44‐14).
Figure 44-14: Installing the Motor Controller

PUSH THE CONTROLLER

TOWARD THE FRONT UNTIL THE
BRACKET ENGAGES THE STUDS
5. Attach the controller with 2 nuts (see Figure 44‐15).

INSTALL 2 NUTS
6. Make sure the terminal screws are unscrewed enough so that they do not restrict the terminal holes.
7. Connect the wires to the large terminal strips by pushing the wires into the wire holes and tightening
the terminal screws (see Figure 44‐16).
8. Pull gently on each of the wires to make sure they are held securely and do not come out.

CONNECT WIRES TO LARGE

TERMINAL STRIPS
9. Connect the motor thermal sensor (see Figure 44‐17).
10. Position all the wires as they were before and secure them in place with cable ties as required.
Figure 44-17: Motor Thermal Sensor Connector

MOTOR THERMAL
SENSOR CONNECTOR
11. Install the controller cover and lightly tighten the screw just enough to hold the cover securely in
place (see Figure 44‐18).
Figure 44-18: Controller Cover Screw

COVER SCREW
12. Remove the drive belt as follows:
a. At the front of the gantry release the main drive motor brake by turning the release knob CW (see

RELEASE
APPLY
b. TAKE NOTE of how the belt is installed ‐ if the belt is installed on the motor pulley so that there is
an open pulley groove toward the motor or toward the back ‐ so the belt can be reinstalled in the
same grooves and maintain the original alignment.
!
CAUTION: Be careful releasing the tensioner since it is under considerable spring force.
c. Using a large screwdriver or other suitable prying device, pry the belt tensioner up to loosen the
belt and slip the belt off the motor drive pulley (see Figure ).
d. Slowly release the tensioner.
Figure 44-20: Belt Tensioner
PRY UP ON
TENSIONER
13. Pull out the front cover service switch plunger to allow operation of the gantry.
WARNING: When in back of the gantry wear laser safety glasses (P/N 453567543401) and Avoid
exposure to the laser beams. Ingenuity systems contain Class 3B Invisible Lasers for the
Optical Data Path. Class 3B Invisible laser radiation is present when the Gantry rear cover is
removed and the interlock is defeated. Failure to avoid exposure may cause eye damage.
on or off.
14. Pull out the rear cover service switch plunger to allow operation of the gantry (see Figure 44‐21 on
page 44‐642).
Figure 44-21: Rear Cover Interlock Switch on Systems Equipped with Class 3B Invisible Lasers

REAR COVER INTERLOCK -
REMOVES GANTRY INTERNAL POWER.

The motor should rotate counterclockwise viewed from the rear of the gantry (clockwise as viewed
from the front of the gantry).
If the motor is rotating the correct direction, commission the controller according to Emerson CSK or
M200 Motor Controller Commissioning on page 663.
If the motor is rotating the wrong direction, check that the wires from the output of the controller to
the motor are connected correctly.
44.3 Restoring the System to Operation

1. After the motor controller is commissioned, install the gantry rear cover See “Ingenuity CT Gantry
Rear Cover Installation” on page 120..
4. If problems persist, troubleshoot the gantry (motion systems).
Section 45
Section 45 M200 Rotor Drive Motor Controller Replacement
Note: The system must have software version 3.5 or higher in order for the Emerson M200 motor controller to
operate properly.
gantry support. Failure to do so may result in serious injury or death.
1. Open the gantry front cover Opening the Ingenuity CT Gantry Front Cover on page 40.
3. Remove the gantry rear cover Removing the Gantry Rear Cover on page 112.
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement M200 Rotor Drive Motor Controller Replacement
motor (see Figure 45‐1).
5. Remove the controller cover. To remove the cover:
a. Release the cover latch by turning the latch approximately 1/8 turn CCW until it releases, and
while holding it released, slide the cover toward the rear until it unlatches.
b. Remove the cover (see Figure 45‐1).
Figure 45-1: Controller Cover Latch
COVER LATCH
6. Make sure that the wires are properly labeled with their destinations. Disconnect the wires from the
large terminal strips by loosening each terminal screw and pulling the wire out (see Figure 45‐2).
Figure 45-2: Controller Large Terminal Strip Connections


LARGE TERMINAL STRIPS
AND GROUND TERMINALS
7. Disconnect the RJ‐45 communication cable (see Figure 45‐3).
8. Make sure that the wires are labeled with their destinations and disconnect the wires from the small
terminal strip (see Figure 45‐3).
Figure 45-3: Controller Small Terminal Strip Connections
DISCONNECT
RJ-45 CONNECTOR

SMALL TERMINAL STRIP
9. Remove the 2 nuts that attach the controller mounting plate to the to the bracket on the side of the
REMOVE 2 NUTS
10. Pull the motor controller toward the rear of the gantry until the mounting bracket is disengaged from
the mounting studs (see Figure 45‐5).
PULL CONTROLLER TOWARD THE

REAR UNTIL THE BRACKET IS
DISENGAGED FROM THE STUDS
11. Lift the controller out of the gantry and place it onto a suitable support (Figure 45‐6).
12. Remove the 4 screws and remove the mounting bracket from the motor controller (see Figure 45‐7).
REMOVE 4 SCREWS
(2 ON OTHER END)

1. Attach the mounting bracket to the motor controller with 4 screws with lockwashers and flatwashers
2. Torque the screws to 15 in‐lb (1.69 Nm).
INSTALL 4 SCREWS
(2 ON OTHER END)
3. Place the controller onto the bracket mounted to the gantry. Slide the controller toward the front of the
gantry until the controller mounting bracket engages with the studs on the gantry bracket (see
Figure 45‐9).
Figure 45-9: Installing the Motor Controller

PUSH THE CONTROLLER

TOWARD THE FRONT UNTIL THE
BRACKET ENGAGES THE STUDS
4. Attach the controller with 2 nuts (see Figure 45‐10).
5. Tighten the nuts to 15 in‐lb (1.69 Nm).
INSTALL 2 NUTS
6. Make sure the terminal screws are unscrewed enough so that they do not restrict the terminal holes.
7. Connect the wires to the large terminal strips by pushing the wires into the wire holes and tightening
the terminal screws (see Figure 45‐11).
8. Tighten the terminal strip screws to 10.33 ft‐lbs (14 N‐m).
9. Tighten the ground terminal screws to 6 ft‐lbs (8.13 N‐m).
10. Pull gently on each of the wires to make sure they are held securely and do not come out.
TERMINAL LABLING
L1 L2 L3 --- + BR U V W
CONNECT WIRES TO LARGE

TERMINAL STRIPS AND
GROUND TERMINALS
11. Connect the RJ‐45 communication cable (see Figure 45‐12).
Note: Note that the terminal numbering is not in sequence. Numbers 3, 6, and 8 are not present.
12. Make sure the terminal strip screws are backed out enough to allow the wires to be inserted onto the
holes and insert each of the wires into to the small terminal strip holes, one at a time and tighten the
screws (see Figure 45‐12).
13. Torque the terminal strip screws to 4.43 in‐lbs (0.5 N‐m).
CONNECT
RJ-45 CONNECTOR
CONNECT WIRES TO
SMALL TERMINAL STRIP
14. To install the controller cover:
a. Position the cover so that the network cable fits into the notch in the cover made for it.
b. Position the cover just a little to the rear of it’s final position and slide it forward until it latches in
position (see Figure 45‐13).
Figure 45-13: Controller Cover Installed
TOP COVER INSTALLED
15. Remove the drive belt as follows:
a. At the front of the gantry release the main drive motor brake by turning the release knob CW (see

.
RELEASE
APPLY
b. TAKE NOTE of how the belt is installed (see Step b on page 659) ‐ if the belt is installed on the
motor pulley so that there is an open pulley groove toward the motor or toward the back ‐ so the
belt can be reinstalled in the same grooves and maintain the original alignment.
!
WARNING: Be careful releasing the tensioner since it is under considerable spring force.
c. Install the tensioner release tool onto the tensioner as shown in Figure 45‐15 and insert the pin as
shown to hold the tool on the tensioner.
Figure 45-15: Installing Belt Tensioner Release Tool
INSERT PIN INTO TENSIONER

RELEASE TOOL
d. Refer to Figure 45‐16. Push down on the tensioner tool handle to release the tension on the belt
until it is loose enough to remove and remove the belt.
e. Slowly release the tensioner.
f. Remove the pin and remove the tool.
Figure 45-16: Releasing Belt Tensioner

PUSH DOWN ON HANDLE TO
RELEASE BELT TENSIONER
16. Pull out the front cover service switch plunger to allow operation of the gantry.
WARNING: When in back of the gantry wear laser safety glasses (P/N 453567543401) and Avoid
exposure to the laser beams. Ingenuity systems contain Class 3B Invisible Lasers for the
Optical Data Path. Class 3B Invisible laser radiation is present when the Gantry rear cover is
removed and the interlock is defeated. Failure to avoid exposure may cause eye damage.
on or off.
17. Pull out the rear cover service switch plunger to allow operation of the gantry (Figure 45‐17 on

page 662).
Commission the controller according to Emerson CSK or M200 Motor Controller Commissioning on
page 663.
Figure 45-17: Rear Cover Interlock Switch on Systems Equipped with Class 3B Invisible Lasers
REAR COVER INTERLOCK -

REMOVES GANTRY INTERNAL POWER.
Section 46
Section 46 Emerson CSK or M200 Motor Controller Commissioning
The following commissioning procedure will set the Emerson Commander SK (CSK) or M200 motor
controller to the electrical operating characteristics of the motor. The Commissioning Tool is an executable
that is provided to commission/configure the motor controller. The commissioning process loads registers
on the motor controller and performs an auto tune operation. The auto tune operation requires spinning
the motor. Upon completion the drive is tuned for optimal performance in the system.
1. On the host, Login as philips_service.
2. Start the scanner application software (so the Estop can be closed later).
WARNING: Hazardous voltages are present in the gantry support. Exercise proper precautions to avoid
contact with live connections while servicing. Failure to do so may result in serious injury or
death.
3. Remove power to the gantry according to the procedure “Gantry Power Down (Except for the Host
4. If the drive belt has not already been removed, remove the drive belt. See the drive belt removal
procedure in the section M200 Rotor Drive Motor Controller Replacement , Step 15 on page 658
Note: For systems with version 4.0 (or newer) software, the commissioning can be done using Service Tools.
Refer to the Ingenuity Hardware Programming (JTAG) Manual for instructions.
Note: Some screen captures shown in this section contain the title “Commander SK Commissioning Tool”;
however, the displays are similar to the ones for the M200 commissioning tool.
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Emerson CSK or M200 Motor Controller
5. Open Windows Explorer (or My Computer) and navigate to the folder C:\PmsCT\Bin\Service.
6. Double‐click the file RotorControllerTool.exe to start the program.
7. When the tool starts, the main screen shown in Figure 46‐1 will be displayed.
8. Click on the Perform Commissioning button. The box shown in Figure 46‐2 on page 665 is
displayed.
Figure 46-1: Commissioning Tool Main Menu

9. Make sure that the Perform Commissioning box is checked (see Figure 46‐2).
10. Make sure that the correct Commissioning Parameter file is selected (see Figure 46‐2) or select:
C:\PmsCT\Config\Service\RotorController\CSKParamters.xml
11. Turn power to the gantry ON according to the procedure “Gantry Power Up” on page 34.
12. Wait for the system application dialog box for closing the Estop to be displayed.
13. Click the Next button. The box shown in Figure 46‐3 on page 667 is displayed.
Figure 46-2: Setup for Commissioning

PERFORM COMISSIONIONING BOX
MUST HAVE CHECK MARK
14. Wait for the initialization progress indicator to finish and for Completed to be displayed (see
Figure 46‐3). This initialization process should only take a few seconds.
15. When the initialization is complete cycle power to the gantry as follows:
a. Turn power to the gantry OFF according to the procedure “Gantry Power Down (Except for the
Host and CIRS)” on page 27.
Note: The belt is already off.
IMPORTANT: Cycling gantry power is an essential step of the commissioning procedure.
b. Turn power to the gantry ON according to the procedure “Gantry Power Up” on page 34.
16. When the E‐Stop dialog box appears, press the Next button. Figure 46‐4 on page 668 is displayed.
Figure 46-3: Initialization

Figure 46-4: Commissioning

WARNING: Make sure to wear laser safety glasses at the rear of gantry when the Gantry rear cover is
removed and the interlock is defeated. Ingenuity systems have Class 3B Invisible Lasers for
the Optical Data Path. Failure to avoid exposure may cause eye damage.
17. Turn the CT box key switch to close the E‐Stop.
The commissioning / auto tune will commence. The progress bar will be updated twice (see
Figure 46‐5) and the motor will begin to spin for the auto tune.
18. While the motor is spinning, go to the back of the gantry and observe the direction of rotation of the
motor. The motor should be rotating counter-clockwise as viewed from the rear of the gantry
(clockwise as viewed from the front of the gantry).
If the motor is spinning in the wrong direction, it will have no effect on the commissioning results.
Allow the Commissioning Tool run to completion. The wiring error can be corrected later in this
procedure.
19. When the commissioning progress bar completes and Completed is displayed next to the progress
bar (see Figure 46‐5), continue with the following instructions to perform the tasks listed on the
displayed dialog box:
Figure 46-5: Commissioning

a. Turn OFF the gantry power (see Gantry Power Down (Except for the Host and CIRS) on page 27).
b. Install the drive belt according to the following:
i. Install the tensioner release tool onto the tensioner as shown in Figure 46‐6 and insert the pin
as shown to hold the tool on the tensioner.
Figure 46-6: Installing Belt Tensioner Release Tool
INSERT PIN INTO TENSIONER

RELEASE TOOL
ii. Refer to Figure 46‐7. Push down on the tensioner tool handle to raise the tensioner until the

belt can be installed and install the belt.
Make sure that the belt is positioned on the motor pulley so the open groove is either at the
front or the rear as noted when it was removed (see Step 15 on page 658).
iii. Slowly release the tensioner.
iv. Remove the pin and remove the tool.
Figure 46-7: Releasing Belt Tensioner
PUSH DOWN ON HANDLE TO

RELEASE BELT TENSIONER
If the motor was rotating the wrong direction when it was observed in Step 18 on page 669, check that
the wires from the output of the controller (terminals U, V, and W) to the motor are connected
correctly (Figure 45‐11 on page 655).
c. Turn ON gantry power (see System Power Up on page 34).
20. when the E‐Stop dialog box appears, press Next. Figure 46.1 on page 673 is displayed.

21. When the dialog box to close E‐Stop is displayed, turn the CT control box key switch to close the E‐
Stop.
The commissioning / auto tune finalization will commence.
The Reading and storing drive parameters progress bar will update to show the progress and
Commissioning Complete will be displayed when the process is finished (see Figure 46‐8). At this
point the commissioning process is complete.
22. Click Next. The main menu shown in Figure 46‐8 on page 672 is displayed.
23. Continue to the next section to “Upload Drive Parameters” on page 673.
Figure 46-8: Reading and Storing Drive Parameters
46.1 Upload Drive Parameters

This option is used to collect all the drive parameters and store them in a file.
1. On the main menu (see Figure 46‐9) click on the Upload Drive Parameters button. The upload setup
dialog box shown in Figure 46‐10 on page 674 is displayed.
Figure 46-9: Commander SK Commissioning Tool Main Menu

2. In the Upload setup dialog box (see Figure 46‐10) make sure that the correct drive parameter file is
selected:
• Select the file: C:\PmsCT\Config\Service\RotorController\CSKParamters.xml
3. Click the Next button to start the upload. The box shown in Figure 46‐11 on page 675 is displayed.
Figure 46-10: Upload Setup

4. The Reading/storing drive parameters progress bar (see Figure 46‐11) will show the progress of the
upload.
Upload Complete will be displayed when the operation is complete (see Figure 46‐11).
At this point the upload process is complete and clicking Next will display the main menu.
5. The uploaded drive parameters are saved in a file at:
C:\PmsCT\Config\Service\RotorController\CSKTunedParametersYYYY_MM_DD
HH_MM_SS.xml.
Figure 46-11: Upload Complete

46.2 Restoring the System to Operation

1. After the motor controller is commissioned, turn OFF the gantry power (see Gantry Power Down
(Except for the Host and CIRS) on page 27)
3. Apply the main drive motor brake (see Step a on page 658).
6. Perform helical and axial scans at different speeds and a dual surview to verify that the system is
functioning properly.
7. If problems persist, troubleshoot the gantry motion systems.
Section 47
Section 47 Three-Phase Filter Removal/Replacement
This procedure describes the removal of the 3‐phase filter, located in the lower right rear of the gantry.
47.0.1 Removal
page 27..
WARNING: Hazardous voltages are present in the gantry. Turn power off before servicing. Failure to do
so may result in serious injury or death.
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Three‐Phase Filter Removal/Replacement
3. Disconnect the 3‐phase filter wires from ground and from terminals L1, L2, L3 on the SpindleBlok
motor controller (see Figure 47‐1).
Figure 47-1: 3‐Phase Filter Connections to SpindleBlok Motor Controller

3-PHASE FILTER
SPIDLEBLOK
MOTOR
CONTROLLER
L3
L2
L1
4. Remove the 4 hex nuts and flat washers securing the 3‐phase filter to the gantry, and remove the filter.
5. Tag and remove the front wire connections from the 3‐three phase filter (see Figure 47‐2).
Figure 47-2: 3‐Phase Filter Front Connections
47.0.2 Installation
1. Connect the wires to the front of the 3‐phase filter (see Figure 47‐2).
2. Install the 3‐phase filter to the studs on the inside panel of the gantry left side column.
2. Apply Loctite #222 to the studs. Place a flatwasher and a nut on each of the 4 studs to secure the filter
and tighten the nuts securely.
3. Connect the 3‐phase filter wires to terminals L1, L2, and L3 of the SpindleBlok (see Figure 47‐1).
Section 48
Section 48 Motor Braking Resistor Removal/Replacement
This procedure describes the replacement of the motor braking resistor located in the lower left rear of the
48.0.1 Removal
WARNING: Turn power off to the gantry before servicing. Hazardous voltages are present in the gantry.
Failure to do so may result in serious injury or death.
1. Turn off power to the gantry See “Gantry Power Down (Except for the Host and CIRS)” on page 27..
2. Remove the gantry rear cover (see ‘Removing the Gantry Rear Cover on page 10‐112).
Figure 48-1: Motor Braking Resistor ‐ Rear Lower Left Gantry

Motor Controller
Motor Braking Resistor
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement PublicationSort Motor Braking Resistor Removal/
3. Disconnect the braking resistor connections from the SpindleBlok motor controller (black lead from
connector DB, red lead from connector +B). Refer to Figure 48‐2 on page 682.
4. Cut the cable ties as necessary to free the cable from the motor controller to the braking resistor.
Figure 48-2: Braking Resistor Connections to SpindleBlok Motor Controller

RED RESISTOR LEAD

TO TERMINAL +B
BLACK RESISTOR LEAD

TO TERMINAL DB
5. Remove the 4 nuts securing the motor braking resistor to the bottom of the gantry (see Figure 48‐3),
and remove the motor braking resistor assembly with cable attached.
Figure 48-3: Motor Braking Resistor Mounting Nuts
Remove 4 nuts
(2 each end)
48.0.2 Installation
1. Place the motor braking resistor onto the 4 studs on the bottom of the gantry and install a flatwasher
onto each stud.
2. Apply Loctite #222 to the 4 studs and install the four mounting nuts and tighten them.
3. Connect the motor braking resistor wires to the motor controller (black lead to connector DB, red lead
to connector +B). Refer to Figure 48‐2 on page 682.
Section 49
Section 49 Tilt Actuator Replacement
The following procedure covers left or right tilt actuator replacement.
Tools Required: Standard FE Tool Kit
Time Required: 1 hour
Notes for Determining the Defective Actuator

Before starting this procedure it is assumed that it has been determined which actuator is defective. The
following are general symptoms of defective actuators:
If an actuator motor has failed: (does not matter if the encoder is working or not)
• If the gantry is tilted forward, the actuator with a defective motor will lift.
• If the gantry is tilted backward, the good actuator will lift.
If an actuator encoder has failed (and the motor is still functioning):
• The gantry will tilt forward without causing an Estop.
• When the gantry is tilted backward, the actuator with a defective encoder will lift.
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Tilt Actuator Replacement
49.1 Determining Actuator Loading
WARNING: Hazardous voltages are inside the gantry. Exercise proper precautions to avoid contact with
any powered points while servicing the gantry. Failure to do so can result in serious injury or
death.
1. Remove power as follows:
• For replacing the left actuator, power down the entire system according to the procedure (see System
Shutdown and Power Down on page 22), including turning off power at the site breaker.
• Also, when working inside the lower left column cover, be sure to turn off the 120/240 VAC to the
room annunciator (X‐ray) indicator light. Power to this light comes from a separate 120/240 VAC
supply and must be turned off by a site wall shut‐off switch.
• For replacing the right actuator it is only necessary to power down the gantry according to the
procedure Gantry Power Down (Except for the Host and CIRS) on page 27.
2. Attempt to turn the lower actuator mounting pin with your fingers (see Figure 49‐1). If the pin can be
turned, skip to Removing the Tilt Actuator on page 695.
Figure 49-1: Lower Actuator Pin

Pin Slot In Bracket

Visible Above Pin
Lower Actuator
Mounting Pin
3. If the lower pin cannot be turned using your fingers because there is pressure against it, determine if
it is compression pressure or stretching pressure by looking at the lower pin.
If the slotted pin hole in the mounting bracket is visible above the pin as shown in Figure 49‐1 on
page 687, there is compression pressure on the actuator.
If the slotted pin hole is not visible above the pin, the actuator is under stretching pressure.
4. If there is compression pressure against the actuator (compression) relieve the pressure using one of
the following 3 procedures:
a) Relieving Downward Pressure on the Actuator Using Gantry Power: on page 688
b) Relieving Downward Pressure By Manually Retracting the Actuator: on page 690
c) Relieving Either Stretching or Compression of the Actuator Using Jogging Buttons on page 692
Note: Do not use the gantry power procedure if the gantry is tilted to the forward limit (+30o) ‐use one of the
other procedures.
5. If there is stretching pressure on the actuator, relieve the pressure according to the procedure:
• Relieving Either Stretching or Compression of the Actuator Using Jogging Buttons on page 692
49.1.1 Relieving Downward Pressure on the Actuator Using

Gantry Power:
Note: This procedure assumes that the gantry is not tilted to the forward limit (+30o). If the gantry is tilted to
the forward limit, use one of the other procedures to relieve actuator pressure.
death.
1. Apply power to the gantry according to the procedure System Power Up on page 34.
2. Close the Estop and allow the rotor to initialize and move to the park position.
3. If the Estop will not close, check the actuator lift switches. If the lift switches for one of the actuators
are not closed, insert a cardboard shim as follows:
a) Cut a strip of normal, single-thickness cardboard about 2” (~5 cm) wide and 6” (~15 cm) long and
fold it in half lengthwise to form a shim about 3/16” (~5 mm) thick (or use any other suitable shim
that size).
b) On the actuator where the lift switches are not closed, place the shim between the 2 lift switch
plungers and the pivot pin for the actuator as shown in Figure 49-2 on page 689. The shim must be
thick enough to activate both switches so the Estop can be closed. Add shim thicknesses as
required to make sure both switches are closed.
c) Close the Estop and wait for the rotor to initialize.
d) Tilt the gantry forward slightly and remove the cardboard shims.
4. On the defective actuator under compression disconnect the motor power leads and the encoder cable
!
WARNING: Stay clear of moving parts during gantry tilting. Failure to comply may result in personnel
injury.
5. Using the front gantry forward tilt (+) control button, jog the gantry tilt forward (+) a little. The Estop
should open when the actuator lifts off the tilt limit switches. Try to turn the lower actuator pin.
6. Once the lower actuator pin can be turned, proceed to Removing the Tilt Actuator on page 49‐695.
Figure 49-2: Shim Inserted to Activate Actuator Lift Switches
49.1.2 Relieving Downward Pressure By Manually Retracting the

Actuator:
1. Loosen the actuator upper mount eyebolt lock nut by turning it counterclockwise using a 1‐1/8” open‐
end wrench, adjustable wrench, or slip‐joint pliers (see Figure 49‐3).
Note: Since the actuator is being replaced, it doesn’t matter if becomes scarred.
Figure 49-3: Actuator Upper Eyebolt Mount

Loosen Lock Nut
2. Rotate the actuator shaft clockwise by hand or using slip‐joint pliers as shown in Figure 49‐4 on
page 691 until the lower actuator mounting pin (see Figure 49‐1 on page 687) can be turned using
your fingers.
3. Once the lower actuator pin can be turned, proceed to Removing the Tilt Actuator on page 695.
Note: Rotating the actuator shaft clockwise will cause the actuator shaft to retract and thus grow shorter.
Figure 49-4: Rotating Actuator Shaft

Slip-joint Pliers
49.1.3 Relieving Either Stretching or Compression of the Actuator

Using Jogging Buttons
Note: Use this procedure if the gantry is tilted to the forward limit (+30o) and cannot be tilted using the panel
controls.
death.
1. Remove the gantry rear (see Removing the Gantry Rear Cover on page 112).
2. On systems that a have rear cover interlock switch, place it in the service position and put on safety
glasses to protect against the invisible lasers.
3. Apply power to the gantry according to the procedure System Power Up on page 34.
that size).
!
WARNING: Stay clear of the rotor as it repositions for estop closure. Failure to comply may result in
personnel injury.
6. On the defective actuator disconnect the motor power leads and the encoder cable (see Figure 49‐7 on
page 697).
!
WARNING: Stay clear of moving parts during gantry tilting. Failure to comply may result in personnel
injury.
7. Start the tilt calibration according to the applicable Ingenuity CT System Calibration manual.
!
CAUTION: The collision circuitry is not in effect when the jog buttons are used to activate the actuators.
Be careful not to drive the gantry to the mechanical limits. Failure to comply may result in
damage to the gantry.
8. Jog the gantry tilt either forward or backward (whichever is needed) a little at a time using the jogging
pushbuttons located on the Gantry Motion Processor board (see Figure 49‐5).until the actuator lower
mounting pin (see Figure 49‐1 on page 687) can be turned by hand.
9. Once the actuator lower mounting pin can be turned by hand, close the tilt calibration procedure and
proceed to Removing the Tilt Actuator on page 695.
Figure 49-5: Tilt Jog Buttons on Gantry Motion Processor

Jog Buttons Gantry Motion Processor Board
49.2 Removing the Tilt Actuator

49.2.1 System Preparation
Proceed with these steps once the actuator no longer has stretching or compression loading according to
the preceding procedure Determining Actuator Loading on page 686.
Note: The photographs in this section are for the right tilt actuator, but the procedure for the left actuator is
similar.
WARNING: Hazardous voltages are inside the gantry side covers. Disconnect power before servicing.
• For replacing the left actuator, power down the entire system according to the procedure System
Shutdown and Power Down on page 22, including turning off power at the site breaker.
• For replacing the right actuator it is only necessary to power down the gantry according to the
2. Remove the lower side cover (see Gantry RH/LH Lower Side Cover Removal on page 142).
3. Remove the cotter pin and the upper actuator retaining nut (see Figure 49‐6).
Figure 49-6: Removing the Tilt Actuator Upper Retaining Nut

Remove Cotter Pin and
Retaining Nut
4. If not already done, disconnect the motor power connector and the encoder connector as shown in
On units that have Tilt Drive Processors, the power leads to the actuator motor do not have a
connector and must be marked and disconnected from a terminal strip on the motor controller board.
Figure 49-7: Actuator Connectors

Motor Power Encoder Connector Motor Power Connector
Lead
5. Using a 1/8” hex key remove the 2 lower screws attaching the lift switch bracket (see Figure 49‐8) and
loosen the top screw enough so that the bracket can be rotated as shown in Figure 49‐8 on page 698.
Figure 49-8: Lift Cover and Switches

Remove 2 Lower Bracket Screws - Lift Switch Bracket Rotated

Loosen the Top One
6. Pull out the actuator pivot pin and remove the actuator assembly from the gantry (see Figure 49‐9).
Note: Keep the lift spring and retaining block that are inside the actuator mounting bracket (see Figure 49‐10 on

page 700). These will be reused.
Figure 49-9: Actuator Pivot Pin

49.3 Tilt Actuator Installation

1. Place the lift spring and retaining block inside the actuator mounting bracket as shown in Figure 49‐
10 on page 700.
Figure 49-10: Retaining Block and Lift Spring Installed

Retaining Block
Lift Spring
2. Place the actuator in place and install the actuator pivot pin (see Figure 49‐11).
Figure 49-11: Actuator Pivot Pin
3. Push down on the actuator until the lower mounting pin compresses the spring and is at the bottom
of the pin slot with the pin slot visible above the pin as shown in Figure 49‐12 on page 702.
Figure 49-12: Lower Actuator Pin
Pin Slot In Bracket

Visible Above Pin
Lower Actuator
Mounting Pin
4. Rotate the actuator shaft clockwise to shorten it or counterclockwise to lengthen it until the eyebolt
will slide over the mounting pin (see Figure 49‐13) when the lower mounting pin is at the bottom of
the slot.
5. Install the flat washer onto the tilt shaft (see Figure 49‐13).
7. Apply Loctite #242 to the castle nut only and install it onto the tilt shaft. Tighten the nut until it is
snug and so that 2 nut notches are aligned to allow the cotter pin to be installed.
8. Install the cotter pin (see Figure 49‐13).
Figure 49-13: Installing the Tilt Actuator Upper Retaining Nut

(RH side shown, left is similar)

Install Retaining Nut and
Cotter Pin
9. Rotate the lift switch bracket back into position (see Figure 49‐8).
Reinstall the Lift Switches

2. Apply Loctite #222 to the 2 lower switch bracket screws (see Figure 49‐8) and install them using a 1/8”
hex key.
3. Remove the top screw, apply Loctite #222 to it and reinstall it.
4. Torque the 3 lift switch bracket screws to 15 in‐lb (1.7 Nm).
5. Connect the actuator encoder and power wires.
6. Power up the system according to the procedure System Power Up on page 34.
that size).
9. Perform tilt angle calibration according to the procedure in the applicable Ingenuity CT System
Calibration Manual.
10. If removed, install the rear cover (see Ingenuity CT Gantry Rear Cover Installation on page 120).
11. Replace the side cover(s) removed (see Ingenuity CT Side Covers Replacement on page 135).
Figure 49-14: Lift Cover and Switches

Install 2 Lower Bracket Screws -

Remove, apply unexpired Loctite #222, and Reinstall the Top Screw
Section 50
Section 50 Tilt Limit Switches Replacement
The tilt limit switches are located on the gantry RH lower side column.
50.1 Removal
WARNING: Hazardous voltages are inside the gantry side covers. Turn power off before servicing.
1. Remove power from the system (see Gantry Power Down (Except for the Host and CIRS) on page
27).
2. Remove the RH upper and lower gantry side covers (see Ingenuity CT Side Covers Replacement on
page 135).
3. Tag and remove wiring connections for switch to be replaced. Refer to Figure 50‐1 on page 707.
4. Remove switch from bracket. Refer to Figure 50‐1 on page 707.
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Tilt Limit Switches Replacement
Figure 50-1: Tilt Limit Switches Location On RH Lower Side Column
Forward Limit Switches
Forward Limit
Forward
Hard Limit
Forward Soft Limit
Reverse Soft Limit
Reverse Hard Limit
Reverse Limit
Reverse Limit Switches
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Tilt Limit Switches Replacement
50.1.1 Installation
1. Install switch to bracket.
2. Install switch wiring connections. Secure with cable ties as required.
3. Replace the side covers removed (see Ingenuity CT Side Covers Replacement on page 135).
4. Verify tilt limit switch settings and operation. Refer to the applicable Ingenuity CT System Calibration
manual.
Section 51
Section 51 Tilt Lift Switches Removal/Replacement
The tilt lift switches are located on both the gantry RH and LH lower side columns. The switches are
mounted under the actuator pivot pins near the base of each column. Procedure is similar for either
switch.
51.0.1 Removal
WARNING: Hazardous voltages are inside the gantry. Turn power off before servicing the gantry. Failure
to do so can result in serious injury or death.
• For replacing the left lift switches, power down the entire system according to the procedure System
Shutdown and Power Down on page 22, including turning off power at the site breaker.
• For replacing the right lift switches it is only necessary to power down the gantry according to the
2. Remove the RH or LH upper and lower gantry side covers (see Ingenuity CT Side Covers
Replacement on page 135).
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Tilt Lift Switches Removal/Replacement
3. Unscrew the switch retaining nut and remove switch from bracket. Refer to Figure 51‐1 on page 710

4. Tag and remove wiring connections for switch to be replaced. Refer to Figure 51‐1 on page 710.
Figure 51-1: Tilt Lift Switches Location ‐ Typical for Both Side Columns
Switch
Retaining Nuts Soft Stop Hard Stop
Limit Switch Limit Switch
Soft Stop
Limit Switch
Hard Stop
Limit Switch
Tilt Lift Switches Mounted to Actuator Mount Close-up of RH Column Tilt

Weldment Under Actuator Pivot Pin Lift Switches and Bracket
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Tilt Lift Switches Removal/Replacement
51.1 Installation
1. Connect the wires to the switch.
2. Insert the switch into the bracket and install the retaining nut. Refer to Figure 51‐1 on page 710
3. Secure the wires with cable ties as required.
4. Replace the side covers removed (see Ingenuity CT Side Covers Replacement on page 135).
5. Verify tilt lift switch settings and operation according to the applicable Ingenuity CT System
Calibration manual.
Section 52
Section 52 Dual Tilt Pot Assembly Replacement
The dual tilt pot assembly is located on the gantry RH lower side column.
52.1 Removal
WARNING: Hazardous voltages are inside the gantry side covers. Turn power off before servicing.
page 27..
2. Remove the RH upper and lower gantry side covers (see Ingenuity CT Side Covers Replacement on
page 135).
3. Remove two hex head screws and flat washers securing dual tilt pot assembly bracket to RH column.
4. Remove pot belt and bracket from RH column. Refer to Figure 52‐1 on page 713.
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Dual Tilt Pot Assembly Replacement
Figure 52-1: DUAL TILT POT ASSEMBLY LOCATION ON RH LOWER SIDE COLUMN
DUAL TILT POT

ASSEMBLY
HEX HEAD SCREWS

AND FLAT WASHERS
52.1.1 Installation
1. Install flatwashers on the 2 hex‐head mounting screws, apply Loctite #242 and attach the dual tilt pot
assembly bracket to RH column as shown in Figure 52‐1 on page 713.
2. Install pot belt around dual tilt pot assembly and timing pulley.
3. Apply tension by adjusting the position of the dual tilt pot assembly. The belt should be adjusted to
allow for 1/8 to 1/4 in. (0.32 to 0.63 cm) deflection. Hand torque screws.
4. Replace the RH side covers removed (see Ingenuity CT Side Covers Replacement on page 135).
5. Perform tilt calibration according to the applicable System Calibration manual.
Section 53
Section 53 Power Brush Block Replacement
There are two power brush blocks in the system. Both brush blocks should be replaced at the same time.
Estimate Time: 90 minutes
53.1 Brush Block Removal
WARNING: Hazardous voltages inside. Remove power before servicing. Failure to do so may result in
serious injury or death.
1. Power down the gantry. Refer to section “System Power Down/Power Up” on page 22.
2. Remove gantry rear cover (see Removing the Gantry Rear Cover on page 112).
3. Remove the gantry rear cone (see Removing the Ingenuity CT Gantry Rear Cone on page 128).
4. Open the gantry front cover enough to allow access the main motor brake and release the brake.
(Refer to section Opening the Ingenuity CT Gantry Front Cover on page 40).
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Power Brush Block Replacement
5. Rotate the rotor CLOCKWISE ONLY until the X‐ray tube is at about the 5 o’clock position. Position
the rotor as needed for best access to the power brush block and reapply the main drive motor brake.
6. Remove the cable ties holding the cables to the power brush bracket and disconnect all wire
connections to the power brush block. On older model brush blocks the cable terminals will be
attached with screws (see Figure 53‐1).On newer brush blocks the terminals will be attached with
nuts (see Figure 53‐2).
7. Remove the four pan head screws securing power brush block to the bracket.
8. Carefully lift the brush block up and out of the slip ring.
9. Clean the slip rings according to the procedure in the Ingenuity System Planned Maintenance
Manual.
Figure 53-1: Upper Power Brush Block Connections (Older Style)

REMOVE SCREWS REMOVE MOUNTING
FROM TERMINALS SCREWS FROM
BOTH ENDS
CONNECTORS ON
OPPOSITE ENDS
Figure 53-2: Upper Power Brush Block Connections (New Style)

CONNECTORS REMOVE NUTS REMOVE MOUNTING

TOGETHER FROM TERMINALS SCREWS FROM
BOTH ENDS
53.2 Installation
Note: The replacement brush blocks will have both connectors positioned at one end as shown in Figure 53‐4 on

page 718. If the brush block removed looks like Figure 53‐3 on page 717 with a connector on each side of
the terminals, the cabling will have to be rearranged as shown in Figure 53‐4 on page 718 to
accommodate the new connector position.
Note: Replacement brush blocks may have either screws (see Figure 53‐3) or studs (see Figure 53‐4) for the

terminal connections. Either type can be used for all systems.
Figure 53-3: Power Brush Block Location (Older Style)

CONNECTOR AT EACH END
(OLDER STYLE)
1. Carefully lay the new power brush block into place on the bracket making sure the brushes are in
their individual grooves.
2. Secure the brush block with the original four pan head screws (see Figure 53‐4).
3. Use a mirror to visually check that all the brushes are properly centered in their grooves.
4. If the brush block removed looks like Figure 53‐3 on page 717 with a connector on each side of the
terminals, cut cable ties as necessary and rearrange the cabling as shown in Figure 53‐4 on page 718 to
accommodate the new connector position.
5. Latch the two connectors together and plug them into the brush block together (see Figure 53‐4).
6. Secure all the cable terminals to the brush block in their original positions with either screws on the
older style or with nuts and star washers on the newer style.
7. On brush blocks with stud terminals, torque the terminal nuts to 28 in‐lb (3 Nm).
8. Secure the cables to the mounting bracket with cable ties (see Figure 53‐4).
Figure 53-4: Upper Power Brush Block Connections (New Style)

CONNECTORS INSTALL NUTS INSTALL MOUNTING SCREWS
TOGETHER ONTO TERMINALS INTO BOTH ENDS
9. Open the gantry front cover enough to allow access and release the main motor brake.
10. Rotate the rotor CLOCKWISE ONLY and listen for any abnormal sounds coming from the power
brush blocks.
11. Lubricate the slip rings according to the procedure in the Ingenuity System Planned Maintenance
Manual.
12. Apply the main drive motor brake and close the front cover.
13. Install gantry rear cone (see Installing the Ingenuity CT Gantry Rear Cone on page 133).
15. Power up the system and verify that it is operating properly.
Section 54
Section 54 Signal Brush Block Assembly Replacement
Estimated Time: 1 hour
54.1 Removal
1. Power down the gantry according to the procedure (see Gantry Power Down (Except for the Host and
CIRS) on page 27).
2. Open the front cover (see Opening the Ingenuity CT Gantry Front Cover on page 40).
3. Remove gantry rear cover (see Ingenuity CT Gantry Rear Cover Removal on page 115).
5. Release main motor brake and rotate the rotor until the DMS is near the 12 o’clock. position. Position
rotor as needed for best access to signal brush block and apply the motor brake.
6. On systems that a have rear cover interlock switch, place it in the service position.
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Signal Brush Block Assembly Replacement
7. Power up the gantry according to the procedure (see Gantry Power Up on page 34).
8. Tilt the gantry back approximately ‐25 degrees.
CIRS) on page 27).
Note: Do not cut the two small cable ties shown in Figure 54‐1 on page 722. The ties are very difficult to

reinstall without removing the brush bracket. The small connector should be able to be removed with the
ties in place.
10. Leave the small cable ties in place (see Figure 54‐1) and disconnect the small connector from the brush
block.
11. Cut the large cable tie (see Figure 54‐1) and disconnect the larger connector from the brush block.
12. Remove the four screws securing signal brush block to bracket (see Figure 54‐1).
Note: Do not remove the brush mounting bracket. If the mounting bracket is removed it must be aligned using a
special tool.
13. Carefully lift the signal brush block up and out of the rings.
Figure 54-1: Signal Brush Block Location
REMOVE 4 BRUSH BLOCK

MOUNTING SCREWS
CUT THIS CABLE TIE
DO NOT CUT THESE

CABLE TIES
54.2 Installation
1. Inspect the new brushes to make sure that all brush fibers are parallel and that none of the brush
fibers cross over others.
2. Carefully lay the new Signal Brush Block into place on the bracket, making sure the brushes are
centered in their individual grooves.
3. Secure the brush block to the mounting bracket with 4 screws. Refer to Figure 54‐1 on page 722.
4. Use a mirror to check that all brushes are properly centered in the grooves.
5. Plug both connectors into the brush block. Attach the larger cable with a cable tie as shown in
6. Release the motor brake and rotate the rotor CW by hand while listening for any abnormal sounds
coming from the brush blocks.
8. Return the gantry tilt to zero degrees.
9. Replace the rear cone (see Installing the Ingenuity CT Gantry Rear Cone on page 133).
10. Replace the gantry rear cover (see Ingenuity CT Gantry Rear Cover Installation on page 120).
12. Perform at least on helical scan to verify that the system is operating correctly.
Section 55
Section 55 64-Slice Stator Optical Slip Ring Assembly Replacement
This section contains the procedure for replacing any of the 4 optical slip ring stator optics assemblies
shown in Figure 55‐1 on page 725. The 4 assemblies are identical and the procedure is the same for each
one of them.
Tools Required:
• FE Tool Kit, 2 optics alignment tools
• Laser Safety Glasses for class 3B visible and/or invisible lasers
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement 64‐Slice Stator Optical Slip Ring Assembly
Figure 55-1: Optical Slip Ring Stator Optics Assembly
55.1 Removing the Stator Optics Assembly
WARNING: Hazardous voltages are inside the gantry rear cover. Turn off power to the gantry as
instructed before servicing. Failure to do so may result in serious injury or death.
CIRS) on page 27).
WARNING: Class 3B invisible laser radiation is emitted from optical slip ring components. Wear laser
safety glasses behind the Gantry whenever the gantry rear cover is open and the optical slip
ring components are energized. Non-compliance can lead to EYE injury due to the hazardous
effects of the laser radiation.
5. Release main motor brake and rotate the rotor (clockwise only) so that the open space opposite the
DMS is at the segment to be replaced to provide access room.
6. Carefully disconnect the fiber‐optic cable for the assembly to be replaced from the optical receiver
box. The 4 stator optics assemblies are numbered from left to right with number one on the left when
viewed from the front of the gantry. These correspond to connectors RX1, RX2, RX3, and RX4 on the
receiver. Refer to Figure 55‐2 on page 727.
Figure 55-2: Receiver Box
ASSY 3 CABLE TO RX3 ASSY 1 CABLE TO RX1

ASSY 2 CABLE TO RX2
ASSY 4 CABLE TO RX4
7. Cut the cable ties as required to free the cable to the stator optic assembly (see Figure 55‐3).
8. Remove the 3 nuts and spherical washer sets at the rear of the stator optic mounting plate (see
Figure 55‐3).
9. Remove the stator optic assembly.
Figure 55-3: Stator Optics Assembly Mounting
STATOR OPTIC ASSY
STATOR OPTIC
MOUNTING PLATE
REMOVE 3 NUTS &

SPHERICAL WASHER
CUT CABLE TIES
55.2 Installing the Stator Optics Assembly

1. Measure the distance between the plate and the outer nut as indicated in Figure 55‐4 on page 730 on
the removed assembly.
2. Remove the 3 threaded rods from the removed assembly.
Note: Do not remove the plastic casing (see Figure 55‐4) from the fiber‐optic cables.

3. Screw the 3 threaded rods into the optics plate (see Figure 55‐4).
Note: The threaded rods must not extend beyond the outer surface of the optics plate assembly.
4. Install a nut onto each of the 3 threaded rods and tighten the nuts against the optics plate to 20 ft‐lb
(27 Nm) (see Figure 55‐4).
5. Install another nut on each of the 3 threaded rods at about the same distance from the plate as the
ones were on the assembly that was removed (see Figure 55‐4).
6. Install a spherical washer set on each of the threaded rods as shown in (see Figure 55‐4). Refer to
Figure 55‐5 on page 731 for the arrangement of the spherical washer sets.
Figure 55-4: Optical Slip Ring Stator Optics Assembly
ADJUST THE NUT UNDER THE SPHERICAL WASHER SET SO THE DISTANCE BETWEEN
THE TOP OF THE NUT AND THE PLATE IS THE SAME AS THE ONE REMOVED
INSTALL 3 RODS WITH 2 NUTS AND A

SPHERICAL WASHER SET ON EACH
(A NUT IS UNDER THE
SPHERICAL WASHER SET)
DO NOT REMOVE
PLASTIC CASING FROM
FIBER OPTIC CABLES
Figure 55-5: Spherical Washer Sets Arrangement
NUT OPTIC ASSY PLATE NUT
SPHERICAL SPHERICAL
WASHER SET WASHER SET
7. Install the stator optic assembly to the mounting plate on the stator. Install the 3 spherical washer sets
and loosely install the 3 nuts (see Figure 55‐6). Refer to Figure 55‐5 on page 731 for the arrangement of
the spherical washer sets.

STATOR OPTIC ASSY
STATOR OPTIC
MOUNTING PLATE
INSTALL 3 SPHERICAL
WASHER SETS AND
NUTS
8. Position the rotor so that 2 rotor ring fiber optic cable cover screws are aligned with the 2 alignment
tool holes in the stator optic assembly plate as shown in Figure 55‐7 on page 733.
9. Remove 2 rotor ring fiber optic cable cover screws as indicated in Figure 55‐7 on page 733.
Figure 55-7: Screws to Remove from the Rotor Ring Fiber Optic Cable Cover
ALIGNMENT TOOL
REMOVE 2 ROTOR RING MOUNTING HOLES IN
FIBER OPTIC CABLE STATOR OPTIC ASSY
COVER SCREWS
10. Loosely mount the 2 alignment tools to the stator ring as shown in Figure 55‐8 on page 734.

11. Adjust the rotor position as necessary so that the holes in the rotor ring align with the holes in the
tools and install the 2 screws to mount the tools to the rotor ring.
Figure 55-8: Optic Alignment Tools Installed

(left assembly shown ‐ others are similar)
2 TOOL MOUNTING
SCREWS INTO STATOR 2 TOOL MOUNTING
OPTICS ASSY SCREWS INTO ROTOR
RING
12. Adjust the position of the stator optic assembly as necessary so that the tools can be easily tightened
flat against the rotor ring and the stator optic assy as shown in Figure 55‐9 on page 735.
13. Position the 3 nuts on the mounting threaded rods (see Figure 55‐9 on page 735 and Figure 55‐10 on
page 736) so that they are just up against the front of the stator mounting plate and tighten the nuts at
the rear of the stator mounting plate just enough to hold the optic assembly in place but loose enough
to allow the plate to be positioned.
14. Move the optic assembly toward the outside of the gantry until the “L” part of the alignment tool is
flat against the inside of the rotor optic ring (see Figure 55‐9).
Figure 55-9: Alignment Tool Mounting
TOOL FLAT AGAINST TOOL FLAT AGAINST NUT JUST AGAINST THE
ROTOR RING AND STATOR INSIDE OF ROTOR RING STATOR MOUNTING PLATE
OPTIC ASSY PLATE (ONE OF 3)
15. Tighten the nuts at the rear of the stator mounting plate to 20 ft‐lb (27 Nm) (see Figure 55‐10).

TIGHTEN 3 NUTS POSITION NUTS AGAINST

AFTER FRONT OF STATOR
MOUNTING PLATE
STATOR OPTIC STATOR OPTIC ASSY

MOUNTING PLATE
16. Remove the alignment tools. If the alignment is correct the tool should come off easily.
17. Install the 2 rotor ring fiber optic cable cover screws as indicated in Figure 55‐7 on page 733 and
torque them to 4 in‐lb (0.45 Nm).
Figure 55-11: Rotor Ring Fiber Optic Cable Cover Screws

(left assembly shown ‐ others are similar)
INSTALL 2 ROTOR RING

FIBER OPTIC CABLE
COVER SCREWS
18. Connect the fiber‐optic cable to the optical receiver box. Refer to Figure 55‐12 on page 738.

19. Slowly rotate the rotor and make sure that there is no interference anywhere.
20. Apply the main motor brake.
21. Install the gantry rear cone (see Installing the Ingenuity CT Gantry Rear Cone on page 133).
25. Run visual diagnostics to ensure that items installed are working, then run a surview, helical, and
axial scan.

ASSY 3 CABLE TO RX3 ASSY 1 CABLE TO RX1
ASSY 2 CABLE TO RX2
ASSY 4 CABLE TO RX4
Section 56
Section 56 64-Slice Rotor Optical Slip Ring Fiber Optic Cable
Replacement
This section contains the procedure for replacing either of the 2 optical slip ring rotor fiber optic
assemblies shown in Figure 56‐1 on page 739. The 2 assemblies are identical and the procedure is the
same for each one of them. One assembly is used for lenses 1 to 8 and the other for lenses 9 to 16.
Estimated Time: 4 hours
Tools Required:
• FE Tool Kit,
• Laser Safety Glasses for class 3B visible and/or invisible lasers ‐ P/N 4535 675 43401
Figure 56-1: Optical Slip Ring Rotor Fiber Optic Assembly
(the lens brackets will not be included)
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement 64‐Slice Rotor Optical Slip Ring Fiber Optic Cable
56.1 Removing the Rotor Fiber Optics Cable
CIRS) on page 27).
5. Release main motor brake and rotate the rotor (clockwise only) for convenient access to the
transmitter on the rotor.
6. Carefully disconnect the fiber‐optic cable to be replaced; either TX A for lenses 1 to 8, or TX B for
lenses 9 to 16. Refer to Figure 56‐2 on page 741.
Figure 56-2: Transmitter Connections
TX B CABLE TO
LENSES 9 TO 16
TX A CABLE TO
LENSES 1 TO 8
7. Cut the cable ties as required to free the cable being replaced all the way to the rotor ring. The
entrance of the cable from TX A to the rotor ring near lens 16 is shown in Figure 56‐3 on page 742.
If the other cable from TX B is being replaced, the cable ties will need to be cut to free the cable up to
its entrance to the rotor ring near lens 8.
8. Rotate the rotor as necessary (clockwise only) for convenient access and remove the rotor ring cover
screws for all the ring covers for the lenses to be replaced; either from lenses 9 to 16 or from lenses 1 to
8, and remove the ring covers (see Figure 56‐3).
Figure 56-3: Rotor Optics Ring Cover Screws
TX A CABLE LENS 16 LABEL 16 LENS 1
RING COVER SCREWS AT LENS 16

(NOT ALL SHOWN)
9. Loosen the clamp screws holding each of the lenses to be removed (see Figure 56‐4), remove the
lenses from their brackets, and remove the cable.
Figure 56-4: Lens Clamp
LOOSEN LENS CLAMP

SCREW AND REMOVE LENS
FROM BRACKET
56.2 Installing the Rotor Fiber Optics Cable

1. To make installation easier, rotate the rotor to so that the lens 1 clamp (for TX A) or lens clamp 9 (for
TX B) is positioned at about the 3 o’clock position viewed from the back of the gantry.
2. Let the lenses hang down and straighten out the new cable fiber lines so they are not tangled or
twisted as shown in Figure 56‐5 on page 744 .
Figure 56-5: Untangling Rotor Fiber‐Optic Lines
LET FIBER-OPTIC LINES HANG

AND UNTANGLE THEM
3. Drape the longest 2 fiber‐optic lines into the back of the gantry as shown in Figure 56‐6 on page 745.
Figure 56-6: Preparing to Install a Rotor Fiber‐Optic Cable
LET FIBER-OPTIC LINES HANG

AND UNTANGLE THEM
DRAPE 2 LONGEST FIBER-

OPTIC LINES INTO GANTRY
4. Clamp the lens with the longest fiber optic line into either the clamp for lens 8 for cable TX A, or the
clamp for lens 16 for cable TX B (see Figure 56‐7).
5. Torque the clamp screw to 4 in‐lbs (0.45 N‐m).
ROUTE FIBER-OPTIC LINE IN

RING CHANNEL
CLAMP LENS WITH LONGEST

FIBER-OPTIC LINE
6. Place foam blocks in the rotor ring groove to hold the fiber optic lines in place as shown in Figure 56‐
8 on page 747.
Figure 56-8: Foam Block to Hold Fiber‐Optic Lines in Rotor Ring Groove
INSTALL FOAM BLOCK TO

HOLD FIBER-OPTIC LINES
IN ROTOR RING GROOVE
7. When the first lens has been clamped in place (either 8 or 16) install a ring cover (those covers extend
into the other section of the ring). Tighten the cover screws to 4 in‐lbs (0.45 N‐m).
8. When the next 2 lenses have been clamped in place, install the next ring cover (see Figure 56‐9). Make
sure that the fiber‐optic lines are in the ring groove and do not become pinched between the cover
and the ring when the cover is installed.
9. Repeat Step 4 on page 56‐746 to Step 8 on page 748 (above) for the next 6 lenses, 2 at a time.
Figure 56-9: Rotor Ring Cover
INSTALL RING COVER
10. When the last lens is installed (lens 1 for TX A or lens 9 for TX B), install the last rotor ring cover.
11. Route the cable and secure it in place with cable ties. For TX A, refer to Figure 56‐10 on page 749; for
TX B refer to (see Figure 56‐11 on page 750).
Figure 56-10: TX A Cable Routing
Figure 56-11: TX B Cable Routing
12. Route the fiber‐optic cable to the transmitter and connect it. Refer to Figure 56‐12 on page 751.

13. Install cable ties as required to secure the cable (see Figure 56‐12).
TX A CABLE TO TX B CABLE TO
LENSES 1 TO 8 LENSES 9 TO 16
TX B CABLE TO
LENSES 9 TO 16
TX A CABLE TO
LENSES 1 TO 8
15. Install the gantry rear cone (see Installing the Ingenuity CT Gantry Rear Cone on page 133).

19. Run visual diagnostics twice to ensure there are no issues, then run a surview, a helical scan, and an
axial scan.
Section 57
Section 57 64-Slice Invisible Laser Optical Transmitter
Replacement
Estimated Time Required: 1 hour
Tools and Material Required:
• FE Tool Kit,
• Loctite #222 ‐ P/N 4535 604 67171 (10 ml)

57.1 Removing the Optical Transmitter (Tx)
WARNING: Hazardous voltages inside. Disconnect power supply before servicing. Failure to do so may
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement 64‐Slice Invisible Laser Optical Transmitter
1. Power down the gantry. Refer to the procedure (see Gantry Power Down (Except for the Host and
CIRS) on page 27).
4. Tag and disconnect the cables from the optical TX. Refer to Figure 57‐1 on page 753.
5. Cut any cable ties that secure the optical transmitter cables to the mounting plate.
6. Remove the 4 optical transmitter mounting plate screws (see Figure 57‐1), and remove the optical
transmitter and mounting plate assembly.
7. Remove the 4 mounting screws and remove the optical transmitter from the mounting plate. The
mounting plate and screws will be reused.
Figure 57-1: Optical Transmitter Connections and Mounting Screws
MOUNTING PLATE SCREWS
57.2 Installing the Transmitter

1. Install the optical transmitter onto the mounting plate with 4 screws. Tighten the #8 screws to 9 in‐lb
(1.0 Nm).
2. Install the optical transmitter and bracket assembly and install the attaching screws (see Figure 57‐1).
Torque the 3/8ʹ bolts to 39 ft‐lb (53 Nm).
3. Connect cables to optical TX.
4. Secure the cables in place with cable ties.
8. Run visual diagnostics to ensure there are no issues, then run a surview, a helical scan, and an axial
scan.
Section 58
Section 58 64-Slice Invisible Laser Optical Receiver Replacement
• FE Tool Kit,
• Loctite #222
58.1 Removing the Optical Receiver (Rx)
WARNING: Hazardous voltages are inside the gantry rear cover. Turn gantry power off before servicing.
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement 64‐Slice Invisible Laser Optical Receiver Replacement
1. Power down the gantry. Refer to the procedure (see ‘Gantry Power Down (Except for the Host and
CIRS) on page 1‐27).
2. Remove the gantry rear cover (see Ingenuity CT Gantry Rear Cover Removal on page 10‐115).
3. Remove the gantry rear cone (see Removing the Ingenuity CT Gantry Rear Cone on page 12‐128).
4. Tag and disconnect the cables from the optical RX. Refer to Figure 58‐1 on page 756.
5. Remove the 4 optical receiver mounting screws (see Figure 58‐1), and remove the Rx.
Figure 58-1: Optical Receiver Connections and Mounting Screws
RX MOUNTING SCREWS
58.2 Installing the Receiver

1. Install the optical receiver onto the mounting plate with 4 screws (see Figure 58‐1). Tighten the #8
screws to 9 in‐lb
(1.0 Nm).
2. Connect the cables to the optical RX.
scan.
Section 59
Section 59 16-Slice Rotor Optical Slip Ring Fiber Optic Cable
Replacement
This section contains the procedure for replacing the 16‐slice gantry optical slip ring rotor fiber optic
assembly shown in Figure 59‐1 on page 758. For 64‐slice systems, see the section (see 64‐Slice Rotor
Optical Slip Ring Fiber Optic Cable Replacement on page 739).
Estimated Time: 4 hours
Tools Required:
• FE Tool Kit,
Figure 59-1: 16‐Slice Optical Slip Ring Rotor Fiber Optic Assembly ‐ P/N 4598 002 14891
59.1 Removing the Rotor Fiber Optics Cable
CIRS) on page 27).
2. Remove the gantry rear cover according to the procedure (see Removing the Gantry Rear Cover on
page 112).
3. Remove the gantry rear cone according to the procedure (see Removing the Ingenuity CT Gantry
Rear Cone on page 128).
4. Open the front cover according to the procedure (see Opening the Ingenuity CT Gantry Front Cover
on page 40).
5. To gain easier access to ring cover screws cut the cable tie holding the cable group shown in
Figure 59‐2 on page 760 and move the cables to one side as shown.
Figure 59-2: Cables Moved to Gain Access to Ring Cover Screws

UNTIE AND MOVE CABLES
6. Release main motor brake and rotate the rotor (clockwise only viewed from the front or
counterclockwise as viewed from the rear) as required for convenient access and remove the rotor
ring cover screws (3 per cover) and remove all 8 ring covers (see Figure 59‐3).
Figure 59-3: Rotor Optics Ring Cover Screws
RING COVER SCREWS
Note: Make sure to keep the foam blocks from inside the ring. they will be needed to hold the optical fibers in
place during installation (see Figure 59‐5).
7. Starting with the lens with the longest cable (see Figure 59‐4) and continuing counter‐clockwise
(viewed from the rear of the gantry) loosen the clamp screws holding the lenses to be removed (see
Figure 59‐5 on page 59‐763), remove the lenses from the ring, and remove the cable assembly from the
ring.
Figure 59-4: Position for Mounting the Lens with the Shortest Fiber‐Optic Line

UMMOUNT LENS
WITH LONGEST
CABLE FIRST
TRANSMITTER

LOOSEN LENS CLAMP

SCREW AND REMOVE LENS
FROM BRACKET
KEEP FOAM BLOCKS

FOR INSTALLATION
8. Carefully disconnect the fiber‐optic cable from the optical transmitter (see Figure 59‐6).
9. Cut the cable ties as required to free the cable being replaced (see Figure 59‐6).
DISCONNECT
OPTIC CABLE
CUT CABLE TIES
59.2 Installing the Rotor Fiber Optics Cable

1. To make installation easier, rotate the rotor to so that the rotor optical transmitter is at about the 10
oʹclock position as viewed from the back of the gantry.
2. Temporarily hang the cable in a convenient position on the back of the gantry as shown in Figure 59‐7
on page 765.
Figure 59-7: Temporarily Hanging Fiber‐Optic Cable
TEMPORARILY HANG
FIBER-OPTIC CABLE
3. See Figure 59‐8 on page 766 and determine the position on the ring where the lens with the shortest

fiber will be installed.
4. Rotate the rotor so that the shortest fiber lens mount is at about the 2 o’clock position (viewed from
the back).
Figure 59-8: Position for Mounting the Lens with the Shortest Fiber‐Optic Line

.
MOUNT LENS WITH

SHORTEST CABLE
TRANSMITTER
5. Route the fiber‐optic cable as shown in Figure 59‐9 on page 767 so that the lens with the shortest fiber

will set into the holder as shown Figure 59‐9 on page 59‐767.
Figure 59-9: Mounting the Lens with the Shortest Fiber
TEMPORARILY TIE CABLE TRANSMITTER MOUNT LENS WITH

SHORTEST FIBER
6. Temporarily secure the cable in place as shown in Figure 59‐10 on page 768 and Figure 59‐9 on

page 59‐767.
Figure 59-10: Preparing to Install a Rotor Fiber‐Optic Cable
TEMPORARILY TIE
CABLE IN PLACE
7. Position the lens so that the face of the lens is flush with the machined surface of the ring as shown in
2. Apply loctite #222 to the lens clamp screw and Install the clamp to hold the lens to the ring as shown
3. Torque the lens clamp screw to 4 in‐lb (0.45 Nm).
Figure 59-11: Mounting the Lens
POSITION LENS FLUSH WITH

MACHINED SURFACE OF RING
4. Free up the hanging cables so that the fiber‐optic lines can be fed in as the rotor is turned.
Note: Lenses are only mounted in every‐other mounting position on the ring.
5. While feeding out the fiber‐optic lines and placing them in the ring channel, rotate the rotor
counterclockwise (as viewed from the back of the gantry). Place foam blocks in the rotor ring groove
to hold the fiber optic lines in place as shown in Figure 59‐12 on page 770.
6. Skip the next lens‐mounting position on the ring and rotate the rotor until the lens with the next‐
shortest fiber‐optic line can be mounted to the ring (see Figure 59‐12).
2. Apply loctite #222 to the lens clamp screw and install the clamp to hold the lens to the ring as shown
3. Torque the lens clamp screw to 4 in‐lb (0.45 Nm).
4. Repeat Step 6 on page 768 to Step 3 on page 770 for the remaining 10 lenses. The last lens will mount
as shown in Figure 59‐13 on page 59‐771.
Figure 59-12: Foam Block to Hold Fiber‐Optic Lines in Rotor Ring Groove
SKIP HOLDER INSTALL FOAM BLOCK TO CLAMP LENS IN PLACE SKIP NEXT
ON RING HOLD FIBER-OPTIC LINES HOLDER ON RING
IN ROTOR RING GROOVE
Figure 59-13: Last Lens Mounting

CLAMP LENS IN PLACE
Note: The ring covers are all the same except that some have 2 laser warning labels and some have only one
label. Install the covers so that the laser warnings are next to the lenses (see Figure 59‐14).
5. When the last lens has been clamped in place install a ring cover next to the first lens installed (see
Figure 59‐14).Tighten the cover screws to 4 in‐lb (0.45 Nm).
6. Position the unused lens clamp at the left end of the last cover to secure the end of the cover as shown
in Figure 59‐14 on page 772. This is to ensure that the cover helps retain the harness as it exits the ring.
7. Install the rest of the lens covers so that the laser warning labels are next to the lenses.
Make sure that the fibers are all inside the ring groove and not trapped between the covers and the
ring flat area.
8. Tighten the cover screws to 4 in‐lb (0.45 Nm).
Figure 59-14: Rotor Ring Cover
NEXT LENS CLAMP LASER LAST LENS INSTALL

POSITIONED TO HOLD WARNING INSTALLED RING COVER
END OF COVER
9. Route the optic cable as shown in Figure 59‐15 on page 773 and connect it to the transmitter.

10. Install cable ties as required to secure the cable (see Figure 59‐15).
Figure 59-15: Optic Cable Routing to Transmitter
CONNECT THE ROUTE AND TIE THE

OPTIC CABLE TO OPTIC CABLE
THE TRANSMITTER AS SHOWN
12. Install the gantry rear cone according to the procedure (see Installing the Ingenuity CT Gantry Rear
Cone on page 133).
13. Install the gantry rear cover according to the procedure (see Ingenuity CT Gantry Rear Cover
Installation on page 120).
14. Close the front cover according to the procedure (see Closing the Ingenuity CT Gantry Front Cover
on page 45).
16. Run visual diagnostics twice to ensure there are no issues, then run a surview, a helical scan, and an
axial scan.
Section 60
Section 60 16-Slice Stator Optics Assembly Replacement
This section contains the procedure for replacing the 16‐slice optical slip ring stator optics assembly
Tools Required:
• FE Tool Kit, 2 optics alignment tools, P/N 4535 675 45411
Figure 60-1: 16‐Slice Optical Slip Ring Stator Optics Assembly ‐ P/N 4598 002 14901

Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement 16‐Slice Stator Optics Assembly Replacement
60.1 Removing the Stator Optics Assembly
CIRS) on page 27).
2. Remove the gantry rear cover according to the procedure (see ‘Removing the Gantry Rear Cover on
page 10‐112).
4. Open the front cover according to the procedure (see Opening the Ingenuity CT Gantry Front Cover
on page 40).
5. Release main motor brake and rotate the rotor (clockwise only) so that the DMS is at the 7 o’clock
position so that the open space opposite the DMS will allow access to the optics assembly.
6. Carefully disconnect the fiber‐optic cable from the optical receiver box. Refer to Figure 60‐2 on
page 777.
7. Cut the cable ties as required to free the cable.
DISCONNECT CABLE CUT CABLE TIES

TO FREE CABLE
8. Cut the cable ties as required to free the cable to the stator optic assembly.
9. Remove the 3 nuts and spherical washer sets at the rear of the stator optic mounting plate (see
Figure 60‐3).
10. Remove the stator optic assembly.
STATOR OPTIC ASSY STATOR OPTIC

MOUNTING PLATE
REMOVE 3 NUTS &

SPHERICAL WASHER SETS
60.2 Installing the Stator Optics Assembly

1. On the removed assembly, measure the distance between the inner and outer nut as indicated in
Figure 60-4: Measuring Stator Optics Assembly Mounting Distance
MEASURE DISTANCE
BETWEEN NUTS
Note: Do not remove the plastic casing (see Figure 60‐5) from the fiber‐optic cables.

2. Remove the outer nut and the outer spherical washer set from each of the 3 threaded rods (see
Figure 60‐5).
Figure 60-5: Stator Optics Assembly
REMOVE OUTER NUT AND 1 SPHERICAL WASHER SET DO NOT REMOVE

FROM EACH OF THE 3 THREADED RODS PLASTIC CASING FROM
FIBER OPTIC CABLES
3. Position the remaining nut on each of the 3 threaded rods at about the same distance from the plate as
the ones were on the assembly that was removed (see Figure 60‐6).
Leave one spherical washer set on top of the nut in the order shown in Figure 60‐7 on page 60‐782 on
each of the threaded rods (see Figure 60‐6).
Figure 60-6: Stator Optics Assembly
ADJUST THE NUT UNDER THE SPHERICAL

WASHER SET SO THE DISTANCE BETWEEN THE DO NOT REMOVE
INNER AND OUTER NUTS IS THE MEASUREMENT PLASTIC CASING FROM
MADE IN Step 1 on page 779 FIBER OPTIC CABLES
Figure 60-7: Spherical Washer Sets Arrangement

NUT OPTIC ASSY PLATE NUT
SPHERICAL SPHERICAL
WASHER SET WASHER SET
4. Install the stator optic assembly to the mounting plate on the stator. Install the 3 spherical washer sets
in the order shown in Figure 60‐7 on page 60‐782 and loosely install the 3 outer nuts (see Figure 60‐8).
STATOR OPTIC ASSY STATOR OPTIC

MOUNTING PLATE
INSTALL 3 NUTS &

SPHERICAL WASHER SETS
5. Position the rotor so that the 2 alignment tools can be loosely installed in holes in the rotor ring and
the stator optics plate as shown in Figure 60‐9 on page 784. Do not attempt to tighten the screws at
this time.
Figure 60-9: Mounting Stator Optic Assembly Alignment Tools

ALIGNMENT TOOL
MOUNTED TO HOLES IN
STATOR OPTICS ASSY
POSITION THE OPTIC PLATE

SO THAT THE ALIGNMENT
TOOL CAN BE TIGHTENED
FLAT AGAINST THE ROTOR
RING WITHOUT FLEXING IT
ALIGNMENT TOOL
MOUNTED TO HOLES IN
ROTOR OPTIC RING
6. If necessary, loosen the nuts on the stator optic assembly (see Figure 60‐10) so that the alignment tools
can be easily tightened flat against the rotor ring and the stator optic assembly as shown in Figure 60‐
9 on page 60‐784.
7. Position the 3 nuts on the mounting threaded rods (see Figure 60‐10) so that they hold the washers in
light contact with the front of the stator mounting plate.
8. Tighten the nuts at the rear of the stator mounting plate just enough to hold the optic assembly in
place but loose enough to allow the plate to be positioned.
Figure 60-10: Optic Plate Positioning

STATOR OPTIC ASSY NUTS HOLDING WASHERS LIGHTLY IN CONTACT

WITH FRONT OF MOUNTING PLATE
STATOR MOUNTING
PLATE LOOSELY TIGHTEN 3 NUTS
9. Move the optic assembly toward the outside of the gantry until the “L” part of the alignment tool is
flat against the inside of the rotor optic ring (see Figure 60‐11).
10. Tighten the nuts at the rear of the stator mounting plate to 20 ft‐lb (27 Nm) (see Figure 60‐10 on
page 785).
11. Remove the alignment tools. If the alignment is correct the tools should come off easily.
Figure 60-11: Position of Stator Optic Assembly Alignment Tools

(viewed from the back)
ALIGNMENT TOOL “L”

AGAINST INSIDE OF ROTOR RING
ADJUST SO THAT
ALIGNMENT TOOL CAN BE
TIGHTENED FLAT AGAINST
THE ROTOR RING WITHOUT
FLEXING IT
12. Install cable ties as required to secure the cable to the stator optic assembly (see Figure 60‐12).
Figure 60-12: Optic Cable Routing
TIE OPTIC CABLE
13. Connect the fiber‐optic cable to the optical receiver box. Refer to Figure 60‐13 on page 788.

15. Apply the main motor brake.
16. Install the gantry rear cone according to the procedure (see Installing the Ingenuity CT Gantry Rear
Cone on page 133).
17. Install the gantry rear cover according to the procedure (see Ingenuity CT Gantry Rear Cover
Installation on page 120).
18. Close the front cover according to the procedure (see Closing the Ingenuity CT Gantry Front Cover
on page 45).
20. Run visual diagnostics to ensure that items installed are working, then run a surview, helical, and
axial scan.
CONNECT CABLE
Section 61
Section 61 16-Slice Invisible Laser Optical Transmitter
Replacement
• FE Tool Kit,
• Loctite #222
•
61.1 Removing the Optical Transmitter (Tx)
CIRS) on page 27).
page 112).
4. Tag and disconnect the cables from the optical TX. Refer to Figure 61‐1 on page 790.
5. Remove the 4 mounting screws and remove the optical transmitter from the mounting plate (see
Figure 61‐1).
Figure 61-1: Optical Transmitter Connections and Mounting Screws
DISCONNECT CABLES MOUNTING SCREWS

(2 ON OTHER END ALSO)
61.2 Installing the Transmitter

1. Install the optical transmitter onto the mounting plate with 4 screws (see Figure 61‐1 on page 790).
2. Tighten the #8 screws to 9 in‐lb (1.0 Nm).
3. Connect cables to the optical transmitter (see Figure 61‐1 on page 790).
4. Install the rear cone. See the procedure (see Installing the Ingenuity CT Gantry Rear Cone on page
133).
5. Install the rear cover. See the procedure (see Ingenuity CT Gantry Rear Cover Installation on page
120).
scan.
Section 62
Section 62 16-Slice Invisible Laser Optical Receiver Replacement
• FE Tool Kit,
• Loctite #222 ‐ P/N 4535 604 67171 (10 ml)
62.1 Removing the Optical Receiver (Rx)
CIRS) on page 27).
page 112).
4. Tag and disconnect the cables from the optical RX. Refer to Figure 62‐1 on page 793.
5. Remove the 4 optical receiver mounting screws (see Figure 62‐1), and remove the Rx.
Figure 62-1: Optical Receiver Connections and Mounting Screws
DISCONNECT CABLES
RX MOUNTING SCREWS
62.2 Installing the Receiver

1. Install the optical receiver onto the mounting plate with 4 screws (see Figure 62‐1 on page 793).
Tighten the #8 screws to
9 in‐lb (1.0 Nm).
2. Connect the cables to the optical receiver (see Figure 62‐1 on page 793).
3. Install the rear cone. See the procedure (see Installing the Ingenuity CT Gantry Rear Cone on page
133).
4. Install the rear cover. See the procedure (see Ingenuity CT Gantry Rear Cover Installation on page
120).
scan.
Section 63
Section 63 Gantry Audio Board Removal/Replacement
The gantry audio board is located on the gantry RH upper side column.
63.1 Removal
1. Remove power from the system (see System Power Down/Power Up on page 22).
WARNING: Hazardous voltages inside. Turn Gantry power off before servicing. Failure to do so may
2. Remove the gantry RH upper side cover (see Gantry RH/LH Upper Side Cover Removal on page
135).
3. Tag and remove all gantry audio board cable connections. Cut ty‐wraps as required. Refer to
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Gantry Audio Board Removal/Replacement
4. Remove six screws securing audio board to mounting bracket, and remove audio board.
Figure 63-1: Gantry Audio Board On RH Upper Side Column
63.1.1 Installation
1. Position gantry audio board to mounting bracket, and secure to bracket with six screws. Use Loctite
#222 on the screws.
2. Install all gantry audio board cable connections and secure with ty‐wraps.
3. Install the gantry RH upper side cover (see Gantry RH/LH Upper Side Cover Installation on page
138).
Section 64
Section 64 I-Box Board Removal/Replacement
This procedure is for replacing the I‐box board located on the gantry RH upper side column, directly
above the gantry audio board (see Figure 64‐1).
Figure 64-1: I‐box Board Location on Gantry RH Upper Side Column
I-box Board
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement I‐Box Board Removal/Replacement
64.1 Removal
WARNING: Hazardous voltages are inside the gantry covers. Turn gantry power off before servicing.
1. Turn gantry power off (see Gantry Power Down (Except for the Host and CIRS) on page 27).
135).
3. Tag and remove all I‐box board cable connections. Cut cable ties as required. Refer to Figure 64‐2 on
page 798.
4. Remove twelve pan head screws securing I‐box board to mounting bracket, and remove I‐box board.
Figure 64-2: Gantry I‐Box Board
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement I‐Box Board Removal/Replacement
64.2 Installation
2. Position I‐box board to mounting bracket with J2 connector at bottom right of board, and secure to
bracket with twelve pan head screws. Use Loctite #222 on screws.
3. Install all I‐box board cable connections and secure with ty‐wraps.
4. Verify that switch S4‐2 on the I‐Box is set to the right and the other S4 switches are to the left as shown
5. Program the I‐Box according to the applicable Ingenuity CT System JTAG Programming Manual.
6. Install the gantry RH upper side cover (see Gantry RH/LH Upper Side Cover Installation on page
138).
Figure 64-3: I‐Box Switch S4 Detail

I‐BOX BOARD SET SWITCH S4‐2
TO THE RIGHT
Section 65
Section 65 Revolution Counter Replacement
The revolution counter is located on the gantry LH upper side column (see Figure 65‐1).
Figure 65-1: Revolution Counter Location on Gantry RH Upper Side Column
Revolution Counter
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Revolution Counter Replacement
65.1 Removal
WARNING: Turn gantry power off before servicing. Hazardous voltages are inside the gantry left side
cover. Failure to do so may result in serious injury or death.
1. Remove power from the gantry (see Gantry Power Down (Except for the Host and CIRS) on page 27).
2. Remove the gantry LH upper side cover (see Gantry RH/LH Upper Side Cover Removal on page
135).
3. Disconnect the cable from the bottom of the counter (see Figure 65‐2).
4. Remove 2 screws securing revolution counter and mounting bracket assembly to the gantry, and
remove the assembly.
Figure 65-2: Revolution Counter On LH Upper Side Column
Revolution Counter
Disconnect Cable
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Revolution Counter Replacement
5. Remove 2 screws securing revolution counter and mounting bracket assembly to the gantry, and
remove the assembly (see Figure 65‐3).
Figure 65-3: Revolution Counter Mounting Screws

Upper Mounting Screw
Lower Mounting Screw
65.1.1 Installation
1. Position the revolution counter mounting bracket onto the gantry, apply Loctite #222 to the 2 screws,
and mount the bracket to the gantry (see Figure 65‐3).
2. Connect the cable to the revolution counter (see Figure 65‐2).
3. Install the gantry LH upper side cover (see Gantry RH/LH Upper Side Cover Installation on page
138).
Section 66
Section 66 AC Control Unit Board Replacement
The gantry ACCU board is located on the gantry LH upper side column (see Figure 66‐1).
Figure 66-1: AC Control Unit Board
ACCU
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement AC Control Unit Board Replacement
66.1 Removal
WARNING: Hazardous voltages ar inside the gantry left cover. Turn gantry power off before servicing.
1. Remove power from the system. Refer to System Power Down/Power Up on page 22 procedure.
135).
3. Tag and remove all AC control board cable connections. Cut ty‐wraps as required. Refer to Figure 66‐
2 on page 804.
4. Remove six screws and washers securing AC control board to mounting bracket, and remove board.
Figure 66-2: AC Control Board On LH Upper Side Column
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement AC Control Unit Board Replacement
66.2 Installation
2. Position AC control board to mounting bracket, and secure to bracket with six screws and washers.
Use Loctite #222 on screws.
3. Install all AC control board cable connections and secure with ty‐wraps.
138).
Section 67
Section 67 Main Contactor (MKD) And Soft Start (S/S) Contactor
Replacement
The main contactor (MKD) and soft start (S/S) contactor are located on the gantry LH upper side column.
Removal and installation is similar for either contactor.
67.1 Removal
WARNING: Hazardous voltages are inside the gantry left cover. Turn gantry power off before servicing.
1. Remove power from the system according to the procedure (see System Shutdown and Power Down
on page 22). Ensure that power is off at the wallbox.
2. Turn off the 120/240 VAC to the room annunciator (X‐ray) indicator light. Power to this light comes
from a separate 120/240 VAC supply and must be turned off by a site wall shut‐off switch.
135).
4. Tag and remove all main contactor / soft start contactor wiring connections. Refer to Figure 67‐1 on
page 807 for first models or Figure 67‐2 on page 808 for later models.
5. Remove two screws and flat washers securing main contactor / soft start contactor to contactor
mounting rail, and remove contactor.
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Main Contactor (MKD) And Soft Start (S/S) Contactor
Figure 67-1: Main Contactor And Soft Start Contactor Location On LH Upper Side Column
Soft Start Contactor
Main Contactor
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Main Contactor (MKD) And Soft Start (S/S) Contactor
Figure 67-2: Main Contactor And Soft Start Contactor Location On LH Upper Side Column
Main Contactor Soft Start Contactor
67.1.1 Installation
1. Position main contactor / soft start contactor to contactor mounting rail, and secure with two screws
and flat washers.
2. Install all main contactor / soft start contactor wiring connections. Secure with ty‐wraps as required.
138).
Section 68
Section 68 Utility & Console Contactor (UTK & CTK) Replacement
(Systems without Console Transformers)
The utility and console contactors (UTK & CTK) are located on the gantry LH lower side column. The
replacement procedure is the same for either contactor.
68.0.1 Removal
WARNING: hazardous voltages are inside the gantry left cover. Turn off gantry power before servicing.
failure to do so may result in serious injury or death.
1. Remove power from the system according to the procedure (see ‘System Shutdown and Power Down
on page 1‐22). Make sure to turn power off at the wall box
3. Remove the gantry LH upper side cover (see Gantry RH/LH Upper Side Cover Removal on page 13‐
135).
4. Remove the gantry LH lower side cover (see Gantry RH/LH Lower Side Cover Removal on page 13‐
142).
5. Tag and remove all the connections to the contactor to be replaced. Refer to Figure 68‐1 on page 810.
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Utility & Console Contactor (UTK & CTK)
6. Remove the two screws with flat washers securing the contactor to the mounting rail, and remove the
contactor (see Figure 68‐1).
Figure 68-1: Utility & Console Contactor Location ‐ Lower LH Column
Utility Contactor (UTK)
Console Contactor (CTK)
68.0.2 Installation
1. Position the contactor onto the contactor mounting rail and attach it with two screws with flat
washers.
2. Connect the wires to the installed contactor. Secure the wires with cable ties as required.
3. Install the gantry LH lower and upper side covers (see Ingenuity CT Side Covers Replacement on
page 13‐135).
4. Power up the system and make sure that it operates correctly.
Section 69
Section 69 Utility and Console Transformer Contactors (UTK & CTK)
(Systems with Console Transformers)
The utility transformer contactor (UTK) and console transformer contactor (CTK) are located on the
gantry LH lower side column. Removal and installation is similar for either contactor.
69.1 Removal
WARNING: Hazardous voltages are inside the gantry left cover. Turn off gantry power before servicing.
1. Remove power from the system according to the procedure (see System Shutdown and Power Down
on page 22). Ensure that power is off at the wall box
135).
4. Remove the gantry LH lower side cover (see Gantry RH/LH Lower Side Cover Removal on page
142).
5. Tag and remove all utility transformer contactor / console transformer contactor wiring connections.
Refer to Figure 69‐1 on page 812.
6. Remove two screws and flat washers securing utility transformer contactor / console transformer
contactor to contactor mounting rail, and remove contactor.
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Utility and Console Transformer Contactors (UTK &
Figure 69-1: Utility Transformer Contactor and Console Transformer Contactor Location
Utility Transformer Contactor (UTK)
Console Transformer Contactor (CTK)
69.2 Installation
1. Position utility transformer contactor / console transformer contactor to contactor mounting rail, and
secure with two screws and flat washers.
2. Install all utility transformer contactor / console transformer contactor wiring connections. Secure
with ty‐wraps as required.
3. Install the gantry LH lower and upper side covers (see Ingenuity CT Side Covers Replacement on
page 135).
Section 70
Section 70 Main Drive Contactor (MDK) Replacement
The main drive contactor (MDK) is located on the gantry RH lower side column (see Figure 70‐1).
Figure 70-1: Gantry Right Column
Main Drive Contactor (MDK)
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Main Drive Contactor (MDK) Replacement
70.1 Removal
WARNING: Hazardous voltages are inside the gantry right cover. Turn off gantry power before servicing.
1. Remove power from the system according to the procedure (see Gantry Power Down (Except for the
Host and CIRS) on page 27).
135).
3. Remove the gantry RH lower side cover (see Gantry RH/LH Lower Side Cover Removal on page
142).
4. Tag and remove all main drive contactor wiring connections. Refer to Figure 70‐2 on page 814.
5. Remove two screws and flat washers securing main drive contactor to mounting rail, and remove
contactor.
Figure 70-2: Main Drive Contactor Location On RH Lower Side Column
Main Drive Contactor (MDK)
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Main Drive Contactor (MDK) Replacement
70.2 Installation
1. Position main drive contactor to mounting rail, and secure with two screws and flat washers.
2. Install all main drive contactor wiring connections. Secure the wires with cable ties as required.
3. Install the gantry RH lower and upper side covers (see Ingenuity CT Side Covers Replacement on
page 135).
Section 71
Section 71 Entire Gantry Replacement
To replace the entire gantry, refer to the applicable system installation manual.
Appendix A
Appendix A Patient Support Subframe Quick Release
A.1 Releasing the Patient Support Subframe Quick

Release
1. Make sure the patient support top is as far away from the gantry as it will go.
2. Unscrew the wing nut or nut on the subframe quick release located under the front of the patient
support (Figure A‐1 on page 818).
a. Unscrew the wing nut or Nylock Nut enough so that the cross‐pin will drop down from the lock
pad it engages.
b. Patient supports that have the stationary threaded rod quick release will require the nut to be fully
removed.
3. Move the patient support subframe away from the gantry. Note that it may take considerable force to
move the subframe out of its normal position. Do not use the floating top as a mechanism to break the
initial resistance. However, after the initial resistance is overcome, the patient support subframe
should move freely.
Ingenuity CT, Ingenuity Core, Ingenuity Core128 CT Scanner Gantry Repair & Replacement Patient Support Subframe Quick Release
Figure A-1: Patient Support Subframe Quick Release

Patient Support Latch Overall Subframe Support Disengaged
Wing Nut Release Threaded Rod / Nut Release Nylock Nut Release
A.2 Engaging the Patient Support Subframe Quick

Release
1. Move the patient support subframe MAX In toward the gantry (Figure A‐3 on page 822).
2. Verify the patient support is raised to access the top subframe quick release.
3. For the Wing Nut / Nylock Nut type quick release, re‐engage the patient support quick release:
a. Verify the subframe is moved all the way toward the gantry.
b. Push the T‐mechanism (cross‐pin) of the quick release up until it goes into the slot of the subframe
bracket (Figure A‐2 on page 821).
c. Tighten the Wing Nut / Nylock Nut on the subframe quick release located at the front of the patient
support (Figure A‐1 on page 818). The Nylock Nut is torqued to 23 ft‐lb (31.2 N/m).
4. For the stationary threaded rod type quick release, re‐engage the patient support quick release:
a. Move the top subframe all the way toward the gantry. The threaded rod will protrude through the
block.
b. Install the nut and torque it to a value of 23 ft‐lb (31.2 N/m). (See Figure A‐1 on page 818.)
A.3 Testing the Patient Support Subframe Quick

Release
1. Tighten nut (wing nut, nylock nut or locking flange nut on stationary threaded rod) on the quick
release.
2. Verify the subframe is secure:
a. For patient supports with the stationary threaded rod, the nut is torqued to 23 ft‐lb (31.2 N/m).
Note: The correct engagement is with the threaded element protruding through the nut.
b. For patient supports with a Nylock Nut:
i. Inspect and make sure the threaded end of the T‐mechanism (cross‐pin) is secured behind the
slotted locking member (Figure A‐2 on page 821).
ii. The nut is torqued to 23 ft‐lb (31.2 N/m).
c. For patient supports with a wing nut:
i. Inspect the threaded end of the T‐mechanism (cross‐pin) and make sure it is secured behind
the slotted locking member (Figure A‐2 on page 821).
3. If wing nut version, continue to Step 4, to test quick release. If nylock nut or stationary threaded rod
version, procedure is complete.
4. Test the patient support subframe quick release engagement (applicable for wing nut version only):
a. With power applied to the patient support (i.e. horizontal drive enabled) and the carbon top
extended into the bore, engage the tape switch to put the carbon top into float mode.
b. While in float mode, using the tape switch handle, move (retract) the carbon top as one would do
in operation.
c. After about 30cm maximum of travel and while the carbon top is still in motion, release the tape
switch, causing the carbon top to abruptly stop.
5. Check the subframe for security:
a. The subframe should not be disconnected. Visually recheck the latch to confirm that the step from
2b(i) or 2c(i) is secure (Figure A‐2).
Figure A-2: Cross Pin Engaged and Secured Behind the Block

Slotted
Lock Pad
Locking Member
Block
Cross Pin
T‐Mechanism)
Cross Pin: Engaged Cross Pin Assembly: Disengaged
Slotted Locking Member
Cross Pin
(T‐Mechanism)
Cross Pin Assembly: Disengaged
b. Verify the subframe is still engaged by visually checking the alignment of the subframe cover to the
lower subframe (Figure A‐3).
Figure A-3: Subframe Patient Support Cover Alignment: Engaged versus Disengaged

Subframe Subframe
Max In)
Subframe Patient Support Engaged, Subframe Patient Support Disengaged,
with Covers Aligned with Covers Misaligned
c. Repeat Step 4 on page 820 thru Step 5 on page 821 and repair as needed, if the subframe is moving

relative to the base assembly.
d. Success criteria: Complete Step 4 on page 820 thru Step 5 on page 821 twice in a row, with no
disengagement or repair.
Import the Colors property from this file to hide the Preliminary watermark and the Date at the top
of the page.
This is only relevant if the text boxes for the watermark and date already exist on the master pages

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Ingenuity CT, Ingenuity

Core, Ingenuity Core128

4598 000 72481

© 2016 Koninklijke Philips N.V. All Rights Reserved. CSIP-1

Safety and Legal Information

Installation and Environment

Diagnostic Imaging Systems - Mechanical-electrical Warning

Diagnostic Imaging Systems - Radiation Warning

ECO # Revision Date Comments

2022885 A Sept. 15, 2010 Original release

2023806 C July 25, 2011 Revised the MRC880 XRT replacement procedure for a revised shipping box.

ECO # Revision Date Comments

E‐079831 L 30 Oct 2016 Updating to resolve CTUDT00589960 and Formatting Documentation

Section 2 Ingenuity CT Gantry Front Cover Opening /Closing: .......................... 40

Section 3 Ingenuity CT Gantry Front Cover Replacement: ................................ 48

3.4 Ingenuity CT Front Cover Position Adjustments ........................................................ 71

Section 4 Gantry Front Cover Gas Spring Replacement: ................................... 76

Section 5 Original Style Front Cover Laser Module Replacement: ..................... 81

Section 6 Newer Style Front Cover Laser Module Replacement: ....................... 86

Section 7 Rotor Laser Module Replacement: ................................................... 92

Section 8 Early Model RH or LH Front Display/Control Panel Replacement: ...... 95

Section 9 Later Model RH or LH Front Display/Control Panel Replacement: ...... 104

Section 10 Replacing the Gantry Rear Cover: .................................................. 112

Section 12 Ingenuity CT Gantry Rear Cone Replacement: ................................ 128

12.3 Installing the Ingenuity CT Gantry Rear Cone ......................................................... 133

Section 13 Ingenuity CT Side Covers Replacement: ......................................... 135

Section 14 Gantry Display/Switch Control Board Replacement: ....................... 150

Section 15 Front Cover Interlock Switch Replacement: ................................... 152

Section 16 Ingenuity CT Gantry Exhaust Fans Replacement: ........................... 154

Section 17 Intake Air Filters Removal/Replacement: ...................................... 156

Section 18 Gantry Intake Fans Removal/Replacement: .................................. 160

18.1 Removal............................................................................................................ 160

Section 19 MRC 880 X-ray Tube Assembly Replacement: ................................. 164

Section 20 MRC 600 X-ray Tube Assembly Replacement: ................................. 254

Section 21 MRC 600 Cooling Unit Replacement: .............................................. 333

21.2 Installation ........................................................................................................ 348

Section 22 Heat Exchanger Fans Removal/Replacement: ................................. 356

Section 23 A-Plane Collimator Removal/Replacement: .................................... 361

Section 24 Reference Converter Board Removal/Replacement: ........................ 410

Section 25 FRC Assembly Replacement: ......................................................... 413

25.2 Installing the FRC Assembly ................................................................................. 419

Section 26 Cathode Power Module Assembly Removal/Replacement: ............... 436

Section 27 Anode Power Module Assembly Removal/Replacement: .................. 475

Section 28 RHost or CPM Control Board Assembly Replacement: ...................... 512

Section 29 High Speed Starter Removal/Replacement: ................................... 527

Section 30 GHost Board Removal/Replacement: ............................................. 533

Section 31 Gantry Motion Processor Board Removal/Replacement: ................. 536

Section 32 Gantry Motion Power Board Removal / Replacement: ..................... 539

Section 33 5 Volt Power Supply Removal/Replacement: .................................. 541

Section 34 Switching 12 Volt Power Supply Removal/Replacement: ................ 544

Section 35 R2D Board Removal/Replacement: ................................................ 547

Section 36 Replacing 5V/24 V DMS Power Supply: .......................................... 550

Section 37 Ingenuity CT DMS Triple 5V Power Supplies Replacement: .............. 553

Section 38 TDMS 48V Power Supply: .............................................................. 557

Section 39 Replacing 5V Reference Converter Power Supply: .......................... 568

Section 40 Main Drive Motor Replacement: ..................................................... 572

Section 42 Main Drive Belt Replacement: ....................................................... 593

Section 43 SpindleBlok Motor Controller Replacement: .................................. 601

Section 44 Commander SK Rotor Drive Motor Controller Replacement: ............ 620

Section 45 M200 Rotor Drive Motor Controller Replacement: ........................... 644

Section 46 Emerson CSK or M200 Motor Controller Commissioning: ................. 663

Section 47 Three-Phase Filter Removal/Replacement: .................................... 677

47.0.1 Removal .................................................................................................. 677

Section 48 Motor Braking Resistor Removal/Replacement: ............................. 681