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1. leeren 29 5 9 T Bottom platon inaina meaa CAU RC RO ea eS Hecke RC NU Bere ee Rw RC RON os 29 5 9 2 TOD DO a oem 86 bind oe Ae Rat BE A ee Sede SO RR CRUS ERR UA E ee Sas Sd 29 5 4 Operation from the platform control boxes eeeeeee eene 29 5 5 Fallatfest dEVICE uu reaa ew Se aes CC 8 OC SC er Dei b OT ee SE D a Ree ewe Nr 29 5 6 Manual descent 2 a 3 xac arid dew wears W gb wire el ee Ge a RO peck NCRCR EUR CI ee KC we 30 5 7 Lateral removable windows for Dolphin A version 0 00 cee eee eee eee 30 5 6 ITOUDICSNOOUMG m P P PO 31 5 9 Out OP SEICE a vac d ocior qas tek eae E BAe Od owe ee DEOR IS cR CR E das es 34 6 MalfitelidiiO Ga ac due qe 98 00 908 CRECNCUER UC REC Re CR GRE AU e En RC ECL COL we eee RU Go C e OL UR o RN 34 SELECT 34 6 2 GAMIONS m 34 6 3 Daily INSPECTION s CC w cect beeen ew a dew Be ee a dee eed ea eke oe es 34 6 4 Annual INSDECIION s dea seo ew poh Reso a OSES PREM OR OS ee DSR ER ERE SO Ou RC CR MESE 35 OF Ee ao aad oe wee op ee ee eee ee See od ee et Se ee oe ee eee 35 6 4 2 Nacion NOISE ereunna on 9 8 C3 OS ee Be ee eee ee eee Oe ee we Ace a S D 35 6 4 3 Fall arrest device 1 ccc cee eee eee eee hh mtr 36 6 4 4 Traction safety and guiding wire ropeS 0 0 cee es 36 604 59 REDAS s scusa cence os Sere eee oa pee oe ee Swe oa a es oe eee Sees 2 382. 3 2 Scope This manual contains instructions for four different versions of the Dolphin lift e Dolphin V CE 240 version Dolphin V CE 350 version Dolphin A CE 240 version Dolphin V AECO 240 version The Dolphin V CE versions are CE certified to the Machinery Directive 2006 42 EC The Dolphin V AECO version is AECO certified to ASME A17 7 CSA B44 7 Q9 9 The product details are described along this manual The product consists of e A service lift which is formed by a cabin a traction system a fall arrest device a control system and safety devices e A guiding system along the tower which is formed by a pair of steel guiding wire ropes wire fixes attached to the tower and guides on the service lift 3 3 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 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 AVANTI Ss recommendations This will require supply of interface components including but not limited to e Platform fences e Power supply protection e An evacuation way e g ladder 3 4 Technical specifications LL The wind turbine manufacturer shall also provide any additional relevant wa
3. 6 4 6 Overload check and adjustment es 38 6 5 Information signs and documents 0 cee eee eee 38 6 6 Ordering spare parts 5523 dc x bab RURALES bd SSK EASE SS Re ididikit kakiihan 38 Appendix A Adjustment of the overload limiter eere 39 Appendix B Safety measures 000 eee ees 41 Appendix C Inspection Checklist creer III Rh nh 42 Appendix D Inspection Log Sheet e ereeeeee hr hn nh 46 Appendix E AVANTI lift anchor i429 acc et eee eee ween eee eae C C TR eee 48 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 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 fr
4. Original instructions VANTI Established 1885 AVANTI SERVICE LIFT User s Maintenance and Installation Manual C Model Service Lift DOLPHIN Certificate of Dolohin V CE 240 and 350 versions EC Type Examination EC Directive 2006 42 EC Article 12 Section 3b Machinery Number of registration 01 205 0799B 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 Hiller d Denmark the close conformity of the product Service lift inside wind turbine from VESTAS V66 V80 V90 V100 V112 V117 V126 V164 including protection fences for service lift holes at landings and fence door interlock system Technical data max load capacity p 350 kg 2 persons net weight traction hoist M500 or M508 M508 version 600 kg safety gear OSL500 or ASL508 ASL508 version 600 kg max lifting height i 180 m lifting speed 18 m min Protection fences Swinging door or sliding door with interlock system or fixed fence Fence Interlock system Guard locking switch system or Trapped key system Modification B to the certificate 01 205 0799A 12 from 2012 10 28 New lift model with a lift capacity of 350 kg with the requirements according to annex of Directive 2006 42 EC about machinery and amending the Directive 95 16 EC of the European Parliament an
5. 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 Cear P 55 85 9671 6336 Il www avanti online com E info avanti online com
6. Return traction hoist for repair Insert the key and turn it to the ON A9 If trapped key system is provid position ed the trapped key is not present or the trapped key switch is in the OFF position A10 If guard locking system of Test Repair defective components fences is provided the guard locking switch and or interlock control box is defective User s Maintenance 31 and Installation Manual Breakdown Solution A11 The service lift is stuck on an obstacle below it a Evacuate the service lift b Inform the supervisor c Check the Bottom obstruction device connection function Replace if necessary A12 Service lift is overloaded Test and or reduce load until buzzer stops buzzer sounds Not applicable to CE versions FA Only applicable to AECO version Service lift goes B1 The service lift is stuck on Carefully move the service lift downwards down but not up an obstacle and remove the obstacle Test the opera tional safety of affected platform compo nents Inform the supervisor B2 Service lift is overloaded Test and possibly reduce load until buzzer buzzer sounds stops Only applicable to CE versions Not applicable to AECO version B3 Top limit switch a Test the top limit switch connection a Top limit switch is defective or function Replace it if necessary not connected b Descend the service lift until the top limit b Top limit switch is activated switc
7. 500 1100 30 100 7 15 4 Dolphin CE 350 ASL 508 600 1320 30 100 7 15 4 3 9 Traction safety and guiding wire ropes Service Lift Fall arrest device Lifting capacity Wire rope Surface Mark Min break diameter Treatment feature resistance Dolphin CE M500 0SL500__ 8 4mm 5x19 HDG no 55 kN eun 55 kN 2 t shackle Service Lift Version Wire rope type Attached with Dolphin CE amp AECO M508 ASL508 8 4 mm 5x19 Dolphin CE 350 M508 ASL508 8 4mm 5x19 HDG no 59 kN 2 venei 53 kN t shackle User s Maintenance 15 and Installation Manual 3 10 Main control box Emergency top limit switch Fall arrest device switch Manual descent buzzer Top obstruction Door guard locking switch switch Bottom Manual descent obstruction switch switch User control box connector Hour counter Green light Ready On if the lift is ready to use no safety devices engaged 3 11 Cabin control box 1 Emergency stop button Press it to interrupt any control 3 11 1 For Dolphin V CE and AECO versions function Pull to reset the control after necessary verifications 2 Trapped key switch Insert and tum the key to the ON position to enable control of the lift The key is now trapped and cannot be removed until it is tumed back to the OFF position Tum and remove the key to interrupt control of the lift Then use the key to open the trapped key lock of the top platform fence 3 UP DOWN buttons hold to
8. 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 be taken as authoritative 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 Additional instructions ATTENTION o 1 IMPORTANT CE VERSION Meaning IMMEDIATE or possibly imminent danger IMMEDIATE or possibly imminent danger of hazardous voltage Potentially hazardous situation Potentially dangerous situation Useful tips for optimum working procedure Differentiation between CE Possible injury if not observed Death or severe injury Death or severe injury Light injury or material damage Damage to equipment or workplace None versions and AECO version Reference to wr
9. arrest device Please check with your local authority regulations if it s mandatory in your case 0 D 0 D Check and replace the respective wire rope s if one of the following defects is found e For traction and safety wire ropes if there are more than one 8 wire strand break on a wire rope length of 250 mm e For guiding wire ropes if there are more than one 8 wire strand break on a wire rope length of 360 mm e f there is severe corrosion on the surface or the inside e f there is heat damage evident by the wire rope colour e For traction and safety wire ropes if the wire rope diameter is less than 8 mm User s Maintenance 37 and Installation Manual e For guiding wire ropes if the wire rope diameter is less than 11 4 mm e If there is damage on the wire rope surface see following figures for most common examples of wire rope damage Kinks resulting from counterweight of traction wire rope not being able to rotate freely Wire rope strap loop which cannot be unwound Loop knot forming eee When a wire loop is ALVA pulled tight Bends resulting from m inappropriate treatment e g securing the load with the wire Damage resulting from crushing squeezing running over etc Wire bags amp Loop formation On AECO service lifts according to A17 1 5 11 traction and safety wire ropes must be replaced after 250 hours of operation or 5 years whichever occurs fir
10. closed when using a 3 step ladder When plugging the service lift to the power supply ensure that supply phases are correct 34 AVANTI Service Lift for Wind Turbines 6 3 Daily inspection Travel zone Ensure that there are no obstacles in the travel zone which may obstruct the travel of the service lift Service lift 1 Check that the service lift components are mounted in accordance with the specifications and without any noticeable defects or missing compo nents 2 Check that the traction and safety wire ropes are not damaged or jammed 3 Check that the safety devices are in place and working 3 1 Main switch Turn the main switch on the interlock control box to the OFF position The green light must be OFF The service lift must not run Turn it ON the light shall be ON 3 2 Green light Ready Service lift Close and lock the bottom platform gallery door and the service lift door Turn the trapped key to the ON position The green light must be ON It should not be possible to remove the trapped key unless it is switched OFF again 3 3 Emergency stop button Press the emergency stop button on the cabin control box The service lift should not move UP DOWN Release the emergenoy stop and drive the lift UP approximately 1 meter 3 4 Service lift door Pull the door to open The door should not open Unlock the top sliding door from the bottom sliding door and pull to open The top sliding door should open the g
11. free Clean only when very dirty During cleaning always ensure sufficient air supply Annual test only by authorized persons a Ensure that no visual defects have appeared b Check that air gap a between brake and disc is 0 3 mm using a thickness gauge LA wyypTT Tr bo mi SSSSS n 4 A siiig pd s 15504 ed Pr e ME amm am um mn nm TUUUUUUT e he AULA VUWWU Int s r H H H i c Test manual descent function d Test speed and current should match the service lift data plate e Check that sound and behaviour are normal Note Optional for CE versions Mandatory for AECO version User s Maintenance 35 and Installation Manual 6 4 3 Fall arrest device The fall arrest device is largely maintenance free Clean only when very dirty Keep free from dirt and lubricate often Using too much oil will not harm the equipment or the gripping function Annual test only by authorized persons a Test the fall arrest device stop lever by pulling down the red locking knob b Test the fall arrest device stop lever reset by pulling down the black unlocking knob c Release safety wire rope bottom attachment in the tower and pull the safety wire rope with a jerk The overspeed device should trigger the fall arrest device automatically d Ensure that no visual defects have appeared 6 4 4 Traction safety and guiding wire ropes Carry out the following i
12. holding the service lift on the safety wire a Lift wire rope breakage a b Evacuate the service lift b Hoist failure A4 The service lift is stuck on an Carefully remove the obstacle obstacle Test the operational safety of affected tower sections Inform the supervisor A5 Power failure Main switch is OFF Turn the main switch ON Grid voltage interrupted Find the cause and wait for the power DANGER Supply between grid connection to return Attempting to and control interrupted Test and if necessary repair the supply use the lift will cable fuses and or wiring from the Jeopardize control box work safety A6 A safety switch is triggered Perform manual descent until the Emergency top limit switch limit stop switch is released is activated Close the top and or bottom sliding Top and or bottom sliding door is door open Adjust manual descent switch so that Manual descent switch is activated it is not involuntarily activated A7 Protection switch on Test repair fuses supply and overheating connection a A phase is missing Clean the motor cover b Motor is not cooling Measure voltage and power c Voltage too high low consumption on the loaded motor If voltage deviates from specifications use Cable with increased dimensions A8 Brake does not open no click on on off Have an authorized person repair a Supply braking coil or replace the supply braking coil and rectifier defective rectifier b Braking rotor closes
13. lever the black unlocking knob on the back part of the lift has to be pulled downwards Tightness of safety wire rope must be frequently inspected to ensure full functionality of fall arrest device 3 21 Overload limiter A lifting force limiter is built into the wire rope traction system and will prevent upward travel in the event of overload In case of overload the lift s upward travel will be blocked and a buzzer will sound in the user control box The buzzer will stop only when the cause of the overload has been removed e Reduce the load to below the overload limit e Lower the lift until it is free of the obstacle and remove the obstacle before using the lift again On entering and starting the lift the buzzer may sound briefly This is due to temporary load peaks occurring as the lift takes off The control box is designed not to activate a amp the buzzer or stop the lift because of peak loads caused by the cabin swinging Attempting to run an overloaded lift is prohibited 3 22 Slack rope sensor Installed on the top of the service lift over the traction hoist when engaged it interrupts descent It detects slack traction wire rope 3 23 Warning light An optional set of warning lights can be mount ed on the top and at the base of the lift The flashes warn that the lift is moving 3 24 Acoustic buzzer An optional audible signal can be installed with the same warning function 3 25 Anchor
14. must be coiled and fastened with at least 3 strips The counterweight and the excess of wire rope shall be able to rotate freely Safety wire rope e _ Traction wire rope Bottom platform Note Optional for CE versions Mandatory for AECO version User s Maintenance 27 and Installation Manual 4 4 2 3 Safety wire rope 1 Open the maintenance cover on the back of the service lift 2 Remove protection guard above rollers 3 Feed the wire rope through the roof into the fall arrest device s wire inlet opening 4 Pull the wire rope through the fall arrest device while turning the release lever clockwise 5 Continue feeding the wire rope around the pulleys tothe back of the lift Safety wire rope 6 Feed the wire rope through the guide bushings of the cabin 7 Feed the wire rope through the guide bushings of the travelling cable pulley 8 Feed the wire rope through the platform holes 9 Feed the compression spring through the safety wire rope 10 Pre tension the safety wire by hand as much as possible before fastening the wire locks 11 Cut the mounting strips that keep the spring compressed This will apply a tension of approxi mately 40 kg to the safety wire rope 4 4 2 4 Travelling cable adjustment 1 Guide the travelling cable through the travel ling cable pulley 2 Connect the outlet socket of the travelling cable to the inlet plug of the service lift using a cable stocking Attach th
15. points The service lift is equipped with two anchor points inside the cabin During operation personnel shall hook themselves up to the anchor points inside the cabin In case of need of evacuation the evacuation procedure must be observed There is an optional external anchor point outside the cabin to facilitate the evacuation and rescue operations 3 26 Internal light The service lift is equipped with a light inside the cabin The light is on when the lift is powered Optionally this light can be battery packed in order to illuminate inside cabin without electric supply once charged 3 27 Lateral removable windows for Dolphin A version The cabin has two lateral windows that are removable to facilitate maintenance tasks on the tower from inside the lift Note Optional for V CE version Not available for A CE version Mandatory for AECO version 2 Note Optional for V CE version Not available for A CE version Optional for AECO version 9 Note Optional for V CE version Mandatory for A CE version Mandatory for AECO version User s Maintenance 23 and Installation Manual 3 28 Front fixed window for Dolphin A version The front fixed window is transparent to enable users look outside without the need to open the door This window cannot be removed Front fixed window 3 29 Travelling cable pulley A travelling cable pulley is suspended on the power cable and is guided along the traction and sa
16. run 4 UP DOWN buttons automatic send Press it to send the lift all the way to the top or bottom of the tower The automatic DOWN button is only operational from the top platform and the automatic UP button is only operational from the bottom platform 5 Overload buzzer It sounds when the cabin is overloaded 6 Bottom obstruction override switch 7 Platform light green 8 Overload light yellow 9 OK light green 10 ASL light red 11 Fault light red Note An interlock system trapped key or guard lock ing is mandatory for the CE versions if platform fences are equipped with doors Optional for the AECO version 16 AVANTI Service Lift for Wind Turbines 3 12 Bottom platform control box The control box is installed at the bottom platform fence The control box has a main switch Turn the switch to the OFF position to cut the power to the service lift The main switch must be set to OFF when the lift is not in use when leaving the wind turbine and while the wind turbine is running It must be set to OFF before starting an electrical generator 3 12 1 For Dolphin V CE versions with guard locking Main switch Green light Ready Power inlet Power outlet Connector from WTG to lift Interlock switch 3 12 2 For Dolphin V CE versions with trapped key and for AECO version 3 12 3 For Dolphin A CE version 3 12 3 1 Call only configuration 1 CCV sticker if applicable 2 DOWN ligh
17. seen Re lubricate the wire ropes before they show signs of corrosion or run dry and taking in mind that A poor lubrication leads to corrosion and to a quick wear of components An excessive lubrication leads to dirt agglomeration on the wire rope surface As a result this can lead to quick wear of wire rope sheaves and drum A correct lubrication keeps the efficiency factor of the wire rope protects against corrosion helps to elongate their lifetime significantly and ensures a safe operation 6 4 4 2 Measuring of the wire rope diameter Q When measuring the diameter of the wire ropes use a digital calliper with broad measuring faces In general measure the diameter of the wire rope at each WTG tower platform and under the service lift where the wire rope is less loaded Specifically if a wire rope wear is detected measure on the affected area measure the minimum and maximum wire rope diameter at each measurement point Rotate the calliper around the wire rope to 6 4 4 3 Discard criteria 1 The discard criteria of the wire ropes shall LH be according to ISO 4309 Cranes Wire ropes Care and Maintenance inspection and discard Determine and eliminate the cause before installing a new wire rope AVANTI recommends to replace the traction and safety wire ropes after 250 hours of operation approximately every 5 years corresponding with the refurbish ment of the traction hoist and fall
18. the service lift for instance from falling parts oe Cabin control from outside of the cabin Automatic The automatic mode function is only available from the control buttons outside of the cabin at the bottom platform and top platform It shall be checked as follows 1 Press the UP button on the control box The lift should ascend 2 Press the emergency stop button on the control box The lift stops 3 Pull the emergency stop button and press the DOWN button The service lift should descend until the bottom obstruction device engages LLI 6 4 Annual inspection Have the entire system tested by an AVANTI trained expert at least once a year especially the traction hoist and the fall arrest device However it may be required more frequently depending on use and the conditions of use and operation The traction hoist and fall arrest device must be overhauled at AVANTI workshops and furnished with new certificate for every 250 hours of opera tion Hour counter is found in the main control box If fall arrest device has engaged an expert must verify the safety of the fall arrest device the wire rope and wire rope fastenings The tower owner must ensure that the results of all annual and extraordinary inspections are logged in the Appendix D Inspection log sheet 6 4 1 Cabin Inspect the cabin structure joints attachments and accessories 6 4 2 Traction hoist The traction hoist is largely maintenance
19. the top limit switch fault has been rectified Note Top limit switch or top obstruction switch if top obstruction device is supplied 3 17 Top obstruction device 2 The top obstruction device switch stops ascent if the service lift e encounters an obstacle e touches the top limit device Descent will be possible for instance to remove the obstacle 3 18 Bottom obstruction device The bottom obstruction switch stops descent if the service lift e encounters an obstacle e touches the ground Ascent will be possible for instance to remove the obstacle In order to put the service lift on the ground the functionality of the Bottom obstruction device can be bypassed with the bottom obstruction override switch in the user control box To do so turn the bot tom obstruction override switch while pressing the DOWN button Release the DOWN button as soon as the rubber bumpers hit the floor Otherwise the lift or the installation may get damaged Emergency top Top limit switch limit switch Top obstruction device 2 Bottom obstruction device Note Top limit switch or top obstruction switch if the top obstruction device is supplied 2 Note Optional for CE versions if platform fences are not railing type Mandatory for CE versions if platform fences are railing type Mandatory for AECO versions User s Maintenance 21 and Installation Manual 3 19 Manual descent system The service lift i
20. top fence door 2 Insert the trapped key in the switch of the user control box and turn it ON 3 Close the service lift door 4 Press the DOWN button 5 4 Operation from the platform control boxes 1 Turn the trapped key switch to ON 2 Close the door of the cabin and of the platform fence 3 Press and hold the UP or DOWN button to ascend or descend the cabin control box is pressed and held the resoonse of the cabin is delayed 5 seconds During this e delay an acoustic signal will sound This way any personnel in the surroundings are warned of the imminent movement of the service lift Transportation of people is forbidden if the operation is controlled from a platform control box 5 5 Fall arrest device f When the UP or DOWN button of a platform If the fall arrest device engages simply disengage it by pulling downwards the black knob on the back of the lift until the fall arrest device is unlocked However this is not possible if the safety wire rope is under tension If this is the case 1 Remove the load on the safety wire rope by pushing the UP button ascending the service lift a few centimetres 2 Manually open the fall arrest device by pulling downwards the black knob until the fall arrest device is unlocked In case of power failure and the fall arrest device is locked with the safety wire rope under tension evacuate the lift according to the evacuation proce dure The safety wire rope and the att
21. 23 3 28 Front fixed window for Dolphin A version 0 00 eee 24 3 29 Travelling cable pulley 4 dos kom ee haw ee Heed Oe Ro m new Sees R8 2 e cm i aca e RR 24 S30 CCV SLICKER Mec PTTETIPPMMT 24 iiis talld EO sore rian Geese ESR ECCE ERU EWE eae en CR REC earn ae deen e Se Serene RR 25 4 1 WTG integration requirements 00 ccc es 25 A OAUUONS sade cece eed weaned oe eee Oe Be oe eee ee eee ee 25 4 3 Electrical CONNECTIONS cu eee cee hh nen eben ee eee eben en eee ene 25 AOA OWE CADE 26s a 2d 9 ped 809 8 a eae be SMSO Uc baw bea ae SOS GSE Prnt ee ee 25 4 3 2 Guard locking system 222 224 ERR RR dak ee es Oe ee x RE ER RR wee eee ee 26 4 4 Guiding traction and safety wire ropeS 0 2 00 erre 26 4 4 1 Top platform i x arca ERRORS YU 9 D nS Oe Wak w CREER ORC RCRUM Paleo we acu Rs Ge D a RR 8 26 AA2BOUOM DIAUONN iussi r8 Ros bal hha Rc RR ea a Seas SSeS we ee 27 4 5 Wire rpe fIX reaa s aaa ma aw wae a eos nde A a Sa aa a Ra RON Se Oe Ga a See ee ee eee 28 4 6 Danger zone sticker 2 cus imn im ees rene e n a ea bd C oe a im Ree ee 28 4 7 Inspection before first use 1 es 28 D Instructions for USe oa 0265 04 6a oo 54 39 478738 eee oe 8740 X 8 203 ee a ee ee ae 29 On PIODIDHOOHHISOS 5a 3 9 3 994 9908 2 2703 9789 308 Chine Oa ee RR CHECA EUR boy Oa eae Ges Base 29 5 2 Operation from inside the cabin manual eren 29 5 3 Operation from outside the cabin automatic
22. 3 kg m 0 16 kg m User s Maintenance 11 and Installation Manual 3 5 Dimensions ODOOOOOOO DOOO QOOOOOOO DOOO 12 AVANTI Service Lift for Wind Turbines OOOOOOOO OOOOOOOOllo OOOOOOOO loC OOOOOOOOlf OOOOOOOO OOOOOOOO OOOOOOOQ OOOOOO OOOOO OOOO OOO Note The top obstruction device is op tional for CE versions if platform fences are not railing type Mandatory for CE versions if railing type is installed Mandatory for AECO versions 3 6 Components 3 6 1 For Dolphin V CE and AECO versions 17 ED Ses So CES 2 eS SS LSESSESS S 5 Seu NEA 1 O O m ANA P 16 oS SORS SS S CSS ESO OSSA SS SO SIS CIS ES CS CIS e SSS ccc DOES gt ass SS E CS So SSIS SSS IUS A ESSA SEU S S Se SR S OS oS OSS ESSLE SSS SEER P 2 SSSSSES gt SOS SS SS e SS SIS Sey ROSSO EO ie SOSA SOS e OSSSSS eae SSBSSSS SSS e s b SSSSSo S sce SSSSSSS5 ES os Se SO 2 oS 959 a gt e S S S e 4 3 j gt B lt e k e c 8 e L 5 A DI DN 9 9 TN SS LLOR Sg d PILITIN o PE PATEN PATEN OOE Ta Og o 9o Qe So Seo Oo L008 9 PAIA PEN 9 ry e MQ Le 9o ec 9 6 MSN D RN 009 OHO 80g NIS Weed Ogo 90 OPTION Soo Solep cgo 9 005 OSEE SEEN REESE 04 1259 OG OQ LOE LOLS eee Sec Oo9Q 04 090 VQ POE OGSOSLO g0 ORTEC 9 199 ENSI
23. Operate the service lift without following the safety warnings and operating instructions e Overload the service lift e Try to repair machine components Only personnel from AVANTI or qualified personnel authorised by AVANTI are allowed to perform service on the machine e o use the ladder unless service lift is out of service or in case of evacuation or rescue e To manipulate switches and safeties e To place objects on service lift roof e To descend on service lift roof 5 2 Operation from inside the cabin manual 1 Turn the main switch of the platform control box to the ON position 2 Enter the service lift and close the bottom top fence door 3 Turn the trapped key switch ON 4 To go up or down push and hold the UP or DOWN button as needed In the event of traction wire rope breaks or traction hoist fails evacuate the service lift e 5 3 Operation from outside the cabin automatic send Transportation of people is forbidden if the operation is controlled from outside the service lift e N Automatic function is only possible from top platform to bottom platform and vice versa 5 9 1 Bottom platform 1 Turn the main switch ON of the platform control box 2 Insert the trapped key inside the switch on the user control box and turn it ON 3 Close the service lift door AN 4 Close the bottom platform fence door 5 Press the UP button using the send tool 5 3 2 Top platform 1 Close the
24. S PEORES ry PINNIS Sage Page s 929 599 e 0020200000 INNS DQSege o 02 509 VOLOTENN BIENES Soge 254 099 Q 09 SY S M 9696 QQ Q 99 99 92 7 CogPogOogoge LeeLee f Lo 5994954 1995 NATIN IE BEININI NYNO S 99599 d 009 CLOT GOOCRGOOLOGSO MOESE OGSS 09995824 1902 OPOHLOHLOY TOOLE te egeto 095999404 10909 Og oo N VQ oe 9o 9 Qo o 9 ORMLOLGG 9o See Oo SHLD CLOR odo 09995925 0 go He Q96 WG POR 9G L0 ENTONCES 0505995914 30 O06 Qe OQ LO SO L0 PITAS 920899239 299 Toleo ORS CP NIY 0059999503 1990 NIIS WLOHLOLOHOOLS af OS 9o 2969 0599597 50 8 NYIN PLIPA NIN INNIN 0699999900690 HOG 9o Sedo COGS Ve 9QOGQ LHS 0059999 500050 ESSE PLOKSGLOLOGLO BPCO CC SL 005959958 09 RSS ESSE DESEE 3933899904 p90 DG GoLOLEGSOLdgS ETSI CON 0099599905 1209 Qe Oe 20 0936 PIII 005059950 Q e WPOHLEOSOLGS Sag PAN 90599997550 joXo PILTON PATINY PIPINS e o 09049099254 lo TODT SqSoQSqrog 00505995 9 NINII IRINN 9999 59990 og 10 ESSERE SENS 0005999954 loo PEAP CAAT 040 99 Q E o 3 o 323009930 260 COSTS 005999950 jo ESSEN IR MR sS 0025959008 090 RNN AIIIN IN 005059950 609 e WOGOG HOSS SS 9999953 1599 N EN NINS 959205 1090 V9 LO Q es i SS 334 1999 o HEIGL 04 050 NSIN CY 990 Qo o NIIN 290 NY Q lp 509 21 Oeo 095 11 NN i 509 ROS 990 S090 09 Log oes 050 ce Qd i 290 RENE SENS 999 12 RON 009 CR 04 5090 ENIRI 954 1209 REPRE P 0299 t090 REISEN 09 0994 090 O
25. achment between the fall arrest device and the service lift are exposed to dynamic loads when a fall is prevented When the service lift has returned to the bottom platform test the fall arrest device functionality Replace any defective fall arrest device components and return them for repair to AVANTI User s Maintenance 29 and Installation Manual 5 6 Manual descent In case of power failure a manual descent without power can be performed To do so 1 Verify that the fall arrest device is unlocked 2 Check that there are no obstacles or persons in the travel zone 3 Take the manual descent actuator from its holder and insert it on the lever extension tube 4 Push the manual descent actuator upwards The service lift will start descent and a buzzer will sound 5 To stop the manual descent stop pushing upwards During the manual descent the door and hatches of the lift shall be kept closed Always look through the perforated floor of the cabin to see if anyone is standing on the ladder Use the walkie talkie to report about the manual descent During the manual descent stop the service lift Just before reaching the bottom platform floor This way the bottom obstruction device will not get damaged The manual descents shall be of maximum 30 m Between two consecutive manual de scents the user shall wait minimum 10 minutes for the centrifugal brake to cool down This way the premature wear of the centrifuga
26. alified authorised person or contact the manufacturer User s Maintenance 33 and Installation Manual 5 9 Out of service 1 Securing the service lift Bring the service lift all the way down until the bottom stop switch stops the cabin 6 Maintenance 6 1 Planning Time Performance 2 Turn off the main switch to prevent inadvertent operation of the lift Turn the main switch to the OFF position power supply is now interrupted Mark the lift OUT OF SERVICE and padlock as neces sary Contact the service technician for repair Component Daily User Operating area and service lift visual inspection Service lift controls and safety devices Annually Expert Annually Expert Fall arrest device 6 2 Cautions Before any maintenance task ensure that walking way surfaces are dry and not slippery During maintenance tasks personnel shall AN Wear at least the following PPE fall arrest equip ment when falling height is more than 2 m hand gloves helmet safety glasses and working gear Place cabin at bottom platform and disconnect power supply Use an electricity measuring tool when perform ing inspection of electrical components Use a hand winch attachable to the ladder when handling big heavy loads and shall be per formed at least by 2 persons Panel parts shall be removed to facilitate access to confined spaces Use a cable grip when replacing travelling cable Keep cabin doors
27. and opening the trapped key lock The key will get trapped until the door is closed and locked again Trapped key lock Trapped i key lock J actuator 3 14 1 2 Guard locking system The platform fence door is fitted with an interlock system keeping the door locked while the service lift is not at the platform The door is unlocked when the service lift is at the platform with the lift detection switch activated The green light is ON when the door is closed Lift detection switch Guard locking switch actuator uard locking switch 3 14 2 Fences for Dolphin V AECO version The platform fences shall comply with ASME A17 1 5 11 Fence of bottom platform Note An interlock system trapped key or guard locking is mandatory for the CE versions if platform fences are equipped with doors Optional for the AECO version User s Maintenance 19 and Installation Manual 3 15 Service lift door The top sliding door is closed by pushing the actuator into the door switch The control will be interrupted if the door is not closed properly or opened while the lift is moving The bottom sliding door is closed by pushing the actuator into the guard locking switch The guard locking switch is automatically unlocked when the cabin is located on the top or the bottom platform Optionally the service lift can be equipped with a platform switch 818 which allows the bottom sliding door to be opened when the service li
28. cation Services Date of publication 5th CE Edition 04 2015 Revision 1 08 04 2015 Manufacturer AVANTI Wind Systems A S Hoennevangs Alle 6 3400 Hillered Denmark mm v 45 4824 9024 45 4824 9124 info avanti online com www avanti online com MANAGEMENT Sales amp Service Australia China Denmark Germany Spain UK USA India Brazil Manufactured Under Process Patent NO 8 499 896 Avanti Wind Systems PTY LTD Avanti Wind Systems Avanti Wind Systems A S Avanti Wind Systems GmbH Avanti Wind Systems SL Avanti Wind Systems Limited Avanti Wind Systems Inc Avanti Wind Systems PL Avanti Brazil Sistemas E licos S L Registered in Europe UU U0 U0 U0 U UUU 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 Page Limited waranty sac 987369 FCRC CECI ede E CAR hee we eee T baw eee ee 8 ITOGUCTIONS ccc pees 866i eee eee ee eas Oe a eee eee eee 9 2 ODSCIWAlIONS excu EE ERU SEE ek ee es He ores oe eed eet acess seus 9 ZemMYMDOIS szxue 92 eres ches Gewese secu Gees et ae ee eee eee eee EAR ES eat one 9 PASE GAUOS esis arak aae ILLIC OILILCS ILIO OL CCELI ee ek amp a eee ee 10 DESCHDUON 4 crea tae eerie tent eaevd twee e a db Co 9 PRECOR ORC UP 9 an 6 Dn CC P 11 OT ISBHIDOSS us domu e QE ER USER RON ER re cR CHO ne a de EO Are ae RC
29. d 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 13 049 1 from 2013 09 30 and is valid only duly considering the requirements mentioned in this document The examination was realized on site in Zaragoza Spain This certificate is valid until 2018 10 02 Certification body ur No 0035 rti i ee n g Walter Ringhausen Cologne 2013 10 02 T V Rheinland Industrie Service GmbH Alboinstrafse 56 12103 Berlin A TUV Rheinland Telefon 49 0 30 75 62 1557 Fax 49 0 30 75 62 13 70 Precisely Right Certificate of Dolohin A CE 240 version EC Type Examination EC Directive 2006 42 EC Article 12 Section 3b Machinery Number of registration 01 205 0869 15 Certification body for machinery NB0035 at TUV Rheinland Industrie Service GmbH herewith confirms for the company AVANTI WIND SYSTEMS A S Rennevangs All 6 DK 3400 Hiller d Denmark the close conformity of the product Service lift inside wind turbine with protection fences for service lift holes at landings and fence door interlock system Technical data Type max load capacity net weight traction hoist safety gear max lifting height lifting speed m om emm w or fixed fence Fence Interlock system Guard locking switch system or Trapped key system
30. de Dr Dada ac E CE M UR UR FUE 11 due OOODB S ss m bea eee eae eens bee V BONA S ee RE GbR Und m be NEC eee ee eee ee 11 Ia WM CIUSIOINS a M E re ee eee 11 3 4 Technical specifications sx 624 4460 ba FG RAN CR NCC AL AG Oe eae OSES SOROS OSE Sw bw OS OO 11 DS WIMCNSIONS cix EXP cue Seas eee oa aes eee Se ere Fe Ge PE EU oe RUN NUR Ic WR ee 12 SO COMDONENIS uerus aene eee oa 80 06 e 8 CARN we iq MES ore eee R2 DER aes we ee 13 3 6 1 For Dolphin V CE and AECO versions leeeeeee eene 13 9 5 2 F r Dolphin A Vel SlODL 0 2 a cic eae a CR NC Sw ow Ee SCR A E OO Sw RU CR RC 14 ek WACOM SYSTE PERRO T TIT DIL T CDI TIDETUR 15 9 0 Fall arrest deVIGO a cu eared dom OXON 98 OR Ra AC CC oc qne acc RO Ceu dcc c o RC LEUR A 15 3 9 Traction safety and guiding wireropes es 15 910 MaM cohltrol DOX x 2394 3 d wp S4 46 66 a bd eae REAL Rod Oe oo PROC RO he SE 9 38 9 RU eee OS ES 16 3 1 Gabin ontrol DOX sriseiti ries edd dem D sce BORA IC ono NOR EO od ee eee Sed ace ede eae 16 3 11 1 For Dolphin V CE and AECO versions cee ee ees 16 3 11 2 For Dolphin A CE version 0 00 cee eee ees 16 3 12 Bottom platform control DOX 0 ee 17 3 12 1 For Dolphin V CE versions with guard locking eee 17 3 12 2 For Dolphin V CE versions with trapped key and for AECO version 17 3 12 3 For Dolphin A CE version llle hh h
31. e schacle to the eyebolt on the back of the service lift 3 Attach the travellin cable to the cabin by means of cable ties 28 AVANTI Service Lift for Wind Turbines 4 5 Wire rope fix Wire rope fixes are installed and adjusted during the first run so that the centres of the wire rope fixes are in the centre of the service lift wireguides Wire rope fixes must be installed on each platform and as required along the tower MAX 30 m to improve guiding to avoid collision with tower elements Use the oblong holes on the wirefix brackets to align and adjust the wire rope fix position Wire rope fix bracket Wire rope fix Wire rope guide 4 6 Danger zone sticker Mount the Danger Zone sticker in the front door of the bottom platform fence Make sure that the fence is clean and dry before attaching the sticker 4 7 Inspection before first use I AVANTI or qualified personnel authorised by dens m AVANTI must carry out an inspection before first use following the Appendix C Inspec tion checklist The inspection before first use must be mE recorded for future reference filling in the ES Kum Appendix C Inspection log sheet 5 Instructions for use 5 1 Prohibited uses The consequences of not following below STOP 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
32. e tower with the guide wire rope outermost on either side 2 Fit the nuts and bolts on the shackles Lock with cotter pins 3 Fit the top limit device on the traction wire rope leaving at least 200 mm between top limit device and shackle Adjust the final position during first run so that the service lift is levelled with the top platform when it stops 4 Uncoil all wire ropes to the bottom of the tower All wire ropes must be evenly uncoiled to prevent looping Do not pull wire rope over edges uiding wire ropes Traction wire rope Safety wire rope Top limit device disc 4 4 1 2 Top limit device bar 4 4 2 Bottom platform 4 4 2 1 Guiding wire ropes 1 Feed the guiding wire ropes through the wire guides on the service lift and the holes in the plat form 2 Fit the correct number of wire rope fixes on the wire rope and feed through the wire rope guides The wire rope fixes are fitted during the first run 3 Pull the guiding wire rope through the platform and fasten it with the tensioning system 4 Pre tighten the wire ropes using the tensioning system 5 Final tightening must be performed after the first run a Feed the wire ropes through the tensioning system b Attach the wire rope to the tensioning system using the wire rope grips and make a mark on the wire rope before starting tensioning C After the first run tightens tension the wire ropes to 4000 N the wire rope st
33. eight 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 on an AS IS basis Avanti service lift Product 8 AVANTI Service Lift for Wind Turbines 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 PARTIC ULAR 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 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 WARRANT Y 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
34. ersion 10 11 12 10 14 13 14 Zz D D LE a 4 4 Li 1 L 1 1 4 1 1 4 LI 1 1 4 i T 1 4 1 LI 1 Top obstruction device Safety wire rope Traction wire rope Guiding wire rope 2x 5 Traction hoist 6 Top obstruction switch 7 Emergency top limit switch S13 8 Fall arrest device 9 Travelling cable 10 Wire rope guide 4x 11 Anchor point 2x 12 Lateral removable window 2x AON it for WI De ee rrr rrr Pe ee S hh ma a a a ta a a a te a a a a a a a a a ttt T om e e e O L O L L L A L A A L A A A e e e o e o o o o Z2 Om ese v oo ee Re Ae i a 13 Maintenance cover 14 Folding step 15 Main control box 16 Hour counter 17 Front fixed window 18 Top sliding door 19 Bottom sliding door 20 Cabin control box 21 Bottom obstruction device 22 Travelling cable pulley Traction system Fall arrest device 3 7 Traction system Lifting Rated Traction Unit weight Service Lift Hoist i capacity current wirerope approx eee Version Traction system type Dolphin CE M500 M508 400V Dolphin CE M500 M508 690V Dolphin AECO M508 400V Dolphin CE 350 M508 400V 50Hz 60Hz Dolphin CE 350 M508 690V 50Hz 60Hz 3 8 Fall arrest device Triggering Safety Unit weight speed wire rope approx Version Type Kg Ibs m min ft min mm Kg Ibs Dolphin CE OSL 500 ASL 508 500 1100 30 100 7 15 4 Dolphin AECO ASL 508
35. fety wire ropes The pulley straightens the power cable at all times 3 29 1 For Dolphin V CE and AECO versions Safety wire rope 24 AVANTI Service Lift for Wind Turbines 3 29 2 For Dolphin A version The travelling cable pulley has two arms at tached to the guiding wire ropes This way the guiding of the pulley improves Pulley E 8 Guiding wire Arms ope Guiding wire rope 3 30 CCV sticker The Cold Climate Version sticker indicates the temperature range wherein the CCV service lift may be operated Note Optional for Dolphin V CE versions Man datory for Dolphin A version and for Dolphin V AECO version 4 Installation 4 1 WTG integration requirements AIC General integration requirements component Voltage 60 Hz 400 V 690 V Protection According to EN 60204 1 Means of evac 1100 mm uation shall be provided with a minimum distance of EN 14122 3 Compliant to requirements of standard Maximum total travel height Forces capable Upon request to withstand from AVANTI Depending on travel path dimensions may need to be larger in order to avoid collisions of travelling cable pul ley with platforms 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
36. ft is levelled with a platform This switch is triggered by the platform activation plates Aen 1 TT i 1 p 4 SSSSSESBSBESBESE SH WM v LU b i 1 Lj 20 AVANTI Service Lift for Wind Turbines Top sliding door actuator Top sliding door switch uard locking switch of bottom sliding door In case of power cut need of evacuation between platforms or need to access intermedi ate platforms the guard locking switch can be unlocked by pushing its emergency release red button To reach the emergency release red button from inside the cabin the following actions are required Remove the lock between the top and bottom sliding door by pushing it down Open the top sliding door Push the emergency release red button and open the bottom sliding door at the same time Lock Sliding door Guard locking actuator of bottom sliding door Emergency release button of bottom sliding door 3 16 Emergency top limit switch At the top of the cabin a top limit switch will stop ascent when activated Descent will still be possible A top limit device activating the top stop switch is installed below the traction wire rope fastenings Emergency top limit switch interrupts the control if the top limit switch fails Manual descent is possible press the DOWN button until the top limit f When the top limit switch is engaged switch is released Do not use the service lift until
37. gauaaduaudunaauududduauu i pe oe kede te Ye ke foe e ree ke ie ie e ke uUGIumnuaulunmunuuuunmauuuuun ja i aad guuusumummuucadsusuunu L 1 ITITLETIBCITCTITITITITCPZTS2TITITIBIRCTITIETIWIM F aon Fr Too SPSS ao SS ar oS a IPITUFDTIYFOFUTGDCIIEOCITUFUT TOTO T FUFCIDGPGIT IP IP GPATZTAFAFIF GP CFLTAF AF IP GAP TF AN IF AF LIT n 1 The doors shall be monitored with an interlock system either trapped key or guard locking 1 Fixed railing per year 3 The railing type fence is only possible if the service lift is accessed platforms access to platform maximum once equipped with a top obstruction device The following types of fences are possible as long as the 2 The fixed fences shall only be installed in infrequently following points are fulfilled 4 Perforated sheets with door f m Aannaunannaasanuanaaanaa T ETAT TIDETUR ELTE mie he fp a pe ee fe bee fe be i AE Se Bee Bea a nnmmm Eie b ee y e e CUTATA TA COLT TLL 2 Railing type with door Trapped Key Actuator e O is O 5 A X T N o g g A a 2 5 A equipped with guard locking 18 AVANTI Service Lift for Wind Turbines 3 14 11 Trapped key system The platform fence door is fitted with a trapped key lock keeping the door locked while the service lift is not at the platform The door can be unlocked by using the trapped key on the user control box
38. h is released Note Top limit switch or top obstruction switch if top obstruction device is supplied B4 A phase is missing Test fuses and power supply B5 Fault in UP control circuit Test and possibly repair connections wiring and relays Service lift can C1 Slack rope sensor is en Check the reason why it is engaged possibly it s ascend but cannot gaged an obstacle under the service lift or the bottom descend obstruction device is not functioning properly Note Optional for CE version Mandatory for AECO version Motor hums loudly D1 Wire ropes are dirty If possible immediately replace the traction or wire ropes hoist and return it for test repair at AVANTI squeak but the lift can go both up and Further use of lift may down STOP result in damage to the traction wire rope Tl 32 AVANTI Service Lift for Wind Turbines Breakdown Service lift will go up but not down Button lamp not lit although operation is normal Service lift de scends when UP button is pressed and ascends when DOWN button is pressed D2 The service lift has encoun tered or is stuck on an obstacle D3 The fall arrest device is holding the service lift on the wire rope a Excessive hoist speed b Too low release speed on fall arrest device D4 Fault in down controller circuit D5 The slack rope sensor is holding the service lift on the traction wire rope D5 Bottom stop switch a Bottom stop switch i
39. h hn 17 3 13 Intermediate and top platform control box for Dolphin A CE version 17 9 14 Platform 1GNCES serako c he es REGE ALEX ORE x Fe a Edu GO Me E RE d ausa 5 18 3 14 1 Fences for Dolphin and ACE versions leeren 18 3 14 2 Fences for Dolphin V AECO version eeleeee nnne 19 S49 Del VICE ITE CIDOE uoa lt lt 573 0 15 3 8 8 228 00809 9897 3 9 8 1 308 Boe ROS ER eee ba bea SEM as RC RURSUS 20 3 16 Emergency top limit switch llle 21 3 17 T p ODSIFUCTION GOVICG u scu enw dae CR Caci t eee ORC C eC c RU TCR a 21 3 18 Bottom obstruction device ee 21 3 19 Manual descent system llllleeeeeeeeeeeeeee eer hh hh 22 3 20 Fall amest dQeviGO o beak epee Eae Rea dc d ee See Od Ar oe a EUER RC A us d 22 ol Overload MMIL ue noun uec do ca om amp eee ow e B AE RR CO Id eR At Ros ew Beet Rem DO A 23 3 22 Slack rope Sensor eaa x EC RUE EO ee whee ee REOR E COR RO RO RO RC DO nies 23 9 29 WANN MOLDE 2502464 306 2 2 1 978 3 1 225 3c BERRY E ROC bee ROSE he bd Ae A RU Bc dicar b did 23 3 24 Acoustic DUZZOFE se Lui uu aci iA rSERCS aos Re bh wwe a IC E ac dc Ro ACRI Br dr ew Se ew ee 23 D 2D ANCNOl DOINGS gate eet Wailea bs ean Cee sine EC RO Ta ded doe aed bee aes 23 3 20 Internal MORE sis PEE 23 3 27 Lateral removable windows for Dolphin A version 0 0 0 0 e eee eee eee
40. ift may not be used by persons who 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 weath er including wind speeds over 25 m s 55 5 mph Personnel of Dolphin AECO version shall be equipped with a wired or wire less two way communication device connected to a location staffed by authorized personnel N Avoid injury follow all instructions The tower owner must verify the need for LLI third party service lift inspections with the iD 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 AVANTI or personnel authorised 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 techni cians 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 connecting bolts and other equipment is made
41. integration that shall include items which are not under AVANTI s scope 4 2 Cautions Please familiarise yourself with these instruc LLI tions and the User s Manual before installing the L v N service lift Ensure that all specified parts are present before commencing installation No warranty is provided against damage and injury result ing from not following this User s Maintenance and Installation Manual i e reconstruction or modification of equipment or use of non original parts which are not approved by the manufacturer 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 elevat ing heavy weights e Use a wire rope clamp or grip when lowering wire ropes in order to avoid the risk of personnel losing the wire rope and wire rope getting damaged or person being hit The clamp shall be secured to a platform anchor point The diameter of the clamps or grips shall match the diameter
42. itten specification documentation User s Maintenance 9 and Installation Manual 2 3 Cautions Use and daily inspection of the service lift shall only be performed by AVANTI or personnel authorised by AVANTI hired by the employer for the job at hand Installation and maintenance of the service lift shall only be performed by AVANTI or qualified personnel authorised by AVANTI hired by the employer for the job at hand Additionally these tasks may be per formed by qualified personnel authorised by a trainer authorised by AVANTI 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 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 faults are found during operation or if circumstances arise which may jeopardize safety immediately inter
43. l brake will be prevented 060607 5 7 Lateral removable windows for Dolphin A version To open the windows 1 Press the emergency stop button of the cabin control box 2 Remove the lateral windows from the cabin lateral panels by unscrewing its riveted screws with a Torx screwdriver To close the windows 1 Install the lateral windows by screwing its riveted screws back on the cabin lateral panels with a Torx screwdriver 2 Press and turn the emergency stop button of the cabin control box The lateral removable windows shall only be used by AVANTI or qualified personnel authorised by AVANTI The lateral removable windows shall only be used for maintenance tasks 30 AVANTI Service Lift for Wind Turbines 5 8 Troubleshooting 1 All tests and repairs to the electronic compo 2 Repairs to the traction hoist the fall arrest nents should be performed by authorised device and to the system s supporting compo personnel only The wiring diagram is placed nents should be performed by qualified in the power cabinet personnel only Breakdown Cause Solution The service lift Ai The fixed EMERGENCY STOP Reset the button in question by pulling or will neither go up button has been activated turning it nor down A2 Wire rope loop on traction hoist Stop work immediately Damaged or defective wire rope or Ask the supplier or manufacturer for help wire rope outlet causes problems A3 The fall arrest device is
44. n box on the first platform over mid tower s height Cut the transport strips which hold the cable and connect the cable inlet to the junction box Uncoil the cable to the bottom platform Connect the power cable outlet socket to the service lift inlet plug 4 3 2 Guard locking system Install the guard locking control box on the bottom platform fence Install the guard locking switch and its actuator on the fence door using the supplied hardware Install the lift detection switch on its bracket on the bottom fence toeboard and connect to the socket on the guard locking control box Connect the power cable power inlet plug to the guard locking control box outlet Note Optional for Dolphin V CE versions Not available for Dolphin A version and for AECO version 2 Note Optional for Dolphin V CE versions Manda tory for Dolphin A version and for AECO version 3 Note An interlock system trapped key or guard locking is mandatory for CE versions if platform fences are equipped with doors Optional for AECO version 26 AVANTI Service Lift for Wind Turbines 4 4 Guiding traction and safety wire ropes 4 4 1 Top platform Guiding traction and safety wire ropes are attached to the suspension beam on the available holes To install them on the suspension beam 1 Mount the guiding wire ropes 12 mm and the traction and safety wire ropes 8 mm using the shackles supplied for the suspension beam at the top of th
45. nspections and adjust if necessary 1 Inspect all the wire ropes along their entire length 2 Pay special attention to the wire rope ends parts of the wire ropes running over sheaves and wire ropes under frictional wear by external components 3 When inspecting the wire ropes consider the following points type and number of wire breaks position and time sequence of wire breaks decrease of the wire rope diameter during opera tion corrosion abrasion deformation influence of heat and operating time 4 Check that the traction and safety wire ropes are fed correctly around the 2 wire rope guide wheels 5 Check that the wire rope ends are coiled separately under the bottom platform and tied with at least 3 cable ties 6 Check that the guiding wire rope tensioning system is correctly installed and that the wire rope locks and fixes are properly fastened 7 Check that the compression spring on the safety wire rope is correctly installed and that the wire rope locks are properly fastened 8 Check that the counterweight on the traction wire rope is properly fastened The traction wire rope coil and counterweight shall be able to rotate freely Do not attach them to a fixed part 9 Check that the guiding wire ropes are correctly tensioned 36 AVANTI Service Lift for Wind Turbines Record any visible change of the LLI condition of the wire ropes on the Appendix C Inspection log sheet and monitor closel
46. o Og 20 0990904 1090 NEPOS 05050054 t09 Ord RATS 9596 o 990 029A 499 X NIINAN 9o 96 00506 9999 13 SCIES ee zi ENS geo So 272 PINY d 1909 TOLOTO olog ANININ 1029 DPQ PaHLOLDGS Gero Ed TNCS 00 OLLO ODOLA VLOG DHZD OOA REPRE OLLORO Pooter o DROHMOCHGL to8e NY PEN NO ANY VIVEK LOLSOL OTTS Se NETS LO 0996 0980 N S S69 d Ses bore oe AM NINNIN IRNI e Se 069 CON SNL SEA NONIS v WEG SERERE NINN g Seg toSee tog ere RIRN o SQLOGOOL ISSO SHLOQSO SOG o SANN RIINA P VQOGS oLdgSocog e q ec 9 VQ NN Z Se 99959530 E 14 SESS CON E NECI E SG E SP e Se v SS QS OS SS QSSOSSS SOSSSS 15 LS SSS SESS e SSSSSS s SOS SS e SSSSSS S9 SSSSSS SOS DI SS SOS CSSSSSE oO SOSSOT uncos ESSSSES QS SIS SOS SSSSS SS SS SS 5e x 1 Emergency top limit stop switch 11 External controls 2 Top limit switch 12 Cabin control box 3 Safety wire rope 13 Bottom sliding door 4 Traction wire rope 14 Maintenance cover 5 Guiding wire ropes 15 Bottom obstruction device 6 Internal Light 16 Traction hoist and fall arrest device 1 1 1 T Main control box 17 Top obstruction device 1 8 Hour counter 18 Top stop bar 9 Anchor points 19 Travelling cable pulley 10 Top sliding door 20 External anchor point optional 21 Waring lights 1 Note Optional for CE versions Mandatory for AECO version User s Maintenance 13 and Installation Manual 3 6 2 For Dolphin A v
47. of the wire ropes e Not work at different levels if tasks involve risk of falling objects 4 3 Electrical connections Before making any connection disconnect any power supply to the service lift and the fence interlock system For CE versions the electrical connection of the system 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 When plugging the service lift to the power supply ensure that supply phases are correct 4 3 1 Power cable 4 3 1 1 Cable bin Hang the cable collect bin underneath the power cable hole of the bottom platform using the straps supplied Attach the straps on the holes User s Maintenance 25 and Installation Manual Tensioning system Power cable outlet socket Cable Spring of safety stocking F wire rope S Cable collect bin suspension straps Cable collect bin Power cable inlet plug Counterweight of traction wire rope Cut the transport strips and tape holding the cable inside the bin and connect the cable stocking to the eyebolt underneath the service lift floor Connect the power cable outlet socket to the service lift inlet plug attaching the cable to the cabin with cable ties 4 3 1 2 Travelling cable If optional travelling cable is used instead of standard cable bin Install the junctio
48. reen light must be OFF and the lift must not move UP DOWN Close the top sliding door and apply the lock to the bottom sliding door 3 5 Activate the fall arrest device by pulling down the red locking knob Press and hold the DOWN button of the cabin control box The service lift should not descend Try to perform manual descent The service should not descend Press and hold the UP button of the cabin control box The service lift should ascend Unlock the fall arrest device by pulling down the black unlocking knob 3 6 Perform a manual descent test for a meter The lift should descend and the buzzer should sound 3 Drive the service lift down until the Bottom obstruction device hits the bottom platform The service lift should stop before the rubber bumpers hit the bottom platform The service lift door and the fence door should be unlocked 3 8 Top obstruction device activate top stop by pressing it down The service lift should not ascend until top obstruction device is released 3 9 Slack rope sensor Activate the slack rope sensor by manually pulling the traction wire rope upwards Descent should not be possible 4 When the lift is at the top platform check the wire rope fastenings 5 Record the hour meter reading in the Appendix D Inspection log sheet If any faults occur during work stop working If required secure the workplace and rectify the fault Make sure that nobody is exposed to danger below
49. retches approximately 50 N mm using the supplied nut Use the second nut to lock the assembly Bottom platform hole arrangement xi d m Safety wirerope Traction wire rope Guiding wire rope 5 sj Guiding wire rope T T S ac Power cable Note Top limit device disc is mandatory for CE versions if top obstruction device is not present Top limit device bar is mandatory for CE versions if top obstruction device is present Top limit device bar is mandatory for AECO version 2Note Power cable hole is only necessary when cable bin is installed 4 4 2 2 Traction wire rope 1 Open the maintenance cover on the back of the service lift 2 Remove protection guard above rollers 3 Feed the wire rope between the two bushings of the slack rope sensor 4 Feed the wire rope through the roof into the traction hoist s wire rope inlet opening 5 Push the UP button of the cabin control box and feed wire rope through until the traction hoist starts pulling Ensure that the wire rope can exit without obstruction 6 Continue feeding the wire rope around the pulleys to the back of the lift Traction wire rope 7 Feed the wire through the guide bushings includ ing pulley ones when using travelling cable 8 Feed the wire rope through the platform holes 9 Secure the 11 kg counterweight on the traction wire rope at least 600 mm below the bottom plat form See figure below The remaining wire rope
50. rning instruction and or training specific to the integration of the service lift necessary for its safe and correct installation LL Service Dolphin V Dolphin V Dolphin A Dolphin V lift CE 240 CE 350 CE 240 AECO 240 165 kg 180 kg 165 kg 165 kg 10or 180or21 nv 18mv min x 1096 18mvmin x 1096 100r21 m min min 10 96 10 96 240 kg 2 350 kg 2 240 kg 2 240kg 2 Persons Persons Persons Persons 15 C to 60 C 15 C to 60 C 15 C to 60 C 15 C to 60 C 6 F to 140 F A third party approval of the final integration might be required depending on the national regulations Tower manufacturer s risk assessment shall include a service lift integration study 6 F to 140 F 25 C to 80 C 25 C to 80 C 25 C to 80 C 25 C to 80 C 13 F to 176 F 13 F to 176 F 13 F to 179 F 13 F to 176 F F to 140 F 5 F to 140 F 80 dB A 80 dB A 80 dB A 80 dB A Shackle 2T Shackle 2T Shackle 2T form Shackle 2T form C form C C with safety pin form C with safety pin 3 Phase 400V 480V 690V 50Hz 60Hz Dolphin V CE 240 5G1 5 400V 5G1 5 480V 4G1 5 690V with safety pin 3 Phase 400V 690V 50Hz 60Hz Dolphin V CE 350 531 5 400V 4G1 5 690V 3 Phase 400V 690V 50Hz 60Hz Dolphin A CE 240 12G2 5 400V 690V with safety pin 3 Phase 400V 480V 60Hz Dolphin V AECO 240 5G1 5 400V 531 5 480V 0 16 kg m 0 16 kg m 0 5
51. rupt the work in progress and notify the supervisor or employer All tests repairs of electrical installations may only be performed by AVANTI or qualified personnel au thorised by AVANTI All repairs to the traction braking and supporting systems may only be performed by AVANTI or quali fied personnel authorised by AVANTI If any supporting parts are repaired or replaced the operational safety of the system must be tested and verified by AVANTI or qualified personnel author ised by AVANTI 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 No modification extension or reconstruction of the 10 AVANTI Service Lift for Wind Turbines 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 Service lift must be inspected by AVANTI or by quali fied personnel authorised by AVANTI before first use Service lift must be inspected at least once a year by AVANTI or qualified personnel authorised by AVANTI In case of high operating frequency or severe condi tions 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 l
52. s defective or not connected b Bottom stop switch is activat ed E The lamp is defective F Ifa phase control relay is not provided two phases changed in the supply Solution Carefully take the service lift up and remove the obstacle Test the operational safety of affected platform components Inform the supervisor Take the service lift upwards to relieve the safety wire rope a b Open the fall arrest device by pressing the handle and test its function Functional test when the lift is back on the ground Replace the hoist and fall arrest device and return them for testing DANGER A defective fall arrest device will threaten the safety of the service lift Replace immediately Insert brake lever into the traction hoist and lower lift manually Test and if necessary have connec tions wiring and relays repaired The slack rope sensor has engaged move the service lift upwards to disengage the device The sensor is not properly installed have a competent technician adjust the device correctly The sensor is defective replace it and return it for test repair at AVANTI a Test the bottom stop switch connec tion function Replace if necessary b Descend service lift until bottom stop switch is released Have an authorised person replace it Have an authorised person switch the 2 phases in the plug If these steps do not identify the cause and rectify the fault Consult a qu
53. s provided with a lever allowing manual release of the electromagnetic motor brake Once the motor brake is released the service lift descends with a controlled speed limited by a centrifugal brake installed between the motor shaft and the gear box PULL DOWN TO LOCK s wa twee e um ud 2 aaa af Fall arrest device unlocking knob black 3 20 Fall arrest device The service lift is equipped with a fall arrest device which will be triggered in case of an overspeed condition The speed of the safety wire rope passing through the device is continu ously monitored and the jaws are automatically closed in the event of sudden excessive speed This device protects the service lift against traction wire rope breakages or traction system failures 22 AVANTI Service Lift for Wind Turbines Fall arrest device locking knob red When the manual descent actuator is pushed upwards the brake release switch Is activated The brake release switch will interrupt any control function The manual descent buzzer will sound while the service lift descends Fall arrest device Lever extension tube Brake release switch Manual descent actuator Li LIN Manual descent actuator holder The fall arrest device can also be engaged manually in an emergency by pulling downwards the red locking knob on the back of the lift this will turn its emergency stop lever counter clockwise To release the fall arrest device stop
54. st corre sponding with the refurbishment of the traction system 38 AVANTI Service Lift for Wind Turbines 6 4 5 Repairs Hepairs to traction hoist equipment must ONLY be performed by AVANTI and only using original spare parts If the gearbox oil needs to be replaced use one of the lubricants specified below corresponding to the temperature range in which the traction hoist equipment is used e Amount required 1 5 e Traction hoist M500 M508 e Specification MSHC 632 VG320 Each oil has to be verified by AVANTI 6 4 6 Overload check and adjustment Annual test Test switches and perform overload test as speci fied in the Appendix A Regulation of overload limiter 6 5 Information signs and documents Verify availability and legibility of all data plates and information signs Replace missing or illegible plates and signs 6 6 Ordering spare parts Only use original parts Spare part lists are available from AVANTI Please indicate lift model when requesting a spare part list 45540046 Dolphin Lift manual EN Revision 1 08 04 15 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
55. t green 3 DOWN button black 4 Main switch 5 UP light green 6 Fault light red 7 OK light green 8 Emergency stop button 9 UP button white 3 12 3 2 Send and call configuration 9 6 3 7 2 8 3 13 Intermediate and top platform control box for Dolphin A CE version 3 13 1 Call only configuration 9 5 6 2 T 8 3 13 2 Send and call configuration 9 5 3 2 7 6 8 User s Maintenance 17 and Installation Manual 3 Fixed perforated sheets 3 14 Platform fences The platform holes shall be protected with platform fences The platform fences consist of structures with or without perforated sheets of different geometries depending on the platforms where they are installed 3 14 1 Fences for Dolphin V and A CE versions The platform fences shall conform to EN 14122 3 Ate a e e Te Th FLA i i annuaaunnnaannnnaaanun CC VEC i CE TETI A mmu a Taka ha ya pi aa hi e pa aa Ya ga ha ee eee ee ee La a Gn e b DER WL A E T i1 t ke kekin ge ie ke eie ae ge ee e ee e ge ke e l Tk LO paata Yr gu ka pafa Ya fu ha pe aa 1A E EL ELLE 7 E EIL EUER A E EL ELA annadaannaasssanaasasan L Ll CS EFLFE TS SE EF E Ae TE Ll uh 4 n44nnaannangnansanunuaaaann ii gauunuaasuanananauuuguaauun 4 VULDOuac c uumomucpmauauuuma 7 4mBhnuannnmosmannmasssnanm S nuaauauunuauumugacuaumuu WOW umauusladuusunmggu Bu0uauaBnaaanaanmesaunsaass s naacauguuaagucndaacuunuauau 4 daauu
56. 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 15 029 1 from 2015 04 09 and is valid only duly considering the requirements mentioned in this document The examination was realized on site in Zaragoza Spain This certificate is valid until 2020 04 13 Certification body Notified r No_0035 ea e Cd T Cologne 2015 04 13 pl 4f g Walter Ringhausen T V Rheinland Industrie Service GmbH H inl Alboinstra amp e 56 12103 Berlin A TUVRheinland Telefon 49 0 30 75 62 1557 Fax 49 0 30 75 62 13 70 Precisely Right Sse Certificate of Dolohin V AECO 240 version UP PN Presents this AECO CERTIFICATE Certificate No 2013042912CA15816 Date 2013 04 29 To Avanti Wind Systems Inc 5150 South Towne Drive New Berlin WI 53151 USA For certification in accordance with the ASME A17 7 2007 CSA B44 7 07 of the following Elevator Subsystem Turbine Service Lift See addendum for details Effective from April 29 2013 Until April 29 2016 SS d bos ON A Issued by Daniel Posner Reviewed by Len Grant Reviewed by William N Bartunek PE AECO Certification Services AECO Certification Services AECO Certifi
57. y throughout time 6 4 4 1 Lubrication of the traction and safety wire ropes 1 Position the lift at the bottom platform 2 Open the maintenance cover by unscrewing its screws 3 Apply lubricant on the traction and safety wire ropes by means of a spray can 4 While applying the lubricant use the second hand to place and hold a cloth around both wire ropes This way the lubricant will be distributed uniformly on both wire ropes 5 While the first user uses the spray can and the cloth a second user presses and holds the UP button from inside the lift This way while the service lift ascends the lubricant is applied along the complete length of the two wire ropes 6 After applying the lubricant leave the mainte nance cover open and carry out a descent back to the bottom platform f While descending check that the two wire ropes have been properly and uniformly lubricat ed 8 Once the service lift is at the bottom platform clean off any lubricant accidentally applied on the cabin panels 9 Finally close the maintenance cover by screwing back its screws Only use specialised wire rope lubricants Do not use lubricants based on lithium soap grease or bitumen Do not use disulphide containing lubri cants like Molycote Apply lubricant using a spray can brush drip applicator or pressurized device Pay special attention to sections of the wire rope where dehydration or denaturation of the lubricant can be
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