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1. User s Installation and Maintenance Manual 43 45540081 Octopus Lift manual EN 1st CE Edition 6 2013 Revision 3 12 06 14 Australia Avanti Wind Systems PTY LTD Unit 15 160 Lytton Road Morningside 4170 Queensland P 61 0 7 3902 1445 F 61 0 7 3902 1252 Avanti Wind Systems Building 4 No 518 Gangde Road XiaokunshanTown Songjiang District 201614 Shanghai P 86 21 5785 8811 F 86 21 5785 8815 Denmark Avanti Wind Systems A S R nnevangs All 6 DK 3400 Hiller d P 45 4824 9024 F 45 4824 9124 Germany Avanti Wind Systems GmbH Max Planck Str 10 25335 Elmshorn P 49 0 41 21 7 88 85 0 F 49 0 41 21 7 88 85 20 Spain Avanti Wind Systems SL Poligono Industrial Centrovia Calle Los Angeles No 88 nave 1 50198 La Muela P 34 976 149524 F 34 976 149508 UK Avanti Wind Systems Limited Caldershaw Business Centre Unit 29 Ings Lane Rochdale OL12 7LQ P 44 0 1706 356 442 USA Avanti Wind Systems Inc 5150 S Towne Drive New Berlin Wisconsin 53151 P 1 262 641 9101 F 1 262 641 9161 India Avanti Wind Systems India Private Ltd Old No 28 New No 41 Vellala Street Aiyanambakkam Chennai 600095 Tamil Nadu P 91 44 6455 5911 Brazil Avanti Brazil Sistemas E licos S L Rodovia BR 116 Km21 Fortaleza Ceara P 55 85 9671 6336 l www avanti online com E infoGavanti online com
2. Original instructions VANTI Established 1885 AVANTI SERVICE LIFT User s Installation and Maintenance Manual C Model Service Lift OCTOPUS EC Type Examination EC Directive 2006 42 EC Article 12 Section 3b Machinery Number of registration 01 205 0833 13 Certification body for machinery NB0035 at TUV Rheinland Industrie Service GmbH herewith confirms for the company AVANTI WIND SYSTEMS A S H gevej 19 DK 3400 Hillerod Denmark the close conformity of the product Service lift inside wind turbine systems Technical data Service lift Octopus L80 L95 max load capacity 240 kg 2 persons traction hoist M508 fall arrest device ASL508 lifting speed protection fences fence Interlock system Trapped key system max distance between brackets net weight max total travel height dimensions of cabin W x D x H 800 x 1040 x 2680 mm 950 x 1040 x 2680 mm Examination place Zaragosa Spain with the requirements according to annex of Directive 2006 42 EC about machinery and amending the Directive 95 16 EC of the European Parliament and the Council from May 2006 for adaptation of legal and administration regulations of the member countries regarding safety of machinery The verification was proved by EC type approval test Test Report No 13 021 1 from 2013 04 29 and is valid only duly considering the requirements mentioned in this document This certificate is vali
3. possible reference E The WTG owner must ensure that the results of this inspection before first use are logged in the Operation log sheet E 4 12 Disassembling In accordance with local authority regulations disassemble in reverse order and dispose 5 Instructions for use 5A Prohibited uses The consequences of not following below prohibitions are extremely hazardous to the physical integrity of the users When using the service lift it is prohibited to e Use the service lift beyond its intended purpose e Operate the service lift without following the safety warnings and operating instructions e Overload the service lift more than its rated load e Try to repair machine components Only person nel from AVANTI or competent persons certified by AVANTI are allowed to perform service on the machine e To use the ladder while service lift is being used e To use the ladder unless service lift is out of service or in case of evacuation or rescue e To place objects on service lift roof e To descent on service lift roof 5 2 Normal use Connect power supply Open fence and service lift doors Enter cabin Close fence door Remove trapped key from fence Close service lift door Insert trapped key in cabin control box and turn to ON position 8 Press and hold UP or DOWN button to travel 9 After use disconnect power supply 5 3 Send function e Push external DOWN button of cabi
4. Dimensions There are two standard sizes L95 A L80 A 950 mm 0292 0084 LALA Sees FETT PAA AA 29099904 l2d2222J Ll Hal ka LI 2 09908 a LAA AAA lili gt 94404000 KA Ki a 800 mm gala LESER ep ennn a a POE anan ep nn diele LALA vi LES nnn PATE ep PALAG a LALO ant LE ve getter Kalayaan on HOD or Kalayaan LANG Kalayaan aettttet LOU PPT FR askal FL atten Gbps tunn Gbr ennn Gbe atten alalang 410081 ep asaran aalala asaran dolitans adi FO LE DE SEDI HAHHAA eee LA honasan LA A LA 444444 patatet bpe LA LABEL LI LEE EE eee PEP L eee PP ALILIL 2680 so a PG EE EE NS HHS EE EK EN t pi EE EEE EEE EEE EEE PE PG t ttt tT OE EEE EG EE EK EK EN eer eee eee ee SASA eee Pee ee HAN HAN ee KA ee ee ee FAH SA eee ee ee EEE ee ee ANS AH AA Pee eet eae SIS r E r ENE er ee eee ee ee eT eT eT eT ee ee SETET ee ee ee ee ee EAT 4sanansns La LA La LA ta LAJ LA LA LA LAJ LAJ LA LA t t t ta LA ert rt L EEE EEE ET EE EE EE E EEE ee ee eT ee eT ee eT eT eS 2 50 seers eee vennnn EEE EE e LL DE EEEE e TITTTIT BB RR t t tatatatnea v LJ LJ Ld LEE PEE EE EE LE KA EE EE er LE a EE ET Lp na a ap w ww w eTreT eT e
5. axis Max angle variance between ladder sections Safety ladder Max distance between brackets 2240 mm Forces capable to withstand by ladder brackets Upon request to AVANTI Forces capable to withstand by ladder sections Upon request to AVANTI adder width for Octopus L80 520 mm Max thickness of top beam for 2 Tn shackles C shape 20 mm Min distance between top platform and top beam shackle holes 3000 mm 1 Depending of travel path dimension may need to be larger in order to avoid collisions of travelling cable pulley with platforms 2 Other dimensions are possible upon request and design verification by AVANTI The WTG manufacturer shall put in place any other means necessary to ensure the safe use of the service lift according to AVANTI recommendations and its own risk assessment for the integration that shall include items which are not under AVANTIS scope The Octopus service lift is designed for a lifetime of 20 years with a frequency of use of approximately 12 5 h year or 250 h during life In case frequency of use is higher service inspections and replacement of components might be more often according to the replacement criteria stated in the maintenance instructions 20 AVANTI Service Lift for Wind Turbines 4 2 Service lift assembly 4 2 1 After transport The service lift is transported in parts Once at destination the service lift parts shall be assembled according to assembly drawing AD000
6. described in appendix of Regulation of overload limiter 6 5 Spare parts Only use original parts Spare part lists are avail able from AVANTI upon request Please indicate service lift model 6 6 Troubleshooting All tests and repairs to the electronic com Repairs to the traction hoist the fall arrest ponents shall be performed by authorized device and to the system s supporting personnel only components shall be performed by quali fied personnel only The wiring diagram is placed in the power cabinet If these steps do not identify the cause and rectify the fault consult a qualified author e ized person or contact the manufacturer Breakdown Cause Specific cause Solution The service lift cannot ascend nor descend An emergency stop button has been actuated Pull button to release it Wire rope loop in traction Damaged or defective wire rope or wire Stop work immediately hoist rope outlet causes problems Ask supplier or manufacturer for help The fall arrest device is Traction wire rope breakage holding the service lift on the Traction hoist failure Evacuate service lift following procedure Carefully remove the obstacle Test the operational safety of affected WTG and service lift components Inform the supervisor If obstacle cannot be removed evacuate service lift Test the operational safety of affected WTG and service lift components Inform the supervisor Power supply is d
7. gloves helmet safety glasses and working gear Place cabin at bottom platform and disconnect power supply Use an electricity measuring tool when performing inspection of electrical components Use a hand winch attachable to the ladder when handling big heavy loads and shall be performed at least by 2 persons Panel parts shall be removed to facilitate access to confined spaces e Guiding rollers shall be replaced one by one e Use a cable grip when replacing travelling cable e Keep cabin doors closed when using a 3 step ladder e Dismount hatch to access the engine room e Ensure that no one is working above them and se cure ladder part against fall with two ropes when replacing a ladder section Only qualified technicians shall perform electrical installation tasks 6 3 Daily inspection procedure Inspect the travel zone control and safety devices and control and safety devices of service tool kit fol lowing the instructions of the Inspection checklist 6 4 Annual inspection 6 4 1 Annual inspection procedure Scheduled inspection is required every year Although it may be required more frequently depending on frequency and a conditions of use and local regulations Annual inspection shall only be carried EN out by AVANTI or an authorized person L following the Inspection checklist for future possible reference During the annual inspection all the components shall be checked to verify that they a
8. lamp External UP button for send function External emergency stop button External DOWN button for send function 14 AVANTI Service Lift for Wind Turbines Fall arrest device triggered lamp Overload buzzer 11 12 13 Cabin control box socket Power supply socket Motor supply socket Motor signals socket Fall arrest device socket Internal light socket Top hatch switch S51 socket Top limit switch S1 socket Top warning light socket Service control box socket Internal emergency stop button Trapped key switch S99 Internal UP button for manual function Internal DOWN button for manual function Override key of bottom obstruction switch S2 3 6 7 Safety switches Top obstruction device hatch switch S51 Top obstruction switch Top cabin 2 S1 hatch switch S53 Ladder access door See switch S19 i Main door guard locking E switch S19 E Trapped key switch S99 Platform level switch Top limit S18 switch a S1 1C p 4 Emergency top limit switch S13c Bottom cabin hatch switch S52 Bottom obstruction device hatch switch S54 Bottom obstruction switch S2 Emergency bottom obstruction breaker 3 6 8 Platform fences They must conform to EN 14122 be 1 1 m high and be equipped with doors These must be monitored with a trapped key system that permits fence door to be opened only w
9. n n won win I non n non non non n na mn nn ann 21 4 8 Safety wire rope elle lel ll ll en ke n kn n an nn n an an n nn an n an nna an n nana n 22 4 9 Travelling cable pullGY eeeeee esseeseseesesesennseso 22 4 10 Activation plates anaana nanne teen eaten teen aeaee 22 4 11 Inspection before first use 0 0 teeta 22 4 12 Disassembling a 22 4 AVANTI Service Lift for Wind Turbines 5 Instructions for USE 0 aasa 23 9 1 Prohibited USES usas paz KA nega et NA KG KG ap A ERROR ROCA OCC Ro PO Ren 23 9 2 Normal US 4 cusa test aie krak SERERE REESE CE e UR ANNA ABR ea WAN Rod PANG een 23 5 DONG UNCON ERR TETTITT TET MG NAIBA LU ET BAWA ecard eee nuke Ka e rede 23 5 4 Enter and exit cabin through door s oeoeeeesesesenn 23 5 5 Emergency stop button cee nene 23 5 6 Fall arrest device 0 enn nn nn n won nna nn n na nan na n aa nn nn nan 23 5 7 Manual descent 0 en nen nn nna nn n nn nin n non min a non nna non n na nan nn n nan n 24 5 8 Out Of service s wana ei aie aa vi ba tak ax Ra k eee wer red e 24 6 Mamklenance icc ori eee oo ti ede Sa ak a jn a a hee ord ie t kd cis B an A ae 25 S PANIG PM 25 6 2 COINS P r Pmm 25 6 3 Daily inspection procedure 2 222202 02 nn 25 6 4 Annual inspection lel et e n an n nn won won non n nn won non non monn non nn mon nna 25
10. of damage and do not have any bumps nor obstacles 5 DOORS AND HATCHES OK Not OK ISSUE DESCRIPTION ee RN DIO aa DA DA A S 5 5 Main service lift door guard locking is properly mounted and tightened EH 32 AVANTI Service Lift for Wind Turbines 6 1 All electrical cables are free of damage specially isolation 6 2 Electric cables are properly layed and fixed with necessary cable ties CD 6 3 Sealing of control boxes is in order 6 4 Internal light illuminates properly with and without power supply emergency function 6 5 Warnings lights function properly Cable reliefs are properly mounted cables not loaded at the cable plug 7 1 Clean only when very dirty ensuring sufficient air supply If hour counter reads 250 h since last overhaul overhaul device at AVANTI workshop and furnish with new certificate N W 7 3 Current matches figure of service lift data plate 7 4 All fixing screws and bolts are present and properly tightened 7 5 Electromagnetic motor brake check that air gap between brake and disc is 0 3 mm 7 6 There is no trace of oil leak around motor and gearbox a 7 Traction hoist is free of damage no dents cracks or similar 7 8 The manual descent system functions properly 7 9 Manual descent actuator is present and is properly stored 7 10 Traction hoist sounds normal during travel L EE 83 If hour counter reads 250 h since last overhaul
11. s essential to the safety that the user always attach the energy absorber as high as possible above his her position to minimize the fall distance most possible in case of a fall The position of the anchor point is crucial for fall arrest the height of the fall elongation of lanyard and energy absorber or pendulum movement of the user should be considered in order to minimize the risk of impact in obstacles in case of a fall It s prohibited for the user to do many modifications or use non original Avanti components when assembling AVANTI LIFT ANCHOR Re use of demounted AVANTI LIFT ANCHORS or parts is not allowed Any changes or other uses beyond this manual are strictly forbidden Any changes or other uses beyond this manual are strictly forbidden This documentation must be kept in the service lift for the purpose of subsequent examinations of the anchor device If there are any doubts to the safety of the AVANTI LIFT ANCHOR or it isn t proper fixed deform or damaged with cracks or similar incompatible harms it may never be used Please contact the manufacture immediately In case of corrosion the anchor immediately needs to be removed Only to be used for fall arrest not to hoist or hang in goods or similar Before attaching in the ANCHOR the user needs to check it is sitting fixed and screws are sitting tight and proper If AVANTI LIFT ANCHOR has arrested a fall it may never be used again Part must be removed from
12. service imme diately E 3 Marking Marking on Lift Anchor plate LIFT ANCHOR POINT EN 795 2012 ANSI Z359 1 2007 AS NZS 1891 4 2000 AIS 304 CAPACITY 22 2KN MAXIMUM 1 USER PO XXXXXX YYYY P N 45512194 After installation marking shall be completely accessible otherwise additional marking near the anchor device will be necessary AVANTI product nam European American standard number Material and Capacity rating Unique identification number Item number E 4 Installation The installation must be performed by a competent AVANTI LIFT ANCHOR person following the instructions of this manual 1 Fix the anchor point to the structure using the supplied hardware as shown in the AVANTI LIFT ANCHOR is tested and approved only picture below to be installed on AVANTI lift AVANTI LIFT ANCHOR made from AISI 304 Steel has to be screwed with two 2 Torque the nuts with 15 N m 11 Ib ft bolts DIN 933 A2 70 M12 mm 4 washers DIN 125A A4 and self locking nuts DIN 985 A4 M12 In case of 3 Make sure the Anchor is fully seated and doubt please contact AVANTI properly tightened Before installing the AVANTI LIFT ANCHOR in heights 4 Fill in Installation form assure to be proper secured against fall from height by using relevant fall arrest equipment 5 Carry out yearly inspection by following the procedure in the section Inspection User s Installation and Maintenance Manual 37 E 5 Ins
13. 6 4 1 Annual inspection procedure ese st un n w n n n wa wow won non nn nn nn nna 25 6 4 2 Air gap between brake and disc tet nn won n nn non n non non n nn non nn 26 6 4 3 Common damages on wire ropes e ne vwe nna nna n nn nna n nna 26 6 4 4 Overload T SE c ue su a e tk ae ee a Rs ec ork cs orc ROS Ge an en ee ate ee eee 26 6 5 Spare parts ne cae een pti a e Cmte ee eek EE 26 6 6 Troubleshooting a 27 Appendix A Regulation of overload limiter a 29 Appendix B Safety measures 222222 222 33 Appendix C Inspection checkliSt vseeeeeeeeeeeeseeneeseeneeus 34 Appendix D Operation log sheet 0 ccc ete ees 35 Appendix E AVANTI service lift anchor 0 0 00 cece eee eee 36 Appendix F Service tool kit 0 0 00 cc ccc cece eee eee ee eee 40 User s Installation and Maintenance Manual 5 1 Limited Warranty Avanti Wind Systems A S warrants that com mencing from the date of shipment to the Customer and continuing for a period of the longer of 365 days thereafter or the period set forth in the standard AVANTI warranty the Product described in this Manual will be free from defects in material and workmanship under normal use and service when installed and operated in accordance with the provisions of this Manual This warranty is made only to the original user of the Product The
14. 67 for L95 and AD00068 for L80 4 2 2 Before transport Alternatively the service lift can be transported already assembled Once at destination the pre assembled lift shall be extracted from the packaging by means of a crane and the lifting eye bolts 4 3 Cautions Prior to installation ensure that e Building sections involved will be able to withstand the service lift loads e All parts are available and fully functional e Travel zone is protected by fences at each platform e Walking way surfaces are dry and not slippery The customer must define the maximum allowable wind speed ensuring safe installation During installation tasks personnel shall e Wear at least the following PPE fall arrest equipment if falling height is higher than 2 m hand gloves helmet safety glasses working gear e Use a hand winch attachable to the ladder when elevating heavy weights e Use a cable clamp or grip when lowering traction and safety wire ropes e Not work at different levels if tasks involve risk of falling objects Installation shall be performed by AVANTI or trained personnel by AVANTI At the end of the workday secu rity measures must be taken to put the service lift out of service and make the ladder accessible 4 4 Service lift installation a A The WTG manufacturer shall provide LI 3D drawings to ensure that installation of lift on ladder is possible 4 4 1 After tower erection The service lift is installed
15. AKA CERE ea e etik fk e OY RON AG oS oe Oe a Ne e e Daw 16 3 6 14 Bottom obstruction device st tt von n w n n n na na na nn nn nannan 16 3 6 15 Top obstruction dEVICE te tn won won n n n nn nw non non non nn nn nn nna 17 3 6 16 Top normal limit SWIICN sss kk Rd RS E 64 60 KANG A X AP KAGAD n RACE in a eens 17 3 6 17 Manual descent system 22 tee ne ven nn won n nn non n na n nn nn nn nn 17 3 06 18 Overload lIMItT x asara ak e ec weed ee MAG A RE weed c 8E 8 A C a 17 3019 Internal P 17 020 Warning OMS ss d ba arabe BA KAMAR NMAN DA Ka SESE ded dcs RO RUE Re Ha dd 17 362I ANCHO DOING 22246246 oc xu bea ced GR NS 18 3 6 22 Rescue pendant COntrOl err 18 3 6 23 Information signs and documents ern 19 3 6 24 Travelling cable pulley ees 19 Installation mV 20 4 1 WTG integration requirementS e eeeseeeeseesesseseon 20 4 2 Preassembly by the WTG manufacturef eeeeeseoo 20 TS O11 1 0 d 21 4 4 TOD DEAM uox cae s 9e x0 C89 Re Se Rc ada ae sek Roc C CR 21 4 5 Electrical connections on site eeeeeeeeooenennnn 21 4 6 Travelling cable eeeueseeeuesuu ee w esensensesenseesn 21 4 7 Traction wire rope 2 lel el en kn kn un a
16. ARE EXPRESSLY DISCLAIMED BY AVANTI IF PURSUANT TO ANY APPLICABLE LAW TO THE EXTENT AN IMPLIED WARRAN TY CANNOT BE EXCLUDED AS PROVIDED IN THIS LIMITED WARRANTY ANY IMPLIED WARRANTY IS LIMITED IN TIME TO THE SAME DURATION AS THE EXPRESS WARRANTY PERIOD SET FORTH ABOVE BECAUSE SOME STATES DO NOT PERMIT LIMITATIONS ON THE DURATION OF IMPLIED WARRANTIES THIS MAY NOT APPLY TO A GIVEN CUSTOM ER THIS LIMITED WARRANTY GIVES CUS TOMER SPECIFIC LEGAL RIGHTS AND CUSTOMER MAY HAVE OTHER LEGAL RIGHTS UNDER APPLICABLE LAWS This disclaimer shall apply even if the express warranty fails of its essential purpose In any cases of dispute the English original shall 2 Introduction 2 1 Observations Only trained people may use this lift This manual must be available to staff at all times during installation maintenance and operation Additional copies are available from the manufacturer upon request All measurements are indicative only and subject to change without notice The pictures and sketches in this manual may not reflect the product aesthetics colours arrangement precisely This has no impact on the function or safety o 2 2 Symbols Symbol Signal word Safety instructions DANGER DANGER CAUTION gt PO Additional instructions ATTENTION e IMPORTANT Order LI Meaning IMMEDIATE or possibly imminent danger IMMEDIATE or possibly imminent danger of hazardous voltage Potentially haz
17. PT pin The trapped key lock is properly tightened to the platform fence and fully functional if cf tx User s Installation and Maintenance Manual 33 15 4 Verity that all information signs and documents are available and legible CA 16 1 Service lift is in overall good operational condition me Name ar een in capital letters Signature of competent s Competent inspection may only be performed by AVANTI or competent person certified by AVANTI L A Every 12 months competent inspection has to be camed out and the Inspection checklist and Operation II log sheet must be completed for possible future reference 34 AVANTI Service Lift for Wind Turbines log sheet ion Operat Appendix D User s Installation and Maintenance Manual 35 Appendix E AVANTI lift anchor E 1 Caution AVANTI LIFT ANCHOR is an anchor point used for protection against falls from heights intended for use with a full body harness approved according to EN 361 or Z359 1 2007 as applicable Connection to the LIFT ANCHOR is only allowed by using self closing connectors according to EN 362 or Z359 1 2007 as applicable Use in connection with other equipment than specified may be potentially dangerous User shall be equipped with a means of limiting the maximum dynamic forces exerted on the user during the arrest of a fall to a maximum of 6kN In case of doubt please contact AVANTI The maximum load that can be tr
18. Push the UP button of cabin control box to continue feeding wire rope through until the hoist starts pulling 5 Open maintenance cover and feed wire rope through guide bushing of service lift 6 Feed through guide bushing of travelling cable pulley 7 Feed through the platform hole see ID00112 for holes position 8 Attach an 11 kg counterweight to it at least 600 mm below the bottom platform 9 Coil and fasten remaining wire rope with at least 3 cable ties 10 Check that wire rope and counterweight are able to rotate freely 8 Safety wire rope Feed the safety wire rope through the roof into the fall arrest device inlet opening 2 Pull the wire rope through while tuming the fall arrest device release lever clockwise 3 Open maintenance cover and feed wire rope through guide bushing of service lift 4 Feed through guide bushing of travelling cable pulley 5 Feed through the platform hole see ID00112 for holes position 6 Feed the wire rope through the compression spring f Fasten cable ties to the compression spring and adjust them to compress the spring 8 Pre tension the safety wire rope by hand as much as possible and fasten the wire lock 9 Cut the cable ties that keep the spring compressed The spring will apply a tension of approximately 40 kg to the safety wire rope Ng 9 Travelling cable pulley Tum the override key of bottom obstruction device switch S2 2 Manually descend service lift unt
19. Service Lift for Wind Turbines Service control box Top railings with nonslip surface Service anchor point oe When service tool kit is installed rated load is decreased from 240 kg to 215kg Top obstruction device becomes disabled when service tool kit is installed During ascent personnel shall constantly verify that travel zone is free of obstacles When connected service control box overrides cabin control box If it is not connected no upwards travel is possible Service control box does not override any safety if any hatch door or limit switch or emergency stop button is triggered no running will be possible Service top limit switches override those ones on the cabin A service top limit plate is attached to the ladder to trigger these switches 00 6 Only one user travelling on top with service tool kit installed is allowed Additionally a second user inside the cabin is also allowed During service lift travelling personnel shall not extend their body parts beyond the service tool kit perimeter No person is allowed at platforms when service tool kit is used F 4 Information signs and documents The following documents signs and labels are supplied with the service tool kit and shall always be available Location Document Standing on top only with service tool kit label Electrical hazard warning label QUICK GUIDE SERVICE TOOL KIT e oo a manga m Product conforms t
20. ansmitted in service from the anchor device to the structure is 22 2 kN in 15 vertical direction The maximum deflection of the anchor point that can occur in service is 10mm AVANTI LIFT ANCHOR is tested and approved only to be mounted on AVANTI lifts This manual always needs to be represented in language of sale and provided for use by all technicians Activities at height are dangerous and may lead to severe injury or even death Gaining an adequate apprenticeship in appropriate techniques and methods of protection is important and is your own responsibility E 2 Danger The AVANTI LIFT ANCHOR is for the use of one person only It is strictly forbidden to carry out work if the person is in unfit mental or physical condition Climbing and working under the influence of alcohol drugs or any medication which can interfere with the safety are also much prohibited Observations Only to be used by instructed workers Instructed workers must be aware instructed and prepared to utilize site rescue plans Only to be used for preventing vertical fall 36 AVANTI Service Lift for Wind Turbines Users are obliged to read and understand this User Manual Further they need to be proper equipped and instructed with the use of the necessary fall arrest equipment and emergency procedures in case of injury or sudden illness Users going to install AVANTI LIFT ANCHOR need to be familiar with the installation section of this manual It
21. ardous situation Potentially dangerous situation Useful tips for optimum working procedure Reference to written Possible injury if not observed Death or severe injury Death or severe injury Light injury or material damage Damage to equipment or workplace None specification documentation User s Installation and Maintenance Manual 7 2 3 Cautions Installation and or maintenance and or operation of the service lift and its suspension may be performed only by qualified personnel hired by the employer for the job at hand The personnel must be at least 18 years of age The staff must be familiar with the relevant accident prevention instructions and must have received proper training in these Personnel are obliged to read and understand this User s Manual Personnel shall wear PPE safety helmet full body harness shock absorber lanyard and slider at all times A copy of the User s Manual must be handed out to the personnel and must always be available for reference If more than one person is entrusted with one of the above tasks the employer shall appoint a supervisor in charge of the operation Electrical connection of the system must be made in accordance with EN 60204 1 Self locking nuts must be used at all times The screw must extend from the nut by at least half of the thread diameter The nut may not be used once it has become possible to loosen by hand If any damage or faul
22. be attached to safety ladder by means of the fall arrest equipment Use a hand winch attachable to the ladder to safely elevate preassembled service tool kit over service lift F 8 Instructions for use at bottom platform To access service tool kit from bottom platform 1 Level service lift floor with platform floor 2 Open ladder access door 3 Attach slider to ladder safety rail and climb onto the ladder 4 Open top hatches and climb through them 5 Close ladder access door and top hatches with your foot 6 Release slider and close swinging profiles 7 Hook your fall arrest equipment to the service anchor point 8 Press and hold the UP and OK buttons simultane ously two hand controls to ascend Egress from service tool kit is done in reverse order 42 AVANTI Service Lift for Wind Turbines F 9 Instructions for use at intermediate and top platforms To egress to intermediate and top platforms from service tool kit Level service lift roof with platform floor 2 Climb over service tool kit fence and overpass platform fence as specified by manufacturer 3 Hook your fall arrest equipment to the service anchor point 4 Press and hold the DOWN and OK buttons simul taneously two hand controls to descend Access to the service tool kit from intermediate and top platforms is done in reverse order F 10 Maintenance planning Frequency Performed by Components Daily Control and safety
23. ce interrupts descent if e t encounters an obstacle e t reaches the bottom platform Ascent will still be possible for instance to remove the obstacle In order to put the service lift on the ground the contact plate functionality can be bypassed with the override bottom obstruction device switch located on the cabin control box To do so turn the override bottom obstruction switch key while pressing the down button Release the DOWN button as soon as the rubber bumpers hit the floor Otherwise the service lift or the installation may get damaged An emergency bottom obstruction breaker permits the bottom obstruction device to be still operational during manual descent Manual descent will be stopped if an obstacle is encountered Guiding shaft 4 supporting wire Guiding shaft 4 supporting wire Bottom obstruction Bottom Emergency bottom switch S2 d obstruction obstruction breaker device plate 3 6 15 Top obstruction device Top obstruction device interrupts ascent if it encounters an obstacle Descent will still be possible for instance to remove the obstacle When the top obstruction device switch S1 is engaged press the down button until it disengages Do not use the service lift until the top obstruction device switch S1 fault has e been rectified Top obstruction TOP Guiding switch S1 obstruction shafts with device plate Guiding shafts spring with spring 3 6 16 Top limit
24. d until 2018 05 13 Cologne 2013 05 13 TUV Rheinland Industrie Service GmbH Alboinstrafse 56 12103 Berlin A TUVRheinland Telefon 49 0 30 75 62 1557 Fax 49 0 30 75 62 13 70 Precisely Right Date of publication 1st CE Edition 6 2013 Revision 3 12 06 14 Manufacturer AVANTI Wind Systems A S R nnevangs All 6 3400 Hiller d Denmark 45 4824 9024 45 4824 9124 info avanti online com www avanti online com TI Tl O QU ALITY MANAGEMENT Sales amp Service Australia Avanti Wind Systems PTY LTD China Avanti Wind Systems Denmark Avanti Wind Systems A S Germany Avanti Wind Systems GmbH Spain Avanti Wind Systems SL UK Avanti Wind Systems Limited USA Avanti Wind Systems Inc India Avanti Wind Systems PL Brazil Avanti Brazil Sistemas Eolicos S L Manufactured Under Process Patent NO 8 499 896 Registered in Europe UU UU U0 UU U0 UU 61 0 7 3902 1445 86 21 5785 8811 45 4824 9024 49 0 41 21 7 88 85 0 34 976 149 524 44 0 1706 356 442 1 262 641 9101 91 44 6455 5911 55 85 9671 6336 Contents L 2 4 Page Limited warranty eeeneetersesseseseeusseensnusnseusesensnn 6 INTOQUCHON sapa ceed tae seer 7 2 1 ODSEIVAB ONE cese gars dH a cd data a ii E e fk A E AERA d 7 Vu KAPA absid fd it ik at a ei e PED PA 7 ZO GAUMONS sararma kl ii scons mi ii HA DA et a ci Aa aes dae PE oop f aie ENA 8 De
25. dant control back in bottom platform Rescue control attachment box Blocked rescue route Rescuer Rescue pendant control User s Installation and Maintenance Manual 31 Appendix C Inspection checklist Date OT Serial n traction system Name of competent DO Serial n fall arrest device Litt e Tower n Total hours of operation EOO Address of installation 1 TRAVEL ZONE OK Not OK ISSUE DESCRIPTION 1 1 Travel zone is clear of obstacles an 2 CONTROL 8 SAFETY DEVICES OK NotOK ISSUE DESCRIPTION 2 mn paon RN J with platform Ey O Poston OK tamp Mamats tascent descent are possible 23 foeseecascent deoentor posee release ascent descent are possible 2 4 Press and hold internal UP button ascent is possible 2 m 25 Counter turn lever door cannot be opened 26 Press and hold red button main guarlocking only for L95 door can be opened Release button door cannot be opened 2 7 Press and hold internal DOWN button descent is possible 0 5 m 28 While OK lamp illuminates 1st user triggers top limit switch S1 1c lever and 2nd user presses internal UP button ascent is not possible While OK lamp illuminates 1st user triggers emergency top limit switch S13c lever and 2nd user presses internal UP button ascent is not possible Press and hold internal DOWN button until bottom obstruction device reaches floor 1 5 N eo CO e m d
26. devices of service tool kit only when mounted F 11 Troubleshooting Breakdown Specific cause Solution The service lift Service tool kitis It overrides cabin control box Use service control box cannot ascend installed nor descend Service emergency top limit Manually descend service lift switch S13r is activated until switch is released Swinging profiles door switch Close door S20 is triggered Service lift can Service tool kit is Service lift has reached top descend but installed and limit cannot ascend service top limitswitch S1 1r is activated 1 CONTROL AND SAFETY D SE TOOL KIT N Press and hold UP and OK Buttons simultaneously cms hand eS ascent is NEM EE NN possible 2 m While triggering service top limit switch S1 1r lever press and hold UP DEBE and OK buttons simultaneously ascent is not possible dg and hold DOWN and OK buttons simultaneously descent is possible 1 HAY m D While triggering service emergency top limit switch S13r lever press and hold HUY UPand OK buttons simultaneously ascent is not pose 15 a ne button descent is not possible Pull to release emergency stop button of service control box and press and hold CAY DOWN and OK buttons simultaneously descent is possible 0 5 m aano ere pt simultaneously descent is not possible Close swinging profiles door and press and hold DOWN and OK buttons DEBE simultaneously descent is possible 0 5 m
27. ds used No Perform a full run to the top PSE boe POC Cee Te FTITEIIILLILITELLL Does overload limiter Yes engage during ascend an Pita ETELE EELE III ETT TT TT TT TETT dubai No 2 Turn the tool clockwise to increase the lifting load limit The overload is correctly set 3 Turn the too counter clockwise to decrease the VE lifting load limit One turn on the adjustment screw repre Travel distance Setup load Setup load Testload Test load sents a change of approximately 40 Kg of L95 kg L80 kg L95 kg L80 kg the lifting load limit 325 360 To adjust the lifting load limit proceed as follows User s Installation and Maintenance Manual 29 Appendix B Safety measures General The service lift is only to be used Operating the the service lift Anyone going in by personnel who have received instructions the service lift must at all times wear PPE safety in operating the service lift in all predictable helmet full body harness shock absorber lanyard situations These instructions can only be given and slider that fits ladder safety rail by a person with the proper knowledge e g Avanti Trainer or Trainer approved by AVANTI The following precautions and procedures are to be followed during operation of and if the service lift stops and the manual emergency descent cannot be performed Evacuation from the cabin is only necessary in extreme situations If necessary follow proce
28. dure below Evacuation through bottom hatches 1 Open ladder access door 2 Attach slider to ladder rail 3 Open bottom hatches 4 Climb out of cabin Evacuation through top hatches 1 Open ladder access door 2 Attach slider to ladder rail 3 Open top hatches 4 Climb out of cabin 30 AVANTI Service Lift for Wind Turbines Rescue of service lift is only necessary in extreme situations If necessary follow procedure below Rescue with unblocked rescue route oO Po NS Climb safety ladder until you reach service lift Open hatches Enter cabin and release slider Close hatches Attend casualty If necessary descend service lift to bottom platform Rescue with blocked rescue route 1 Take the rescue pendant control stored in bottom platform and attach it to your harness by means of a carabiner Climb safety ladder up to service lift carrying rescue pendant control Plug the rescue pendant control to rescue control attachment box Power the service lift 4 m approximately and then climb the ladder that same distance Repeat previous action until you reach the nearest platform Climb off the ladder to the platform floor Level service lift floor 100 mm approximately over platform floor open fence and service lift doors and attend casualty Unplug pendant control from rescue control attachment box so cabin control box is operational again Store rescue pen
29. ee eee eee eeepeeeeneeeata 1040 f User s Installation and Maintenance Manual 11 3 6 Components 3 6 1 Overview Hangin gn ABA NE ANYA E md asa Fa S sae 7 r oP ii Ta Taa E i i EENI 1 c mm omg TAE kje oat q ee NG BA NA a APP LP Lm gor Traction system Fall arrest device Cabin light Anchor points Maintenance cover Cabin control box Bottom obstruction device Guide ladder Guiding rollers O O NO 0 Bk ON 12 AVANTI Service Lift for Wind Turbines 10 Main control box 11 Hour counter 12 Ladder access door 13 Full sliding door 14 External controls 15 Top obstruction device 16 Safety wire rope 17 Traction wire rope 18 Travelling cable pulley 3 6 2 Traction hoist Tightness of safety wire rope must be Electro frequently inspected to ensure full m Dee functionality of fall arrest device spring loaded brake It is largely maintenance free Motor Manual descent Centrifugal actuator brake Traction system Gearbox The service lift is powered up and down along the traction wire rope by means of an electrical powered hoist It features a motor a gearbox and a traction system The motor is equipped with a motor overheat limiter Black unlocking knob Red locking knob and an electromagnetic motor brake oul down tavbloase bull down to chalaj fall arrest device fall arrest device Reliability endura
30. em is trig gered no running will be possible including the ob struction device switches S1 and S2 Therefore there is no risk of moving service lift hitting rescuer Pendant control overrides cabin control box and service control box if installed 18 AVANTI Service Lift for Wind Turbines 3 6 23 Information signs and documents The manual and quick guide are accessible from inside the cabin The following documents signs and labels are supplied with the service lift and shall always be available A rescue pendant control emergency sign shall be present at the bottom platform clearly indicating storage location of rescue pendant control Location Document Main control box 3 6 24 Travelling cable pulley Travelling cable is connected from power supply socket over mid tower s height platform to service lift socket and it is provided with a cable relief on each end A travelling cable pulley is suspended on the cable and is guided along the traction and safety wire ropes Travelling cable Travelling cable pulley Traction wire rope jt Safety wire rope The travelling cable pulley straightens the cable at all times Ford mna an QUICK GUIDE OCTOPUS Oniy personnel
31. escent is not possible and OK lamp stops illuminating 11 When service lift is levelled with platform main door can be opened While first user stands on and compresses top obstruction device second user presses land holds internal UP button ascent is not possible 2 13 Ascend to top platform wire rope fastenings are free of damages N N N N re A 1 Descend to bottom platform and record hour counter reading on operation log sheet It is less than 250 h since last overhaul 15 Cabin control box is free of damage g 2 17 All internal buttons of cabin control box are fully functional 18 All external buttons of cabin control box are fully functional send function zl 19 Bottom obstruction override switch of control box is fully functional 2 20 Emergency bottom obstruction breaker functions properly 3 CABIN OK NotOK ISSUE DESCRIPTION 3 1 Cabin is free of damage and properly assembled 3 2 Cabin is clean and in overall good condition 33 Bottom obstruction device is free of damage properly installed and fully functional it compresses and decompresses properly Top obstruction device is free of damage properly installed and fully functional it m e vv rr compresses and decompresses properly 35 Anchor points are free of damage without cracks dents and have no permanent deformation and properly tightened 4 GUIDING SYSTEM OK Not OK ISSUE DESCRIPTION 45 Ladder stiles and fish plates are free
32. fective fall arrest device will Replace it immediately threaten the safety of the service Manually descend service lift Test and repair or replace connections wiring and relays Ascend service lift to disengage the device The device is not properly installed pave a COMPETED technician adjust ne device correctly Send device to AVANTI to test repair or replace Have an authorised person replace it Appendix A Regulation of overload limiter Verification and or adjustment of the overload device on the service lift can only be done by a qualified person who must have been instructed by AVANTI to perform this task Avoid injury by strictly following the instructions Place the service lift on the lowest travel point Required tools material Apply the setup load from the table depending on the WTG height e Security Torx 40 Increase the lifting Decrease the lifting e Test weights for applying the test load festene pe NG lo load limit To modify the lifting load limit me vi dae 1 Insert the overload adjustment tool in the No adjustment screw through the hole as shown in the figure Remove 20 Kg from the setup load and push the UP button Overload adjustment tool No Can service lift ascend Review the values l of the loads used Yes Apply the test load from the table depending on the WTG height Review the values Can service lift ascend Yes of the loa
33. hen service lift is present Trapped key is attached to cabin by means of a wire rope preventing loss of key In case service tool kit is provided platform fences of intermediate and top platforms feature nonslip surfaces 3 6 9 Main service lift door Main access to the cabin is done through the full sliding door installed on the front The full sliding door opening dimensions are 2100 x 500 mm It features a guard locking system that e Prevents service lift to travel if the door is open This opening condition is monitored by the guard locking switch S19 3 Permits door to be opened only when service lift is levelled with a platform This levelling condition is monitored by the platform level switch S18 which is triggered by the safe zone plates Toe V Safe zone plate on all platforms Platform level switch S18 It is possible to manually release guard locking system in order to open main door between platforms for maintenance tasks or installation of WTG parts Internal manual release of guard locking of L95 External manual release of guard locking of L95 Manual release of guard locking of L80 accessible from outside and inside User s Installation and Maintenance Manual 15 3 6 10 Ladder access door Ladder access door consists of two hinged sheets that fold up when opened thus optimizing space In case of evacuation the ladder access door permits d
34. il rubber feet reach bot tom platform floor 3 Unplug travelling cable inlet from power supply socket over mid tower s height leaving it attached with the cable relief 4 Unplug travelling cable outlet from service lift socket 5 Demount plug head from cable and adjust cable length by cutting off excess 22 AVANTI Service Lift for Wind Turbines 6 Feed cable through pulley until it is positioned 2 cm from service lift wire rope bushings f Feed cable through cable relief mount plug and plug it back to service lift 8 Plug travelling cable inlet from power supply socket over mid tower s height relief Travelling cable Bottom platform floor Travelling cable pulley Rubber feet Traction wire rope Safety wire rope 4 10 Safe zone plates and top limit plate Adjust the final position of the safe zone plate on each platform so that the service lift floor is levelled with the platform floor when it stops Adjust the final position of the top limit plate so that the service lift floor is levelled with the top platform floor when it stops 4 11 Inspection before first use A service lift inspector must carry out an inspection before first use following the Annual inspection procedure and filling in the Inspection checklist Inspection shall only be carried out by Lt AVANTI or an authorized person l Ye following the Annual inspection procedure Ana filling in the Inspection checklist for future
35. irect access to ladder and ladder rail A safety switch interrupts control when door is open 3 6 11 Maintenance cover Maintenance cover allows safe and fast inspection of traction and safety wire ropes from inside the cabin while travelling 3 6 12 Bottom hatches Bottom hatches can be opened from both sides thus allowing egress and ingress from underneath Bottom cabin hatch opens inwards and bottom obstruction device hatch opens outwards Each of them has a safety switch that interrupts control when hatch is opened Once top hatches and ladder access door are open clear area is at least 500 x 500 mm and ladder becomes totally accessible Direct evacuation to ladder is possible at any position along the WIG 16 AVANTI Service Lift for Wind Turbines Ei A Si 1 mi E ui r3 ar meg m pi 3 6 13 Top hatches Top hatches can be opened from both sides thus allowing egress and ingress from above Each of them has a safety switch that interrupts control when hatch is opened Top cabin hatch consists of two hinged sheets that fold up when opened thus optimizing space Top obstruction device hatch opens outwards Once top hatches and ladder access door are open clear area is at least 500 x 500 mm and ladder becomes totally accessible LI Li i LI si THIT kh op HI a r foal it E Burt C BH M NN LE m 3 6 14 Bottom obstruction device Bottom obstruction devi
36. isconnected Connect power supply The service lift is stuck by an A Nempting obstacle to use the W lift will jeopardize work safety Grid voltage interrupted daig cause and wait for the power to Supply between grid connection and Test and repair or replace connections 5 Power failure control interrupted wiring and fuses A A A A A A A A A Slack rope sensor1 is engaged 1 Note Optional feature Mandatory for Test slack rope sensor s functionality AECO versions Top limit switch S13c is activated Manually descend service lift until switch is released Main door guard locking switch S19 3 Ladder access door switch S19 is Close door A top hatch switch S51 4 S53 is Close hatches A bottom hatch switch S52 amp S54 is Close hatches Adjust manual descent switch so that it is not involuntarily activated Test and repair or replace connections wiring and fuses o Q lt o D Q 6 A safety switch is engaged Q Ko D I Dm Q Manual descent switch is activated A phase is missing 3 KO KO D Dm e Motor is not cooling Clean the motor cover Measure voltage and power consumption on the loaded motor If voltage deviates from Overheating protection switch is activated Voltage too high low specifications use cable with increased dimensions Electromagnetic motor brake Power supply failure does not re
37. lease no click Braking coil or rectifier is defective sounds when UP or DOWN _ Braking rotor does not open The trapped key is not 9 present or the trapped key Have an authorized person test and repair 1 2 3 4 7 B or replace the traction hoist Insert the key and turn it to the ON position switch is in the OFF position 10 The guard locking switch is Test and repair or replace defective or not functioning properly damaged components Check the slack rope sensor1 connection function Replace if necessary 1 Note Optional feature Mandatory for AECO Slack rope is engaged version Overload buzzer sounds Service lift is overloaded Reduce load until buzzer stops Two phases are changed in Have an authorized person switch the 2 12 Phase monitor relay interrupts control the power supply phases in the plug Use rescue pendant control in case of rescue It overrides cabin control box event Otherwise unplug pendant control A A Rescue pendant control is ids plugged User s Installation and Maintenance Manual 27 Breakdown Service lift can descend but cannot ascend Specific cause The service lift is stuck with an abstacle over it Top obstruction device is engaged Switch is defective Service lift has reached upwards travel limit Bottom obstruction device is engaged Top final limit stop switch is activated B3 A phase is missing Fault in UP cont
38. n control box to send the service lift to bottom platform e Push external UP button of cabin control box to send the service lift to top platform NOOR ON 5 4 Enter and exit cabin through door 1 Hook up your shock absorber to an anchor point every time the service lift door is open 2 Be aware of tripping risk if service lift floor is not perfectly aligned with platform floor 5 5 Emergency stop button 1 Press the emergency stop button to interrupt any control function 2 Pull to reset the control after necessary verifications 5 6 Fall arrest device 1 Pull the red locking knob downwards to manu ally engage the fall arrest device in case of an emergency 2 Pull the black unlocking knob downwards to release the fall arrest device 3 If the fall arrest device cannot be released as cend the service lift a few centimetres to remove the load on the safety wire rope When a fall is arrested service lift is exposed to dynamic loads Inspect and replace damaged wire ropes wire rope fastenings fall arrest device and guiding system including ladder User s Installation and Maintenance Manual 23 5 7 Manual descent Manual descent shall only be done in case it is strictly necessary e To ensure a safe manual descent person nel shall use walkie talkies between them Verify that the fall arrest device is released 2 In case it cannot be released evacuate the service lift follo
39. n of the service lift necessary for its safe and correct installation ELI Tower manufacturer s risk LI assessment shall include a service lift integration study User s Installation and Maintenance Manual 9 3 4 Technical specifications Service lift Traction hoist Travelling cable Travelling cable type Intended for use in WTG Travelling cable weight approx 0 18 kg m Travelling cable minimum breaking strength 1500 N Socket type To be agreed with customer Ladder requirements 1 mose m en 1 Other dimensions are possible upon request and design verification by AVANTI 40 kg Dimensions 266x300x61 mm Vertical speed under operation 18 m min 20 96 Service tool kit Power 50 Hz 1 5 kW Service tool kit weight lt 25 kg Power 60 Hz 1 8 kW Service lift rated load when service tool kit 215 kg Rated current 400V 690V 50 Hz 4 1A 2 3A installed Fall arrest device mode ae nn vntwegm a te Traction and safety wire ropes Weight 1 o7wm Cabin dimensions L95 Cabin weight 200 kg L80 Cabin weight 192 kg Distance from the rung center to the cabin outer edge Min Emergency exit free pass dimen 500 x 500 mm Power supply Power supply type 3 Phase PE N Voltage 400V 690V 5 Yo Ar ais Power 15 50 Hz 1 5 kW Rated current 4 1 A 2 3A Voltage 400 V 480 V 690 V 5 Power supply 30 He Power O aw Fue pma 10 AVANTI Service Lift for Wind Turbines 970 mm 3 5
40. nce and safety of this hoist are only possible with the use of AVANTI e approved wire ropes 3 6 4 Guiding system It is largely maintenance free The service lift is safely guided along ladder stiles by means of guiding rollers 3 6 3 Fall arrest device Ladder dimensions shall be compatible The service lift is provided with a fall arrest device with guiding rollers which will be triggered in case of an overspeed e condition The speed of the safety wire rope passing through the device is continuously monitored and the jaws automatically close in the event of sudden excessive speed This device protects the service lift against traction wire rope breakages or traction system failures The fall arrest device can also be engaged manually in an emergenoy by pulling the red locking knob downwards To release the fall arrest device pull the black unlocking knob downwards User s Installation and Maintenance Manual 13 3 6 5 Main control box o KON 1 Rescue control attachment box socket 1 2 Top hatch switch S53 socket 12 3 Top limit switch S1 1c socket 19 4 Emergency top limit switch S13c socket 14 5 Ladder access door switch S19 socket 19 Main door guard locking switch 819 3 amp platform 16 level switch 818 socket 17 7 Bottom obstruction switch S2 socket 18 8 Bottom hatches switches S52 amp S54 socket 19 9 Bottom warning light socket 20 10 Hour counter 3 6 6 Cabin control box Platform level
41. nections on site on wards 4 5 Electrical connections on site Before making any connection disconnect any power supply to the service lift and the fence interlock system and verify with WTG respon sible The electrical connection of the traction hoist must be made in accordance with EN 60204 1 The power supply must be protected by a fuse and against indirect contacts according to local regulations Verify that the rated grid and motor voltages are identical Electrical system shall be properly insulated 4 6 Travelling cable 1 Install power supply socket over mid tower s height platform and install a cable relief on the platform fence Platform fence Support Cable Relief Travelling Cable 2 Feed travelling cable through the cable relief without plugging it to power supply socket 3 Uncoil the cable to the bottom platform The travelling cable must be evenly uncoiled to prevent looping 4 Plug travelling cable outlet directly to service lift provi sional connection 5 Plug travelling cable inlet to power supply socket over mid towers height User s Installation and Maintenance Manual 21 4 7 Traction wire rope 1 Uncoil both wire ropes to the bottom of the WTG All wire ropes must be evenly uncoiled to prevent looping 2 Check that traction and safety wire ropes are not crossed 3 Feed the traction wire rope through the roof into the traction hoist inlet opening 4
42. nutes 3 6 20 Warning lights A set of warning lights is mounted on the top and on the bottom of the service lift The flashes warn that the service lift is moving User s Installation and Maintenance Manual 17 3 6 21 Anchor points The service lift features two anchor points inside the cabin Each anchor point may only be used by one user simultaneously During operation personnel shall hook themselves up to the anchor points inside the cabin in order to prevent falling risks In case of need of evacuation the evacua tion procedure will be followed 3 6 22 Rescue pendant control Rescue pendant control is only mandatory if rescue route of service lift can be somehow blocked A blocked rescue route is an event where e A person is unconscious inside the service lift blocking the bottom hatch e the rescuer is below service lift and e the service lift is stopped halfway through a platform hole blocking rescue route since platform has no extra hatch There shall be one rescue pendant control per WTG and it shall be stored in the WTG bottom platform A clearly visible sign shall e indicate its exact location It features three buttons UP DOWN and emergency stop button When necessary pendant control is plugged to cabin bottom socket It has a 4 m long cable that permits service lift to be powered up down that same distance When plugged pendant control does not override any safety switch If any of th
43. o ACCESS 8 EGRESS AT INTERMEDIATES AND TOP PLATFORMS Standing on top only Service tool kit with service tool kit Quick guide Electrical hazard warning label F 5 WTG integration requirements Special attention shall be given to the integration of the service tool kit WTG General integration component requirements Treatment of top surfaces of fences of intermediates and top platforms If service tool kit is supplied F 6 Service activation plate If service tool kit is supplied adjust the final position of the service travel limit activation leaving at least 350 mm between plate and top beam holes for shackles P Top beam F sa 7 Min 350mm Service top limit plate F 7 Installation Service tool kit shall be assembled on bottom platform floor 1 Position the preassembled structure over service lift roof 2 Insert vertical profiles through top obstruction device holes 3 While a first installer stands on and compresses the top obstruction device a second installer fastens a bolt through each vertical profile 4 Connect electrical cables to two hand control boxes 5 Feed them thorugh top obstruction device hole 6 Connect them to main control box Service tool kit fixing bolts 1 i LET LET pi a i 1 Li a Bh User s Installation and Maintenance Manual 441 Disassembling is done in reverse order When standing on top of cabin installer shall
44. o are under the influence of alcohol or drugs which may jeopardize working safety Service lift shall ONLY be used when the turbine is not generating power All wind farm site specific rules must be followed Service lift shall not be used during inclement weather including wind speeds over 18 m s Avoid injury follow all instructions The tower owner must verify the need ELI for third party service lift inspections LH with the local authority and comply with the standards specified 3 Description 3 1 Purpose The service lift purpose is to transport persons plus their tools and equipment to the most convenient height for performing work in wind turbine generators WTG Its use is limited to authorized personnel by AVANTI holding the relevant training certificates The access to the WTG and consequently to the service lift is controlled and forbidden to public access The service lift is used primarily to transport technicians their tools and spare parts from the bottom platform or lowest accessible point to the top platform or highest accessible point It is also used to access intermediate platforms where inspection and service of WTG connect ing bolts and other equipment is made 3 2 Scope The Octopus service lift system consists of the following subsystems e Cabin e Traction and fall arrest systems e Guiding system e Control safety and power systems including an interlock system on
45. of the periodic examination must be recorded in the Registration form of anchor 38 AVANTI Service Lift for Wind Turbines E 7 Registration form of anchor Identification no Avanti Wind Systems A S DK 3400 Hiller d Avanti lift Anchor Tel 45 48 24 90 24 Fax 45 48 24 91 24 www avanti online com Date first put into service User s Installation and Maintenance Manual 39 Appendix F Service tool kit F 1 Purpose If optional service tool kit is provided it is possible to perform visual inspection repairs and service of components along the WTG while safely riding on the top of the cabin F 2 Technical specifications Service tool kit Service tool kit weight lt 25 kg Max n persons on service tool kit 1 person F 3 Description The service tool kit is an optional portable tool that allows personnel to ride on top of the service lift in order to perform installation and service tasks along the travel zone e During erection of WTG installing WTG power supply and auxiliary cables running close to the lift e Maintenance tightening and verifying torque of WTG flange bolts e Repair replacing components which are accessible from the lift lights junction boxes and cables Swinging OK button profiles door Swinging profiles door switch S20 Service top limit switch S1 1r Service emergency top limit switch Service tool kit is lighter than 25 kg 40 AVANTI
46. on to the ladder after tower erection 1 Mount safe zone plates top limit plate and rest platforms on ladder according to installation drawing IDOO112 2 Fit the nuts and bolts to the shackles and lock with cotter pins 3 Mount traction and safety wire ropes 08 mm using the shackles supplied for the top beam at the top of the tower 4 Follow instructions from chapter 4 5 Electrical connec tions on site onwards 4 4 2 Before tower erection Alternatively the service lift can be installed on to the ladder before tower erection With the tower section lying horizontally 1 Mount safe zone plates final limit activation plates and rest platforms on ladder according to installation drawing IDOO112 2 Fit the nuts and bolts to the shackles and lock with cotter pins 3 Mount traction and safety wire ropes 08 mm using the shackles supplied for the top beam at the top of the tower 4 Attach coiled wire ropes to top beam by means of cable strips to prevent them from moving during transport of tower section 5 Position service lift on ladder at bottom platform by means of a crane and the lifting eyes and according to dimensions of installation drawing ID00112 6 Mount fixing set for transport to prevent lift from mov ing during transport of tower section 7 The tower sections shall be transported to the wind farm 8 After tower erection takes place follow instructions from chapter 4 5 Electrical con
47. overhaul device at AVANTI workshop and furnish with new certificate It is well lubricated using too much oil will not harm the equipment or the gripping function NEN Fall arrest device engages when performing overspeed hand test safety wire rope is HE fl 8 5 pulled by hand from first platform ns eret egg re Si wn parea on se The black unlocking knob releases fall arrest device when pulled down ko n o a C Vi TRACTION AND SAFETY WIRE ROPES OK UE DESCRIPTK They are clean and slightly greasy with a standard multipurpose grease free of disulphide CA 10 2 There are no 8 wire strand breaks or more on a wire rope length corresponding to 30 times the wire rope diameter P There is no reduction of wire rope diameter by 596 or more compared to nominal wire rope LO diameter Wire ropes are free of damages described in common damages on wire ropes Ei IT OTTO IF RMO OK Not OK ON E 11 1 Safety wire rope is properly mounted with a spring according to specific type manual Pf nn y Traction wire rope is provided with 2 properly tightened wire rope locks beneath the Dad counter weight Traction and safety wire ropes are properly coiled up and fixed with 3 cable ties each ee p e f 1 fi Top b 12 4 Lop beam is properly mounted and properly tightened to WTG or if welded its welding is m in good condition Each wire rope is properly mounted with a shackle a nut and a bolt locked with a cotter
48. pection After installation An inspection must be carried out by a competent person following the inspection form in this manual Before use Each time using the AVANTI LIFT ANCHOR the user inspects the ANCHOR visual and manually by twisting pulling Check the parts are properly fixed and free of deformities damages cracks or similar Periodical examination A periodic examination at least every 12 month is essential for the safety of the AVANTI LIFT ANCHOR The examination must be performed by a competent person following the inspection form in this manual For the AVANTI LIFT ANCHOR the competent person authorized in writing by AVANTI only needs to be trained in any metallic component covered unacceptable defects by the European American standard norms for fall arrest equipment E 6 Inspection form Avanti Lift Anchor PPE Anchor OK not OK 1 Lift structure does not show any deterioration 2 Anchor locking screws are fully inserted and tightened with 15 N m 3 Anchor does not show cracks deformities corrosion or other damages 4 Anchor installed on the lift structure according to the instructions 5 Anchor marking is clearly readable Signature of competent Name of competent in capital letters Date Is the Anchor in good condition to be used Yes Needs Repair Replace oo mm If the AVANTI LIFT ANCHOR is found not OK it must be removed replaced by a new AVANTI LIFT ANCHOR The result
49. platform fence doors e Arescue pendant control only mandatory if rescue route of service lift can be somehow blocked Each of the subsystems listed above and their components are described in detail throughout the document The system fully complies with essential health and safety requirements of European Machinery directive There are two versions L80 and L95 which differ in size Additionally there are two different configurations for working temperature ranges in particular there is a standard configuration and a low temperature configuration where traction system and main control box components are chosen specifically 3 0 Exclusions The service lift shall not be used outdoor or in potentially explosive atmospheres The service lift is not designed to carry a person on its top unless service tool kit is installed The wind turbine manufacturer is responsible of integrating the service lift and ensuring compliance with the essential health and safety requirements as stated on the 2006 42 EC Machinery Directive and the applicable harmonized standards following the manufacturer recommendations This will require supply of interface components including but not limited to Ladder system Brackets for ladder sections Platform fences with doors Power supply protection The wind turbine manufacturer shall also provide any additional relevant warning instruction and or training specific to the integratio
50. re mounted correctly free of damage and that none are missing in order to guarantee that the service lift can be used safely User s Installation and Maintenance Manual 25 The WTG owner must ensure that the results of all annual and extraordinary inspections and tests are logged in the Operation log sheet 6 4 2 Air gap between brake and disc Check that air gap between brake and disc is 0 3 mm using a thickness gauge IN AAA KORAN N VZZ LLI LAN N N 26 AVANTI Service Lift for Wind Turbines 6 4 3 Common damages on wire ropes Wire ropes shall be inspected as described in EN 12385 3 2004 A1 2008 including but not limited to inspection of following common damages Kinks resulting from counterweight of traction wire rope not being able to rotate freely SS Fa JIJ Sos s 8 Wire strand breaks Reduction of the Wire diameter Wire strap loop which cannot be unwound Loop knot forming when a wire loop is pulled tight Bends resulting from inappropriate treatment e g securing the load with the wire Damage resulting from crushing squeezing running over etc Wire bags Loop formation 6 4 4 Overload test Load the service lift to 12596 of its rated load When an attempt is made to start the hoist over load limiter should engage and prevent ascent and the overload buzzer should sound In case overload limiter does not engage follow procedure
51. rol circuit Wire ropes are dirty Further use of service lift may result in The service lift is stuck with an obstacle below it Motor hums loudly or wire ropes squeak but the service lift can ascend and descend damage to the traction hoist Service lift can ascend but cannot descend Traction hoist speed is too high The fall arrest device is holding the service lift onthe Triggering speed of fall arrest device is wire rope The device has engaged Fault in DOWN control circuit The slack rope sensor is holding the service lift on the traction wire rope 3 po The device is defective OK lamp does not illuminate although operation is normal The OK lamp is defective 28 AVANTI Service Lift for Wind Turbines Solution Carefully move the service lift downwards and remove the obstacle Test the operational safety of affected WTG and service lift components Inform the supervisor Test and repair or replace top normal limit switch Test fuses and power supply Test and repair or replace connections wiring and relays Clean wire ropes Test and repair or replace traction hoist at AVANTI Carefully move the service lift upwards and remove the obstacle Test the operational safety of affected WTG and service lift components Inform the supervisor Ascend service lift to free safety wire rope Release fall arrest device by pulling black lift A de
52. scription eeeeeeuensenensnuosenus Rh nnns 9 Gal UND OSE EMT 9 SU ceo a ne wal ai rat kn ki t diri ke l e de a f pin A tb at bee ra eee eee cae aide fk Aa di n 9 9 9 IEEXCIUSIOTIS oe arivis d UI an po di mon epe a ti pea a NDN dene dit ak a l ye n see eee eee ees 9 3 4 Technical specifications seteseeesesusnsesesensnsesesenn 10 3 0 DIMENSIONS ses KATA KANG dee op eek rede PAD KANAN ANA AAH ee 11 3 6 Go 10 916 2202452 ich ii ii KA NG KANA fat ai KANAN HLAG bA NOD NG MANA KABA DAA 12 GE OT ie aid KANAN GG a a a ea ee AA AN AN ee ee ee NG 12 9 5 2 ITA CHO MOIS wi cu ma ment nar ene VE a Cn 2 C Rec a WA UU T ee 13 3 6 3 Fall arrest device icai ere ewe ROC SCR KEN TRA ee ON AA KR pcm COR CR RR 13 9 6 4 Guiding SYSTEM s a w Ka ridic aues S S KANAN ANG mos NG eRe e f EE AA CE EUG A ii fan par od 13 3 0 5 Main CONLIOI DON Leren 14 3 06 Cabin Control DOK su ncs m RR CR n RC T Rc need EO A C XC E a OE ACA ed 14 3 6 7 Safety SWICNES s unida 9 hx thw we Ce eee RES KE DAANAN Ead EE RES Ra RU ES 15 9 D 9 Platform TE NC S 500 054 445 650 56640685 R a STAR Red nace BC RO ar ap da kk 15 3 6 9 Main service lift door 0 rh nn nna 15 3 60 10 Ladder access GOO w wi pama een whos om Cmm CR eR Fe ca C i T 16 3 6 11 Maintenance cover hh n n nn nn nn nna 16 5 12 DOLLOM NAICHES 45 4 make Rob AC ei kof f 829 9 3c he a po AE BARA PSK dak NGA 16 3 6 19 TOP AIC NE Se an sava n K
53. sole and exclusive remedy and the entire liability of Avanti under this limited warranty shall be at the option of Avanti a replacement of the Product including incidental and freight charges paid by the Customer with a similar new or reconditioned Product of equivalent value or a refund of the purchase price if the Product is returned to Avanti freight and insurance prepaid The obligations of Avanti are expressly conditioned upon return of the Product in strict accordance with the return procedures of Avanti This warranty does not apply if the Product i has been altered without the authorization of Avanti or its authorized representative ii has not been installed operated repaired or maintained in accordance with this Manual or other instructions from Avanti iii has been subjected to abuse neglect casualty or negligence iv has been furnished by Avanti to Customer without charge or v has been sold Avanti service lift Product 6 AVANTI Service Lift for Wind Turbines on an AS IS basis Except as specifically set forth in this Limited Warranty ALL EXPRESS OR IMPLIED CONDITIONS REPRESENTATIONS AND WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OR CONDITION OF MERCHANTABILITY FITNESS FOR A PAR TICULAR PURPOSE NON INFRINGEMENT SATISFACTORY QUALITY COURSE OF DEAL ING LAW USAGE OR TRADE PRACTICE ARE HEREBY EXCLUDED TO THE MAXIMUM EXTENT PERMITTED BY APPLICABLE LAW AND
54. switch Top limit switch S1 1c interrupts ascent if it is triggered by the top plate Emergency top limit switch S13c is triggered in case the top limit switch fails to engage It cuts off power supply so only manual descent will be possible Top limit plate is mounted on the ladder Top limit plate only on top platform Emergency top limit switch S13c Top limit switch S1 1c 3 6 17 Manual descent system The service lift features a manual descent system that can be used in case of emergency To activate it push the manual descent actuator upwards The electromagnetic motor brake is released The service lift descends with a controlled speed limited by means of a centrifugal brake installed between the motor shaft and the gear box 3 6 18 Overload limiter An overload limiter is built into the traction hoist In case of an overload it will prevent any movement of the service lift by interrupting control and a buzzer will sound until overload condition is eliminated Attempting to run an overloaded service lift is prohibited 3 6 19 Internal light The service lift is equipped with a light inside the cabin When service lift is connected to power supply this light illuminates at all times The internal light is battery packed in order to illuminate the inside of the cabin in case of a power failure When fully charged it will last at least for 30 mi
55. trained to use the service it may Batre using tha Product Working load limit Use of PPE label N persons label Manual descent label FAD de activation labels Main door guardlocking label Wiring diagram Electrical hazard warning label Rescue pendant No standing on top control emergency sign prohibition label User s Installation and Maintenance Manual 19 4 Installation 4 1 WTG integration requirements WTG component General integration requirements Power supply type Power supply e ocation of power supply connection for service lift Distance from rung center to platform outer edge for platforms over mid tower Distance from rung center to platform outer edge for platforms below mid tower Hole width for L95 Hole width for L80 Minimum clearance around service lift Minimum height rlvulnli lt lt 315 0 o m r en OD t CO O O KO c io O ai HH Oo OIO EM T NIN Nos 3 Phase PE N 400V 690V t 5 Yo 400 V 480 V 690V 5 Yo 16 A Acc To EN 60204 1 Over mid tower s height 1035 mm 1105 mm 1070 mm 920 mm 60 mm 600 mm Height Platform fences Compliant to requirements of standard EN 14122 Fence door interlock system Trapped key system Max total travel height for L95 125 m pisa pig tower total Max total travel height for L80 135 m typical 150 m tower total height Max angle between ladder axis and vertical
56. ts are found during operation or if circumstances arise which may jeopardize safety immediately interrupt the work in progress and notify the supervisor or employer All tests repairs of electrical installations may only be performed by qualified electricians All repairs to the traction braking and supporting systems may only be performed by qualified install ers If any supporting parts are repaired or replaced the operational safety of the system must be tested and verified by an expert Only original fault free parts may be used Use of non original parts will render the manufac turer s warranty void and any type approval invalid 8 AVANTI Service Lift for Wind Turbines No modification extension or reconstruction of the service lift is allowed without the manufacturer s prior written consent No warranty is provided against damage resulting from reconstruction or modification of equipment or use of non original parts which are not approved by the manufacturer Before using the lift an inspection by the authorized inspection organisation must be carried out Service lift must be inspected at least once a year by an expert trained by AVANTI In case of high oper ating frequency or severe conditions of use more frequent inspection is required Service lift is designed for a lifetime of 20 years with an operating frequency of approximately 12 5 h year 250 h in total Service lift may not be used by persons wh
57. wing the evacuation procedure Check that there are no obstacles or persons in the travel zone Take the manual descent actuator from its holder Push and hold the manual descent actuator up wards Position service lift at bottom platform 5 8 Out of service 1 2 3 Secure service lift bringing it all the way down until bottom normal switch is engaged Disconnect power supply to prevent inadvertent operation of the service lift Place a warning sign SERVICE LIFT OUT OF SERVICE DO NOT USE Padlock as necessary Contact technical service for repair 24 AVANTI Service Lift for Wind Turbines 6 Maintenance 6 1 Planning In order to guarantee that the service lift is ready to be used scheduled inspections shall be carried out Frequency A Every 250 h AVANTI of use aS i Fall arrest device Before any maintenance operation check that the service lift is properly out of ser Vice Components S 7 Platforms Performed by Traction and safety wire ropes RN inteock system Platforms Traction hoist In case of a fault do not use the service lift until it is solved If required secure work place 6 2 Cautions Before any maintenance task ensure that walking way surfaces are dry and not slippery During maintenance tasks personnel shall Wear at least the following PPE fall arrest equip ment when falling height is more than 2 m hand

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