iCR3600LF

SERVICE MANUAL
iCR 3600TM – Service Manual

Forward

Proprietary Notice and Disclaimer

The information herein disclosed is the property of iCRco., Inc. Information in this
document is subject to change without notice and does not represent a commitment by
iCRco to incorporate changes or improvements in units previously sold or shipped.

No part of this document may be reproduced or transmitted in any form, electronic

or mechanical, including photocopying and recording, for any purpose other than the
purchaser’s own use without the express written permission of iCRco.

Copyright
Copyright c iCRco Inc. 2003, 2004, 2005, 2006, 2007, 2008, 2009
All rights reserved.

Trademarks
iCR 2600 ,R iCR 1000 ,
R iCR 1000 Dual , R iCR 2600 ,R iCR 2600 Dual ,
R iCR 2600SF ,
R
iCR Vet ,
R iCR CR Vet Dual ,R iCR Mobile , R iCR 1-D ,
R iCR Chiro ,
R iCR Chiro Dual ,
R
iCR 3600 ,R iCR 3600SF , R iCR VERTX ,iDR
R ,www.icrcompany.com
R and QPC XS-
CAN32 are the trademarks of iCRco. All other trademarks are the property of their
respective owners, and are hereby acknowledged.

Terms
Any one of the following iCR products will be referred to as the “CR unit” throughout this
document: iCR 1000 , R iCR 1000 Dual , R iCR 2600 , R iCR 2600 Dual , R iCR 2600SF , R
iCR 3600 , R iCR Vet ,R iCR Vet Dual , R iCR Mobile , R iCR 1-D , R iCR Chiro , R iCR
Chiro Dual R iCR VERTX R Any one of the following iCR products will be referred to as
“iCR dual unit” throughout this document: iCR 1000 Dual , R iCR 2600 Dual , R iCR Vet
Dual , iCR Chiro Dual Any one of the following iCR products will be referred to as
R R
“iCR desktop unit” throughout this document: iCR VERTX . R The iDR will
R be referred
to as the “DR unit” throughout this document.

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Contact Information
iCRco., Inc.
Address: 2580 West 237th Street, Torrance, CA, 90505
Phone: 310.921.9559
Fax: 310.542.7236
Email: info@icrcompany.com
Web: http://www.icrcompany.com

CR Information
Please Enter the details of the CR system here:
CR Model:

Serial Number:

Date Purchased:

Interface Type: USB 2.0

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Contents

Forward 1
Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1 Introduction 5
1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 FCC Notification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2 Pre-Installation 11
2.1 Voltage Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4 Connectivity and Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.5 Physical requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3 Software Installation 13
3.1 USB Driver Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2 QPC XSCAN32 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4 Hardware Installation 17
4.1 Installing Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2 Power Switch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.3 Power and Scan Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.4 USB 2.0 Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.5 Computer Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.6 Wall Mounting Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5 System Operation 20
5.1 Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.2 Cassette Handling & Loading . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.3 Acquiring an Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

6 Theory of Operation 27
6.1 Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.2 System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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7 Diagnostics 31
7.1 Using the Focus Tool for Hardware Diagnostics . . . . . . . . . . . . . . . . 31
7.2 Image Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.3 Hardware Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.4 Error Message: No Data Acquired . . . . . . . . . . . . . . . . . . . . . . . 42

8 Service & Maintenance Procedures 47

8.1 Removing Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8.2 Removing Back Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.3 Accessing the Scan Slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.4 Replacing the PMT Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
8.5 Removing the Optical/Electrical Module from the Case . . . . . . . . . . . 53
8.6 Replacing the Motor Controller Board . . . . . . . . . . . . . . . . . . . . . 56
8.7 Replacing the Main Power Supply . . . . . . . . . . . . . . . . . . . . . . . 57
8.8 Replacing the Galvo Controller Board . . . . . . . . . . . . . . . . . . . . . 59
8.9 Replacing the Power Distribution Board . . . . . . . . . . . . . . . . . . . . 59
8.10 Cleaning the Fan Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8.11 Cleaning the Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
8.12 Checking the Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
8.13 Changing the Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
8.14 Cassette Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

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1. Introduction
1.1 Overview
The CR unit is an ultra high resolution Computed Radiography device. It is designed to
scan cassettes containing phosphor screens (CR plates) using patented technology. CR
plates are transported past a scanning head without bending or using rollers. This flat
scan path results in ultra high resolution images with high fidelity across the entire image.
High resolution is achieved from the CR plates by coupling the flat scan path with a high
energy laser.

The CR unit collects 16 Bit data that is converted to a DICOM 3.0 image and can be
stored, viewed, manipulated, and sent to any other storage device, printer, or viewing sta-
tion through DICOM. This document contains a basic technical overview of the CR unit
including the optical systems, electronic components, and driving software subsystems.
A general description of the systems functionality and user interfaces will be described.
Unpacking of the hardware is covered, as is software installation, and troubleshooting
are also included. This document is intended for users or service people who need to
understand the basic underlying principles of operation for the CR unit.

1.2 Safety Information

Be sure to read and understand the installation and operating instructions before applying
power to the CR unit.

1.2.1 Conventions

DANGER: A DANGER indicates that personal injury may occur if the Service person

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does not perform the procedure correctly.

WARNING: A WARNING indicates that a user must be constantly aware of something

that may prove hazardous.

CAUTION: A CAUTION indicates that damage to the product or user may occur if the
user does not perform the procedure correctly.

Note: A NOTE indicates important information that helps you make better use of your
CR and Software.

Notice: A NOTICE indicates either potential damage to hardware or loss of data and tells
you how to avoid the problem.

1.2.2 Laser Safety

CAUTION: This equipment employs a laser. Laser radiation may be present if the CR
system is operated without the covers. Avoid the laser beam. Direct exposure to laser
light must be avoided.

The CR unit incorporates a Red ≥ 80mw high-power solid-state laser diode. The CR
covers protect the service person from direct exposure to laser light. These covers will
protect a user/service person only if they are properly installed. Covers must be removed
and replaced by properly trained service personnel. Contact iCRco if there are any issues
with the covers being damaged and/or replacement covers are needed.

1.2.3 Electrical Hazards

The equipment must be serviced by properly trained technicians certified by iCRco,
Inc. Do not connect the CR unit with a damaged or sub-standard power cable. Do not
use an extension cord with this device. The CR unit should be properly grounded and
power connections inspected to ensure safe operation. Use at least a 1300VA (780W)
uninterruptible power supply (UPS) with this device, as it is sensitive to variations in
power.

WARNING: This equipment is operated with hazardous voltages which can shock, burn,
or cause death.

Notice: The CR unit must be connected to a uninterruptible power supply (UPS). Failure
to use a (UPS) will void the warranty.

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1.3 FCC Notification

This equipment generates, uses, and can radiate radio frequency energy, and if not
installed properly, can cause interference with radio communications.

1.4 Warranty Information

iCRco, Inc. (“iCRco”) values your business and always endeavors to provide high quality
products and services. All iCRco products are provided with an initial warranty so you
are covered from the date you purchase them. This limited warranty solely applies to
new products manufactured by or for iCRco and originally purchased from iCRco or an
authorized dealer of iCRco products for your own use. In addition, an extended warranty
is available for most new and recently purchased iCRco products for an additional charge.

1.4.1 Hardware Limited Warranty

iCRco warrants its hardware products to be free of defects in materials and workmanship
for a period of one (1) year from the date of original shipment from iCRco subject to
the limitations set forth herein. iCRco phosphor plates sold with and for use in iCRco
cassettes are warranted to be free of defects in materials and workmanship for a period
of (3) years from the date of original shipment subject to limitations set forth herein.
If a product proves to be defective in material or workmanship during the warranty
period, iCRco will, at its sole option, repair or replace the product with a similar product.
Repaired and replacement products may be or include refurbished or remanufactured
parts. Any replacement item assumes the remaining warranty period of the original
product. iCRco provides no warranty for any third party hardware or software included
with any product or later acquired.

1.4.2 Software Limited Warranty/Support

iCRco warrants that its QPC XSCAN32 software originally provided with any product
will substantially conform to iCRco’s specifications and that the media, not including
hard drives, on which the software is furnished will be free from defects in materials and
workmanship under normal use for a period of one (1) year from the date of original
shipment from iCRco. iCRco’s sole obligation under this warranty is limited to making
reasonable efforts to ensure such conformity and to supply the consumer with a corrected
version of the software as soon as it is practical after the consumer has notified iCRco
of any non conformity. iCRco does not warrant that the operation of any software will
be uninterrupted, glitch or error free or that functions contained in the software will
operate in the combinations which may be selected for use by the user or meet the user’s
requirements. This limited software warranty will be void if the software is modified
without the written approval of iCRco or is used outside of the recommended parameters

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or equipment. iCRco does not provide any warranty or support for any other software.

iCRco agrees to provide one (1) year of telephonic and/or e-mail based support for
QPC XSCAN32 software originally provided with any new iCRco product from the
date of original shipment from iCRco. All software support shall be limited to making
reasonable efforts to resolve iCRco software issues and shall be limited to iCRco’s regular
business hours. In addition, iCRco will provide revisions and upgrades to its software
upon request (when available) during the first year after the software was originally
shipped from the iCRco factory. The initial support period will include support via
remote login software (GoToMeeting), only if the customer has access to the Internet from
that PC and only if the customer agrees iCRco shall have no liability in connection with
its support efforts. Remote login software allows iCRco technical support to remotely
access the customer’s PC via the Internet for the purposes of rendering technical support.
Please note that this warranty, including software support, does not include computer
hardware, third party software or operating system or network issues, which are outside
the control of iCRco.

1.4.3 Warranty Product Technical Requirements

iCRco requires that all CR, Scanner and/or products requiring PCs be fitted and installed
with an uninterruptible power supply (“UPS”). iCRco recommends the APC BR1300LCD
model UPS or equivalent. For warranty evaluation and service, iCRco requires the
customer to provide a network drop (DSL or Dial up) or the minimum of a phone line
accessible by an extension cord to the product enabling iCRco technicians to perform
remote diagnostics on installed equipment. In addition, each iCRco product must be
installed, maintained and operated in accordance with the respective product manual.
Failure to comply with these requirements will result in a voided warranty claim.

1.4.4 Requesting Warranty Service

For information on obtaining warranty service, call iCRco’s customer support at (310)
921-9559. In order to evaluate a warranty service request, iCRco requires the following in-
formation: the iCRco serial number of the product, a detailed description of the problem,
customer name and contact information; product location and operating conditions; a
copy of the purchase documents, and sufficient information and authorization, including
a liability release as to any loss of data (that should always be backed up), software or
network injury, or downtime, allowing iCRco technicians remote access to the product.
Product may not be returned to iCRco without first obtaining a Return Material Autho-
rization (“RMA”) number from iCRco. Prior to providing an RMA, iCRco may require
remote access to the product. If iCRco determines that the product may be defective,
is under warranty and necessitates a return to iCRco for service, an RMA number and
instructions for return of the product will be given. iCRco is not responsible for any

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unauthorized returned product, i.e. one for which an RMA number has not been issued
by iCRco.

Warranty service requires all authorized returns be shipped to the iCRco factory prepaid
and insured. All such authorized returns are the customer’s responsibility. For products
sold and located within the United States, iCRco will pay for return shipping.

Products being returned are only to be shipped in iCRco approved shipping containers.
The original box and packaging materials are approved and should be kept for moving
and/or shipping the product. Original and approved packaging my also be purchased
from iCRco. iCRco shall have no liability nor responsibility for warranty service to any
product that is not shipped in an iCRco approved shipping container or that is damaged
from incorrect packaging or damaged during shipping.

1.4.5 Additional Warranty Limitations and Extent of Warranty

This warranty does not apply if the product has been damaged by accident, misuse or
abuse. In addition, warranty service does not include the repair of failures or defects
caused by: unauthorized attachments to any iCRco product, unsuitable physical or
operating environment, maintenance or repair by anyone other than iCRco or the iCRco
authorized dealer that sold the product, operation of a product beyond its duty cycle,
use of the product outside of its specifications, the use of supplies, parts, materials, soft-
ware, or interfaces not furnished, authorized or recommended by iCRco. If the product,
including any software has been opened, tampered with, modified or altered in any way
without written authorization by iCRco, the warranty will also no longer apply.

This warranty applies only to products manufactured by, or for, iCRco, and that can be
identified by an “iCRco” serial number as originally affixed to the product. Any modifi-
cation to the iCRco serial number tag or its attachment to the product shall immediately
void this warranty.

This warranty is non-transferable and subsequent owners must contact iCRco to es-
tablish if the equipment is eligible for an extended warranty.

THERE ARE NO WARRANTIES, EXPRESS OR IMPLIED, WITH RESPECT TO ANY

iCRco PRODUCT OTHER THAN AS SPECIFICALLY SET FORTH HEREIN, AND
iCRco SPECIFICALLY DISCLAIMS ANY IMPLIED WARRANTIES OR CONDITIONS
OF MERCHANT ABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND SAT-
ISFACTORY QUALITY. ANY WARRANTIES THAT MAY NOT BE DISCLAIMED
UNDER APPLICABLE LAW ARE LIMITED IN DURATION TO THE INITIAL WAR-
RANTY PERIOD AND NO WARRANTIES, EXPRESS OR IMPLIED, WILL APPLY
AFTER THIS PERIOD. ALL INFORMATION, SPECIFICATIONS, PRICES, AND SER-

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VICES ARE SUBJECT TO CHANGE AT ANY TIME WITHOUT NOTICE.

1.4.6 Limitation of Remedies and Liability/Exclusion of Damages

The exclusive remedy for any defective product is limited to the repair or replacement
of the defective product. iCRco shall have a reasonable time after determining that a
defective product exists to repair or replace a defective product. iCRco’s entire liability
for any product is limited to the actual purchase price for the product. This limitation
applies even if iCRco cannot or does not repair or replace any defective product and your
exclusive remedy fails of its essential purpose.

IN NO EVENT WILL iCRco BE LIABLE FOR ANY GENERAL, SPECIAL, CONSEQUEN-

TIAL OR INCIDENTAL DAMAGES, including but not limited to, damages related to
the loss of use, loss of recorded product, the installation of replacement product, or any
inspection, testing, or redesign caused by any defect or by the repair or replacement of
any product arising from a defect in any product. This exclusion of damages applies
even if the customer advises iCRco or an iCRco dealer of the possibility of such damages.
This limitation of remedies also applies to claims against any suppliers or dealers of iCRco. iCRco
and its suppliers’ and dealers’ limitations of remedies are not cumulative. Such suppliers and
dealers are intended beneficiaries of this limitation. iCRco is not liable for any claim by or against
the customer arising from a third party claim.

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2. Pre-Installation
2.1 Voltage Requirements
The CR unit incorporates an international switching power supply. iCRco employs CE
certified medical grade universal power supplies to allow the unit to work between 90 to
253V AC 50/60Hz. In order to run the unit with different power types, apply voltage to
the power input module at the end of the CR unit. For international units, a local power
cord must be used that can handle the power requirements of the unit. A 13A/125V
power cord is sufficient.

2.2 Environmental
The CR unit should not be placed in a room with a film processor present. This will void
the warranty. The humidity and temperature limits are 20 to 80% non-condensing, and
50 to 95◦ F (10 to 35◦ C) operating, respectively. The room should have good ventilation.
Another factor to consider prior to installing the CR unit is dust and particulates in the
environment. The CR unit is designed to be resistant to dust and particulates that may
be present at the installation site.

2.3 System Specifications

Power Requirements Scan Rate
Domestic 100 to 120V, 50/60Hz, 3.5A Scan Rate 60 lines/second
International 220 to 240V, 50/60Hz, 1.75A
Grey Scale Resolution
Temperature Conditions
16 bits (65,535 shades of gray)
◦ ◦
50 to 95 F (10 to 35 C) - operating
0 to 150◦ F (-18 to 65◦ C) - non-operating
Interface
Humidity USB 2.0

20 to 80% non-condensing
Dimensions
iCR 3600 10W x 22H x 44L inches
Pixels per Line Resolution
3500 (High Resolution) over 356mm (14
Vibration/Acceleration
inches) 2048 (Normal Resolution) over
356mm (14 inches). 3-4G Max (in shipping)

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Altitude Weight
0 to 9,500 ft. - operating iCR 3600 78 lbs

2.4 Connectivity and Power Supply

The room needs to have wall power and should not be used with an extension cord.
Please use at least a 1300VA (780W) UPS between the wall power and the CR unit. It is
also required to have a network connection for fast technical support. Alternatively, the
user must have a phone/fax line that can be connected to the PC in order to comply with
iCRco warranty terms.

2.5 Physical requirements

The CR unit requires a stable operating environment. It is important the system is placed
on a table, stand or wall mount that provides adequate support.

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3. Software Installation
3.1 USB Driver Installation
Installation of USB drivers are automatic with the installation of the iCRco software (i.e.,
QPC XSCAN32).

3.2 QPC XSCAN32 Installation

QPC XSCAN32 software comes bundled with the CR unit. This software package will
allow the user to interface with the CR unit.

Note: If you have QPC XSCAN32 already installed on your computer and it is running
while you are trying to install the new version, an error will appear in the installation
process. Please close QPC XSCAN32 and reinstall the new version.

1. Insert the media containing the QPC XSCAN32 installer into the computer. Navi-
gate to the QPC XSCAN32 folder.

2. Launch the QPC XSCAN32 installer by double clicking Setup.exe.

3. Click Next at the welcome screen.

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4. Click Yes to agree to the Software License Agreement.

5. Make sure both QPC XSCAN32 Software and Software Key Driver boxes are checked,
then click Next.
Note: If upgrading XSCAN, the software key drives do not need to be installed.

6. Select Scanning Station or Reading Station depend on the use, then click Next to
continue.

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7. Select the appropriate modality, then click Next to continue.

8. The Destination Folder should be set to C:\Xscan32, then click Next to continue.

9. The Program Folder name should be set to QPC XSCAN32, then click Next.

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10. QPC XSCAN32 will begin to install. Please be patient while XSCAN32 installs.

11. Insert the USB Dongle into a free USB port if you have not done so already, then
click OK to continue.

12. Click Finish to complete the installation of QPC XSCAN32. The installation pro-
gram will close.

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4. Hardware Installation
4.1 Installing Power Cable
1. Plug the power cable for the CR unit into the power switch unit.

2. Plug the other end of the power switch cord into the UPS.

3. Make sure the UPS is not in bypass mode.

4. Plug the UPS into a standard wall outlet.

4.1.1 International Power Cable

The CR unit utilizes an international IEC grade connector for the power cable. Systems
are shipped with a standard NEMA 5-15 hospital grade cable. The cable needs to be
changed depending on the male end, which varies from country to country.

4.2 Power Switch Location

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The power switch for the CR unit is located on the left hand side of the unit, directly to
the right the fan.

4.3 Power and Scan Lights

The power and scan lights are located on the lower left-hand side
of the CR unit. When the unit is powered on, the green light is
illuminated. While the unit is scanning the yellow light will blink.

4.4 USB 2.0 Cable Installation

1. Visually inspect the cable to ensure that it is not cut, frayed, or otherwise damaged.
2. Plug the USB B cable end to the CR unit’s USB port.
3. Plug the USB A cable end into a free USB 2.0 port on the computer

4.5 Computer Mounting Bracket

1. Align the computer mounting bracket on the back of the cassette tray.
2. Once the screw holes are aligned, fasten the computer mounting bracket to the CR
unit using four (4) 6-32 x 83 ” truss head screws.

3. Align the computer with the mounting holes on the bracket.

4. Fasten the computer to the mounting bracket using four (4) 6-32 x 12 ” truss head
screws.
Note: For easy access to the CD-ROM drive, make sure the drive opens towards the
outside of the unit.

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4.6 Wall Mounting Plates

Notice: Wall mounting plates must be installed by a licensed contractor.

1. Attach the large wall mounting plate against wall at desired height. Allow the
contractor to determine the proper screws to fasten the large wall mounting plate
to the wall.

2. Attach the small wall mounting plate to the CR unit with three (3) 6-32 x 38 ” flathead
undercut screws and two (2) 10-32 x 34 ” truss head screws.
CAUTION: Always practice proper heavy lifting procedures. Improper lifting may
cause injury.

3. With at least two people, lift the CR unit onto the large wall mounting plate so that
the bottom of the small wall mounting plate rests in the top notch of the large wall
mounting plate.

4. Secure the bottom of the CR unit to the bottom of the large wall mounting plate
with two (2) 10-32 x 34 ” truss head screws.

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5. System Operation
5.1 Power-Up
1. Make sure the power cord is properly installed in the power module.

2. Make sure the power cord is properly installed in the UPS and the UPS is plugged
into a standard wall outlet.

3. Make sure the USB 2.0 cord is properly installed in the unit and computer.

4. Power on the computer.

5. Power on the CR unit by pressing the power switch.

5.2 Cassette Handling & Loading

5.2.1 Overview
Unlike other CR solutions, the iCR unit does not allow for contact to the delicate phos-
phor imaging plate. The hard X-ray cassette is designed to protect the plate and allow
for it to be read by the iCR 3600. The delicate imaging plate is embedded within a rigid
cassette in such a way that nothing touches the plate during the scanning or handling
process.

The digital x-ray cassette is carbon fiber with an embedded aluminum/lead back plane.
There is a release catch to allow the service person to access the plate within the cassette.
Using a pencil, push the release catch located within the bottom extrusion on the cassette.

All cassettes should be stored in the cleanest, driest conditions possible. Always store
cassettes in a location where they are not likely to be knocked over or damaged. With
careful handling the cassette plate system should provide years of service as there is no
known lifetime for the phosphors used in the plate system.

5.2.2 Cassette Loading

1. Before loading the cassette, orient it properly, with the blue side of the cassette
facing towards the operator with the arrows pointing upwards.

2. Locate the proper sized guide lines on the bezel of the CR unit.

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3. At an angle, load the cassette bottom first into the scan bar.
CAUTION: Do not use excessive force when loading the cassette! The cassette will
not fit if the orientation is incorrect.

4. Gently push the top of the cassette into place.

5. If loaded correctly, the user will see the white guide lines around the edge of the
cassette.

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6. Close the bay door.

5.3 Acquiring an Image

WARNING: This equipment employs a laser. Laser radiation may be present if the CR
unit is operated without the covers in place. Avoid the laser beam. Direct eye exposure
to laser light must be avoided.
Note: The instructions in this section represent a typical CR workflow. Every workflow
varies in process.
1. Open the door on the CR unit.
2. Load the cassette into the CR unit. The blue, non-carbon fiber side of the cassette
faces away from the CR unit.
CAUTION: Do not use excessive force when loading the cassette! The cassette will
not fit if the orientation is incorrect. If the user requires more instruction on cassette
loading, please see Section 5.2.2.
3. Open QPC XSCAN32.
4. Create or edit patient profile. To do this, click New or Edit, respectively.

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5. If creating a new patient, enter the relevant patient info, or if editing a patient,
change the information accordingly, then click Save and View.

6. Click on Scan to bring up the Quality Processing Center Scan dialog. (if it is a
patient with no images the scan dialog will automatically appear).

7. The iCR Quality Processing Center dialog will appear.

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8. Select the anatomy by mousing over the skeleton on the left hand side of the Quality
Processing Center dialog.

9. Select the cassette size by clicking the correct button (i.e. 14x17 in, 10x12 in). This
will start the scan.

10. The preview window will display the image as it is scanning. Once it has finished
scanning it will automatically import the image into QPC XSCAN32.

11. Open the scanned image by double clicking on the thumbnail.

12. Rotate/Flip to correct orientation using the Rotate and Flip buttons in the main tool
bar.

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13. Remove any collimation by using the Auto Crop(located in the main toolbar), Mask,
or User Mask (located in the Image Processing dialog) functions.

14. Process using ICE or ICE2 (located in the Image Processing dialog).

15. Window/Level the image using the Window/Level or Smart Box tools.

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16. Accept and Save the image to save the processing and W/L settings by clicking the
Save and Accept button in the upper left hand corner of the image.

17. Return to the Patient Information window. Select the patient(s) to send to a PACS or
viewing station. If you wish to send more than one patient, hold the Ctrl key down
and left mouse click to select multiple patients.
18. After selecting the patient(s), click the DICOM Send button.

19. The DICOM Targets window will appear, choose the desired target, then click OK

20. The results of the DICOM Send will appear in the DICOM Controller window’s
Event log.

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6. Theory of Operation
6.1 Product Overview
The iCR 3600 is a desktop/wall mount/portable CR that scans one cassette at a time. It is
designed to accomplish this in about one minute to enable high throughput for a high
volume X-ray room. It can be mounted on the wall directly beside or behind an X-ray
control panel.

The 3600 produces a diagnostic quality image from a medical grade storage-phosphor
image plate. The optical assembly provides a flying spot laser with a focal spot size of
50 microns. The laser scans across the plate and data is captured at a given rate. Each
sample is reassembled to create an image. The capture sampling rate can be modified
to create images with resolutions from 100 microns (250 DPI) to 200 microns (120 DPI).
The unit can scan images up to 14 x 17”. The laser spot focused to 50 microns is moved
back and forth across an imaging plate as the plate is moved through the CR unit. The
resulting Digital X-ray can be viewed, manipulated and stored and even printed to a
film or paper image. The images are stored and manipulated using the standard medical
image format (DCM) and the medical imaging transfer protocol, DICOM 3.0.

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6.2 System Configuration

6.2.1 Optical Beam Path
The iCR 3600 contains a 664 nm 40 mW laser, laser power supply, Lens optic and two
mirrors, a scanning galvanometer, and a light collection system.

The round laser spot is focused through a collimation lens to produce a round out-
put beam. The beam is deflected by a galvanometer scanner to produce the scan across
the plate. The folding mirrors bend the beam and the focused laser spot travels vertically
down the plate as it moves horizontally across the scan head.

In order to reach the plate, the beam passes through an integrating collection cylin-
der. As it hits the surface of the plate, the red light from the focused laser stimulates
blue emission from the image plate in direct proportion to the X-ray energy stored in
the image plate as a result of the exposure. This blue light is collected by the integrating
cylinder. The red light is blocked from reaching the photomultiplier tubes by blue glass
filters.

The collected blue light is detected by photomultiplier tubes, which convert the photons
into a signal.

This signal is then logarithmically amplified, corrected for spatial variations in the system
sensitivity across the width of the screen, and then digitized by an A/D converter.

6.2.2 Galvonometer Board

The Galvo Servo board contains a feedback amplifier that results in extremely accurate
control of the mirror mounted on the shaft of the scanning galvanometer.

The galvo motor shaft oscillates back and forth through an arc of approximately 30
degrees at a rate of 90Hz. A small mirror attached to the shaft intercepts the static laser
beam and sweeps (scans) it across the width of the image plate.

6.2.3 Indicator Board

Two LED indicator lamps are used to signal scanner power ON and SCAN status. The
SCAN indicator is turned on only while a scan is in process; it also blinks whenever the
plate is in the optical path.

6.2.4 Anti-Jitter Board

A small L shaped board located at the end of the integration cylinder.

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6.2.5 PMT Board

The photomultiplier tube amplifies the photons from the CR plate and converts them
into electrical signals.

6.2.6 Power Distribution Board

WARNING: Do not handle supply when unit is on. Do not disconnect cables when unit is
powered up.
Large supply: ± 18 V, ± 12 V, +5 V.
Small supply: +24 V.
High Voltage Supply (PMTs): 1000 V.

6.2.7 LED Eraser Board

The LED Eraser board provides single wavelength light to erase CR plate.

6.2.8 Motor Controller Board

This section of the CR controls the stepping motor to drive the plate past the scan head
and return it to the “home” position.

6.2.9 Analog to Digital Conversion

During the scanning process signals are generated by the PMT sensors and transmitted
to the computer through a USBII interface cable. A trigger signal generated by the laser
spot is transmitted to the PMT board to trigger a line capture. Image is assembled from
lines of captured data that is held in registers and translated into a 16 bit raw source file.
There is no way to pause the data capture process. Cancel will cause the machine to stop
and return to home position. Data on the CR plate will be lost.

Note: If an image is canceled during the scan process, the plate will have to be erased
again to ensure that the plate is entirely erased.

6.2.10 Calibration
Gain Adjustment
Gain Control is used to compensate for reduction in sensitivity of the PMT detectors due
to age. The gain can be adjusted in the software.

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6.2.11 PMT Amplifier

The amplifier is the interface between the PMT receiving the stimulated light from the
collection chamber. The amplifier serves as a current to voltage converter and a log
amplifier.

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7. Diagnostics
If a system failure occurs, it is necessary to diagnose the cause before beginning the
repair. This section describes the diagnostic tools and techniques used to isolate various
types of system failures. This chapter covers the most common failures and their fixes. If
the user is unsure how to proceed with troubleshooting, please contact Technical Support.

The cause of some failures may be obvious. In these cases, the Service Engineer may
proceed directly to the repair. Before beginning an investigation, it is a good practice to
record as much information about the current state of the system as possible. This infor-
mation may include, but is not limited to, symptoms, conditions under which symptoms
exist, voltages, settings, cleanliness, and visual state. Normal generic troubleshooting
techniques apply. With knowledge of the system, isolate the failure to a particular sub-
system. With knowledge of the subsystem, trace the symptom back to its cause. In many
cases, failures are caused by lack of periodic maintenance and cleaning. If a system is
known to be behind schedule for its maintenance and cleaning at the time of the failure,
it is a good practice to clean and re-calibrate the system before extensive troubleshooting.
In many cases this solves the problem or provides clues as to the cause.

WARNING: This equipment is operated with hazardous voltages which can shock, burn,
or cause death.
WARNING: This equipment uses a laser. Direct exposure to the laser beam must be
avoided.
WARNING: Do not operate the unit with the covers removed. Operating the unit with
the covers removed may result in damage to unit and/or cause harm to the operator.

Preliminary Checks:
1. Make sure the CR unit is powered by at least a 1300VA (780W) UPS (uninteruptable
power supply).
2. Make sure that the CR unit is connected to the acquisition computer using a USB
2.0 cable (USB 1.0 or 1.1 cabling is not sufficient).
3. Check that the CR unit is powered by a standard NEMA 5-15 hospital grade cable.
4. Make sure that other devices that emit strong radio frequencies are not in close
proximity to the CR unit.

7.1 Using the Focus Tool for Hardware Diagnostics

The Focus tool is an efficient test that can provide the Service Engineer with valuable
feed back regarding the functionality of the CR unit’s hardware. There are a series of

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questions following the work instructions that are designed to help include/eliminate
potential failures in the CR unit’s subsystems.

1. Leave the Cassette out of the unit and close the bay door.

2. Open QPC XSCAN32, access the Scan interface, then click the Settings button on
the Scan interface.

3. Enter the password earl in the dialog box.

4. Click on the FOCUS tool Button along the bottom edge of the settings window.

5. A new window will come up, indicating the settings for the FOCUS tool. Use the
standard settings in the focus tool. Click OK in the dialog box. This moves the
carriage 4 inches into the unit, and begins to capture data.

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6. If the unit is working correctly, you will see a red data line, moving as the data is
passed to the PC, one line at a time. In the default configuration, the scale is 65,000
levels of gray along the vertical axis of the window, and pixel location along the
horizontal axis of the window. The Data line will be between zero and 2,500. If the
line is not between zero and 2,500, you may need to re-adjust the zero point of the
scanner.

7. Open the dust cover of the CR unit, the Data line should rise and lower slightly
according to the position of the bay door. If the room is illuminated by high
frequency fluorescent lights, the line may become sinusoidal (Wavy) and move
away from the zero point.

What can we see by looking at the digital output of the CR unit?

1. The unit must be capturing data because there is data being captured by the PC

2. The Laser is working because the laser moving past a start scan sensor tells the unit
to start capturing data

3. The Start Scan sensor is working

4. The Galvanometer is working, swinging the laser back and forth

5. The Motor is working, moving the carriage 4 inches into the CR unit

6. The unit is sensing light variations as the line is rising due to more light leaking
into the scan head.

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7. The electronics are functional, and the cables are connected properly

8. The unit’s amplifier is working, as is the ADC and the USB 2.0 interface on the unit

If the focus tool does not come up, what questions can we ask?
1. Is there power to the unit (Green Power light on and steady?, Orange scan light off,
or on and blinking?)

2. Does the unit move before an error condition is seen? If so, motor is working and
carriage is functioning. If not, several things can be wrong: No connection to PC,
No power to Unit, bad USB cable.

3. Is there a NO DATA ACQUIRED error after the motor comes to rest at the scan
position?

This indicates that the unit is not transmitting data to the PC. Please see Section 7.4
for more information.

7.2 Image Symptoms

7.2.1 Lint in the Scan Path

Symptom: Sharp, white lines, usually only a pixel or two in width and spanning the
length of the entire image.
Cause: Lint or other particulate matter in the scan slot.
Solution: See Section 8.3 for instructions on accessing the scan slot. Once the user has
access to the scan slot, visually inspect the area in and around the scan slot for particulates
and remove them by hand, or with a vacuum if necessary.

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7.2.2 Dust Lines

Symptom: Light, blurred lines across the long axis of the cassette.
Cause: Dust or lint on the mirrors.
Solution: To clean the mirrors, please see Section 8.11 for instructions.

7.2.3 Horizontal Lines in Image

Symptom: Horizonal lines in Images.

Cause: Bump in motion path .
Solution:
1. Ensure that there is no blockage in the cassette scan path.
2. If there is no blockage of the scan path, the user may need to reposition the Caterpil-
lar Brush. Please see Section 8.13 for instructions. If the Caterpillar Brush is worn
out, please contact Technical Support to obtain a replacement brush.
3. If a solution has not been reached, please contact Technical Support.

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7.2.4 Banding Top/Bottom 17” Length

Symptom: Horizontal line in image.

Cause: Unstable power supply / Excessive ambient light / Bad PMT board / PMT
sensor / Bad Galvo
Solution:

1. Ensure that the CR unit is powered via a UPS. Ensure the UPS is not in bypass
mode.

2. Ensure that the ambient room light is no more than 2EV. Turning off or dimming
the room light should be adequate.

3. Unplug the network cable from the computer, then make a test scan to see if the
banding is eliminated.

7.2.5 Up-side Down Cassette

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Symptom: Honeycomb/hexagonal pattern throughout the image.

Cause: Exposing a cassette up-side down.
Solution: First ensure that the cassette is erased, then re-expose the cassette with the
carbon-fiber side facing up, then re-scan.

7.2.6 Grid Lines/Moiré Effect

Symptom: Grid lines/Moiré Effect

Cause: A grid with the wrong LPI, or a misoriented cassette under the grid.
Solution: To alleviate grid lines/ moiré effect, first ensure that the grid being used is 178
LPI. If the grid in use is 178 LPI, then rotate the cassette 90◦ under the grid.

7.2.7 Eraser Offset

Symptom: A gap of white space between the edge of the image and the physical edge of
the cassette after scanning.

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Cause: Eraser offset needs to be increased or decreased.

Solution:

1. Open XSCAN32.

2. Create/edit a patient, then click Save & View.

3. Click the Scan button (if it is a patient with no images, the Scan interface will
automatically open).

4. Click the Settings button, then enter the password earl (case sensitive).

5. Locate the setting for Eraser Offset.

6. The user may need to adjust this setting several times before achieving the desired
result. Expose a couple of cassettes, then scan and adjust the Eraser Offset until the
image is acceptable.

7.2.8 Image Jitter

Symptom: Jittery image.

Cause: Inconsistency in the CR unit’s galvanometer.
Solution: Image jitter issues are not serviceable in the field. Please contact Technical
Support for assistance with image jitter.

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7.2.9 Over Exposure

Symptom: Lines in images / images look more “translucent”– the images lack the proper
contrast and density.
Cause: Over exposure.
Solution: Make an exposure using your current exposure settings. Scan and evaluate
the image. Then, reduce the exposure parameters, expose another plate, then scan and
evaluate the image. Compare the results of both exposures, then adjust the “standard”
exposure accordingly.

7.2.10 Random Imaging Shifting

Symptom: Random Image Shifting.
Cause: Bad USB 2.0 connection.
Solution: Visually inspect the USB 2.0 cable connecting the CR unit to the computer.
Make sure there are no visible cuts, freys or other damage. Move the USB 2.0 cable to a
different USB port on the computer. If the problem persists, try swapping out the USB
2.0 cable for a new one.

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7.3 Hardware Symptoms

7.3.1 Failure to Initialize USB

The Failure to Initalize USB error can be caused by several issues:

1. Make sure the CR unit is powered on.

2. Make sure the USB cable is firmly connected to both the CR unit and PC.

3. Visually inspect the USB cable for cuts or freys. The user may want to swap out the
USB cable to ensure its integrity.

4. Make sure the CR unit is recognized in the Windows Device Manager. Additionally,
make sure the device drivers are properly installed. To do this:

(a) Go to Start → Control Panel → System → Hardware → Device Manager

(b) In the Device Manager, make sure there are no unrecognized USB devices.
(c) In the Universal Serial Bus entry, the user should see an entry for the CR
unit. If there is no entry, or there are yellow question marks in the Device
Manager, please re-install the device drivers. If the user does not have the
original installation CD containing the device drivers, please contact Technical
Support.

7.3.2 No Motor Movement

Symptom: When initiating a scan from the software interface, no sound is heard from
the CR unit.
Cause: Bad fuses, motor controller, cable, or motor.
Solution:

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1. Check the fuses as cover in Section 8.12.

2. If the fuses are not at fault, remove the back cover as covered in Section 8.2, and
check that connectors J1, J2, J3, J4, J5, and J7 are firmly connected to their respective
boards.

WARNING: Do not operate the unit with the covers removed. Laser & LED lights
may cause harm to the operator.

3. If the motor controller light is flashing or solid red, then the motor controller board
will need to be replaced.

7.3.3 Clicking Noise Returning to Home

Symptom: Clicking noise heard from CR unit when returning to the home position.
Cause: At the end of the scan: Eraser offset.
At home position: Fuses / sensor.
Solution: At the end of the scan: Change eraser offset.
At home position: Check fuses as cover in Section 8.12. Check the Power Distribution
board / Move sensor.

7.3.4 Not Finding Home Position

Symptom: The CR unit is not finding the home position.
Cause: Bad fuses, Power Distribution board, or Move sensor.
Solution: Check fuses as cover in Section 8.12. Check the Power Distribution board /
Move sensor.

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7.3.5 Motor Gear/Slide Lines

Symptom: Noises while scanning.
Cause: Bad slide / misaligned motor gear
Solution: Listen for noises while making a test scan. Leave the bay door open and watch
the cassette to see if it bumps or shifts during the scan. If this is the case, the unit will
either need to be realigned or have the slide repaired/replaced. Please contact Technical
Support, as motor gear/slide issues are not serviceable in the field.

7.3.6 Cassette Door Stays Open

Symptom: Carbon fiber door will not stay closed.
Cause: Broken catch.
Solution: A broken catch is not serviceable in the field. Please contact Technical Support
for more information.

7.3.7 Cassette Stuck in CR unit

Symptom: Cassette stuck in CR unit.
Cause: Misloaded cassette / pressure from Caterpillar Brush.
Solution:Power cycle on & off CR unit, then hit Reset in the Scan interface. This should
cause the cassette to come out of the eraser cover. If the problem persists, and it is
verifiable that the cassette is being loaded correctly, then the Brush Bar Brush is putting
too much pressure on the cassette. To fix this, decrease the Stage Velocity by five.

1. Open XSCAN32.

2. Create/edit a patient, then click Save & View.

3. Click the Scan button (if it is a patient with no images, the Scan interface will
automatically open).

4. Click the Settings button, then enter the password earl (case sensitive).

5. Locate the entry for Stage Velocity, then decrease the current number by five.

7.4 Error Message: No Data Acquired

7.4.1 Failure Analysis 1
1. When turning on the CR, see if there is a pop-up message in the lower right hand
corner of the Windows task bar stating “This USB device can perform faster if it is
connected to a hi-speed USB 2.0 port.” If so:

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• make sure the CR is plugged into a USB 2.0 port. Some older PCs only have
USB 1.0 or 1.1 ports. These older variety of USB ports are not sufficient in
speed to acquire data from the CR unit.
• make sure the BIOS does not have any options set for conserving power
(especially on laptops). Sometimes the PC will not run the USB ports at their
full potential to save power. Please consult the PC’s user manual for more
information.
• try unplugging the USB cable from the CR unit and then plugging it back in.
If the message does not appear try to scan. In some instances, turning the CR
unit on with the USB cable plugged in causes Windows to recognize the device
as USB 1.0. In some instances, unplugging and replugging the USB cable can
correct this.
2. After clicking on the scan button, listen for the motor and see if the CR slide moves
at all. If it does not move at all, then the motor controller board may be at fault.
• open the back of the CR unit (see Section 8.2 for instructions) and locate
the motor controller board on the lower left. The motor has cables directly
connected to the board.
• look for either a red or green indicator light on the board. It may be covered
by silicone, which can be removed.
• a green light on the motor controller board indicates that the board is in
working condition, while a red light indicates a faulty board that will need to
be replaced. If the board needs replacement, please contact Technical Support.
3. Check the following:
• check the fuses on the power distribution board (see Section 8.12 for instruc-
tions)
• check that the laser and eraser lights turn on: With the slide away from the
home position, see if the laser turns on (full beam from top to bottom). The
laser beam must also overlap the trigger board behind the long mirror.
• if the laser does not turn on, check if the galvo mirror oscillates.
• if the galvo is on and the laser is not, wiggle the cable coming from the laser
body to see if the laser turns on.
• follow the c able to the laser connector on the PMT board and make sure it is
not loose. Unplug and replug the connector.
Note: the slide must be away from the home position fro the laser to turn on.
• if the galvo does not turn on, check the galvo cables. Wiggle them, then unplug
and replug the connectors.
4. If the galvo does not turn on, the galvo or PMT board may need to be replaced. If
the galvo turns on the but the laser does not, replace or repair the laser

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7.4.2 Failure Analysis 2

Note: Failure possibilities are listed in order or likelihood.

Fault: Laser trigger pulses are not being received by XSCAN32.

Assumptions: In order for the CR unit to arrive at this point:

• The CR unit is powered up and communicating via the USB to the XSCAN32
software.

• Motor movement and magnet/reed switch are most likely functional as RETURN
TO HOME followed by START SCAN commands operate without apparent error.
These commands are executed prior to expecting laser triggers.

Setup:

1. Power off the CR unit.

2. Remove back cover (see Section 8.2 for instructions) and back optical cover (see
step 3 from Section 8.11 for instructions).

3. Switch off PMT board hi-voltage by switching the one red switch on the PMT board
inward, towards the center of the PCBA.

4. Power on the CR unit.

5. Press and hold the two Power Distribution board push-button switches. If all five
Diagnositc LEDs do not brightly illuminate, stop! Possible failures include:

• Power Distribution fuses are blown (see Section 8.12 for instructions)
CAUTION: If fuse(s) are found to be bad and replacement fuse(s) continue to
blow, STOP! A potentially dangerous electrical situation may exit and the CR
unit should be returned to the factory for repair.
• Bad Power Distribution board or cabling.
• Bad +24V Power Supply or cabling
• Bad Quad Power Supply or cabling
• If a fix has not been accomplished by this point, the machine should be returned
to the factory for repair.

6. Turn the slide motor shaft by hand until the slide is observed to be well away from
the HOME position.

Checks:

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1. If the Eraser LEDs do not illuminate, STOP! Possible failures:

• If eraser lights are switch-able, then verify the eraser switch is in the ON
position.
• Power Distribution fuse(s) has blown.
CAUTION: If fuse(s) are found to be bad and replacement fuse(s) continue to
blow, STOP! A potentially dangerous electrical situation may exit and the CR
unit should be returned to the factory for repair.
• Bad Power Distribution board or cabling
• Bad +24V Power Supply or cabling
• Bad Quad Power Supply or cabling
• If a fix has not been accomplished by this point, the machine should be returned
to the factory for repair.

2. If the galvo mirror is not oscillating, STOP! Possible failures:

• Bad PMT board or cabling

• Bad Galvo/Controller or cabling
• Bad Quad Power Supply or cabling
• If a fix has not been accomplished by this point, the machine should be returned
to the factory for repair.

3. If the Laser is not illuminated, STOP! Possible failures:

• If the laser has an external power supply, check to verify that the programmable
power setting is not set too low
• Bad laser, laser/supply combo, or cabling
• Bad PMT board or cabling
• Bad Quad Power Supply or cabling
• If a fix has not been accomplished by this point, the machine should be returned
to the factory for repair.

4. Temporarily place a Post-it or

R similarly light-colored paper behind the Trigger
board. This enables viewing of the laser beam.

5. If the laser beam is not observed to OVERLAP the Trigger board, STOP! Possible
failures:

• Galvo AMP setting too low; try increasing AMP setting

• Bad PMT board or cabling
• Bad Galvanometer/Controller or cabling

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• Beam may require re-alignment. This alignment is accomplished by galvo

adjustment and is beyond the scope of this failure analysis. Please contact
Technical Support for further assistance.
• If a fix has not been accomplished by this point, the machine should be returned
to the factory for repair.

6. If the laser beam does not cross through the center of the trigger sensor, STOP!
Possible failures:

• Bad Trigger board

Note: The Trigger board cable is un-keyed and is therefore prone to miscon-
nection.
• Bad PMT board or cabling, specifically the TILO cable
• Bad Quad Power Supply or cabling

If a fix has not been accomplished by this point, the machine should be returned to the
factory for repair.

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8. Service & Maintenance Procedures

8.1 Removing Front Cover
1. Make sure the CR unit is powered off. Remove the power cord from the unit.

2. Orient the CR unit on its back.

3. Remove four (4) 10-32 x 21 ” truss head screws from the feet.

4. Remove four (4) 6-32 x 38 ” flathead screws from the front cover.

5. Slide the top cover back, then lift the cover off.

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6. Slide the door to the open position.

7. There is a plastic release latch on the underside of the door. Squeeze the latch
towards the feet of the unit to release the door from the door slide, then slide the
rail back, removing it from the door.

8.2 Removing Back Cover

1. Make sure the CR unit is powered off. Remove the power cord from the unit.

2. Remove nine (9) 6-32 x 38 ” flathead undercut screws from the back cover.

3. Gently pull the back cover away from the CR unit.

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8.3 Accessing the Scan Slot

1. Make sure the CR unit is powered off. Remove the power cord from the unit.

2. Orient the CR unit on its back.

3. Remove four (4) 10-32 x 12 ” truss head screws from the feet.

4. Remove four (4) 6-32 x 38 ” flathead screws from the front cover.

5. Slide the top cover back, then lift the cover off.

6. Slide the door to the open position.

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7. There is a plastic release latch on the underside of the door. Squeeze the latch
towards the feet of the unit to release the door from the door slide, then slide the
rail back, removing it from the door.

8. Remove two (2) 6-32 x 14 ” & two (2) 6-32 x 1” truss head from the brush bar cover.

9. The scan slot is located under the brush bar cover.

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8.4 Replacing the PMT Board

1. Make sure the CR unit is powered off. Remove the power cord from the unit.

2. Remove nine (9) 6-32 x 38 ” flathead undercut screws from the back cover.

3. Gently pull the back cover away from the CR unit.

4. Remove two (2) 6-32 x 14 ” truss head and eight (8) 4-40 x 38 ” lock washer and panhead
screws from the back optical cover.

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5. Remove the USB, phone jack and four (4) power connectors from the PMT board.

6. Remove six (6) 4-40 x 12 ” screws from the PMT board.

7. Ease the PMT board from the PMT Tube contacts.
8. The PMT board is now free and can be removed.

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8.5 Removing the Optical/Electrical Module from the Case

1. Make sure the CR unit is powered off. Remove the power cord from the unit.
2. Remove nine (9) 6-32 x 38 ” flathead undercut screws from the back cover.

3. Remove the internal USB connector from its external connection, the power switch
plugs from the main power supply and the eraser power supply.
4. Orient the CR unit on its back.
5. Remove four (4) 10-32 x 12 ” truss head screws from the feet.

6. Remove four (4) 6-32 x 38 ” flathead screws from the front cover.

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7. Slide the top cover back, then lift the cover off.

8. Slide the door to the open position.

9. There is a plastic release latch on the underside of the door. Squeeze the latch
towards the feet of the unit to release the door from the door slide, then slide the
rail back, removing it from the door.

10. Remove two (2) 6-32 x 14 ” & two (2) 6-32 x 1” truss head from the brush bar cover.

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11. Remove eight (8) 10-32 x 21 ”screws from the chasis.

12. With two (2) or more people, lift the module out of the outer shell.

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8.6 Replacing the Motor Controller Board

1. Remove the module from the case, as covered in Section 8.5 on page 53.

2. Using a small flathead screw driver, unscrew the wires from the Motor Controller
board.

3. Remove the phone cord from the Motor Controller board.

4. Using a pair of needle nose pliers, pinch each of the four (4) fasteners, freeing the
Motor Controller board.

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5. Remove the Motor Controller board from the CR unit.

6. Replace the Motor Controller board, then reassemble the CR unit in the reverse
order from taking it apart.

8.7 Replacing the Main Power Supply

1. Remove the module from the case, as covered in Section 8.5 on page 53.

2. Unplug the power connectors from the board.

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3. Unscrew four (4) 6-32 x 38 ” screws from the Main Power Supply.

4. Remove the Main Power Supply from the CR unit.

5. Replace the Main Power Supply, then reassemble the CR unit in the reverse order
from taking it apart.

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8.8 Replacing the Galvo Controller Board

1. Remove the module from the case, as covered in Section 8.5 on page 53.

2. Remove the connectors from the board.

3. Remove two (2) Allen bolts and nuts.

4. Remove two (2) screws and nuts.

5. Remove the Galvo Controller board from the CR unit.

6. Replace the Galvo Controller board, then reassemble the CR unit in the reverse
order from taking it apart.

8.9 Replacing the Power Distribution Board

1. Remove the module from the case, as covered in Section 8.5 on page 53.

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2. Remove all of the connectors from the Power Distribution board (cut the zip ties
holding the cables in place if necessary).

3. Remove four (4) 6-32 x 38 ” screws, washer, and lock washer from the Power Distri-
bution board.

4. Remove the Power Distribution board from the CR unit.

5. Replace the Power Distribution board, then reassemble the CR unit in the reverse
order from taking it apart.

8.10 Cleaning the Fan Filter

1. With a small, flathead screwdriver, gently pry the fan filter housing away from the
machine. It should pop off with minimal force.

2. Remove the fan filter.

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3. To clean the filter, wash throughly in warm water, then air dry the filter over night.

8.11 Cleaning the Mirrors

1. Make sure the CR unit is powered off. Remove the power cord from the unit.

2. Remove the back cover, as covered in Section 8.2.

3. Remove two (2) 6-32 x 14 ” truss head and eight (8) 4-40 x 38 ” lock washer and panhead
screws from the back optical cover.

4. Locate the mirrors.

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5. Apply the glass cleaner on the soft, lint-free tissue. Do not put cleaner directly on
the mirrors. Clean the mirrors in a circular motion and do not apply much force.
Use a flashlight to make sure that there are no dust particles or smearing residue on
mirrors.

8.12 Checking the Fuses

8.12.1 Power Fuses
1. Make sure the CR unit is powered off. Remove the power cord from the unit.

2. With a small screwdriver, gently pry off the protective flap.

3. Gently removed the fuse housing.

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4. The fuses are located on the back of the fuse housing.

5. The fuses are 3A/250V.

8.12.2 Power Distribution Board Fuses

1. Make sure the CR unit is powered off. Remove the power cord from the unit.

2. Remove the front cover, as covered in Section 8.1.

3. There are five fuses located on the power distribution board. Remove & check
them:

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8.13 Changing the Brushes

1. Make sure the CR unit is powered off. Remove the power cord from the unit.

2. Remove the front cover, as covered in Section 8.1.

3. Remove two (2) 6-32 x 14 ” & two (2) 6-32 x 1” truss head from the brush bar cover.

4. Apply masking or gaffers tape over the scan slot to minimize dust entry.

5. The user now has access to the Caterpillar and Brush Bar Brushes.

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8.13.1 Caterpillar Brush

The Caterpillar brush is located next to the eraser lights.

1. To remove the Caterpillar Brush, ensure that there are no brush clips holding it
down.
2. If there are brush clips, remove the four (4) 4-40 x 38 ” or 12 ” (depending on the CR
model) panhead screws from the light bar.

3. Pull the Caterpillar Brush from the light bar.

4. Using a finger, rub away any extra adhesive from the light bar.
5. Remove the double-sided tape from the new Caterpillar Brush.
6. Apply the new Caterpillar Brush in the same position as the old one. Ensure that
the brush goes on smooth, as bumps in the brush may cause cassette bumps.

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8.13.2 Brush Bar Brushes

The Brush Bar Brushes are located on the back side of the brush bar.
1. To remove the Brush Bar Brushes, remove six (6) 6-32 x 14 ” flathead undercut screws
from the Brush Bar.

2. Slide the old brush out of its holder.

3. Trim any stray brush hairs from the new brush using a razor blade.

4. Slide the new brush into the holder.

5. Apply a dab of E-6000 adhesive to the non-bent side of the brush.

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6. Screw the brush holder back into the Brush Bar.

8.14 Cassette Cleaning

CAUTION: At no time should abrasive cleaners or chemicals be used to clean the cassette
or plate.

8.14.1 Cleaning the Outside of the Cassette

1. Apply Simple Green to a clean, lint-free cloth.

2. Wipe down the cassette covers thoroughly.

3. Allow the cassette to air dry.

8.14.2 Cleaning the IP Plate

1. With a finger, press the cassette catch located on the bottom rail on the cassette.
This will release the carbon fiber door from the cassette.

2. Examine the imaging plate for dust or particulates.

3. Using iCRco plate cleaner, apply the plate cleaner to a clean, lint-free cloth.

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Note: If iCRco Plate Cleaner is not available, please contact Technical Support at
1-310-921-9559 to obtain more.

4. Gently wipe down the imaging plate with the clean, lint-free cloth.

5. Allow the plate to air dry before sliding the carbon fiber door back into place.

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