1,2, 5 Year Service and maintenance package completed on Carrier. All reducers repacked with Molub-Alloy 777-1 ES grease. Main drive train and all bearings relubricated. No issues. Operational.

 Jack 7R pulled apart and inspected for deficiencies, all parts deemed to be in working order, jack was rebuilt and lubricated with Molub-Alloy 777-1 ES. Jack is deemed fully operational for next swap. 

  Jack 7L pulled apart and inspected for deficiencies, alignment monitored with prussian blue and deemed acceptable wear. All parts in working order, jack was rebuilt and lubricated with Molub-Alloy 777-1 ES. Fully operational for next shutdown period swap.

The rope and pulley system that is used to raise the festooning rail across the vault shield door has been re-routed. It now makes use of all three pulleys and is easier to raise and lower without interference. 

 We removed the left bushing that is around the air cylinder on the festooning rail, right outside the cyclotron. It was cracked. Will need to replace next year when the vault door opens again.

 The vault shield door has been closed and seal inflated. The operation was performed with no issue.

During the 2023 shutdown outrigger 1 failed. While performing the HE Probe removal we found that the outrigger could only travel vertically about one inch in each direction.

Upon further inspection we found that the linear bearings had been pulled off the ball screws. And 2/3 of the ball screws had been bent. Additionally one of the linear bearings broke and was missing some of the balls, the parts were later found inside the tank.

The event that caused the failure is unknown, but one guess is that while the outrigger was in the home position the shoulder joint was opened before the elbow joint.

The outrigger was repaired on March 21st, using parts from the old outrigger. After the shutdown the parts should be replaced again with new parts. Additionally it was observed that the linear bearings are quite old so they should be replaced on outrigger 2 also.  See photo for details on which parts where repairs or replaced.

Update 2023-09-01: Both outrigger 1 and 2 had the linear bearings replaced with brand new bearings. Note that the same brand and part number was used (Thomson super-12-OPN ball bushing), however the quality of the new ones seems to have decreased and likely will not last as long as the previous ones. It is recommended that we review if they need to be replaced again in 5-10 years. 

 Damaged "H" channel removed from the first festooning car, and spare channel was put in place.

Note: it seems like the aluminum channel is not strong enough for the forces its being put under, and is resulting in deformations (See picture "Festooning car H channel deformation"). We suspect this has happened in the past, notches were cut out where the deformation likely occurred and then the part was flipped and put back in place. There was two notches on the bottom face of the part we took out, and there was already one on the spare part. (see picture "Festooning car H channel bottom face"). A new channel needs to be designed out of steel for the first car to prevent this from reoccurring.

 All the bearings on both the upper and lower wheel were replace to see if it will improve the accuracy of the orbital position reading. See drawing SK-2489 for list of bearings used.

The encoder was also replaced to match the style used elsewhere.

Remote Handing is ready for January, 8 2018 Cyclotron lid up. Elevating system service has been completed.

A Cyclotron Lid raise was attempted on Monday, January 8 at 12:00, however this attempt was aborted after lifting the lid several millimeters due the motor
brake on Station #9 that would not release properly. After troubleshooting the elevating system for several hours, motor brake wires were disconnected from
the motor terminal block at the station and pulled through the vertical conduit down the B2 level below the Cyclotron for further inspection. The inspection
showed severe damage to the wire insulation and conductor over an 18" interval, which corresponded to the position directly across the mid-plane of the
cyclotron. New wires were spliced to the existing wires at the bottom of the vertical conduit section, which were run through the conduit and reconnected to
the motor terminal block.

The motor drive wires on Station #9 were also removed for inspection, which revealed major damage to the wire insulation over the same 18" interval;
however, the conductor remained intact and was covered in electrical tape and re-run through the conduit vertical and reconnected to the terminal block. The
elevating system was then tested and the motor brake on Station #9 released as expected.

The Cyclotron Lid was successfully raised on Monday, January 8 at 20:00. The initial station readings are shown below:

00075 - Master
00045 - Station #1
00044 - Station #2
00042 - Station #3
00045 - Station #4
00044 - Station #5 
00044 - Station #6
00045 - Station #7
00044 - Station #8
00044 - Station #9
00047 - Station #10
00048 - Station #11
00045 - Station #12

The final lid-up station readings are shown below:

47422 - Master
- Station #1
- Station #2
- Station #3
- Station #4
- Station #5 
- Station #6
- Station #7
- Station #8
- Station #9
- Station #10
- Station #11
- Station #12


The Cyclotron Lid was lowered on Tuesday, February 20, between 11:30 and 12:00. The final station readings are shown below:

00081 - Master
00086 - Station #1
00089 - Station #2
00054 - Station #3
00016 - Station #4
00087 - Station #5
00087 - Station #6
00085 - Station #7
00083 - Station #8
00086 - Station #9
00087 - Station #10
00089 - Station #11
00088 - Station #12

While lowering the lid, the following observations were made:

- The left High Field gear reducer on Station #1 made noise intermittently during the middle of the lid lowering operation
- The right High Field gear reducer on Station #2 made noise intermittently during the end of the lid lowering operation
- The right High Field gear reducer on Station #11 made noise intermittently during the beginning of the lid lowering operation

Outrigger #1 and #2 have had their controls system overhauled as part of the O503 project. The previous controls enclosure and the elements have been replaced with a new aluminum enclosure which contains DIN rail relays, a 5V power supply, and a +-12V Power supply. The new centrepost slave PLC unit handles the control logic of OR1, OR2, the Bridge and is connected to the main PLC in the control room through Ethernet. Both outriggers were tested individually.

Systems Tested:

Vertical Drive - Up, Down, 5V Position (Inches) Potentiometer

Radial Drive - In, Out, Encoder (Inches) 

Shoulder Drive - Home, Out, 5V Position Potentiometer (Deg) 

Elbow Drive - Home, Out, 5V Position Potentiometer (Deg) 

Wrist Drive - Pan Left, Pan Right, Tilt Up, Tilt Down, 5V Position Potentiometer (Deg)

Camera - Zoom In, Zoom Out, Focus Near, Focus Far

Testing Methodology:

We used the control panel which the Outrigger operator will be using during shutdown to confirm that the buttons translate to correct movements of each individual system. Direction control for the motors is done with relay switching of 24V to flip the polarity applied to the motors. +-12V is used for the zoom focus control of the HCZ-6320N camera. Correct movements was observed for both outriggers.

Position feedback was calibrated by adjusting the potentiometer's voltage to 2.5V at the mid point and spanned from 0V at low end to 5V at high end. Correct positions for both outriggers was observed on the HMI screen.

Next Steps

Testing the bridge orbit drive, orbit encoder, centrepost camera, centrepost light, both OR1 and OR2 simultaneously.

 Service bridge, Outrigger #1, and Outrigger #2 have had the controls system migrated to PLC controls. The 5069-AENTR control unit is located at the centrepost and will be mounted there after wiring is cleaned up. Preliminary testing consisted of operators simulating a shutdown task was performed today and was a success. Minor adjustments to the encoder logic will be made before the commissioning test. The follow tests were done: 

PLC box:

Check Relays toggling over correctly. 

OR1:

Radial In/Out & HMI Feedback Accurate

Vertical Up/Down & HMI Feedback Accurate

Shoulder Home/Out & HMI Feedback Accurate

Elbow Home/Out & HMI Feedback Accurate

Pan CW/CCW & HMI Feedback Accurate

Tilt Up/Down & HMI Feedback Accurate

Cameras Zoom/Focus

4 movements at once

Random camera restart noted (could be tied to grounding issue. will further investigate)

OR2:

Radial In/Out & HMI Feedback Accurate (Encoder Swap direction)

Vertical Up/Down & HMI Feedback Accurate

Shoulder Home/Out & HMI Feedback Accurate

Elbow Home/Out & HMI Feedback Accurate

Pan CW/CCW & HMI Feedback Accurate

Tilt Up/Down & HMI Feedback Accurate

Cameras Zoom/Focus

4 movements at once

Bridge:

Orbital Motor & Encoder HMI Feedback (Orbital Motor controls using Outrigger CP only active when ORs not selected) (set range to 0 to 360 same direction)

Centerpost Camera PTZF

Light

Speed Control

Vid Trolley:

Test operating video trolley with bridge controls and outriggers

Top/Bot LED

Implement radial speed control using pot

The Cyclotron Elevating System planned maintenance work this year was performed on Jack Station #3, #8, #9, and #10.

Start date: January 10, 2017
End date: January 23, 2017

Lockout procedure
 - Performed electrical lockout of Cyclotron Elevating System

Jack Station #10
 - Disconnected power from electric motor
 - Noted initial station counter reading and yoke gap
 - Removed limit switch
 - Removed complete spare set #14 from station (2x Duff-Norton screw jacks, 2x Highfield gear reducers, and 1x electric 
motor)
 - Installed complete original set #10 onto station (2x screw jacks, 2x Highfield gear reducers, and 1x electric motor)
 - Installed limit switch
 - Set yoke gap and station counter reading according to initial values
 - Reconnected power to electric motor


Jack Station #9
 - Noted initial station counter reading and yoke gap
 - Removed 2x screw jacks from original set #9 for early inspection
 - Lifted 2x screw jacks to RH active shop
 - Broke-out worm-screw from screw jack #9R
 - Inspected worm-screw and worm-gear surfaces: observed discoloured grease, similar to that found while servicing this 
screw 
jack in 
September 
2015
 - Decided not to reinstall screw jacks from original set #9 so that they can be serviced again after shutdown
 - Installed 2x screw jacks from spare set #14
 - Set yoke gap and station counter reading according to initial values

Jack Station #8
 - Disconnected power from electric motor
 - Noted initial station counter reading and yoke gap
 - Removed complete original set #8 from station (2x screw jacks, 2x Highfield gear reducers, and 1x electric motor)
 - Installed complete spare set #13 onto station (2x Duff-Norton screw jacks, 2x Highfield gear reducers, and 1x electric 
motor)
 - Set yoke gap and station counter reading according to initial values
 - Reconnected power to electric motor
 - Lifted complete original set #8 to RH active shop for inspection and servicing
 - Inspected and serviced upper bearing: ok

Jack Station #3
 - Unable to remove screw jacks from original set #3 for inspection and servicing since there no remaining spare screw 
jacks 
available
 - Decided to postpone removal of complete original set #3 until January 2018
 - Inspected and serviced upper bearing: ok

Pre lid-up preparations
 - Tested Jack Station #8 and #10 to verify correct motor phasing
 - Indexed all jack stations to 0.25"

Performed continuity test at Cyclotron center post with RH and Operations group members using the service bridge, 
tool trolley, and probe attachment on 2017-03-03.

Lower tank:
Quad #1: All six plates PASSED.
Quad #2: All eight plates PASSED.
Quad #3: All six plates PASSED.
Quad #4: All eight plates PASSED.

Upper tank:
Quad #1: Had some repeat-ability challenges with all six screw-heads/wires. Retest required.
Quad #2: All eight plates PASSED.
Quad #3: All six screw-heads PASSED.
Quad #4: All eight plates FAILED. Retest required.

Performed extra continuity test at Cyclotron center post with RH and Operations on 2017-03-06: achieved a 
successful test on all upper quad #1 and #4 screws/plates. One unconfirmed explanation for the successful retest 
is that the multimeter cable was firmly grounded against the computer monitor rack in the RH service bridge 
control room (see attached picture), which may not have been the case during the initial test.

The seven copper blockers were removed from the Cyclotron tank by the RH group using the service bridge, lift 
trolley, and attached checklist on 2017-01-30.

The monitor box (NE/SW-5/8/10) and series 200, 400, 500, 600, and 700 shields were installed in the Cyclotron 
tank by the RH group using the service bridge, lift trolley, and attached checklist on 2017-01-31 and 2017-02-
01.

The seven port hole covers were installed in the Cyclotron tank by the RH group using the service bridge, tool 
trolley, and vacuum unit on 2017-01-02.

The two ladders were installed in the Cyclotron tank by the RH group using the service bridge, lift trolley, 
and ladder attachment on 2017-01-02.

=================================================================================================================

The monitor box (NE/SW-5/8/10) and series 200, 400, 500, 600, and 700 shields were removed from the Cyclotron 
tank by the RH group using the service bridge, lift trolley, and attached checklist on 2017-03-07 and 2017-03-
08.

The seven port hole covers were removed and the Cyclotron tank seal was cleaned by the RH group using the 
service bridge, tool trolley, and vacuum unit on 2017-03-09.

The two ladders were removed from the Cyclotron tank by the RH group using the service bridge, lift trolley, 
and ladder attachment on 2017-03-09.

The seven copper blockers were installed in the Cyclotron tank by the RH group using the service bridge, lift 
trolley, and attached checklist on 2017-03-09.

The start of shutdown photo and video survey was performed in the Cyclotron tank by the RH group using the 
service bridge and video trolley on 2017-01-27 (see attached pictures).
 
The end of shutdown photo and video survey was performed in the Cyclotron tank by the RH, Probes, and 
Operations group using the service bridge and video trolley on 2017-03-08 and observed the following:
- Observed a small piece of melted plastic and wire near the 180° lower tank D-gap; this item has been present 
since the 2016 shutdown based on photographic evidence (see attached picture).
- Observed a large strip of paper on Q2L2, close to where the ladders were placed beside the CP (see attached 
picture). 
- Observed a bent periscope alignment target near Q4U7 (see attached picture).

A proposed guideline for conducting future video surveys is attached (via djacks@triumf.ca and genge@triumf.ca).

The unshielded radiation survey was performed in the Cyclotron tank by the RH group using the service bridge, 
tool trolley, and radiation survey attachment on 2017-01-30 (see attached plot).

The shielded radiation survey was performed in the Cyclotron tank by the RH group using the service bridge, 
tool trolley, and radiation survey attachment on 2017-02-02 (see attached plot).

A obsolete version of the radiation survey procedure (from Don Jackson) that needs revising and the MATLAB code 
for generating a radiation survey map (from Maxim Kinakin) is attached.

A simulated removal of the LE2 Probe from the Cyclotron tank was performed by the RH and Probes group using the 
service bridge, upper resonator trolley, LE probe attachment, and the (soon to be) attached LE Probe removal 
procedure on 2017-02-23.