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1. T Established 1885 45540046 DOLPHIN AECO 4th EN R2 indd 1 03 06 2014 16 39 17 CE certificate of Dolphin CE version and of Dolphin CE 350 version 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 Hogevej 19 DK 3400 Hillerod 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 Type E Dolphin ES max load capacity 350 kg 2 persons net weight traction hoist safety gear max lifting height lifting speed Protection fences 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 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 te
2. 3 8 Fence system CE versions The following types of fences are available 1 Fixed railing 2 Railing type with door Trapped Key Actuator AS y Ss SS Sy AOS A 09 DNS Y LN TY Q 55 LN SZ ES A 7 iN A os Y gt Y N Le a N User s Maintenance 15 and Installation Manual 03 06 2014 16 39 28 Trapped key lock actuator Ox O 2 9 gt o p xXx uard locking switch Lift detection switch switch actuator Guard locking switch i 1 emergency release button guard locking is mandatory for CE versions if platform fences are equipped with doors Note An interlock system trapped key or Optional for AECO version the service lift is not at the platform The door can be unlocked by using the trapped key on the user control box and opening the trapped key lock The key will get trapped until the door is closed and locked again 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 system keeping the door locked while the service lift door is closed trapped key lock keeping the door locked while The platform fence door is fitted with an interlock The platform fence door is fitted with a 3 8 2 Guard locking system 3
3. 1 IMPORTANT LS VERSION Meaning Possible injury if not observed IMMEDIATE or possibly imminent Death or severe injury danger IMMEDIATE or possibly imminent danger of hazardous Death or severe injury voltage Potentially hazardous Light injury or material damage situation Potentially dangerous Damage to equipment or workplace situation Useful tips for optimum None working procedure Differentiation between CE versions and AECO version Reference to written specification documentation 8 AVANTI Service Lift for Wind Turbines 45540046 DOLPHIN AECO 4th EN R2 indd 8 03 06 2014 16 39 19 T e 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 cop
4. 14 20 06 03 m e Traction system Fall arrest device Lifting Wire rope c Rated Traction Unit weight capacity current wire rope O approx Version Traction system type 3 5 2 Fall arrest device Triggering Safety Unit weight speed wire rope Y approx Version Type Kg Ibs m min ft min mm Kg Ibs Dolphin AECO ASL 508 500 1100 30 100 7 15 4 Service Lift Fall arrest device Lifting capacity 3 5 3 Traction safety and guiding wire ropes Wire rope Surface Mark Min break Service Lift Version Wire rope type Attached with diameter Treatment feature resistance Dolphin CE amp AECO M508 ASL 508 8 4 mm 5x19 55 kN t shackle User s Maintenance 13 and Installation Manual 45540046 DOLPHIN AECO 4th EN R2 indd 13 e 03 06 2014 16 39 27 3 6 Control boxes 3 6 1 Main control box descent buzzer Top obstruction obstruction switch User control box Emergency top limit switch Fall arrest device switch Manual Door guard locking switch switch Bottom Manual descent switch connector Hour counter Green light Ready On if the lift is ready to use no safety devices engaged TRAPPED KEY SWITCH 3 6 2 User control box EMERGENCY STOP BUTTON Press to interrupt any control function Pull to reset the control after necessary verifications DOWN UP N Automatic BOTTOM OBSTRUCTION OVERRIDE SWITCH OVERLOAD BUZZER Turn the key to ON to
5. 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 3 13 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 Top limit switch Emergency top limit switch Top obstruction device Bottom obstruction device Release the DOWN button as soon as the rubber N bumpers hit the floor Otherwise the lift or the installation may get damaged 45540046 DOLPHIN AECO 4th EN R2 indd 19 e User s Maintenance 19 and Installation Manual 03 06 2014 16 39 29 BOO e 3 14 Manual descent system The service lift is provided with a lever allowing When the manual descent actuator is pushed manual release of the electromagnetic motor upwards the brake release switch is activated brake Once the motor brake is released the The brake release switch will interrupt any service lift descends with a controlled speed control function The manual descent buzzer will limited by a centrifugal
6. 3 6 Control DDX6S saa e 3 6 1 Main control DOX 5 cuc v4 ee eda REE a 3 6 2 User control DOK 244 4430 kx scan d Pars be deed eed xe as 3 6 3 Bottom platform control box 3 8 Fence system CE version 3 8 1 Trapped key system 3 8 2 Guard locking switch 3 9 Fence system AECO version 3 10 Service lift door 0 cc cc ee a 3 11 Emergency top limit switch 3 12 Top obstruction device 3 13 Bottom obstruction device 3 14 Manual descent system 3 15 Fall arrest device as paes sia y eee ee sms ee re eee 3 16 Overload limiter 3 17 Slack rope sensor sans sacras e de wee ee owe wim SO Warning ION ei bone Oded bate cavas as cee oe ou 3 19 Acoustic buzzer poor rra eee ees ROCA Rn eee D BHOI DOINGS sa 25 2 se 91 N dre ba oe bee ee een eae es 9 21 Internal NOM x 9 76 cea ees cece ee ada sees ane wt oe ek eo 4 IASTallat N aoe eo 808 ee o ae dI TIGI succes nuce wx x C RLE a R R A donc 4 2 Electrical connections 4 3 Guiding traction and safety wireropes 4 3 1 Top platform uu ac cre s ca CR CUR eb ue de SC etwas does 4 3 1 1 Top limit device
7. 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 must be coiled and fastened with at least 3 strips The counterweight and the excess of wire rope shall be able to rotate freely gar ety wire rope Traction wire rope pn Bottom platform 24 AVANTI Service Lift for Wind Turbines 45540046_DOLPHIN AECO 4th EN R2 indd 24 4 3 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 th
8. 6 Cable collect bin is in proper condition and mounted according to the manual E Cable opening of bottom platform floor is properly mounted with a rubber edge protection profile N Y 7 8 Travelling cable pulley is in proper condition and mounted according to the manual q co Cable stockings are properly mounted cables not loaded at the cable plug 7 10 The flat travelling cable is free of damages The roung electrical cable is free of damages The mid tower electric cable support is properly installed and tightened PEL TION HOIS K Net pc SCIIE DESCRIPTIC 36 AVANTI Service Lift for Wind Turbines 45540046 DOLPHIN ARCO 4th EN R2 indd 36 e 03 06 2014 16 39 35 OO e MN A 52 umshwihnewcerkate RT RM S furnish with new certificate DID DIDIT NN NN RR RN ES ES There are no signs of Teflon snow dust beneath the pulleys O IN NN NM RN DULL A EN LIII DULCI A A DILDO A NN A E E O Fall arrest device no visual defects have appeared Clean only when very dirty ensuring sufficient air supply 9 3 If hour counter reads 250 h since last overhaul overhaul device at AVANTI workshop and furnish with new certificate 9 4 It is well lubricated using too much oil will not harm the equipment or the gripping function AN Fall arrest device engages when performing overspeed hand test safety wire rope is 9 5 pulled by hand from first platform The
9. disc 4 3 1 2 Top limit device disc 4 3 2 Bottom platform ise rk xy REX RERO ns ET RA 4 3 2 1 Guiding wire ropes 4 3 2 2 Traction Wire rope 4 3 2 3 Safety wire rope 4 3 2 4 Travelling cable adjustment 4 4 Wire rope fiX ous data PE bene dA dE EUR IR RR 4 5 Danger zone sticker x su lt e rm Ry om REX Rcx Re EC RR 4 6 Inspection before first use 5 Instructions for USE 4 s lt lt x lt lt bias RACAOR OR RCACRCAOE AREA 5 1 Prohibited USOS 5c uu ox wa a so cer She we a Oe cet RS ane 5 2 Operation from inside the cabin manual 5 9 Operation from outside the cabin automatic 5 3 1 Bottom platform lt e des e e RS oe ws x XR EUROS A ORC 5 9 2 Op PIANO S E rea doser e NR d 5 4 Fall arrest device xxx ww reino ROCKS EO E Y REOR NW RR Cn 45540046 DOLPHIN AECO 4th EN R2 indd 5 e 03 06 2014 16 39 17 T e 5 5 Manual descent uos sence vivos ERES ERREI PEREIRAS DC PESTE TES Da 26 DD IFOUDICSNOOUNG i duse sd Ree teed Ped eal oe eo ees oe Rie nec bass anne ee ts 27 Of QUI OF SENICE santos cera eerie LR CT IT T T AAA sewers bees 30 6 Maintenance ius sc ucsacs RC da rea 30 PIANO NS ee de ose costa de se cut ete de 30 D VAMOS es Ge ee made SS de eee oe o
10. information signs Replace missing or illegible plates and signs 6 6 Ordering spare parts Only use original parts opare part lists are available from AVANTI Please indicate lift model when requesting a spare part list User s Maintenance 33 and Installation Manual 03 06 2014 16 39 34 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 Required tools material Security Torx 40 Test weights for applying the test load To modify the lifting load limit 1 Insert the overload adjustment tool in the adjustment screw through the hole located at the back of the cabin as shown in the figure below 2 Turn the tool clockwise to increase the lifting load limit 3 Turn the tool counter clockwise to decrease the lifting load limit Note One turn on the adjustment screw represents a change of approximately 40 Kg on the lifting load limit Service Lift Dolphin CE 8 AECO Dolphin CE 350 travel distance Setup Test Setup _ Test COI COCA COI CODES memm w w a 34 AVANTI Service Lift for Wind Turbines 45540046_DOLPHIN AECO 4th EN R2 indd 34 Place the service lift on the lowesttravel Apply the setup load from the hei table depending on the WTG increase the lifting a
11. 21 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 Note Optional for CE versions Manda tory for AECO version User s Maintenance 21 and Installation Manual 45540046 DOLPHIN AECO 4th EN R2 indd 21 e 03 06 2014 16 39 30 4 Installation 4 1 Cautions Please familiarise yourself with these MM instructions and the User s Manual before ER installing the service lift Ensure that all specified parts are present before com mencing 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
12. 3 Railing type is only possible if top obstruction device is installed on service lift 16 AVANTI Service Lift for Wind Turbines 45540046 DOLPHIN AECO 4th EN R2 indd 16 3 9 Fence system AECO version Fences are 1 1 m high shall at least have a door with self closing self latching system and conform to ASME 17 1 5 11 or one of the door interlock systems de scribed before Fence of bottom platform 45540046 DOLPHIN AECO 4th EN R2 indd 17 e User s Maintenance 17 and Installation Manual 03 06 2014 16 39 29 3 10 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 lift is levelled with a platform This switch is triggered by the platform activation plates XEM 18 AVANTI Service Lift for Wind Turbines 45540046 DOLPHIN AECO 4th EN R2 indd 18 Top sliding door actuator Top sliding door switch uard locking switch of bottom sliding door In case of power cut need of evacuation between p
13. 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 40 AVANTI Service Lift for Wind Turbines 45540046 DOLPHIN AECO 4th EN R2 indd 40 e 03 06 2014 16 39 35 E 5 Inspection After installation Periodical examination An inspection must be carried out by a competent A periodic examination at least person following the inspection form in this manual every 12 month is essential for the safety of the AVANTI LIFT ANCHOR The examination must be performed by a competent person following the Before use inspection form in this manual Each time using the AVANTI LIFT ANCHOR the user inspects the ANCHOR visual and manually by For the AVANTI LIFT ANCHOR the competent twisting pulling Check the parts are properly fixed person authorized in writing by AVANTI only needs and free of deformities damages cracks or similar 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 t
14. and release your first shock absorbing 3 Release your fall protection system slider from the safety lanyard from the ladder line of the ladder see Fig 6 User s Maintenance 35 and Installation Manual 45540046 DOLPHIN AECO 4th EN R2 indd 35 e 03 06 2014 16 39 35 OO e Appendix C Inspection Checklist Date oe Serial n traction system Name of competent od Serial n fall arrest device Lift M Tower n Total hours of operation Address of installation In 1 LLL ea M EC NN NN RN TN OS RN gt AVE ONE OK No A gt CF 3 1 TR SAFETY DEVICES OK Not OK SSUE DESCRIPTIC All external buttons of user control box are fully functional send function fo Bottom obstruction override switch of control box is fully functional a 3 5 The ready lamp green functions properly EN 3 6 The platform indicator green functions properly 3 7 All emergency stop buttons function properly 3 8 Bottom obstruction switch sits and functions properly 3 9 Emergency bottom obstruction breaker functions properly 3 10 Top obstruction switch sits and functions properly The emergency top limit switch functions properly and is properly adjusted at top and bottom platforms oO 11 3 12 Slack rope sensor is fully functional 4 1 Cabin is free of damage and properly assembled 4 2 Cabin is clean and in overall good condition 4 3 All screws assembling the cabin are mounted
15. and safety wire ropes 4 3 1 Top platform 4 3 1 2 Top limit device bar 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 the 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 Note Top limit device disc is mandatory for CE shackle Adjust the final position during first run so that versions if top obstruction device is not present Top the service lift is levelled with the top platform when it A limit device bar is mandatory for CE versions if top stops obstruction device is present Top limit device bar is 4 Uncoil all wire ropes to the bottom of the tower mandatory for AECO version 4 3 2 Bottom platform All wire ropes must be evenly uncoiled 4 3 2 1 Guiding wire ropes to prevent looping 1 Feed the guiding wire ropes through the wireguides on the service lift and the holes in the platform 2 Fit the correct number of wire rope fixes on the wire rope and feed through the wire rope Do not pull wire rope over edges guides The wire rope fixes are fitted during the first run 3 Pull
16. button as needed 5 3 Operation from outside the cabin automatic Transportation of people is forbidden if the operation is controlled from outside the service lift A Automatic function is only possible from top platform to bottom platform and vice versa 5 3 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 26 AVANTI Service Lift for Wind Turbines 45540046_DOLPHIN AECO 4th EN R2 indd 26 4 Close the bottom platform fence door 5 Press the UP button using the send tool 5 3 2 Top platform 1 Close the 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 b 5 4 Fall arrest device In the event of traction wire rope breaks or traction hoist fails evacuate the service lift 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 pow
17. first shock absorbing the yellow anchor point of the cabin one user per anchor lanyard from the cabin point and open the service lift door see Fig 1 4 Climb round the ladder to its climbing side Note if external anchor point is installed attach your second shock absorbing lanyard to the external anchor point and 5 Attach your fall protection system slider to the safety line then release your first shock absorbing lanyard of the ladder see Fig 3 secure yourself to the ladder with your positioning lanyard see Fig 2 2 Attach your second shock absorbing lanyard to the ladder anchor point If ladder anchor point is not reachable attach 6 Release your shock absorbing lanyard from the ladder your shock absorbing lanyard to the ladder stile 7 Climb down the ladder see Fig 4 Fig 1 Fig 2 Fig 3 Rescue of lift from the ladder is only necessary in extreme situations If necessary AVANTI recommends the following procedures 1 Climb up the ladder and position yourself at the same 4 Climb round the ladder to the opposite side of the ladder level as the service lift 5 Open the service lift door and attach your second shock 2 Attach your first shock absorbing lanyard to the ladder absorbing lanyard to the yellow anchor point of the cabin anchor point If ladder anchor point is not reachable attach one user per anchor see Fig 7 your shock absorbing lanyard to the ladder stile see Fig 5 6 Step into the cabin
18. gear e Useahand winch attachable to the ladder when elevat ing heavy weights e Useawire 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 of the wire ropes e Not work at different levels if tasks involve risk of falling objects 4 2 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 gt 4 2 1 Power cable 4 2 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 22 AVANTI Service Lift for Wind Turbines 45540046_DOLPHIN AECO 4th EN R2 indd 22 Tensioning system Power cable outlet socket Cable Spring of safety stocking Les wire rope Cable collect bin suspension straps Cable collect bin Power cable inlet plug Counterweight of
19. ncrease the lifting Press the UP button lifting load limit load limit Review the values ofthe used Can service lift ascend Yes Ho Remove 20 Kg from the setup load and push the UP button No Can service lift ascend Review the values ofthe loads used Yes Apply the test load from the table depending on the WTG eight Can service lift ascend Yes Ho Apply the working load limit and perform a full run to the top overload limiter Yes engage during ascend No The overload is correctly set Fill in the Inspection checklist 03 06 2014 16 39 34 BOO e Appendix B Safety measures General Only use service lift if you have received Operating the service lift Wear your PPE at all times instructions in operating the service lift in all predictable safety helmet full body harness shock absorber lanyard and situations These instructions can only be given by a person runner fitting the fall protection system on the ladder with the proper knowledge e g Avanti Trainer or Trainer approved by AVANTI If service lift stops and manual emergency cannot be performed follow evacuation procedure Evacuation of personnel from the service lift is only necessary in extreme situations If necessary AVANTI recommends the following procedures 1 Confirm that your shock absorbing lanyard is attached to 3 Step onto the ladder and release your
20. the guiding wire rope through the platform and fasten it with the tensioning system 4 Pre tighten the wire ropes using the tension ing 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 stretches approximately 50 N mm using the supplied nut Use the second nut to lock the assembly N a EDS N S N AS A A Ls AA TIPA 17 27 wire ropes Bottom platform hole arrangement Traction wire rope 1150 30 Safety wire rope i Top limit Safety wire rope Traction wire rope device disc Guiding wire rope Guiding wire rope 2 TS Power cable L 2Note Power cable hole is only necessary when cable bin is installed User s Maintenance 23 and Installation Manual 45540046_DOLPHIN AECO 4th EN R2 indd 23 e 03 06 2014 16 39 31 4 3 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 Note Optional for CE versions Mandatory for AECO version 4 Feed the wire rope through the roof into the traction hoist s wire rope inlet opening
21. traction wire rope CUL 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 2 1 2 Travelling cable If optional travelling cable is used instead of standard cable bin Install the junction 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 2 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 CE versions LS P Not present for AECO version Note Optional for CE versions Not present for AECO version 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 03 06 2014 16 39 30 BOO e 4 3 Guiding traction
22. 8 1 Trapped key system ae Sd La 0 95959 EMA LT hh OT Th CV 12000200027022000002000 dana ano 00000 Laa Ka aa tuba 33220059509282000940009595 U JET fa aff Dea E fe fe TEE ET 9290000090900039 te ke kelele j a hs OOO S C D ee a aa ee el ER aAnumuuamuuumuauuuuduuuuau i annadaannaaaaanaaaann LI 01410010101 aaa a pra O KL Q ELA A 5 23006005320006222002002029008 202002922000020000002000 aaa jala DO KR D DO a q SOS SOS DDD nuaauanuumnuauumaaaaumia c400000109091000001000700 SOS SSSR SOUS DERE GVOUO SES E coda AQU 11 00700000700700000200000200 00000009000000900000000 4 220000990000020000002000 r4 sansooncononanconnens L0 ii aaa aaa oda S LT 6011010147912 LETT 200074 osa ba ha he te B DOE DL DOOD S AT TERRE EURE LEE D sto Th EK ade CL CL CE ON N EK EL DS e e ST AT AT ENS OTT TO P e e ET Er pra ee rra Pp ra o e pr foe 7 P P i o A 03 06 2014 16 39 29 3 Fixed perforated sheets BEE ETE e EP GT FAT IF UP ITUR NT 4 Perforated sheets with door 5 Perforated sheet type of 2 4m high and with door equipped with guard locking accessed platforms access to platform maximum once per year Any combination of fences is possible as long as all the 1 Fixed fences shall only be installed in infrequently following points are fulfilled 2 Doors shall be equipped with an interlock system either trapped key or guard locking
23. Avanti Wind Systems GmbH Max Planck Str 10 25335 Elmshorn P 49 0 41 21 7 88 85 O 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 www avanti online com E info avanti online com
24. ITTED 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 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 User s Maintenance 7 and Installation Manual 45540046 DOLPHIN AECO 4th EN R2 indd 7 e 03 06 2014 16 39 18 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 e
25. N ARCO 4th EN R2 indd 25 e 4 6 Inspection before first use LL AVANTI or qualified personnel author ised by AVANTI must carry out an inspection before first use following the Appendix C Inspection checklist The inspection before first use must be recorded for future reference filling in the Appendix D Operation log sheet User s Maintenance 25 and Installation Manual 03 06 2014 16 39 32 5 Instructions for use 5 1 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 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 To 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 Togo up or down push and hold the UP or DOWN
26. and tightened Bottom obstruction device is free of damage properly installed and fully functional it 29 compresses and decompresses properly 45 Top obstruction device is free of damage properly installed and fully functional it compresses and decompresses properly 46 Anchor points are free of damage without cracks dents and have no permanent deformation and properly tightened DI M 5 1 Wire rope guides are free of damage and are properly mounted and tightened 5 2 Wire rope fixes are mounted at a correct distance at platform openings 5 3 Each platform opening is mounted with 2 wire rope fixes 5 4 All wire rope fixes are free of damage normal shape and without cracks 5 5 Bolts of wire rope fixes are properly tightened 6 1 Door is properly mounted and tightened 6 2 Main service lift door is fully functional opens and closes properly 6 3 Main service lift door guard locking is fully functional locks and unlocks properly 6 4 Main service lift door guard locking is properly mounted and tightened 6 5 The emergency manual release button is fully functional 7 1 All electrical cables are free of damage specially isolation 7 2 Electric cables are properly layed and fixed with necessary cable ties 7 3 Sealing of control boxes is in order N 4 Internal light illuminates properly with and without power supply emergency function 7 5 Warnings lights function properly
27. anti online com www avanti online com HI an do QUALITY MANAGEMENT Sales amp Service Australia Avanti Wind Systems PTY LTD P 61 0 7 3902 1445 China Avanti Wind Systems P 86 21 5 85 8811 Denmark Avanti Wind Systems A S P 45 4824 9024 Germany Avanti Wind Systems GmbH P 49 0 41 21 7 88 85 0 opain Avanti Wind Systems SL P 34 976 149 524 UK Avanti Wind Systems Limited P 44 0 1706 356 442 USA Avanti Wind Systems Inc P 1 262 641 9101 India Avanti Wind Systems PL P 91 44 6455 5911 Brazil Avanti Brazil Sistemas E licos S L P 455 85 9671 6336 Manufactured Under Process Patent NO 8 499 896 Registered in Europe 45540046 DOLPHIN AECO 4th EN R2 indd 4 e 03 06 2014 16 39 17 BOO e Contents 1 Limited Warranty 3 4 es aaa 2 INTOCUCHION ua 9 8 dans dima esta oe a A 2 1 ODS FVALIONS ssa eae heute eo E ada aaa bbb eee eee ee od ea O 2 2 OVIMDOlS sececne se ees esse a Beet T ia 2 3 CAUNONS cassinos edb we E38 3 RR a dba ia DUAS ed d DESCHDUON asas id 0546046055 5000 CRORE AAA OA Ul 2 S 9 E an ATE NT o ida eee ee oe v an DZ COPO sirena D O 3 3 Technical specifications 3 4 DIMENSIONS es ne ae a ce ia do Doro 3 9 Components 4 uus mania Gr dicc a date C RC assoc 3 5 1 Traction System miedos wo ove qe cie ao R RRR RR E o eee 3 5 2 Fall arrest device 3 5 3 Traction safety and guiding wire ropes
28. at no visual defects have appeared Appendix D Operation log sheet b Check that air gap a between brake and disc is 0 3 mm using a thickness gauge If any faults occur during work stop working if required secure the workplace and rectify the fault 6 N Z oe ANA Make sure that nobody is exposedto l F danger below the service lift for instance from falling parts D Cabin control from outside of the cabin E E y Automatic JR mrn g The automatic mode function is only available q 1272222 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 C Test manual descent function should ascend d Test speed and current should match the 2 Press the emergency stop button on the control service lift data plate box The lift stops e Check that sound and behaviour are normal 3 Pull the emergency stop button and press the DOWN button The service lift should descend until the bottom obstruction device engages User s Maintenance 31 and Installation Manual 45540046 DOLPHIN AECO 4th EN R2 indd 31 e 03 06 2014 16 39 33 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 p
29. ated Note Top limit switch or top obstruction switch if top obstruction device is supplied B5 Fault in UP control circuit C1 Slack rope sensor is en gaged Note Optional for CE version Mandatory for AECO version D1 Wire ropes are dirty Further use of lift may STOP result in damage to the traction wire rope 28 AVANTI Service Lift for Wind Turbines A11 The service lift is stuck on Solution a Evacuate the service lift b Inform the supervisor c Check the Bottom obstruction device connection function Replace if necessary Test and or reduce load until buzzer stops Carefully move the service lift downwards and remove the obstacle Test the opera tional safety of affected platform compo nents Inform the supervisor Test and possibly reduce load until buzzer stops a Test the top limit switch connection function Replace it if necessary b Descend the service lift until the top limit switch is released B4 A phase is missing Test fuses and power supply Test and possibly repair connections wiring and relays Check the reason why it is engaged possibly it s an obstacle under the service lift or the bottom obstruction device is not functioning properly If possible immediately replace the traction hoist and return it for test repair at AVANTI 03 06 2014 16 39 33 Breakdown Service lift will go up but not down Button lamp not lit although operati
30. brake installed between sound while the service lift descends the motor shaft and the gear box Fall arrest device Lever extension tube Brake release switch Manual descent actuator 2 2 A PP ARARAS E P P P A FAA m AR Manual descent actuator holder Fall arrest device Fall arrest device unlocking knob locking knob red black 3 15 Fall arrest device The service lift is equipped with a fall arrest The fall arrest device can also be engaged device which will be triggered in case of an manually in an emergency by pulling downwards overspeed condition The speed of the safety the red locking knob on the back of the lift this wire rope passing through the device is continu will turn its emergency stop lever counter ously monitored and the jaws are automatically clockwise To release the fall arrest device stop closed in the event of sudden excessive speed lever the black unlocking knob on the back part of the lift has to be pulled downwards This device protects the service lift against traction wire rope breakages or traction system failures Tightness of safety wire rope must be frequently inspected to ensure full functionality of fall arrest device 20 AVANTI Service Lift for Wind Turbines 45540046 DOLPHIN AECO 4th EN R2 indd 20 e 03 06 2014 16 39 30 3 16 Overload limiter Attempting to run an overloaded lift is A lifting force limiter is built into the wire rope prohibited traction system an
31. curing the load with the wire Damage resulting from 1 crushing squeezing running over etc Wire bags EX Loop formation These examples do not however replace the relevant provisions of ISO 4309 and of A17 6 2010 b Check and ensure that all wire ropes are mounted at the top and ground level as specified in this manual C Check the guiding wire rope tensioning system is correctly installed and the wire rope fixes are properly fastened 5 11 traction and safety wire ropes must be replaced after 250 hours of operation or 5 years whichever occurs first corresponding with the refurbishment of the traction hoist EA On AECO version service lifts according to A17 1 03 06 2014 16 39 34 6 4 5 Repairs Repairs 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 45540046 DOLPHIN AECO 4th EN R2 indd 33 e 6 5 Information signs and documents Verify availability and legibility of all data plates and
32. d 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 the buzzer or o stop the lift because of peak loads caused by the cabin swinging 3 17 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 18 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 19 Acoustic buzzer An optional audible signal can be installed with the same warning function 3 20 Anchor 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
33. e ee T A 30 D Dally IMSPCCHOMN vs cote D Lis sc ci ai DA PA oo sos cea a 30 6 4 Annual INS DECO a E CE a on WIE db a bee eae ee eo 31 ROAD dd da ile aaa Arda ou 31 6 42 Trac HOD GLS ER EA RE E 31 6 4 3 Fall arrest device 4 4 eee ees 32 64 4 WIWETODGS ee TO P RA SS CE ET CO R DO a i 32 DO REDAS 5252 How rro Do oe rie TUSD E ue eee TO ese P 33 6 4 6 Overload check and adjustment cr 33 6 5 Information signs and documents lt s e e e cera 33 6 6 Ordering spare partS sapeca P 3E ee career FRASE m RE V E tea 33 Appendix A Regulation of overload limiter 34 Appendix B Safety MeasureS 0 cccccccccccc hh 35 Appendix C Inspection Checklist 36 Appendix D Operation log sheet 000ocococccn hh hh hh nnn 38 Appendix E AVANTI lift anchor 444 RII IR hh 39 45540046 DOLPHIN AECO 4th EN R2 indd 6 e 03 06 2014 16 39 18 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 Thi
34. e lift should ascend box Unlock the fall arrest device by pulling down the black unlocking knob If fall arrest device has engaged an expert 3 6 Perform a manual descent test for a meter must verify the safety of the fall arrest device The lift should descend and the buzzer should the wire rope and wire rope fastenings sound e 3 Drive the service lift down until the Bottom obstruction device hits the bottom platform The service lift should stop before the rubber bumpers The tower owner must ensure that the results hit the bottom platform The service lift door and LLI of all annual and extraordinary inspections are the fence door should be unlocked logged in the Appendix D Operation log 3 8 Top obstruction device activate top stop by sheet pressing it down The service lift should not ascend until top obstruction device is released 6 4 1 Cabin 3 9 Slack rope sensor Activate the slack rope Inspect the cabin structure joints attachments sensor by manually pulling the traction wire rope and accessories upwards Descent should not be possible 6 4 2 Traction hoist Note Optional for CE versions Mandatory for The traction hoist is largely maintenance free AECO version Clean only when very dirty During cleaning always ensure sufficient air supply 4 When the lift is at the top platform check the wire rope fastenings Annual test only by authorized persons 5 Record the hour meter reading in the a Ensure th
35. er failure and the fall arrest device is locked with the safety wire rope under tension evacuate the lift according to the evacuation proce dure 5 5 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 ostop the manual descent stop pushing upwards The safety wire rope and the attachment 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 03 06 2014 16 39 32 5 6 Troubleshooting 1 All tests and repairs to the electronic compo nents should be performed by authorised personnel only The wiring diagram is placed in the power cabinet Breakdown The service lift will neither go up nor down DANGER Attempting to use the lift will Jeopardize work safety 2 Repairs to the traction hoist the fall arrest device and to the system s supporting compo nents should be performed by qualified personnel
36. ersons 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 Wire ropes Always keep the wire ropes clean and slightly greasy Wire ropes must be greased regularly with standard multipurpose grease Greases contain ing disulphide must not be used Annual inspection a Check and replace the respective wire rope s if one of the following defects are found 8 wire strand breaks or more on a wire length corresponding to 30 times the wire rope diameter Severe corrosion on the surface or inside Heat damage evident by the wire colour Reduction of the wire diameter by 596 or more compared to the nominal wire diameter Damage on the wire rope surface See figures below for common examples of wire rope damage 32 AVANTI Service Lift for Wind Turbines 45540046 DOLPHIN AECO 4th EN R2 indd 32 Kinks resulting Se from counterweight of traction wire rope not being able to rotate freely Wire rope strap loop which cannot be unwound Loop knot forming Mon When a wire loop is RA pulled tight Bends resulting from m inappropriate treatment e g se
37. essible means of evacua tion shall be no more than 1 1 m Note Mandatory for CE versions Op tional for AECO version 03 06 2014 16 39 19 3 4 Dimensions 45540046_DOLPHIN AECO 4th EN R2 indd 11 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 User s Maintenance 11 and Installation Manual 03 06 2014 16 39 22 ts n pone m Co 5 3 itch Itc sw it stop plimits to ey h en Itc Ei i sae e 2 A o ida rop 3 an ht X 4 isti d bo 6 Inte dai E Main E r Y ied el doo 9 p To 10 ines bin Tur ind Win r xs ice VIC Ser TI AN AV 12 12 indd in R2 EN 4th eee H LP O D 46_ 00 54 45 10 11 13 18 12 14 15 17 So SS gt A Lo 2 Dm NN gt e o lt ee ee SE ee 8 y S y 9 S So i 3 gt o e o o Saz B o eS NL e gt o b e o Sa Sa P o SS Le o S Ses o soose o o Ses o Vo SES e ess A o ESSE p a S e e S 5 d e o 5 9 8 ss NN cs Qo Q pm Q Sos SNO Sod NEN Sa g Ne m o ON sakes 2909 um NC Soge LYS S 9 o o o qus SA NR RRN dues 96 90 SEN nuns E eo dog Sue n
38. est equip ment when falling height is more than 2 m hand gloves helmet safety glasses and working gear e Place cabin at bottom platform and disconnect power supply e Use an electricity measuring tool when perform ing inspection of electrical components e Usea hand winch attachable to the ladder when handling big heavy loads and shall be per formed at least by 2 persons e Panel parts shall be removed to facilitate access to confined spaces e Usea cable grip when replacing travelling cable e Keep cabin doors closed when using a 3 step ladder A 30 AVANTI Service Lift for Wind Turbines When plugging the service lift to the power supply ensure that supply phases are correct 45540046_DOLPHIN AECO 4th EN R2 indd 30 Annually Expert wask Expert laaa 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 lif
39. he lift structure according to the instructions 5 Anchor marking is clearly readable Signature of competent Is the Anchor in good condition to be used Name of competent in Yes Needs Repair Replace capital letters ot pate lf the AVANTI LIFT ANCHOR is found not OK it must be removed replaced by a new AVANTI LIFT ANCHOR The result of the periodic examination must be recorded in the Registration form of anchor User s Maintenance 41 and Installation Manual 45540046 DOLPHIN AECO 4th EN R2 indd 41 e 03 06 2014 16 39 35 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 of purchase Date first put into service 42 AVANTI Service Lift for Wind Turbines 45540046_DOLPHIN AECO 4th EN R2 indd 42 e 03 06 2014 16 39 36 45540046_DOLPHIN AECO 4th EN R2 indd 43 e 03 06 2014 16 39 36 45540046 Dolphin Lift manual EN 4th CE Edition 10 2013 Revision 2 4 04 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 China 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 Ronnevangs Alle 6 DK 3400 Hillered P 45 4824 9024 F 45 4824 9124 Germany
40. lar 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 service imme diately User s Maintenance 39 and Installation Manual 03 06 2014 16 39 35 E 3 Marking Marking on Lift Anchor plate AVANTI product nam European American standard number LIFT ANCHOR POINT EN 95 2012 ANSI 2359 1 2007 ASINZS 1891 4 2000 AIS 304 CAPACITY 22 2KN MAXIMUM 1 USER PO XXXXXX YYYY P N 45512194 a After installation marking shall be completely accessible otherwise additional marking near the anchor device will be necessary 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
41. latforms 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 03 06 2014 16 39 29 3 11 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 When the top limit switch is engaged press the DOWN button until the top limit e switch is released Do not use the service lift until the top limit switch fault has been rectified Note Top limit switch or top obstruction switch if top obstruction device is supplied 3 12 Top obstruction device 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
42. ment to the most convenient height for performing work in wind turbine generators WTG Its use is limited to AVANTI or personnel author ised 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 system consists of a service lift which is formed by a cabin a traction system a fall arrest device a control system and safety devices a guiding system along the tower which is formed by a pair of steel guiding wire ropes attachments to the tower and guides on the service lift traction and safety wire ropes made of steel a power supply system and protective fences at platforms including their interlock system1 The protective fences consist of structures with or without perforated sheets of different geometries depending on the platforms where they are installed The protective fences shall comply with the relevant regulations of EN14122 3 for CE versions OSHA 1926 502 for AECO version The system details are described along this manual A This manual contains inst
43. 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 lift 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 Avoid injury follow all instructions third party service lift inspections with the local authority and comply with the standards specified R The tower owner must verify the need for LA User s Maintenance 9 and Installation Manual 03 06 2014 16 39 19 e 3 Description 3 1 Purpose The service lift purpose is to transport persons plus their tools and equip
44. on is normal Service lift de scends when UP button is pressed and ascends when DOWN button is pressed 45540046 DOLPHIN AECO 4th EN R2 indd 29 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 is defective or not connected b Bottom stop switch is activat ed E The lamp is defective F If a 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 a b Take the service lift upwards to relieve the safety wire rope 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 Insert brake lever into the traction hoist and lower lift manually Test and if necessary have connec tions wiring and relays repaired DANGER A defective fall arrest device will threaten the safety of the service lift Replace immediately The slack rope sensor has engaged move the se
45. only Cause Solution A1 The fixed EMERGENCY STOP Reset the button in question by pulling or button has been activated turning it A2 Wire rope loop on traction hoist Damaged or defective wire rope or wire rope outlet causes problems Stop work immediately Ask the supplier or manufacturer for help A3 The fall arrest device is holding the service lift on the safety wire a Lift wire rope breakage b Hoist failure a b Evacuate the service lift A4 The service lift is stuck on an obstacle Carefully remove the obstacle Test the operational safety of affected tower sections Inform the supervisor A5 Power failure Main switch is OFF Grid voltage interrupted Supply between grid connection and control interrupted Turn the main switch ON Find the cause and wait for the power to return Test and if necessary repair the supply cable fuses and or wiring from the control box A6 A safety switch is triggered Perform manual descent until the a Emergency top limit switch limit stop switch is released is activated Close the top and or bottom sliding b 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 45540046_DOLPHIN AECO 4th EN R2 indd 27 A7 Protection switch on overheating a A phase is missing b Motor is not cooling c Voltage too high low A8 Brake does not open no click on on off a Su
46. operate the lift The key will be trapped and can t be removed until it is switched OFF Remove the key and use it to open the trapped key lock on the top gallery 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 UP DOWN BUTTONS Automatic Send Push the automatic UP or DOWN button to send the lift all the way to the top or bottom of the tower Automatic DOWN is only possible from the top platform and Automatic UP is only possible from the bottom platform UP DOWN Manual Sounds when the cabin is overloaded 14 AVANTI Service Lift for Wind Turbines 45540046 DOLPHIN AECO 4th EN RZindd 14 03 06 2014 16 39 27 3 6 3 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 CE control box if guard locking system is provided Power inlet from WTG Main switch Green light Ready Connector Interlock switch Power outlet to lift CE control box if guard locking system not provided and AECO control box 45540046 DOLPHIN AECO 4th EN R2 indd 15
47. pply braking coil or rectifier defective b Braking rotor closes A9 If trapped key system is provid ed the trapped key is not present or the trapped key switch is in the OFF position A10 If guard locking system of fences is provided the guard locking switch and or interlock control box is defective Test repair fuses supply and connection Clean the motor cover Measure voltage and power consumption on the loaded motor If voltage deviates from specifications use cable with increased dimensions Have an authorized person repair replace the supply braking coil and rectifier Return traction hoist for repair Insert the key and turn it to the ON position Test Repair defective components User s Maintenance 27 and Installation Manual 03 06 2014 16 39 33 Breakdown Service lift goes down but not up Service lift can ascend but cannot descend Motor hums loudly or wire ropes squeak but the lift can go both up and down Tl 45540046_DOLPHIN AECO 4th EN R2 indd 28 an obstacle below it A12 Service lift is overloaded buzzer sounds Not applicable to CE versions e Only applicable to AECO version B1 The service lift is stuck on an obstacle B2 Service lift is overloaded buzzer sounds Only applicable to CE versions Not applicable to AECO version B3 Top limit switch a Top limit switch is defective or not connected b Top limit switch is activ
48. red locking knob engages fall arrest device when pulled down O es The black unlocking knob releases fall arrest device when pulled down Pf PY LT Not ESCRIPTION they are and slightly rase With greasy with a standard multipurpose grease free of disulphidis 112 There are no 8 wire strand breaks or more on a wire rope length corresponding to 30 times the wire rope diameter There is no heat damage evident by the wire rope colour UN ie There is no reduction of wire rope diameter by 5 or more compared to nominal wire rope E diameter 11 6 Wire ropes are free of damages described in common damages on wire ropes E IRE i R N JE DESCRIPTION Safety wire rope is properly mounted with a spring according to specific type manual a Safety wire rope is provided with 2 properly tightened wire rope locks NM Traction wire rope is mounted with an 11kg counterweight Traction wire rope is provided with 2 properly tightened wire rope locks beneath the 08 counter weight Traction wire rope coil and counterweight are free to rotate Ton Demi is TT mounted and properly tightened to WTG or if welded its welding is in good condition 13 2 Each wire rope is properly mounted with a shackle a nut and a bolt locked with a cotter pin 14 2 The trapped key lock is properly tightened to the platform fence and fully functional 14 3 Trapped key switch of service lift is fully functional mI In
49. rough 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 3 2 4 Travelling cable adjustment 1 Guide the travelling cable through the travelling cable pulley 2 Connect the outlet socket of the travelling cable to the inlet plug of the service lift using a cable stocking Attach the schacle to the eyebolt on the back of the service lift 3 Attach the travellin cable to the cabin by means of cable ties Note Optional for CE versions Mandatory for AECO version 03 06 2014 16 39 32 4 4 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 5 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 45540046 DOLPHI
50. ructions for three different versions of the Dolphin lift Dolphin CE version and Dolphin CE 350 version which are compliant with essential health and safety requirements of European Machinery directive and are CE certified Dolphin AECO version which is compliant with requirements of 5 11 of ASME A17 7 CSA B44 7 and is AECO certified 10 AVANTI Service Lift for Wind Turbines 45540046_DOLPHIN AECO 4th EN R2 indd 10 Service lift Dolphin CE 165 kg 100r 18 0r21 m min 10 96 240 kg 2 Persons 15 C to 60 C 5 F to 140 F 25 C to 80 C 13 F to 176 F Shackle 2T form C with safety pin 3 Phase 400V 480V 690V 50Hz 60Hz Dolphin CE 5G1 5 400V 5G1 5 480V 4G1 5 690V 3 3 Technical specifications Dolphin CE 350 180kg 18 m min 10 350 kg 2 Persons 15 C to 60 C 5 F to 140 F 25 C to 80 C 13 F to 176 F Shackle 2T form C with safety pin 3 Phase 400V 690V 50Hz 60Hz Dolphin CE 350 531 5 400V 4G1 5 690V Dolphin AECO 165kg 10or21 nv min 10 240 kg 2 Persons 15 C to 60 C 5 F to 140 F 25 C to 80 C 13 F to 176 F 80 dB A 80 dB A 80 dB A Shackle 2T form C with safety pin 3 Phase 400V 480V 60Hz Dolphin AECO 531 5 400V 531 5 480V 0 16 kg m 0 16 kg m 0 16 kg m Maximum evacuation distance from the point of emergency exit to the acc
51. rvice 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 qualified authorised person or contact the manufacturer User s Maintenance 29 and Installation Manual 03 06 2014 16 39 33 5 7 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 6 2 Cautions Before any maintenance task ensure that walking way surfaces are dry and not slippery During maintenance tasks personnel shall e Wear at least the following PPE fall arr
52. s 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 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 on an AS IS basis Avanti service lift Product 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 PERM
53. st 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 Cologne 2013 10 02 TUV Rheinland Industrie Service GmbH AlboinstraRe 56 12103 Berlin A TUVRheinland Telefon 49 0 30 75 62 1557 Fax 49 0 30 75 62 13 70 Precisely Right 45540046 DOLPHIN ARCO 4th EN R2 indd 2 e 03 06 2014 16 39 17 e es S C3 AECO certificate of Dolphin AECO version not of Dolohin CE nor Dolohin CE 350 PTT 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 A Los ON A Issued by Daniel Posner Reviewed by Len Grant Reviewed by William N Bartunek PE AECO Certification Services AECO Certification Services AECO Certification Services 45540046 DOLPHIN ARCO 4th EN R2 indd 3 e 03 06 2014 16 39 17 T e Date of publication 4th CE Edition 10 2013 Revision 2 4 04 14 Manufacturer AVANTI Wind Systems A S Ronnevangs Alle 6 3400 Hillerod Denmark 45 4824 9024 45 4824 9124 info av
54. t 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 03 06 2014 16 39 33 e es S 3 4 Service lift door Pull the door to open The 6 4 Annual inspection door should not open Unlock the top sliding door from the bottom sliding door and pull to open Have the entire system tested by an AVANTI The top sliding door should open the green light trained expert at least once a year especially the must be OFF and the lift must not move UP traction hoist and the fall arrest device However it DOWN Close the top sliding door and apply the may be required more frequently depending on lock to the bottom sliding door use and the conditions of use and operation 3 5 Activate the fall arrest device by pulling down The traction hoist and fall arrest device must be the red locking knob Press the DOWN button of overhauled at AVANTI workshops and furnished the User control box The service lift should not with new certificate for every 250 hours of opera move down Press the Up button of the User tion Hour counter is found in the main control control box The servic
55. terlock control bor pax is iS propery tightened and functions properly including main 1 disconnect Switch 15 2 Interlock detection switch of platform fence is properly adjusted and tightened IE T f 1 N 17 1 Verify that all information signs and documents are available and legible FS N 3SESSMEN OK N JE DESCRIPTI 18 1 Service lift is in overall good operational condition Gisa competentis in capital letters Signature of competent s Competent inspection may only be performed by AVANTI or competent person certified by AVANTI Every 12 months competent inspection has to be camed out and the Inspection checklist and Operation log sheet must be completed for possible future reference User s Maintenance 37 and Installation Manual 45540046 DOLPHIN AECO 4th EN R2 indd 37 e 03 06 2014 16 39 35 Operation Log Sheet Appendix D 38 AVANTI Service Lift for Wind Turbines 03 06 2014 16 39 35 45540046_DOLPHIN AECO 4th EN R2 indd 38 45540046_DOLPHIN AECO 4th EN R2 indd 39 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
56. 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 transmitted 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 Users are obliged to read and understand this User Manual Further they need to be proper equipped and instructed with
57. 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 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 simi
58. us nutum 0 n nuns Ss VQ ARE qus nu S S us b qus Q nnus b Su Re lo nuns QQ 9e SRE Sn S qus SS STE VQ SEES nuns Q SEES NN SESS E DN S NN SERE nuns E Q ou SENS SS Q n NN S VQ ARE RN y 2 ESOS unu S RR Soe lo 50990 SS b gree Se QG Co lo dog SS Soge Q RS Q O S06 MN QQ unu ESC 96 lc SCE SS CLODT x lle CEGO VQ nuu eod EAGLE S808 Wu Stan Y Soe 9059 XQ Co SIS Yoc 90 x o VG o e e e S Q Q e e e So a NS 990 SN SN ST 9 NS S VQ SONS Qo NAN NN NS Se Doc ON PON Qo N ES SES Co Co OSSO 0 RRRS Co RSS SESS IN 1 E VQ LES SON VOSSO See SENSO ON 9o N NS COS NN Q GG NY QG o l NON QG S NEN NS 06 SES SEN COQ SLES la Q usu SE SONS AS y uu ES NN 00 SUN S goer SN S Sess es US nS Doc SONNO uu SON SONNO QQ SONES SONES SN SONES SN nuu SS SN Oo SUN Q Suns ES SS RRS 96 quens SONNO NN RSS NN y ES RRRS Q SS NIN E SOUS SN S 9 RS SOC NES N Seg SS 0 0 DOO e e SSSE q Q SS O 1 E o o Se o o DE SOS TAS e UM poc im Im SSE dom NC WE NN 19 Is tro X bin con ing d er Na ay Ti E bin slid CON n 2 G ance aoe N i en and vice a m is de be Borom cto ley 1 ptional 15 ac t u O Tr bs ar pun t iis ee cable EM 17 p ing To elli nc 1 18 rav nala hts 19 Extra ig 20 a W 21 jon vers CO AE for fory da n Ma sions ve CE I for a tion Op te O U N 27 39 16
59. y 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 interrupt 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 45540046 DOLPHIN AECO 4th EN R2 indd 9 e service lift is allowed without the manufacturer s prior written consent No warranty is provided against damage resulting from reconstruction or

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