Two small (approx. 5 cm across) puddles of green fluid were discovered on the floor, directly below the crane trolley.  The hook block was lowered and inspected.  No fluid found on hook block.
The plant group (Neil Wong) was notified and asked to schedule an inspection when the maintenance crew is on site to inspect the ISAC target hall crane.

The crane bridge and trolley were moved to another position on Friday evening and parked over the weekend.  The floor directly below the crane trolley was inspected on Monday morning.  Three very small (1-3cm diameter) puddles of green fluid were found.

On Tuesday, February 14th I finished modifying Jason's boxes for the remote crane tests by adding shelves to mount cameras... Apart from given the edges a quick sanding (so no one gets slivers)...which I will try and do tomorrow.

On March 29, 2017, a 9 tonne steel shield block was transferred from the ARIEL Target Pit and placed into a 
wood container on the Target Hall B1 level with the overhead crane main hoist in Local Mode without incident. 
Afterwards, the overhead crane was switched into Test Mode (which is the same as Remote Mode but without the 
Target Hall interlocked) and an attempt was made to transfer the shield block from the wood container on the B1 
level to a wood container in the Target Pit remotely with the main hoist. At 11:51:09, after lifting the shield 
block ~1 m above the B1 level, a "136. Main Hoist West Drum South Motor Drive Fault (900 VFD)" alarm pop-up was 
shown on the overhead crane HMI in the crane control room which disabled the controls on the remote console. 
The reset button on the remote console was pressed and the remote lifting operation was resumed briefly until 
the same fault occurred at 11:51:42 and the reset button was pushed once again. While attempting to lower the 
shield block back down to the ground this fault-reset sequence reoccurred at 11:57:25, 11:58:16, 11:58:28, 
11:58:43, 11:59:27, and 12:00:27, at which point the remote crane operation was aborted and the shield block 
was lowered down to the Target Pit floor with the main hoist in Local Mode, without incident. The Test Mode 
faults did not appear to depend upon the speed/acceleration of the lift, nor did they appear to be spaced apart 
by a fixed time interval. Upon closer inspection of the alarm history screen in the HMI (shown below) and the 
exported alarm log (attached below), almost every time the fault #136 occurred, the following three additional 
faults were logged simultaneously in the alarm history (but were not displayed as a pop-up on the main HMI 
screen):
"103. Main Hoist East Drum North Motor Drive Fault (700 VFD)" 
"104. Main Hoist East Drum South Motor Drive Fault (800 VFD)" 
"135. Main Hoist West Drum North Motor Drive Fault (1000 VFD)" 

On March 31, 2017, the overhead crane main hoist was operated once again in Test Mode; however, no load was 
connected to the hook block to determine if the faults that occurred two days earlier could depend on the load. 
The main hoist hook block was remotely lowered ~3 m below the upper 'home' position, and then remotely raised 
as high as possible to function test the upper limit switch in remote mode; at 14:21:05 immediately after 
initiating the 'hoist up' motion, the same four faults occurred simultaneously. This incident shows that these 
specific faults do not depend on what load is connected to the hook block. Note: the crane position data from 
March 31 is attached below, however the times shown are 1 hour fast due a DST adjustment error.

Follow up with the crane supplier, COH, is required to obtain a index and troubleshooting guide for these (and 
all other) fault codes.

2017-04-06 update: Sylvain Raymond of COH has been assigned to resolve these crane faults by Maxime Dubé-Blanchet 
of COH.

 Powered down ARIEL Target Hall Crane today by switching off main power switch on B1 level in preparation for site-wide BC Hydro power outage on Dec. 27-29.

The non-existent safety limit switch for the target hall door which prevents remote motion has been bypassed in the crane PLC control panel to allow for remote operation of the crane. This will be un-bypassed when a switch is installed. Specifically, a jumper was placed from terminal 18001 to 20121 and 20141 which will enable the hall lock safety relays 2012SR and 2014SR. The crane is currently operational in both local and remote mode.

An issue was observed in which the North Aux hoist failed to travel West when commanded to, but the East motion was functioning. The North Aux hoist Trolley was stuck in a position up against the East wall.

Present during troubleshooting: Adam N, Maico D, Tom K, Allon M, Travis C

After troubleshooting, it was determined that:

• There were no fault messages on the HMI display relating to this issue
• The HMI indicated "Bridge Not in North Limit and/or Auxiliary Trolley North Not in East or West Limit" - the Bridge was not in the north limit as described, and this message implies the PLC thought the North Aux hoist was somewhere along the middle of its travel
• The West run signal was reaching the remote receiver from the crane pendant
• The West and East run signals were correctly reaching their respective input pins on the VFD (DI1, DI2)... upon swapping wires and commanding it to run East, the West direction still did not function
• The VFD was displaying the correct output frequency information on its display when commanded to run East, but not west
• The limit switch was not related to this issue

Upon swapping out the VFD with the working one from the South Aux hoist, the North Aux hoist Trolley was able to move both East and West, as normal. It was therefore determined that the VFD had failed and must be replaced.

Current state of system as of July 3, 2020:

• The North Aux hoist is fully functioning (contains VFD from South one)
• The South Aux hoist is disabled (no VFD, breakers shut off)
• The North Aux hoist limit switch flag has been temporarily bypassed to allow for crane work in the target hall (not a safety issue - extended bumpers are installed and the regular bridge limit switches are functioning normally... this is only to allow the bridge to run its full length of travel when the North Aux hoist is at its fully East position)

Next steps:

• Adam Newsome requested quote for replacement drive (Delta Electronics TDN007E1100WM0) - will advise when replacement arrives
• Install replacement drive into South Aux hoist upon arrival (note: check EMC level modification)
• Verify entire system functioning as normal
• Reinstall North Aux hoist limit switch flag

See E-Log 44 for details on North Aux Hoist failure.

A replacement VFD was ordered by Adam Newsome and installed by Tom Kauss.

Adam and Tom replaced the VFD in the South Aux hoist (which had been relocated to the North Aux hoist). The original braking resistor was used. No functionality changes to the system.

Both Aux hoists were tested: E/W travel, up/down travel. Each hoist is functioning correctly. E/W speeds were compared between the two hoists and found to be the same (~14 Hz for slow speed, ~95 Hz for fast speed).

The replacement job is complete and the issue outlined in E-Log 44 is resolved, although the original cause for failure has not been determined.

Current state of system as of Sept 9, 2020:

• The North Aux hoist is fully functioning (contains original VFD from South one)
• The South Aux hoist is fully functioning (contains newly replaced VFD with original braking resistor)
• The North Aux hoist limit switch flag has been temporarily bypassed to allow for crane work in the target hall (not a safety issue - extended bumpers are installed and the regular bridge limit switches are functioning normally... this is only to allow the bridge to run its full length of travel when the North Aux hoist is at its fully East position)

Next steps:

• Reinstall North Aux hoist limit switch flag (TBD when Target Hall installation work is done)

A fault occurred which presented as "114. Main Hoist Cable Broken (3200PX)". This occurred when a SEG block was suspended approximately 1 m off the ground.

Upon inspection, it was determined that the cable was in fact not broken, but wrapped around itself. There are no guides, and it is possible for the cable to double wrap if loaded in an usual fashion. This condition triggered the "Hoist Rocker Switch 1" sensor, 3200PX. The sensor is not visible or accessible from ground level, and could not be inspected, but it was confirmed that there was no 24 VDC PLC input at 30000EA:I.Data[7].0, as would be expected under normal operating conditions.

To rectify the issue:

• The sensor was bypassed in the control panel by connecting wire 32001 directly to 24 VDC after confirming that there would be no adverse affects from doing this.
• With careful supervision, the load was lowered, while watching the cabling.
• The load was removed from the crane.
• The hoist was then lowered to its extreme lower limit, and the cable unwrapped itself naturally as it was being lowered.
• The sensor bypass was removed.
• The sensor began functioning normally again when the wrapping issue was resolved.
• The hoist was raised and lowered multiple times to confirm the cable wrapping issue was no longer present.

The crane is returned to its normally functioning state. Operators will keep a lookout for any more issues relating to the hoist cable. The crane will be inspected on Sept. 22, 2021.

The bridge motion was slowed due to encoder homing issue. It is likely that the problem which occurred yesterday caused an velocity fault (mismatch between encoder speed and commanded speed), which unlatches the homing status for the bridge motion axis.

When the bridge was in the southmost position (bumper pressed against wall), the position readback was: 0.353 m, encoder count = 5164003.

The bridge was moved to the "zero position" as indicated on the remote display - the tick was aligned with the zero.

The encoder was homed at this position. The home position readback was: 0.356 m, encoder count = 5164447. Note that this position is in alignment with the measuring tape zero mark, not pressed up against the wall.

The bridge was run to its full extreme positions in either direction to confirm proper slowdown and stopping behaviour. It appears to be functioning normally again.

The load cell which is located on the crane itself to display the load to operators was reported not working during the week of November 15. It is planned to investigate on Nov. 25 and this e-log will be updated with the status.

Edit (2022-02-02): the load cell is functioning again. No changes were made.

Edit: as of May 30, 2022, the modification has been reversed, and the crane is functioning normally as per the manufacturer's limits. 

Modifications have been made to the crane to allow for the South Aux Hoist to reach closer to the South wall during the ARIEL Hot Cell installation period. These modifications are temporary, and were considered to be a safer and simpler alternative to the modification proposed by the hot cell contractor workers, which involved installing a sort of come-along on the wall and pulling the hoist closer to obtain the desired reach. The following modifications were made:

1. Removal of the bumpers on the south side (T. Kauss). There are no bumpers on the South side of the crane’s bridge currently.

2. Modification of the PLC program to reduce the software limit by approximately 4 inches (A. Newsome). The previous soft limit was set at 0.36 m and it was reduced to 0.26 m (~3.9 inch reduction).

 These changes have been tested – the crane stops in the expected position. However, it is very close to the wall now. If you are using the crane anywhere near the South wall: exercise extreme caution. The crane automatically slows down when approaching the South wall, and there is plenty of time for the operator to react and further slow the motion by only holding the joystick down at about 20% speed. I strongly recommend operating at about 20% speed when close to the wall (on top of the automatic speed reduction I mentioned).  

• These changes are based on Work Permit A2022-01-06-1
• Changes have been noted in the crane’s logbook

See attached screenshot of PLC program indicating that the new limit has been reached.

Contact me (Adam Newsome) for more detailed information.

An issue was observed in which the North Aux hoist failed to travel West when commanded to, but the East motion was functioning. The up/down motion was also functioning. The North Aux Hoist Trolley failed during regular usage, seemingly randomly, when it was about 70% towards the West end of travel. Note that the West motion VFD inside the North Aux Hoist is the one previously taken from the South Aux Hoist (the same issue with the North Aux Hoist was observed last year, and the VFD was swapped, and a new one was installed in the South Aux Hoist).

A replacement VFD (Delta TDN007E1100WM0) will be ordered and installed, and this e-log will be updated.

Edit 2022-03-15: the replacement VFD has been installed and the system is operational. See e-log 52.

Naimat Khan noticed after using the crane that some grease dropped onto a spreader bar, and believes it is a leak from the main hoist (see attached photo). The hoist should be inspected.

Edit: Dan McDonald notes that this has been observed since the crane was installed and is likely due to excess grease dropping out. Perhaps not a major concern.

The North Aux Hoist VFD which had failed (e-log 50) was replaced today by Tom Kauss and Adam Newsome on Work Permit A2022-03-15-1.

The hoist's motions were all tested - it is functioning normally again.