In mid-2020 design analysis was completed on the steel plate & pin assemblies (ITA6550) used to connect the ISAC target hall crane hook block to the module lifting yoke assembly ITA0494.  The released design note is Document-184431.  

In November 2020 fabrication was completed on two full plate & pin assemblies (photos attached below).  As per the relevant ASME standards (identified in the design note), each assembly has been identified with serial numbers (#1 and #2).  Material test reports for the steel plate and round bar material used for fabrication are attached in PDF format.  For both materials the tested tensile yield strength (from the MTR) exceeds the value used in design calculations (from Document-184431):  117ksi vs 100ksi for the plate material;  138si vs 103ksi for the round bar material.

On February 8, 2021 both plate and pin assemblies were load tested by David Wang and Frank Song.  The total load applied to each was 31,400 lbs (as per the ISAC target hall crane load cell) which exceeds the 125% of rated capacity (31,250 lbs) required for the test.  The lifts were conducted successfully and no deformations or other damage to the assemblies were observed.  Photos of the load test are also attached.

Both plate & pin assemblies are now certified for use up to their rated capacity.  As specified on drawing ITA6550 and in Document-184431, a monthly visual inspection must be performed to check for structural deformation, cracks, excessive wear, and loose or missing fasteners.  In addition, an annual inspection must be performed to check for structural deformation, cracks, excessive wear, loose or missing fasteners, and missing or illegible markings or safety labels.  A written record of the annual inspection must be documented and kept readily available.

The crane pendant for the auxiliary hoist was upgraded to a FLEX EX2 style pendant by Canco Cranes. The installation work was performed by Canco, supervised by Tom Kauss and David Wang. Installation work was performed in one day (I2021-03-26-1).

Items installed include: new pendant (2 motion, 2 speed)

The existing antenna and receiver box located in the Target Hall were used.

The new system was tested by David Wang. Everything is reported to be in working condition.

An issue was observed in which the target hall crane was not functioning: the N-E-S-W and up/down motions did not work, however the rotation motion did work. These symptoms were similar to what was observed in the past under https://elog.triumf.ca/TIS/RH-ISAC/2039 and https://elog.triumf.ca/TIS/RH-ISAC/1845

The crane control console was not powered (i.e. pressing the ON/OFF buttons when the selector switch was set to remote mode, even when safety conditions were met, did not enable/disable remote functionality). The power supplies were checked and everything appeared to be powered as would be expected, except for items which depended on the main contactor (O-K1) being energized. This contactor needs the PLC to be in an operational state, fault-free. The PLC was checked and the red fault light was flashing. The battery light was not on (i.e. battery was OK).

The program was re-downloaded to the PLC. During an attempt to go online with the PLC, error code 0004h appeared (see attached image for description). This is an unfamiliar error code - typically the aforementioned symptoms arise due to a battery failure and the program being lost. In this case it is uncertain at this time what the cause of this fault is. It will be monitored in the future to determine if it occurs again, and further investigation will be performed.

After re-downloading the program and placing the PLC in RUN mode, the crane was fully restored to its operating state - the main contactor was able to be energized once again. The crane was put into remote mode and a brief functionality test on the motion axes was performed: OK.

Tom Gauss inspected  two target module lifting frames ITA0494-1997-01 and ITA0494-1997-02.. He certified the use of these two frames. Inspection tags have been issued and attached to frames. He has inspection record on them. See attachments.

Tom Kauss inspected target hall crane below hook attachment pins and plates ITA6550-01. He certified the use of these pins and plates. The inspection of these pins and plates was in Target hall crane annual check list. It was issued as a calibration index by Isaac Earle in 2022-Feb-08.  After inspection, The inspection tag  was issued and attached to pin. Tom has an inspection record on this job. See attachments.

Tom Kauss finished target hall overhead crane annual inspection today. The crane works fine. He issued new inspection tag and e-logged the job. 

[edit 2023-01-03] The crane was powered back on this morning - there do not appear to be any faults and it seems that the crane was unaffected by the power outage.

The ISAC target hall overhead crane was powered off for the holidays. Note that this may result in the commonly observed PLC battery failure issue when the crane is powered back on in the new year.

Tom Kauss inspected target hall crane yesterday. The crane works fine. Tom has this inspection record in his file. The inspection tag has been issued.

Tom Kauss  finished TH crane annual inspection yesterday. The crane woks fine. Tom has this inspection record in his file. The crane inspection tag has been issued for 2023.

Tom Gauss inspected  two target module lifting frames ITA0494-1997-01 and ITA0494-1997-02 yesterday. He certified the use of these two frames for 2023. Inspection tags have been issued and attached to frames. He has inspection record on them. 

Tom Kauss inspected target hall crane below hook attachment pins and plates ITA6550-01 yesterday. He certified the use of these pins and plates. The inspection of these pins and plates was in Target hall crane annual check list. It was issued as a calibration index by Isaac Earle in 2022-Feb-08.  After inspection, The inspection tag  was issued and attached to pin. Tom has an inspection record on this job

The pail handling tool which is used to move 5 gallon pails around the target hall was inspected by A. Newsome, N. Jorgenson, and E. Lahe. The main tool as well as spare were checked for the following items. The tools are in good, working condition. It is noted that some fasteners on the hook assembly were slightly loose, but have been tightened.

• Inspect structural integrity of long tube - check for bending, warpage, dents, cracks, rust/corrosion
• Inspect structural integrity of hook assembly - check for bending, warpage, dents, cracks, rust/corrosion
• Inspect fasteners - check all fasteners installed as per drawings, fasteners are tight
• Inspect crane interface assembly - check for damage and wear where the tool connects to the crane
• Check alignment - verify the tool connects to the crane and hangs vertically with no major misalignment (this step was not done - alignment is regularly checked during operations, and there was no concern as the tube was straight)

 Note: these tools are being inspected monthly by D. Wang and F. Song.

In an effort to clean up the camera installation on top of the ISAC target hall crane to resolve a fault, the position measuring tape and its associated camera were removed from the target hall crane on July 31, 2023.

Still to do: clean up power bar installation.

 The cleanup of the ISAC Target Hall crane and installation of the new SICK laser which replaced the IBEO laser for the EW crane position was completed on Aug 03 2023.

The clean up tasks which were completed: (Removal of tape viewing camera, Removal of tape, Installation of extension cord, Consolidation of power supplies for the lasers and removal of old laser) 

Currently power bar is still present to act as an extension cable. This will be removed when 2m extension cord is made and put in next target exchange cycle.
   

The installation and testing of new SICK Laser:

1. Calibration points were taken at the 4 corner limits of the crane. North South and East West positions were recorded.

2. Crane was parked at the ladder access position and mounting bracket was machined and installed.

3. A new cable was made and installed for the SICK laser. Continuity test was performed from the control room and crane to ensure pinout of the laser worked with existing serial communication setup in the control room PC.

4. The feedback values from the new SICK laser and old IBEO laser were compared to determine that a calibration offset of 0.06m was needed in the Laser Position Feedback program.

5. Laser Position Feedback program was re-compiled to communicate with 2x SICK lasers with the calibration offset value included in the EW feedback position. (Laser Crane PositionDlg.cpp)

6. Calibration points were taken at the 4 corner limits of the crane again with the new Laser. North South and East West positions were recorded.

There was less than 0.1% variance between the new laser and old laser which is well within the tolerance of the lasers themselves. It can be determined that it was properly calibrated.

It is reported that the crane's hook rotation is not working currently. It was working yesterday (Nov 22). Investigation to follow, and this e-log will be updated.

Edit [2023-11-23]: the issue was a result of a tripped circuit breaker. Perhaps the motor became overloaded. It is advised to monitor the rotation mechanism over the new few operations, and rotate the hook CW and CCW prior to performing any critical operation to confirm it is working.

Tom Kauss finished TH crane annual inspection yesterday. The crane woks fine. Tom has this inspection record in his file. The crane inspection tag has been issued for 2024.

Tom Gauss inspected  two target module lifting frames ITA0494-1997-01 and ITA0494-1997-02 yesterday. He certified the use of these two frames for 2024. Inspection tags have been issued and attached to frames. He has inspection record on them. 

Tom Kauss inspected target hall crane below hook attachment pins and plates ITA6550-01 yesterday. He certified the use of these pins and plates for year 2024. The inspection of these pins and plates was in Target hall crane annual check list. It was issued as a calibration index by Isaac Earle in 2022-Feb-08.  After inspection, The inspection tag  was issued and attached to pin. Tom has an inspection record on this job.

The pail handling tool which is used to move 5 gallon pails around the target hall was inspected by A. Newsome. The main tool was checked, but not the spare as it is currently in a disassembled and unusable state. The tool appears to be in good, working condition. The following items were checked.

• Inspect structural integrity of long tube - check for bending, warpage, dents, cracks, rust/corrosion
• Inspect structural integrity of hook assembly - check for bending, warpage, dents, cracks, rust/corrosion
• Inspect fasteners - check all fasteners installed as per drawings, fasteners are tight (note: one fastener on crane interface subassembly was loose - all fasteners in these subassembly were tightened as a precautionary measure)
• Inspect crane interface assembly - check for damage and wear where the tool connects to the crane
• Check alignment - verify the tool connects to the crane and hangs vertically with no major misalignment (this step was not done - alignment is regularly checked during operations, and there was no concern as the tube was straight)

 Note: these tools are being inspected monthly by D. Wang and F. Song.

Photos can be found in G:\remote handling\Facilities and Projects\ISAC\Pail Handling Tool\Inspections\June 2024

IMPORTANT: the maximum load capacity and lifter tag for the tool are not present. There is a plan in place to affix these two labels in the very near future.

D. Wang reports that recently the overhead crane has been exhibiting a delayed start (approx. 1 min) when operating in local mode. This issue applies to the main hoist's up/down functionality only and does not seem to apply to other motion axes. T. Kauss briefly investigated but did not find any obvious cause.

This issue will be monitored and investigated over the following weeks and this log will be updated as more information becomes available.

Suggested troubleshooting steps:

• Isolate the issue to local or remote mode to confirm this suspicion (it appears to be present in both local and remote mode)
• With help from someone locally operating the crane, confirm at the receiver in the control room whether signals are coming through for up/down commands immediately, or whether the receipt of signals itself is delayed. At the same time, confirm whether the PLC input card is receiving the command signals from the receiver immediately or in a delayed manner. (it appears that the command signals are being received by the VFDs - the issue seems to be on the output side)
• Time the delay, and repeat to confirm if the timing is consistent every time as reported by D. Wang (it appears timing is inconsistent. After a weekend of no use, it was approximately 2 minutes. After a few hours of no use, it was around 10 seconds).
• Check if delay is present across various crane positions in the target hall (completed by D. Wang - result: yes)
• Inspect controls hardware in the cabinet in the control room, as well as the remote IO on top of the crane, for obvious issues (checked cabinet but not remote IO - nothing obvious)
• Go online with the PLC and test up/down commands to see if the program indicates any obvious issues (note: this may not actually help - seems to be an electrical issue isolated to the VFD-related electronics)
• Mechanical inspection of the motor (not likely an issue)
• Disconnect motor, repeat test of trying to command up/down motion and see if the motor itself had any effect on the delay

Update, 2024-09-09 [DW]:  Confirmed both local and remote mode have the same problem on delayed main hoist functional issue after crane was switched on. The delay time is 1 minutes 40 seconds to 2 minutes. It happens mostly when first time the crane was switched on. But if the crane was not used in the rest of day after first time switching on , the problem showed again 5 to 6 hours after in same day.

Update, 2024-09-09 [AN]: Checked again around 11:30am... tested running both hoists A and B in remote mode. Upon first attempt to lower hoist, no motion occurred. Hoist A VFD exhibited fault code 51, and Hoist B exhibited fault code 52. Both hoists appeared to receive the command from the PLC to attempt to move. Both hoists (initially) had their "ready" status as ON. When attempting to move, however, hoist B's ready status dropped out. Note also that the delay observed between the failed attempt to start, and when motion was actually possible, was only approximately 10-20 seconds. Perhaps this correlates to the fact the crane was recently operated this morning. It is suspected that the charging circuit for hoist B's DC bus voltage is faulty.
Tomorrow, another test will be performed by checking A and B independently to see if one can run but the other cannot.

Update, 2024-09-10 [AN]: Tested the crane using only Hoist A: working upon first power-up of the day. Tested using only Hoist B: not working, fault 52 re-appears. We are certain the issue lies with Hoist B. Furthermore, upon observing the motor contactors and status LEDs when attempting to energize the motor, the following is observed:

• For Hoist A (normal, working operation) - on power up K1 toggles on (in). When pressing down button, K7 toggles (in). The hoist begins to move.
• For Hoist B (non-functioning), on power up K1 toggles on (in). When pressing down button, K7 does NOT toggle. K1 toggles OFF (it should not) then comes back, then triggers the fault.

Upon further inspection it was noted that for K1 for Hoist B, there appears to be a snubber (XEB2202) wired in across the A1 and A2 terminals of the contactor. The fact that a time-dependent circuit is involved matches earlier theories about a charge-timing related issue. Suggested action: attempt to remove the snubber and test again to determine if the issue persists.

Update, 2024-09-11 [AN]: Under work permit I2024-09-10--3, the following was tested and observed:

• Run Hoist B to confirm it is not working (expected behaviour) - confirmed
• Power off crane, remove the snubber from Hoist B's contactor K1
• Power on crane, attempt to run Hoist B - the hoist did not run
• It was noticed also that Hoist A did in fact have a snubber installed as well - it was hidden. The snubber for Hoist B's capacitance was measured and confirmed to match what it should be, so it is suspected that it is working fine.
• This indicates that the snubber is not the issue. The snubber was reinstalled and the system returned back to normal state. Tested - working.

At this time the root cause remains unknown, but the snubber has been eliminated from the possibilities.

It appears that the issue can be isolated to the fact that contactor K1 momentary toggles off when attempting to operate the hoist. This short blip would explain the fault code related to insufficient line voltage. The drawings indicate the only way that K1 can turn off is if the 48 VAC supply from the transformer drops out momentarily, or if an unnamed relay located (presumably) in the VFD momentary toggles.

Further troubleshooting steps could include:

• Probe for 48VAC at A2 terminal of K1 and attempt to operate the hoist - see if it drops off briefly. If so, the issue is either the transformer or the relay contact in the VFD. Perform continuity check across the relay contact, repeat attempt to operate hoist, and determine if it is the relay contact causing the issue. This test will significantly isolate the issue.
• Check inside Hoist B's VFD circuitry and measure the DC bus voltage during attempted operation, and compare to Hoist A. There may be an issue with the charging circuit inside the inverter.

Update, 2024-09-13 [AN]: Under work permit I2024-09-10--3, the following was tested and observed:

• Probe the A2 terminal of K1 for Hoist B with respect to the transformer's 0V output upon initial power-up of the system: ~53VAC measured (should be 48VAC but 53 is acceptable)... this confirms that the appropriate relay coil voltage is present upon power-on, as expected because it is observed that the relay toggles upon power-up.
• Continue probing A2 while attempting to jog Hoist B down, with min-hold set on the multimeter to check for voltage drops: the voltage measured was approximately 24VAC during one attempt and 36VAC during another. This implies that K1's coil voltage does in fact drop out instantaneously, resulting in K1 very briefly disengaging which causes the observed VFD vault. The fact that the measured min voltage is different can be attributed to the mulitmeter's sampling rate, catching the voltage during its decline towards 0.
• Because of the aforementioned test results, it is confirmed that there is an issue associated with K1's coil voltage briefly dropping out when attempting to run the hoist. There are only two reasons this could happen: 1) the transformer power output of 48VAC actually drops, or 2) the relay contact in series with this (located inside the VFD) opens up as a result of a VFD fault. The latter is more likely.
• Upon investigating the VFD further, it was determined that another fault code was present prior to the above mentioned code 52. This fault code happened very briefly at the same time as K1 toggling, but was then covered up by code 52. This fault code is 2, which states that there's an overvoltage condition - the DC bus voltage has exceeded 911 VDC (135% of device maximum nominal voltage of 500V). This can be attributed to a supply voltage surge in which it is raised 35% above its nominal value.
• Note: line-to-line voltages were measured at the input to K1 after the "warm up period" and the issue was resolved, when the hoist was sitting idle. These were measured to be almost exactly 480VAC. This represents a reference condition.
• What seems to be happening is that when the hoist motion attempts to start, there is a line voltage surge for some reason (back-emf?) which causes this fault condition for a temporary instant, but then when the voltage dissipates the fault instantly clears. This explains why contactor K1 very briefly flickers during motion attempt - the fault is only briefly present. But then, fault code 52 takes over and remains present (because of the line voltage disruption).
• Still, the root case of this issue is unknown. It is not confirmed whether there is actually a voltage surge or not (to be measured next week), and why it seems to only happen for the first ~2 minutes of the day.
  It could be attributed to one of the following reasons:
  • Coil voltage rectifying diode partial failure inside K1... the diode may need time to "warm up"
  • Brake solenoid partial failure for Hoist B (causing additional friction which leads to overvoltage condition for the motor)... the brake may need time to "warm up"
  • Charging capacitor issue in DC bus voltage charge circuit inside the VFD

Suggested troubleshooting steps:

• Probe line-to-line voltage at input terminals to K1 during attempt to operate Hoist B in max-hold mode: check for surge, record values
• Probe DC bus voltage during the same condition, record value
• Determine if the above indicate a true overvoltage condition, and determine why this may be

Update, 2024-09-16 [AN]: Under work permit I2024-09-10--3, the following was tested and observed:

• Probe L1-L2, L2-L3, and L1-L3 line voltages on input side of contactor K1 for Hoist B with max hold set on multimeter to confirm whether there is a surge when attempting to move the hoist - no surge was observed. 480VAC constant was measured in each case.
• There may be another issue causing the DC bus overvoltage condition (an issue with the motor or an issue with the drive itself)

Suggested troubleshooting steps:

• Probe DC bus voltage during the faulted condition, record value
• Disconnect the motor from the drive and check motor winding resistances before and after the "warm up" period to see if there is a change, and also compared to Hoist A
• With the motor disconnected, attempt to run the drive - determine if fault code 2 shows up or if the drive appears to be working.. this may eliminate the motor from the list of potential issues

 Update, 2024-09-16 [AN]: Under work permit I2024-09-16--3, the following was tested and observed:

• Probed DC bus voltage on Hoist B's VFD prior to attempting to move hoist, and during the attempt to move it. In both cases it remained a constant 690 VDC. No temporary spike was observed. This is also lower than the threshold that the VFD's manual stated the fault would typically occur at (~911 V) so it casts doubt on whether this is the root cause of the problem.
• Probed DC bus voltage for Hoist A's VFD, for comparison - same measurement.

Suggested troubleshooting steps:

• Disconnect the motor from the drive and check motor winding resistances before and after the "warm up" period to see if there is a change, and also compared to Hoist A
• With the motor disconnected, attempt to run the drive - determine if fault code 2 shows up or if the drive appears to be working.. this may eliminate the motor from the list of potential issues
• Swap VFDs between Hoist A and B to determine if the problem tracks the drive
• Swap K1 between Hoist A and B

Update, 2024-09-16 [AN]: Under work permit I2024-09-16--3, the following was tested and observed:

• Measured motor winding resistance between every combination of lines for both Hoist A and B (for comparison). Note: this was done mid-day, prior to any use of the crane for the day. In each case, the resistance was measured to be 2.2 Ohms. There is no difference between the A and B. This is not likely the root cause of the issue.

Suggested troubleshooting steps:

• With the motor disconnected, attempt to run the drive - determine if fault code 2 shows up or if the drive appears to be working.. this may eliminate the motor from the list of potential issues
• Swap VFDs between Hoist A and B to determine if the problem tracks the drive
• Swap K1 between Hoist A and B

Update after email discussion with Kone service tech, 2024-09-23 [AN]:

The Kone service tech said "This is a obsolete inverter and there is not a direct replacement available or parts for repair .  It is recommended to replace inverter with a conversion panel. The conversion panel consists of new, correctly sized components including D2V inverter, to have the same functionality as original panel. All components mounted and prewired to a back panel that fits directly inside the existing enclosure. All inputs and outputs are terminated at a terminal strip. Interconnecting wiring diagrams are also provided for ease of installation. The lead time for a conversion panel is approximately 10-12 weeks after receipt of a Purchase order."

A quote will be obtained from Kone for the replacement.

Update after K7 swapping between hoist A and B with Jason, Mike, Julie, 2024-10-09 [DW]:

Contactor K7 was swapped between hoist A and B. On hoist B we saw F52 fault and K7 did not engage in properly. On hoist A we saw F51 fault which is "stop limit has be tripped" and K7 also did not engage in properly. After 2 minute wait, both hoist A and B are back to normal. The plan for tomorrow: switch to A hoist and test. right after, switch to B and test. 
UPDATE FOR PAST THREE DAYS TESTS AND PROGRESS.  DAVID WANG 2024-10-12
2024-10-09 noon. Left crane with power on for 1 hour. switched off power on crane for rest of day to Thursday morning test.
2024-10-10 morning. Set to A hoist only. Switched on main power and tested hoist A down. It was normal, no delay. Right away switched to hoist B and tested hoist B down . It was normal, no delay. Switched to A and B and tested hoist up and down. It was normal, no delay.

2024-10-10 noon.  Replaced spark quenchers on hoist B K1 and K7. Tested crane after replacement. Everything works fine. Used crane to lift up F308 around 1:30. Then switched off crane for next morning test.

2024-10-11 morning. Set to A and B. Tested crane hoist down twice 2-3 seconds each time with 3 second between. No fault. Hoist worked fine.  3 second after, tested hoist up and found  K7s were not on on both A and B. 10 seconds after tested hoist up again and it worked. Then tested all crane movements. Everything was normal. Crane was used for spent target moves to 2:30pm . Then switched off.

2024-10-12 morning: Set to A and B.  Right after power on, tested hoist up for 5 seconds. wait 3 seconds, tested hoist down for 5 seconds. Repeated same up and down test within 3 seconds.  No fault. the hoist A and B works fine. Tested N-S,E-W movement. all good.  at the last, tested hoist up and down 10 seconds each. Hoist A and B are still good. The plan for next morning test: Leave crane power off to Tuesday morning and test hoist A+B(48 hours power off). Also plan to replace spark quenchers on hoist A /K1 and K7 if any delay is found on Tuesday morning test. 
2024-10-15 morning: Set to A and B. tested hoist up and down one click on each. I saw K7 momentarily "on" then drop off symptom as before. I saw F51 on A and F52 on B. Switched to A right away and tested. A works fine. Then switched to B and tested. B works fine. The total test time from A+B to B then to A is about 30 seconds. Then i switched back to A+B for checking. everything works fine as anticipated.

2024-10-16  A-K7 snubber was replaced yesterday after morning test . Tested hoist A+B this morning after 24 hours crane power off. Hoist A+B works fine on both up and down. 

2024-10-17 Tested A+B hoist this morning after 22 hours crane power off. Hoist A+B works fine on both up and down.

2024-10-18 Tested A+B hoist this morning after 24 hours crane power off. Hoist A+B works fine on both up and down.

2024-10-21 Tested A+B hoist this morning after 72 hours crane power off. The delay issue on hoist B appeared. Hoist A is fine. B/K7 was momentarily on then dropped off. By the same time B/K1 was momentarily dropped off then on with F52 code.

2024-10-22 Tested A+B hoist from target hall this morning after 22 hours crane power off.  hoist A+B  works fine on both up and down.

2024-10-22 noon.  Swapped  hoist A/K1 and B/K1. Crane power off at 9:30am after flask/pail repacking job.

2024-10-24. Tested A+B hoist this morning after 46 hours crane power off. Hoist A+B works fine on both up and down. Crane will be left as power off for 48 hours for next test.

2024-11-21. In the past month ,I tested crane multiple times. 24 hours power off test results are good always. 48 hours or longer power off test results are not consistent. Hoist B had 15 to20 seconds delay on early checks after last e -log. But in recent  6 days power off check and 3 days power off check, the hoist B has no delay. The next step: 1, keep on multiple days power off check. 2, replace Hoist B K1 (line+auxiliary) contactors with new parts.

2024-11-25. tested hoist A+B this morning after 4 days crane power off. No delay. everything works fine. Replacement contactors for K1 have been requested. Line contactor is in 5 weeks back order status from Digikey so we will replace Hoist B K1 next year in January mostly.

2024-12-02. Tested hoist A+B this morning after 4 days crane power off. No delay. everything works fine. It looks like  no delay status is stable now by watching on past 40days morning check result. Daily and multiple days check on hoist B  will be kept on.

2025-01-02. Tested hoist A+B this morning. The last time of crane using in 2024 should be 18th Dec. No delay . Crane works fine.