Update 2024-09-12: C. Fisher confirms this is actually normal behaviour. The Y-axis motion is inhibited when X and Z are in a certain configuration, which was true when the manipulator was mounted on the wall in storage position. Non-issue. A note about this has been made in the operator manual.

It was observed today that for the spare manipulator (Model N, Serial 9351), the Y-axis motion was not functioning. X motion and Z motion are functioning as expected. Note that the Y-axis linear actuator was recently replaced and successfully tested and has not been used since the replacement (see e-log 2422).

The following information was determined from troubleshooting:

• X motion functioning correctly
• Z motion functioning correctly
• Y motion selection functioning correctly - the indicator light on the operator control box lights up to confirm Y is selected, and the relay on the main control board which selects the Y axis toggles, as expected
• Y motion motor contactors do not function as expected when toggling in either direction. Note that these contactors are shared in common with the other two motion axes, so they are functioning correctly and presumably the motor controller itself is as well, since the other axes work.
• Most likely, because of the above reasons, there is an issue with the inhibit signal that is specific to the Y axis. The inhibit signal which runs from the main control board to the motor control board is shared in common with all motion axes (same for the two direction select signals). It is suspected (not yet confirmed), that the microcontroller is not outputting the inhibit signal as it should be. This is not due to a limit switch related issue because the Y axis does not have limits. Troubleshooting this has been difficult because the schematics do not show the full extent of the circuitry.

Further troubleshooting steps:

1. Check inhibit signal functionality - is it working for Y axis?
2. Check direction control signal functionality - are they working for Y axis?
3. Swap motor select wires to "trick" the microcontroller into thinking it is running a different motor, to further isolate the issue.
4. If required, swap the entire main control board with another manipulator's, to see if the issue is related to the circuitry which is not described in the schematics.

At the time, this issue is not deemed critical because this is a spare unit.

On Friday, September 6, 2024 Model 'N' remote arm #9352 was removed from the NHC right side installed position to investigate  an ongoing issue with the tong motion circuit (no motion on the remote side when handle on operator side operated).

Inspection revealed that the tong cable on this arm have hopped its cable drum and rapped around the shaft of the cable drum. As well, the tong cable had hopped a lower pulley and was jammed between the pulley and casting of the pulley housing. These issues were corrected and arm#9352 was reinstalled onto the right hand position. This repair resolved an ongoing tong motion system stemming from November 2023 described below.

initial tong motion problem from November 2023 when the tong system jammed, operator side arm #9763, remote arm #9342.

Remote arm #9342 was removed and replaced with arm #9352 as it was suspected there was a hopped cable on #9342. Upon removal it was confirmed the tong cable on remote arm #9342 had indeed hopped the pulley. After installation of the "spare" remote arm #9352 that hAd not been installed since previous servicing and should have been completely operational, it was found the tong system still did not work properly.

Upon thorough inspection of operator arm # 9763 it was found that the tong cable was prematurely reaching the end of its travel on its drum causing the inability to activate the circuit. The tong cable was reset on its drum as per manufacture's specs with one full cable rap on the drum and one full pretension wrap of the tong drum spring.

Although this resolved part of the problem and allowed a full squeeze of the operator handle it did not result in transfer of motion through the system to the remote end.

Further investigation continued, separating the operator side arm from the seal tube and testing the seal tube and operator side arm independently. Both systems worked fine independently, pointing to a potential problem between the seal tube and spring loaded coupler on the remote arm.

Remote arm #9352 was removed and couplers visually inspected and end of seal tube on the hot side was inspected and found that the pin in the end of the shaft on the tong circuit was not installed symmetrically which could cause uneven pressure on the spring loaded coupler of the remote arm. This pin was adjusted and all pins on the hot side of the seal tube were dimpled and loctite applied as a precautionary measure.

This still did not remedy the tong motion problem. These led to the September 6, 2024 removal and repair of remote arm #9352. This arm had previously been serviced by a CRL technician in December of 2017 and had not been installed or used since and should have been in operational status. It is still not clear why it was not.

Model N remote arm serial #9342 tong cable has been un-jammed from between pulley 3D (see picture) and casting (this is an ongoing issue with #9342 and 9352) and cable restrung and exercised to check motion. Tong system is now functional but exhibits excessive slack. Next step will be to check tension of the elevation/twist cables and adjust the pulley block if required (this pulley block houses both the elevation twist cable pulleys and the tong cable pulley 3D which is the site of the persistent cable hop)...I suspect adjusting the tension here will at least slightly improve the slack. In addition I will also investigate repositioning the tong drum screws (the procedure used to adjust the tong opening).

2 broken lights of NHC were replaced in Target Hall. see pics attached.

On March 27 remote end 9342 was installed on the west position (right hand as viewed by operator) and arm 9764 removed and moved to anteroom.

Previous to this installation, arm 9342 received tensioning of the elevation twist pulley block and tightening of the tong cable opening via the tong cable drum. Tong opening was reduced to roughly 2" to achieve tension in the tong cable such that slack upon release of the system was reduced and tong cable didn't hop pulley in elevation/twist pulley block (this 2"opening is not enough to grasp the air ratchet but is suff. for holding a target...right manip will have to hold the air tool for now. It is also notable when dealing with the tong cable system that slack can cause the tong cable to hop off the secondary pulley in the wrist joint (where two cables run through a secondary pulley that has no retention feature).

Notable during this repair was the fact the the lock-down set screws on the elevation/twist pulley block were missing. These lock down the tensioning screws once the block has been tensioned. New set screws were installed after elevation twist cables were tensioned to their nominal value of 15 in lbs.

It is my recommendation that, when the spare remote arm is fixed and there is a window that this arm come back out and the tong cable be replaced (we have 6 on hand).

Tong cable on remote arm 9**4 has be relocated onto its pulleys and tong opening adjusted at the tong cable drum by changing the position of the tong cable screws by two positions (tightened/closed) such that the air tool will fit in the tong and some of the slack in the tong system has been taking up.

An attempt was made to also adjust the elevation twist pulley block which would also aid in taking up slack in the tong system however, the elevation twist pulley block was already and the end of its adjustment. Elevation twist cables are measuring 10 in lbs, the nominal value that they should be at is 15.

Tong system has been cycled multiple times and the tong cable itself looks good. This arm should be good for service however, I recommend a new pulley block be ordered and the new one dimensional compared to the existing. If they are the same we may consider shortening the new pulley block to achieve a window for tensioning, after which I would recommend the pulley blocks be swapped...swapping should only take place after 9342 has had the tong cable replaced and we can be more confident in its operational state, or in the 2026 shutdown in allowed.

TM4 was moved from Safe Module Parking to the North Hot Cell today.

 TM4 with new target UCx#48 installed was E/L checked on the top of NHC, see attachment uploaded with pls.

C. Fisher, A. Schmidt, A. Tam

UC#48 Handover satisfactory

• Target taken out of glovebox and tested for fit
• The left most triplet conductor leg was seen to be slightly misaligned, but the test fit showed that the bolt still threads on with some flexing from the suspect target leg.

Target inserted into NHC successfully

•  tight fit with IGLIS means some rubbing of the two conductor legs did occur with the tool port tunnel
• NHC target tray used, so tray from transportation was left in anteroom 
• HVAC vacuum pressure dropped below threshold for a minute while toolport door was open.
  • Operations chained off SHC doors and RPG got involved to ensure the safety of everyone in the area

Target Install successful

• A moment of rough handling of the target occurred when tilting the target towards operator in preparation for install
• The suspected misaligned conductor leg did not initially accept a screw, but the use of a T-handled allen key and using a different screw from the package worked
• Leak checks successful
• Electrical checks successful

Replacements of NHC tool cart has been built, but some modifications may be made before it is inserted into the hotcell

Findings

• During April 2025 safety walk ID: 2796 , it was noted that the oil level in NHC window oil expansion tank was below the indicator range.
• previous safety walks from July, October, Jan 2024 did not show any issues, but this was not a recorded item, only to check for leaks 
• No visible leaks from the exterior can be seen. 
• No air gap can be seen inside the window, so it is completely filled
• Last fill date September 28, 2022, no notes of finding a leak prior to, or after the fill
  •  ID: 2369 Entry time: Wednesday, September 28, 2022, 13:15

NHC Window Oil Filling

• Oil used was from a separate pail labeled Hot Cell Window Oil, believed to have come from the 55gal mother pail containing Penreco Drakeol 10 B LT Mineral Oil NF
• Nitrogen supply needle valve was closed to prevent oil from blocking this line
• Oil was filled from the removed pressure relief valve position which deviates from the procedure previously used ( ID: 2369 )
  
  • This was done to avoid oil from entering nitrogen supply line and limit oil from entering pressure gauge 
  • Valve from previous fill location (alleged old accumulator location) was also open to encourage better breathing
• ~1,775mL added via squeeze bottle before oil was seen in the indicator tube. Another ~1100mL was added via squeeze bottle to bring oil fill indicator to the previous 2022 fill mark that is about halfway up the tube. 2,875mL Total
  • This is considerably more oil added than in 2022 (1.5L)
  • Location of oil level and fill date marked on indicator tube and on reservoir  with blue Sharpie 
• Accumulator valve closed, Pressure relieve valve re-installed, nitrogen supply line valve opened 
  • 1.8 inH2O reached in ~10 minutes. 2.2inH2O was indicated the next morning 

Notes

• Oil level check on quarterly safety walks will be added
• Increased checking interval during the first quarter will be performed 
• Unrelated NHC entries in 2024 did not note any oil leaks, so not sure where 2.5L+ of oil has gone in 2.5 years
• SHC window oil level has remained about halfway up the indicator tube. 

  -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

May 12, 2025 - Aaron Tam 

Oil fill check 

• Two observations were made on the oil level. Once on May 6th with ~0.5cm below mark and may 12th ~1cm below mark
  • Photos uploaded 
• Nitrogen pressure is higher than last recorded at 3.1 inH2O
• I have a suspicion that a large gas bubble exists above the window in a separate holding tank. More observations to come 

Remote end 9352 replaced with end 9764 due to signs of an issue with the tong cable (tong opening excessively large and slack in cable on one side). Upon replacement tong opening on 9764 also opened larger then the remote end was set to. Everything is operational but this phenomenon indicates the handle cable system on operator side must be where the excess is coming for. This is further indicted but the position of the locking screw on the handle cable drum on the operator side, typically ccw of the hole location but now cw of the locking hole location. When there is a two week period between target changes in the NHC I would suggest swapping this operator arm with the spare.

 TM2 with new target UC#49 installed is E/L checked on the flange of NHC in TH. see attachment for detail.

May 7th, 2025 - Aaron Schmidt, Aaron Tam 

UC#49 Handover - good

• April 30th - Initial fit check was performed
  
  • This is a new procedure that allows time for any potential modifications to be made. 
• May 7th ~9:00am Target taken out of glovebox and tested for fit
• Target legs and mounting bolts all thread in nicely. Bottom 2 conductor leg mounting holes have slightest misalignment.
• Target bagged, and brought to ISAC Hot-cells anteroom

Target inserted into NHC - successful

•  Target loaded onto cart without issue

Target Install - Complicated 

• Gas line gasket dislodged upon fully inserting target onto source-tray guide-pins
• During the attempt to remove target from source-tray, East manipulator tong cable hopped off a pully
  • This is the same slave manip that was recently replaced ID: 2799 
• Attempts to reinstall the gasket proved unsuccessful, and gasket was ultimately lost under the source-tray
• 3 more gaskets were inserted into the Hot cells, with the same unsuccessful outcome
  • gaskets lost underneath source-tray
• One attempt to install a side loading gasket was tried
  
  • stopped after the first try as the tool is liable to fling the gasket to a critical area 
• Aaron Schmidt made a new tool to install a male-side gasket
  • This proved to be successful (photo shown)
• The rest of the install procedure was successful 
  
  • without the East manipulator functional, west manipulator was used
  • west manipulator has a smaller tong opening to avoid cable hopping 
  • Finishing at 3:00pm UC target exposed to air for ~6 hours

TM#4 with UC#48 was moved from the East target station to the North Hot Cell for target exchange. 

Reading at ITE = 36 mSv/h
Reading at NHC = 133 mSv/h

 TM4 with new target number C#5 installed had been leak/electric checked on NHC flange in TH. see pic attached with pls.

 June 17th, 2025 - Aaron Tam, Brady Borrmann, David Wang, Travis Cave

UC#48 Removal 10:20am - 11:35am

• Upon loosening of right-side water line, some leakage was observed (photos attached)
  • As soon as this was noticed, VCR nut was tightened and lines were purged for an additional 10 minutes
  • Second attempt removing water line nuts successful
• Multipin connector disconnected smoothly 
• Most 3/8" bolts loosened with very little resistance. Target Tube Conductor Leg bolts remained tight (Use of torque wrench and washers may have aided in this result)

Post Irradiation Examination

• Target brought down onto a plastic container carefully to avoid handling damage before photos
• Photos taken of target from all six sides 
  • Target is noticeably clean for an irradiated target 

Disposal 

• Multipin removed and placed inside empty 5 gallon pail #141
• Argon filled for 40 minutes before removing tube and closing lid 

June 19th - Aaron Tam, Chad Fisher 9:15am-10:30am

• UC#48 removed from Pail#141 and placed into Pail#303
• Small metal parts and compressible waste was also placed into Pail#303
  • 1 target tube conductor leg bolt was left in Hot cell. This was placed into pail#141 till next spent target pail loading
  • previous pail clamp lever was left out to be loaded another time
• Plastic bag was a little short and was standing proud of the top of the pail (will cut longer bag next spent target) (Short bags are unable to tuck into itself)
• Skill issue with clamping the lid solved by Chad Fisher 

June 17, 2025 - Aaron Tam, Brady Borrmann, David Wang

Target handover 8:30am

• Checks were made a day prior to insertion to leave time for adjustments
• Lower conductor leg holes were ovalized and aligned with job
• Final inspection on the jig was conducted the day of insertion, and brought to the anteroom

Target Insertion 8:50am

• Target insertion completed without issue
• This was done before TM4 was moved into North Hot Cell

Removing UC#48 10:20am - 11:35am

• Details in ELOG# 2816

Target installation 11:40am - 12:45pm

• Water from UC#48 removal had visually dried out by the time UC#5 was set for installation 
• Successfully passed leak check and electrical check on first attempt

Over the course of September 9th - September 13, 2024 a CRL manipulator technician carried out the following manipulator maintenance:

NHC operator side arm #9763 (right side installed position) - Inspection and re-tensioning of tong cable prior to re-installation (was a little too tight). Operational.

E-HD clean spare #8015 - repaired stuck manual 'Z' motion - removed one rouge 5-40 screw that had been dropped inside remote end during 'Z' motion cable run through in 2017, found that related 5-40 screws from the cable end clamp were not tight and therefore proud and also jamming. Complete tape replacement and tensioning. This manipulator is fully back to operational status other then needing some screw for the air restriction on the remote end.

E-HD "dirty" spare #7985 - inspection and evaluation of parts on the operator side require to return to operational status. Wrist and handle reassembled (all parts of wrist and handle accounted for) Ball and socket joint at and of motion lock replaced (parts were on hand already) as well as tape motion lock assembly (parts on hand already). This arm may be missing a relay or two. Remote side still bagged with unrecorded issue (suspect it is only a broken tong cable) this will be put in the maintenance schedule for earl 2025.

NHC operator side "spare" arm #9351 - Damaged 'Z' motion tape replaced. Tensioning. Operational once 'Y' motion linear actuator re-installed.

Meson hall warm cell manipulators evaluated/inspected - No issue found

Broken tong cable on West manipulator (serial #8106) replaced.

Wrist joint with broken cable was replaced with the spare wrist joint, pre-strung with a new tong cable. Tong cable is routed the "new" way (as described in April 3, 2024 wrist replacement), over the interior spacer.

Both East and West manipulators now have wrists with cables routed in this fashion which, in theory should result in longer cable life.

Tong cable in East manipulator #7986 was visually checked and looks in good shape.

Handle cable on #7986 is still routed under the spacer in the wrist and should be replaced with a new cable routed above the spacer next time it needs service.

MCR Travis Curucz and I finished BL2A MAA ASU test per document 154779. everything works fine. Travis kept  the test document.