AVANTI WORK CAGE
Contents
1. o9ogegogoSege9gogof 90500900090 9425062625200 08060806 08069 20202020202020202020202020202020202020209 90909090909090909090909090909090909090 OOOSOSOSOSOSOSOSOSOSOSO 09090 OoOo 0090 6800 262425250 020909090 90905909090 Lifting capacity e Motor LE500P 533 Lbs 240 kg max 2 persons Weight of lift L 242 Lbs kg 110 To the weight of the lift should be added the weight of the power supply cable approx 0 22 Lbs per foot 0 23 kg per m Standing height Under spine 1980 mm Under Traction hoist 2100 mm Dimensions in mm Shark A B C D E F G N H Standard wire guide narrow wire guide Details p 46 Users Manual 15 4 5 4 Drive system safety gripping device and controls Fig 4 Fig 5 Fig 6 Fig 7 Fig 8 Fig 9 Traction hoist Safety brake Safety brake Electrical Pendant Remote LE500P BSO 500E BSO 500 control box control control 1 Insertion point 5 Control handle 5 Control 10 Hand Auto 13 EMERGENCY 16 On Off for brake lever gear lever handle gear matic STOP button 17 Connection 2 Motor 6 Safety brake lever 11 Ready lamp 14 UP Cable 3 Wire traction stop button 6 Safety brake ON 15 DOWN2. 27 11 2 Wire ends 27 11 3 Removing the lifting wire 27 11 4 Removing the safety wire 2 2 l l llle 27 12 Maintenance 2 2 2 27 Maintenance 27 12 1 Yearly inspection 2 2 28 12 1 1 Traction hoist wire 2 28 121 2 i s s s lt lt 2 2 k lt 2 X G ERE COREE w Q TUR 4 28 12 1 9 Work cage 28 12 1 4 Suspension wires cables 2 2 2 2 2 28 12 1 5 Overload limiter information 5 0 5 29 122 REDAS 94 S 59 4 29 13 Ordering spare parts 2 0 0 0 30 13 1 Wire rope 39 Ex X SEHE X PUR E E d S WR X EE S S d d 30 13 2 Motor and brake 30 15 9 Electric control s ss ke v ow X bo lt 8 2 amp w HG SAREE HEE Rd 30 13 4 Safety brake gripping device 2 2 2 2 2 2 30 13 5 Rating plates and information signs ll 0004 30 Installation manual 1 Assembling SHARK cabin 2 2 2 2 2 2 2 2 2 2 5 2 31 1 1 Parts list SHARK sliding door 33 34 1 2 Parts list SHARK double door 35 37 2 Mounting 2 o o 38
3. 0 49 Appendix Test report of 51 55 Appendix C Report of defects 00 0000 0000000000008 56 User s Manual 5 Limited Warranty Avanti Wind Systems A S warrants that commencing 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 Avanti work cage 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 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 author ized representative ii has not been installed operated repaired or maintained in accordance
4. AVANTI WORK CAGE pss Ir lt User s Manual and Installation Manual C UL US Model SHARK Date of publication 3rd UL Edition September 2008 Manufacturer AVANTI Wind Systems A S Hogevej 19 3400 Hillered Denmark 45 4824 9024 45 4824 9124 info avanti online com www avanti online com QUALITY MA AGEMENT SS Ir v lt WORK CAGE U AS TO LOAD CAPACITY ONLY L US 12xz This product is UL Classified See the complete Classification marking above Sales amp Service USA Avanti Wind Systems Inc 5150 S Towne Drive New Berlin Wisconsin 53151 USA P 1 262 641 9101 F 1 262 641 9161 www avanti online com opain Avanti Wind Systems SL Poligono Industrial Centrovia C Los Angeles No 88 nave 1 50196 La Muela opain P 34 976 149524 F 34 976 149508 www avanti online com China Avanti Wind Systems Building 14 Weishi Industrial Park No 599 Zhongxin Road Dagang Town Songjiang District 201614 Shanghai China P 86 21 5785 8811 F 86 21 5785 8815 www avanti online com Germany Avanti Wind Systems GmbH Weddingstedter Strasse 52 25 46 Heide Germany P 49 48142 1570 0 F 49 48142 1570 29 www avanti online com UL International Netherlands B V An Affiliate of Underwriters N 3905 PH Veenendaal The Netherlands Laboratories Inc Telephone 31 0 318 581310 Fax 31 0 318 581340 e mail in
5. SHARK Sliding door Top Shark L Spine Shark L Safety brake BSO500E UL Guard small for Spine Shark Guard large for Spine Shark Cabin right Shark Cabin left Shark Bottom Shark Hatch Shark Wire guide Traction hoist LE500P 480V or 690V UL 3Ph 1E Hubbell plug female 480V Anchor point yellow Roller 1 for spine Shark Roller 2 for spine Shark Bracket for BSO500 UL Blockstop BSO500 UL Bracket for top switches 200mm Top stop swich S1 UL Emergency top stop switch 513 UL Pendant control holder Shark Emergency stop button Shark UL Override automatic operation switch Step Shark Handle for cabin black Front for sliding door UL Shark Door middel for Shark sliding door UL Door left for Shark sliding door UL Door rail 1 Shark sliding door UL Door rail 2 Shark sliding door UL Door stop switch Shark sliding door UL Handle for Shark sliding door UL Eye not M8 FZV Angel for wirebush Guide for wirebush Install fig 14 Manual fig 10 Manual fig 10 Manual fig 13b Manual fig 13b 33 35 36 37 38 39 40 41 42 43 34 45303143 79999503 45515004 45303128 45512064 45502070 45512005 45303100 45512060 45515001 45512011 45512001 45502080 45512003 45512056 45511001 45512010 45303101 45541105 45541106 45541011 45541012 45541025 45541040 Optional 45502053 45502075 45502076 45502077 45303148 3549901 1 35499010 Parts list SHARK
6. 2 1 Towertop 2 2 2 2 2242525225252525252525255 5 38 2 2 Measures for positioning of wires 2 2 2 2 2 2 39 2 3 Securing the guide wire groundlevel 2 2004 40 2 3 1 Method 1 Wedge anchor a a 40 2 3 2 Method 2 Tripod ole s 41 2 3 3 Method Steel beam 41 2 3 4 Tensioning of the guide wires 012mm 0 08 41 2 4 Electrical connections 42 2 4 1 Powersupply l l s 42 2 4 Supply cable e a s s e eo 42 24 3 42 2 5 Installation of drive and safety wire in work cage 43 2 5 1 Drive wire installation oa a a a 43 2 5 2 Safety wire installation 43 2 6 Securing the drive and safety wire 44 2 6 1 Method 1 Drive wire contra weight 44 2 6 2 Method 2 Safety wire wedge anchor with spring 4 44 2 6 3 Method Safety wire pushspring 2 2 008 45 2 6 4 Steelbeam 2 45 2 7 Wire fix alignment 46 2 8 Adjustment of top stop disc 47 Danger zone Sticker 0 0 0 0 0 0 0 000 02 e s s en 47 4 Inspection before initial use 48 Appendix A Adjusting instructions for overload limiter
7. 2 Sliding door 3 Drive and safety wires 4 Second safety brake gripping device 5 Guide wire 6 Wire guides 7 Bottom safety stop Details see Page 13 18 User s Manual 11 Fig 1b SHARK L 4 door version BF Fond 4 Aig LL 1 ch B I I 1 1 1 41 ANTI 1258 Cabin 4 door Drive and safety wires Guide wire Wire guides Bottom safety stop For details see pages 13 18 O QI gt N 12 AVANTI Work Cage for Wind Turbines 4 5 2 Cabin with safety gripping device traction hoist electrical control box and N pendant control AyANTI Estab ished 1085 Cabin Traction hoist Electrical control box Anchor point Safety brake safety gripping device Second safety brake safety gripping device 11 12 of vent aie at NT LL ii nn 22222222 ae Cable connection behind the lift EMERGENCY STOP button fixed Inside cabin optional Pendant control Override automatic operation switch optional Door stop switch Bottom safety stop 13 14 15 16 17 18 Shackle Safety wire Lifting wire Top stop disc for 17 18 EMERGENCY limit stop switch Operation limit stop switch User s Manual 13 4 5 3 Technical data for the work cage L and XL Fig 3a Dimensions sliding door Lifting capacity e Motor LE500P 533 Lbs 240 ko max 2 persons 650 Lbs 300 kg max 2 pers
8. Avanti Wind Systems Inc 5150 S Towne Drive New Berlin Wisconsin 53153 P 1 262 641 9101 F 1 262 641 9161 www avanti online com Spain Avanti Wind Systems SL Poligono Industrial Centrovia Calle Los Angeles No 88 nave 1 50196 La Muela P 34 976 149524 P 34 976 149508 www avanti online com China Avanti Wind Systems Building 14 Weishi Industrial Park No 599 Zhongxin Road Dagang Town Songjiang District 201614 Shanghai P 86 21 5785 8811 F 86 21 5785 8815 www avanti online com Germany Avanti Wind Systems GmbH Weddingstedter Strasse 52 25746 Heide P 49 48142 1570 0 F 49 48142 1570 29 www avanti online com
9. Guide wire 12mm IMPORTANT All wires are evenly un coiled as shown in Fig 5a to prevent looping 38 AVANTI Work Cage for Wind Turbines 2 2 Measures for positioning of wires Holes in base platform in the tower for wire bushing are positioned as outlined below Fig 6 Minimum shaft clearance dimen sions required for the work cage to run and distance between the guide wires Dimensions Shark A B G D E S s Standard wire guide narrow wire guide details page 46 The holes are positioned with a tolerance of 5 mm Hole with diameter 0200 mm are fit ted with rubber edging Attention DANGER Ensure that no obstacles are in the Ensure that lift evacuation to the way of the work cage tower ladder is possible Installation Manual 39 2 3 Securing the guide wire ground level IMPORTANT Before feeding guide wires through the j platform place correct number of wire fix on wire and feed wire through wire guides See Fig 7 and Fig 14 page 46 Wire fix are mounted during first run Feed the guide wire through the 2 times 60mm holes in the platform Underneath the platform the guide wires are fastened and tightened using one of the following three methods 2 3 1 Wedge anchor Mount wire as shown in Fig 8 following proce dure below 1 Drill two 16x75mm holes the floor under neath the 2
10. in particular use of other wires than the prescribed original trac tion hoist wire will render the manufacturer s warranty void and the CE approval invalid q No modification extension or reconstruc tion of the work cage is allowed without the manufacturer s prior written consent r No warranty is provided against damage re sulting from reconstruction or modification of equipment or use of non original parts which are not approved by the manufacturer S Before using the work cage an inspection by the authorised security organisation must be carried out The tower owner must verify the need 2 for 3rd party work cage inspections with the local authority and comply with the standards specified 3 Instructions a Before using check all parts for proper func tion and damage to component parts Do not use a damaged or improperly func tioning platform A platform exposed to excessive heat as in the case of fire should be immediately removed from service and destroyed due to loss of structural strength Do not permit oil grease or slippery mate rial to accumulate on climbing or gripping surfaces Do not use the product if the decking sur face is damaged or has deteriorated Peri odically coat wood decking and rails with a transparent wood preservative Do not paint Do not use the product for cantilever appli cations Never stand on that portion of the product that extends beyond the supporting p
11. load device are not allowed unless the manu facturer has agreed to in writing e AVANTI assumes no liability for damages due to retrofit alterations on equipment or where non original spare parts are used especially the prescribed traction hoist wire rope that the company has not approved in writing f The manufacturer of the work cage assumes no liability for damages due to retrofits and al terations on equipment or where non original spare parts are used that the company has not approved in writing and the UL CSA ap proval becomes invalid The result of the verification adjustment of the overload device must be written down in the Test report of annual inspection and must be signed by the supervisor If only adjusting takes place no annual inspection simply fill in point 5 9 and sign 1 Purpose of this instruction It may occur that the overload limiter inside the traction hoist of the work cage stops the upwards travel although the work cage is not under overload In the case that other causes can be excluded by following the instructions of section 2 2 the overload limiter has to be adjusted according to section 3 2 1 With older hoists you may need an allen key size 6 2 Adjusting instruction 2 1 Preparation Required tools material Allen keys size 2 and 4 ballast for applying the test load NOTE Before driving to the work cage make sure that the work cage can be l
12. w overload 7 Inspection stop button 12 Override bot protection window 7 Inspection tom limit stop 4 Drive system 8 Safety wire window key switch gearbox 9 Connection cable Table 1 Traction hoist Construction in accordance with DIN 15 020 Traction hoist sound noise level emitted max 72 dB A Subject to technical change without notice Lifting Rated Traction Unit weigth Measures dimensions DEREN capacity Effect current Hoist wire approx a b C Traction hoist type Lbs kg Feet min m min Lbs kg mm 1 Weight without wire Table 2 Safety brake Safety gripping Lifting capacity To max Traction hoist Unit weigth Measures dimensions device wire speed wire approx a b Safety brake type Lbs kg Feet min m min Lbs kg mm BSO 500 Electrical 880 400 a san zw 121 4 5 5 Drive wire safety wire and guide wire Original traction hoist Guide wire and safety brake wire Wire diameter 12 Wire diameter 8 mm 4x26 or 5x19 Surface treatment galvanised Surface treatment galvanised Min break resistance 85 kN Mark feature 1 red string cord Anchoring Min every 115 ft 35 m Min break resistance 39 7 kN Tighten to 2 to 4 kN Attached with 2 t shackle Form C Attached with Shackle 2t 16 AVANTI Work Cage for Wind Turbines 4 6 Safety devices 4 6 1 Safety brake Electromagnetic spring loaded brake which engages automatically on releasing the direction selector and on power
13. Important Order BS 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 Reference to written Possible injury if not observed Death or severe injury Death or severe injury Light injury or material damage Damage to equipment or workplace None specification documentation User s Manual 7 2 Cautions CAUTION Avoid injury follow all instructions a Installation and or maintenance and or op eration of the work cage and its suspension may be performed only by qualified staff hired by the employer for the job at hand b The staff 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 c Staff is obliged to read and understand this User s Manual d A copy of the User s Manual must be handed out to the staff and must always be available for reference e If more than one person is trusted with one of the above tasks the employer shall ap point a supervisor in charge of operation STOP DANGER f Whenever installation ascending and or descending involves danger of falling all persons inside the danger area must wear personal protective equipment which will prevent them from falling down by means
14. cable length is found prior to ordering The power cable is marked with length check for accuracy before installing b Minimum cross sectional dimension of the supply cable Important with increased dis tance between grid connection generator and traction hoist respectively 18 c Use heavy rubber cable ducts for fastening live wire on work cage d An installed generator will have to provide at least 2 5 times the output of the traction hoist Table 3 42 AVANTI Work Cage for Wind Turbines Fig 9 Cable suspension 2 4 3 Power connection a Push the EMERGENCY STOP button b Check that the various stop switches cables and safety brake cable are connected to the power cabinet according to colour code Place or hang the cable collect bin under neath the 0200 mm hole in the platform d Cut the transport strips and tape that holds the wire inside the bin and connect the cable suspension Fig 9 to the eyebolt underneath the work cage floor Connect the socket to the lift plug on the back of the work cage f Connect the power cable plug to the grid 400V 3Ph gnd 60 Hz 480V 3Ph gnd 60 Hz Pre fuse 10 A g Turn the two EMERGENCY STOP buttons Fig 10 and Fig 10a clockwise to deactivate h The power is turned on and the green indica tor on the electrical control box lit In order for the work cage to be operational the door must be locked and the HAND AUTOM
15. damage and injury resulting from not following this User s Manual and Installation Manual i e reconstruction or modification of equipment or use of non original parts which are not approved by the manufacturer 1 Assembling SHARK cabin The work cage SHARK version sliding doors and version double doors are assembled close to their final mounting position as follows Installation holes have been pre drilled Bolts nuts etc can be found in the plastic bags supplied 1 Assemble the right left and bottoms sec tions with the cabin resting on its back 2 Mount the roof spine and then slide the roof into position and fit to the cabin 3 Fit the wire guides 4 Mount the traction hoist and safety brake to the spine 5 Attach the cabin front 6 Mount the 4 bottom rubber feet to the bottom of the cabin 7 Mount the operation limit stop switch and emergency limit stop switch on the roof using the contact bracket 8 Attach the bottom safety stop beam includ ing the wires that hold the bottom safety stop beam 9 Bring the cabin to its upright position 10 Double door version Mount the doors 11 12 13 remembering the ground wire at the top hinge Mount the steps and handle inside the cabin Feed the power cable through the rear hole and fit the socket to the back using the strips Mount the bottom safety stop switch and adjust Connect the switch cables to the power cabinet according
16. failures 4 6 2 EMERGENCY STOP When the red EMERGENCY STOP Pendant control switch is pushed in emergencies all control is interrupted After remedying the fault control is reactivated by turning the switch clockwise until it pops out again 4 6 3 EMERGENCY STOP fixed optional Only in work cages with function AUTOMATIC installed A backup switch to the pendant con trol EMERGENCY STOP switch situated on the right hand panel inside the work cage Works like described above See Fig 9 4 6 4 Override automatic operation switch A switch situated inside the pendant control holder It prevents the work cage from being controlled from the inside when the control is in automatic mode 4 6 5 Phase monitoring relay With three phase power operation the phase monitoring relay will interrupt operation when a faulty phase sequence is detected preventing faulty assignment of UP DOWN direction power which deactivates the limit stop switch and the lifting force limiter functions Remedy Have an electrician switch two phases in the electric plug 4 6 6 Mechanical lifting force limiter The lifting force limiter is built into the wire trac tion system and will prevent upward travel in case of an overload A warning signal buzzer is triggered which will stop only when the cause of the overload has been removed Possible reasons for activation of the limiter The work cage is overloaded or The work cage e
17. of a safety system secured to the building g Only fault free suspension devices cabin components traction hoist equipment safety brake gripping devices original trac tion hoist wires and stopping devices may be used h Electrical connection of the system must be made in accordance with EN 60204 1 i Prior to mounting all parts must be tested to ensure their completeness and full function ality j Self locking nuts must be used at all times and the following must always be observed 8 AVANTI Work Cage for Wind Turbines The screw must extend from the nut by at least half of the thread diameter The nut may not be used anymore when it has become possible to loosen it with the fingers k Prior to mounting the suspension system ensure that the building sections involved Will be able to carry the load If any damage or faults are found during operation or in case of circumstances which may jeopardise safety Immediately interrupt the work in progress and notify the supervisor or employer m All tests repairs of electrical installations may be performed only by qualified electricians n All repairs of the traction hoist safety brake gripping device and the system s support ing parts may be performed only by qualified fitters o If any supporting parts are repaired or re placed the operational safety of the system must be tested and verified by an expert p Use of non original parts
18. the rubber feet of the cabin reaches the tower ground level When the bypass switch is activated it should be possible to take the lift all the way down to the ground Door stop switch Open the doors it should neither be pos sible to take the lift up nor down If optional function AUTOMATIC is installed Set selector HAND AUTOM on AUTOM Holding the handle the lift should remain still if button UP or DOWN is activated ATTENTION If any defects occur during work stop working if required secure the workplace and remedy the defect See page 24 26 DANGER Make sure that nobody is exposed to danger below the work cage for instance from falling parts Suitable measures Pent roof or barriers HAND AUTOM Optional Ready lamp ON Override bottom safety stop EMERGENCY STOP UP DOWN User s Manual 19 5 4 Automatic operation control Perform only this inspection if function AUTO MATIC is installed a Push EMERGENCY STOP button on pen dant control Turn HAND AUTOM switch on electrical control box to the right to activate automatic operation Fig 13 page 19 b Deactivate EMERGENCY STOP button by turning button clockwise Check EMERGEN CY STOP button fixed is deactivated The work cage should stand still It is forbidden to manipulate with the over ride automatic operation switch With closed doors push UP and DOWN but tons Neither upward nor downward tra
19. the work cage upwards to Too low release speed on relieve the safety wire safety brake Open both safety brake by pressing the handle and test its function as specified in section 5 6 on page 20 Functional test when the lift is back on the ground Replace the hoist and safety brake and return them for testing DANGER STOP A defective safety brake Will threaten the safety of the work cage Replace immediately D3 Fault in down controller circuit Insert brake leaver in on traction hoist the traction hoist and lower lift manually See details in section 7 Test and if necessary have connections wiring and relays repaired Green lamp E Thelamp is defective Have an electrician replace the bulb not lit although operation is normal If these steps do not clarify the cause and remedy the fault Consult a qualified electrician or contact the manufacturer 26 AVANTI Work Cage for Wind Turbines 10 Out of service a Securing the work cage b Switch off the power supply to prevent Bring the work cage all the way down until Inadvertent operation of the work cage the contact plate switch stops the cabin Push in the EMERGENCY STOP button fixed all controls are now blocked Mark the work cage OUT OF SERVICE Contact the service technician for repair 11 Removing wires for replacement CAUTION 11 3 Removing the lifting wire AN Wear protective gloves when handling wires a Turn the override bo
20. 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 6 AVANTI Work Cage for Wind Turbines Except as specifically set forth in this Limited Warranty ALL EXPRESS OR IMPLIED CONDITIONS REPRESEN TATIONS AND WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OR CONDITION OF MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE NON INFRINGEMENT SATISFACTORY QUALITY COURSE OF DEALING LAW USAGE OR TRADE PRACTICE ARE HERBY 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 WARRANTY CANNOT BE EXCLUDED AS PROVIDED IN THIS LIMITED WARRANTY ANY IMPLIED WARRANTY IS LIMITED IN TIME TO THE SAME DU RATION 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 CUS TOMER THIS LIMITED WARRANTY GIVES CUSTOMER 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 1 Explanation of symbols used in this manual Symbol Signal word Safety instructions DANGER N DANGER AN CAUTION Additional instructions Attention
21. 2 9 ue XB SO UQ WE DU S Sag dee hs IR N 4 3 Work cage models 4 4 Temperature 4 5 Components 4 5 1 4 5 2 Cabin with safety gripping device traction hoist Power cabinet and Pendant control 2 048 4 5 3 Technical data for the work cage 4 5 4 Drive system safety gripping device and control box 4 5 5 Drive wire safety wire and guide wire a 08 4 6 s t 4 6 1 Safety brake 2 2 2 2 2 2 2 252424225222 5252 52 25 405 2 EMERGENCY STOP EO rue e 4 6 3 EMERGENCY STOP fixed a 4 6 4 Override automatic operation switch cl ln 4 6 5 Phase monitoring relay 0 00 a 4 6 6 Mechanical lifting force limiter 0 0 0 200 008 4 6 7 Safety gripping device 4 6 8 Sliding door lock uuu cw ox 3A de RUE RO 9 ORE 4 6 9 1 Top limit stop switch 2 2 2 2 2 2 4 6 9 2 Emergency top limit stop switch 4 6 9 3 Bottom safety stop l l s 4 6 9 4 Door stop switch cee exe pend te ER ERES Go UR Ox x X HABER SE 4 5 9 5 Limit stop switch 4 7 Othernsks 4 4 9 99 4 ow oo ox HERE Xo X
22. 2626L6L585852696865 90000000 POLOLO OLOLLO OLOLLO GOGOOOSOSOOSOOOSOSOSOOSSOO 0900000 PROZOLOLOLGLG8SR5RaROL02 GOSOSOSOSOSOSOSOSOSOSO 09000000 200000009999999995959595 8999999999999999999090 09090909090909090909090 OLdLSQGLoQG8oLQ5Ro2GRo8 20 o995909590909090 Googo9o9o9e9o9o 0000000 50506005060500050000 690909090999096909090 99909900 ROSOLG8OLG8 0268026802680 OBOROROROROSORORORO OO 0000000 POOOOOSOSOSOSOSOSOSOSOSO SOKO 090959095909500959095909 Ld8a2d2oL5R8o858o8680865 0000000 09090909590909090590905959 95009500900095009090 00000000 000909090909090909090909 9990 POLdL6L526L590L62L2526L2526 95000500500005009500950 0000000 5 0 000050650500 o9690969090909099909969 2999900 KOGO LOLOL LOLOL 50505050050600500950090 5050005000500500005000500 d85268625262526852686 0000000 BL6L56268620262526852086 50505050050600500050090 90650000 0500505050505000050500050 90909090909090909909090 7 5050605065950006005060500 GODOOOOSOSOSOSOSOSOSO 0000000 090909090909090909090959 1 2 SEE POLdL62L25296L520L625262526 o999090909090909990909 0500050050605065050095 505065050006005060050095 00000000 ROSOLS8OLG8OL68O26802680 ASoLoSoko okoSoko o2oS 0000000 5050505000500590005050500 o9690969090909090909090 90000000
23. 9959585959995958 99 8999399939993999399938 9090959090909090 2626 O o9o9o 05 O62 ooo 22 23 Installation Manual 35 OO O a fF C C G ww wow N N N N NBO DN N a a O LEO eh CO LN es KON EOM gt oe C 36 45303112 45303107 45108037 45303121 45303120 45303105 45303106 45303111 45303117 45511002 45502080 45512004 45570001 45547002 45303146 45108038 45303145 45502071 45502072 45303118 45502074 45303116 45512009 45303108 45303109 45303110 45502078 45502007 79999562 45303123 45512006 45303143 79999503 45515004 Parts list SHARK Double door Top Shark Spine Shark L Safety brake BSOSOOE UL Guard small for Spine Shark Guard large for Spine Shark Cabin right Shark Cabin left Shark Bottom Shark Hatch Shark Wire guide Traction hoist LE500P 480V or 690V UL 3Ph 1E Hubbell plug male 480V Anchor point yellow Roller 1 for spine Shark Roller 2 for spine Shark Bracket for 50500 UL Safety brake BSO500 UL Bracket for top switches 200mm Top stop swich S1 UL Emergency top stop switch S13 UL Pendant control holder Shark Emergency stop button Shark UL Override automatic operation switch Step Shark Handl
24. Break down The work cage will neither go up nor down DANGER Unplug the power supply before opening the power cabinet Cause DANGER Avoid serious injuries 2 Repairs on the traction hoist the BLOC STOP safety brake and on the system s supporting components should be per formed by qualified fitters only Remedy 69 DANGER Attempting to use the lift will jeopardise work safety A1 The fixed EMERGENCY STOP button has been activated A2 Wire loop on traction hoist Damaged or defective wire or wire outlet causes problems A3 The safety brake aligning device is holding the work cage on the safety wire Lift wire breakage Hoist failure A4 work cage is stuck on an obstacle A5 Failing power supply Control not switched on or deactivated Grid voltage interrupted With 3 phase motors Phases switched in the supply the built in protection against phase switching blocks control Supply between grid connection and control interrupted A6 Limit stop switch functions EMERGENCY limit stop switch was hit Door limit stop switch blocks or is defective A7 Protection switch on overheating a Aphase is missing b Lacking motor cooling c Voltage too high low Deactivate the button in question by turning it clockwise until it pops out Stop work immediately Ask the supplier or manufacturer for help a b Evacuate the work cage and follow the directions in section 9 Carefully
25. Fig 9 page 17 b To go up or down push and hold the direc tion selector in the relevant direction c To place work cage on floor after the bottom safety stop has stopped the lift Turn override bottom safety stop switch Fig 6 page 16 clockwise and hold Push DOWN button until the work cage rests on the floor and let go 6 4 Automatic Only in work Cages with function AUTOMATIC installed a Push EMERGENCY button on pendant con trol Turn HAND AUTOM switch on power cabinet to activate automatic operation b Close door c Push UP or DOWN button respectively and the cabin starts ascending descending d Remove pendant control from holder e Return HAND AUTOM button to HAND 6 5 Remote operation a On the electrical control box switch the HAND AUTOM switch to hand fig 7 b On top of the remote operation receiver switch the device on fig 9 c For ascending push upward arrow on remote operation transmitter d For descending push downward arrow on remote operation transmitter e Once the operation is complete switch the remote operation function off 6 6 Lifting force limiter a In case of an overload the lift s upward travelling should be blocked and a buzzer should sound in the connection cabinet CAUTION Attempting to go up in an overloaded lift is prohibited b Remove enough of the load to make the buzzer stop and enable upward travel WARNING On entering and starting
26. Like the lifting wire continue feeding the wire underneath round the front guide wheel over the back guide wheel and through the back panel d On the back of the work cage pull the safety wire to tighten it e Replace roller protection guard f Feed wire through platform floor ON Locked OFF Open Fig 12 Back side Drive wire Safety wire 3955555555 Ensure that the wires can exit freely Drive wire contra weight Safety wire push spring Installation Manual 43 2 6 Securing the drive and safety wire The drive wire is fastened as described in point 2 6 1 beneath and the safety wire is fastened in one of three ways described in point 2 6 2 2 6 3 or 2 6 4 2 6 1 Drive wire contra weight An 11 kg weight is mounted approximately 300mm above the floor on the drive wire Excess wire is coiled with at least 3 strips See Fig 13 2 6 2 Safety wire wedge anchor with spring Like in point 2 3 1 above the wire is fastened using a rigging screw with spring See Fig 13a Mounting safety wire without spring will cause the safety brake block often Excess wire is coiled with at least 3 strips e At wire length of 60 m tighten the rigging screw so the wire stretches 9 mm e At wire lengths of 100 m tighten the rigging screw so the wire stretches 15 mm This will tighten the wire to approximately 400 500 N 88 100 Lbs 44 AVANTI Work Cage for Wind Turbines o IMPORTAN
27. O60mm holes in the platform 2 Fasten the wedge anchors in the holes and mount an M16 lifting eyebolt 3 After loosening the rigging screw as much as possible the rigging screw is fastened to the eyebolt in one end and the wire using wire grips in the other 4 Tighten the wire as described in section 2 3 4 page 41 5 Excess wire is coiled and hung by means of wire strips Use at least 3 strips 6 Mount the second wire 40 AVANTI Work Cage for Wind Turbines Fig 7 Wire fix Fig 8 Method 1 Wedge anchor cCoiled guide wire Guide wire Wire grips Thimble Higging screw Lifting eye bolt Wedge anchor 2 3 2 Tripod Pull the guide wire through the platform and fasten with tripod See Fig 8a 1 After feeding the guide wire through the plat form continue feeding the wire through the tripod and the 16 mm x 1 5 mm aluminium tube Lock the aluminium tube the wire and the treated rod using a wire locking device Make sure to place the tube so no contact appear between wire and treated rod See Fig 8a 3 Tighten the bolts with 75 Nm 4 Mount the second wire N centre of the wire guides See Fig 6 page 39 ATTENTION Tighten the wire locking device after the first run ATTENTION Check the distance between wires so that the wire fix and wires are in the 2 3 3 Steel beam There may be a steel beam beneath the platform intended for work cage m
28. Po9oeo9o9o9o9CoCoSoCoSoQ o d2526852526252685626L62 0000000 BL6L56262625262526252686 629262626862 6L625262L5 95 ESE poo969596909069606960696 0909090909000000000004 00000000 0000000 d 21 26 in 39 050505050000050050000 46 SOSOSOSOSOSOSOSOS 059505050506050690500590 505050505005050000959590 99935898099959909090090 0595050000595 99590859095959099609090 90909550959090909090 0909099009090929090 ILOLO LOROLO LOZO SOSO OOOSOSOSSSOSSOOSO 8683868885 E 88885888 e 99590059000959095950590 959090009059090909090 i 92559998995899989998 9 99505000090560650600 32 AVANTI Work Cage for Wind Turbines OO N Oj a fF WwW C OO CQ N N N N N NYO NY YN a a on EX no Bao BF O OB Oo EMO EH C 45303112 45303107 45108037 45303121 45303120 45303105 45303106 45303111 45303117 45511002 45502082 45512004 45570001 45547002 45303146 45108038 45303145 45502071 45502072 45303118 45502074 45303116 45512009 45303153 45303154 45303155 45303125 45303126 45502073 45303124 79999562 45303123 45512006 Parts list
29. Ro woo X X XD b RR o 5 Daily inspection by the supervisor 2 2 2 2 5 1 Workcage 2 2 2 24252525252525252525 55 525 5 2 Operating area l l 5 3 Control functions 5 4 Automatic operation 5 5 Remote operation controll 2 2 2 2 5 6 5 lt lt 2 6 Operation work cage transport 6 1 Enty andexit owe Ew Roue k Q X Q w aa lt S GU Q Q OE ew 6 2 Stop EMERGENCY STOP 6 3 Normal operation 2 2 2 2 2 2D5 D25 2 5 6 4 Automatic 0 0 0 0 2 6 5 Remote operation 2 2 2 2 2 2 2 2 52 2 25 2 25 25 6 6 Lifting force limiter 7 Manualoperation 7 1 EMERGENCY descent ll s 7 2 lt 4 AVANTI Work Cage for Wind Turbines Page 8 What to do if the safety gripping device engages 23 9 Remedying 5 24 26 10 Out of service Rex cw om E X s o OE X eX Y o9 4o RRR Boy d 27 11 Removing wires forreplacement 2 0 c s l l lll 27 11 1 Parking the
30. Sliding door Top stop bar UL Threaded rod M8 A2 m Push spring for top safety stop Bottom stop bar Shark Wire 02 3mm coated Bottom stop swich Shark UL Safety wire Drive wire 28 Guide wire 012mm Schackle 2 ton Tripod Threaded rod M16 FZV L 330mm Push spring for safety wire Contra weight 11 kg for drive wire Cable bucket Power cable 4G1 5 UL Hubbell plug male 480V Cable suspension Snap hook Galv L 7O0mm Wirefix Bracke for wirefix 70 Top stop disc Quick guide English Quick guide Spanish Warning UL amp CSA approved MAX 533 Ibs UL amp CSA approved Warning sign hook on to anchor point Rating plate for Shark UL Remote control 2 transmitters Flash yellow 277v UL Base for flash 2nd base for yellow flash UL Fitting for UL flash Safety bar for sliding door Double button stop 0 45 1 1 0 62 1 2 2 2 Manual fig 13 2 Install fig 8a 2 Install fig 8 1 Install fig 12 1 Install fig 12 1 1 1 1 Install Fig 9 1 Install Fig 9 10 Install fig 14 10 Install fig 14 1 Manual fig 2 1 Manual fig 21 1 1 Manual fig 21 1 1 1 Manual fig 21 1 Manual fig 9 2 2 2 12 1 2 Parts list SHARK Double door Fig 1 42 19 20 34 30 16 17 11 18 Ps 13 25 99999089999089999 080995990995990999 090 985955
31. T Before fastening the safety wire carry out the safety brake test See Installation Manual section 4 2 e page 48 Fig 13 Method Drive wire contra weight Fig 13a Method 2 safety brake safety wire Left wire on work cage viewed from the front Safety wire Wire lock 2 pieces Thimble Spring Higging screw fork fork Eye bolt Wall anchor 2 6 3 Safety wire push spring Fig 13b Method 3 safety brake safety wire Underneath the platform the wire is fed through Left wire with push spring on lift the two holes at each end of the push spring viewed from the front The wire is then tightened as much as possible before being fastened with the wire locking device If prior to mounting the spring was held tight by strips cut them loose If properly tightened this will stretch the spring by approxi mately 15 mm See Fig 13b 2 6 4 Steel beam There may be a steel beam beneath the plat form intended for lift mounting If so use wire screws as described in method 2 6 2 for mount ing the safety wire to the steel beam Installation Manual 45 2 7 Wire fix alignment Having mounted the work cage the wires and the power the wire fix fittings are adjusted during the initial ascent a Perform the tests prescribed in the User s Manual section 5 page 19 ff b Install wires as shown in Fig 14 Fig 14 Wire guide CAUTION Wire fix shall be mounted on guide wires at all platforms wit
32. e In addition to the item number and name of the spare part always state the safety brake type the wire diameter and lift serial no A spare parts list is available from the supplier or directly from AVANTI Fig 21 Operating instructions inside the lift QUICK GUIDE Work cage SHARK Only personnel train Before rained to use the work cage may operate syste efore using the work cage carefull QUICK GUIDE Work c nly personnel trained to use efore using the work cage age SHARK bed ae Operate this system gee Observe all Operating instructions CMS SHARK Sliding door Work cage ids p SHARK Double door AVANTI Work Cage for Wind Turbines this 5 m ly read and observe all operating instructions 13 5 Rating plate information signs Verify the completeness and legibility of all rating plates information signs see Fig 21 Replace missing or illegible plates signs Rating plate on the work cage back frame AVANTI Hogqpesej 19 DE 2400 Hilberad Tel 545 4824 0024 Fax 45 4824 0124 Email inlaiavanti anline cem Se pr lt P r 9 Information signs Installation Manual Please familiarise yourself with these instructions and the User Manual Model SHARK before installing the work cage Ensure that all specified parts are present before commencing installation No warranty is provided against
33. e 21 of the User s Manual Manual lowering will activate the work cage again The work cage is now ready for use Prior to use however carry out the inspection specified in Installation Guide section 5 Installation Manual 47 4 Inspection before initial use An officially recognised expert must a Inspect the work cage as specified in section 11 1 of the User s Manual carry out a test run with the maximum rated load Overload test The test load depends on the work cage motor Load the cabin as follows Motor LE500P load 662 Lbs kg 300 125 of lifting capacity When an attempt is made to start the work cage the platform should stop and the buzzer in the connection cabi net should sound If not see Appendix A Adjusting instruc tions for overload limiter on page 49 d The guide drive and safety wires as well as the top and bottom wire fastenings must be tested at full length as part of the initial test run b O Fig 15 Safety OFF Safety brake stop button Window Safety brake 48 AVANTI Work Cage for Wind Turbines e Testing of the two safety brake safety grip ping devices IMPORTANT Before testing the tightening spring beneath the access platform must be removed Remember to secure it again after testing Fig 13a or 13b pages 44 45 DANGER If the safety brake safety gripping device is engaged it must not be
34. e for cabin black Front for double door Shark Double door right Double door left Double door switch Shark UL Cable 1 5Q Flex yellow green Eye not M8 FZV Angel for wirebush Guide for wirebush Top stop bar UL Threaded rod M8 A2 m Push spring for top safety stop Install fig 14 Manual fig 10 Manual fig 10 Manual fig 13b Manual fig 13b 37 38 39 40 41 42 45303128 45512064 45502070 45512005 45303100 45512060 45515001 45512011 45512001 45502082 45512003 45512056 45511001 45512010 45303101 45541105 45541106 45541011 45541012 45541040 Optional 45502053 45502075 45502076 45502077 45303148 35499033 3549901 1 35499010 Parts list SHARK Double door Bottom stop bar Shark Wire 02 3mm coated Bottom stop swich Shark UL Safety wire Drive wire 28 Guide wire 012mm Schackle 2 ton Tripod Threaded rod M16 FZV L 330mm Push spring for safety wire Contra weight 11 kg for drive wire Cable bucket Power cable 4G1 5 UL Hubbell plug female 480V Cable suspension Snap hook Galv L 70mm Wirefix Bracke for wirefix 70 Top stop disc Quick guide English Quick guide Spanish Warning UL amp CSA approved MAX 533 Ibs UL amp CSA approved Rating plate for Shark UL Remote control 2 transmitters Flash yellow 277v UL Base for flash 2nd base for yellow flash UL Fitting for UL flash 4 door folding type Shark UL Safety bar for slid
35. es at LH W 4 6 9 4 Door stop switch Sliding door The red door lock switch will in terrupt control if the door is not closed properly Double door A switch Fig 12 will interrupt control if the door is not closed properly 4 7 Other risks hazards AN CAUTION The following risks relating to the traction hoist and safety brake safety gripping device have not been specifically determined for the con struction in question The safety brake safety gripping device will provide its safety function only if the safety wire between the wire attachment and the safety brake is tight no loose wires Safety brake is tight no loose wires Therefore any loose safety wire must be secured with a tightening spring approx 20 cm below the ac cess platform See page 45 Anchor points STOP Avanti work platform is equipped with one or two anchor points Fig 2 page 12 During operation user should hook up to the Anchor point Further an optional safety bar can be mounted Fig 11 EMERGENCY STOP button LIS P UN Door limit stop switch In door frame ete i LM I Uu ttet 5 Daily inspection by the supervisor 5 1 Work cage a Before every operation ensure that the traction hoist the safety brake and all auxiliary com ponents stoppers wire guide wheels etc are mounted in accordance with specifica tions and without any noticeable defects b Check w
36. expert must verify the safety of the saftey break the wire and wire at tachment 2 The tower owner must ensure that results of all annual and extraordinary testing are logged Appendix B 12 1 1 Traction hoist The traction hoist is largely maintenance free Clean only when very dirty During cleaning always ensure sufficient air supply Annual test a Ensure that no visual defects appear b Test emergency descent function See Users s Manual section 7 1 12 1 2 Safety brake The safety brake is largely maintenance free Clean only when very dirty Keep free from dirt and lubricate often See table 4 page 29 Using too much oil will not harm the equipment or the gripping function Annual test a Test safety brake stop button b Test safety brake stop button reset c Release safety wire bottom attachment in tower and Perform wire acceleration test by hand See Installation Manual 4 e 2 d Repeat with the second safety brake 12 1 3 Work cage Annual test Inspect the work cage as specified in User s Manual section 5 1 28 AVANTI Work Cage for Wind Turbines 12 1 4 Suspension Wires Cables Always keep the wires clean and slightly greasy Use ordinary universal lubricating grease how ever do not use bisulphide containing lubri cants like Molycote Annual test a Check and replace the respective wire s if one of the following defects are found 8 wire strand breaks or more on a wire le
37. fo ut com Wwww u europe com NOTICE OF AUTHORIZATION TO APPLY THE UL MARK 2006 08 31 Mr Niels Bramsen Avanti Stigefabrik A S Hogevej 19 Hilleroed 3400 Denmark Fax number 45 4824 9124 E mail niels bramsen avanti dk net Reference File SA13063 Project 06CA 30988 P O Number 492603 1 Product USC CNC UL CLASSIFICATION OF NEW MODEL SHARK WITH SLIDING amp DOUBLE DOORS Dear Mr Bramsen Any information and documentation provded to you involving UL Mark services are provided on behalf of Underwriters Laboratories Inc UL s investigation of your product has been completed under the above project number and the subject product was determined to comply with the applicable requirements This letter temporarily supplements the UL Follow Up Services Procedure and serves as authorization to apply the UL Classification Mark only at the factory under UL s Follow Up Service Program to the subject product which is constructed as described below Identical to the subject model which was submitted to UL for this investigation The UL Records covering the product will be in the Follow Up Services P rocedure File SA13063 Volume 1 This authorization applies only to the address on this letter This authorization is effective from the date of this Notice and only for products at the indicated manufacturing locations Records in the Follow Up Services Procedure covering the product are now being prepared and will be sent to
38. for ascend ing and descending on a wire secured to the building Two safety brake safety gripping devices se cures the work cage to a separate safety wire Upward and downward travel is controlled from within the work cage in hand mode from the remote control transmitter in remote mode optional or from the outside in the automatic mode optional A lifting force limiter prevents upward travel in case of an overload of the traction hoist Two guide wires on either side of the work cage prevent the lift from swivelling tilting 10 AVANTI Work Cage for Wind Turbines 4 3 Work cage models This User s Manual and Installation Manual describes the following models e SHARK L Sliding Double door 4 door with 533 Lbs 240kg lifting capacity e SHARK XL sliding door with 650 Lbs lifting capacity 300 kg 4 4 Temperature Operating temperature 5 F 140 15 C 60 Survival temperature 13 F 176 F 25 C 80 Low temperature kit is also available Operational temperature low temperature kit 13 F 104 F 25 C 40 O 4 5 Components 4 5 1 Cabin overview Fig 1 Double door AyANTI Estadliched 1885 Cabin Double door Drive and safety wires Second safety brake gripping device Guide wire Wire guides Bottom safety stop Details see Page 13 18 NO QI 8 N Fig 1a Sliding door ANTI Eatabliafeed 7555 LN NO HOHEM 2 5 6 7 1 Cabin
39. g securing the load with the wire 12 2 Repairs Damage resulting from crushing squeezing Repairs to traction hoist equipment may ONLY be performed by the manufacturer or a hoist service centre and only using original spare parts Wire bags If the gearbox oil needs to be replaced use one of the lubricants specified in the following table corresponding to the temperature range in Loop formation which the traction hoist equipment is used Table 4 Amount required traction hoist LE500P 1 4 I Temperature 5 F to 176 F 31 F to 104 F range 15 C to 80 C 35 C to 40 C Synthetic oil PGLP ISO VG 460 PGLP ISO VG 100 See table 4 API specification Oil specifikation Use of other synthetic oil only with approval by AVANTI 1 Standard filling User s Manual 29 13 Ordering spare parts 13 1 Wire ropes In addition to the item number and name of the spare part always state the traction hoist type wire diameter and production number 13 2 Motor and brake In addition to the item number and name of the spare part always state the motor type and the type and coil voltage of the brake 13 3 Electric control When ordering spare parts or making requests always state the electricity category and wiring chart number See the rating plate at the con nection cabinet There is a wiring chart in the connection cabinet and in the motor terminal box 13 4 Safety brak
40. gages If the safety brake engages simply disengage by pusing down the lever Fig 16 until it clicks However this is not possible if the work cage is hanging on the wire if so see below DANGER On lifting wire breaks or hoist failures evacuate staff from the work cage The safety wire suspension and the attachment between the safety brake and the work cage are exposed to dynamic loads when a fall is blocked If the safety brake has locked and the work cage is hanging on the wire ascending is blocked Do as follows a Remove the load on the safety wire by taking the work cage upwards On power failures operate the work cage manually as explained in section 7 2 Manually open the two safety brake by pressing down leavers Fig 16A until they disengage On ground level perform test as Z specified in Installation Manual section 4 e and User s Manual section 5 6 before resuming normal operation Fig 16 Safety wire ATTENTION When the work cage has returned to ground level test the safety brake function as specified in Installation Manual 4 e and User s manual 5 6 CAUTION N Replace any defective safety brake components and return them for repair to the manufacturer Users Manual 23 9 Remedying break downs 1 All tests and repairs of the electronic compo nents should be performed by an authorised electrician only The power chart is placed in the traction hoist s power cabinet
41. h max 30 m between each wire fix 46 AVANTI Work Cage for Wind Turbines By means of the oblong holes in the wire fix fittings adjust the fittings so that the two parts pass each other easily when the work cage passes Narrow wire guide Standard wire guide Wire fix Bracket platform Optional ATTENTION During the first run make sure the power cable untwists evenly ATTENTION If tripods are used for guide wire fixing tighten the wire locking device after the first run 2 8 Adjustment of top stop disc The top stop disc is adjusted so the operation limit stop switch stops the work cage in align ment with the top landing platform however at least 200 mm before contact with wire thimble The emergency limit stop switch is a backup It is adjusted so it stops the work cage in case the operation limit stop switch fails See User s Manual Fig 10 on page 18 3 Danger zone Sticker Mount the sticker Danger Zone in the tower behind the work cage and the yellow marking ribbon on the floor Make sure the wall and plat form is clean and dry before attaching sticker and ribbon DANGER Make sure that nobody is exposed to danger below the work cage for instance from falling parts Suitable measures Pent roof or barriers The emergency limit stop shuts off everything just like an emergency stop If the emergency limit stop is activated lowering can only be done manually as described on pag
42. hether the drive and safety wires are feed correctly around the two wire guide wheels c Wire ends of 3 m or more in length must be coiled separately at the floor and tied with strips at least 3 places d Check lifting capacity see the rating plate or section 3 5 3 the extra load persons and materials must not exceed the maxi mum rated lifting capacity 5 2 Operating area a Ensure that there are no obstacles within the work cage s operating area which may cause the cabin to be stuck or hit the ground b Ensure that all relevant and required protection measures below the cabin are in place Such measures could include pent roofs or barriers to protect the staff against falling objects 5 3 Control function a Close doors Push EMERGENCY STOP Button Pushing button UP DOWN the lift should remain still To restart turn EMER GENCY STOP button clockwise If EMER GENCY STOP button fixed is installed Fig 9 page 17 test this button likewise b Test the Operation limit stop switch During upward travel push the switch manu ally and the work cage should stop imme diately Pushing the limit stop switch should enable the lift to travel down again c Test EMERGENCY limit stop switch During upward travel push the switch manu ally and the work cage should stop imme diately Following this neither upward nor downward travel should be possible d Bottom safety stop Take the lift down it should stop before
43. ing door Double button stop 0 62 H R 10 10 YE Manual fig 13 Install fig 8a Install fig 8a Install fig 12 Install fig 12 Install fig 9 Install fig 9 Install fig 14 Install fig 14 Manual fig 2 Manual fig 21 Manual fig 21 Manual fig 21 Manual fig 21 Manual fig 9 37 2 Mounting of wires 2 1 Tower top 1 The 12 mm guide wire and the 8 mm drive and safety wires are mounted using the Wire lengths depend on tower height and should shackles supplied for the suspension beam be specified when ordering The coils are marked at the top of the tower with the guide wire with length check for accuracy prior to mounting outermost on either side Measures See Do not pull wire over any edges Uncoil correctly Fig 6 and dimensions page 39 Fig 5a 2 Nuts and bolts are mounted Lock with cot ters 3 The top stop disc is mounted on the suspen ATTENTION sion wire leaving at least 200mm between Do not pull wire over edges disc and shackle See Fig 5 4 All wires are led to the bottom of the tower e IMPORTANT See Fig 5 Place all wire coils on the top platform j when tower is raised or use the tower mounting crane to place the wires on the top platform before nacelle is mounted It may also be possible to use the internal tower crane to hoist wires Fig 5 Shackle 2t Safety wire 8 safety brake Drive wire 28 traction hoist Shackle 2t Top stop disc
44. ivates a warning signal A hydraulic shock absorber 5 neutralizes the dynamic overload when starting the hoist 3 2 Adjusting a Apply the Max work load MWL see work cage name plate to the cage and close the door b Activate the control and push the UP button When upwards travel is NOT possible go down to the parking position and adjust the setting of the overload limiter c Apply the test load MWL 25 d Loosen set screw 7 in casing cover with Allen key size 2 e Remove the cap 8 Put Allen key size 4 150 long into the adjusting screw 6 1 With older hoists you may need an Allen key size 6 Appendix A f Turn the adjusting screw 6 clockwise until the test load can be lifted g Step by step reduce the trigger point of limit switch 4 by means of the adjusting screw 6 until the test load can no more be lifted 1 Turn the adjusting screw by 1 4 turn anti clockwise to reduce the trigger point 2 push UP button Upwards travel is still possible YES Stop go down with the cage and repeat step 1 NO Continue with h h Tighten set screw 7 off the tools k Insert the cap 8 to the casing hole Fill in the Test report of annual inspection check point 5 9 and sign 45540006 AVANTI AVANTI H gevej 17 19 3400 Hiller d Denmark P 45 4824 9024 F 45 4824 9124 l www avanti online com E infoGavanti online com USA
45. ncounters an obstacle during upward travel Operator intervention Reduce the load to below the overload limit or lower the lift until it is free of the obstacle and remove the obstacle before using the lift again 4 6 7 Safety gripping device Hoistable personal transportation means must be equipped with 2 safety gripping devices which will prevent the load from falling Safety brake Type BSO The safety brake BSO safety gripping device is opened manually Fig 8 Fig 8 Safety brake Fig 9 Emergency stop and override bot tom stop switch ON Locked OFF Open Emergency stop button Override automatic operation switch Window Stop button Fig 9a Yellow flash The speed of the safety wire passing through the device is continuously monitored and the jaws automatically close in case of sudden excessive speed This protects the lift against a Lifting wire breaks and b Hoist failures The safety gripping device can also be engaged manually in emergencies by pressing the EMER GENCY STOP switch The window is used to monitor the centrifugal force mechanism s func tion during operation For information on re quired intervention when the safety gripping device engages See section 8 on page 23 4 6 8 Sliding door lock Sliding doors are closed by pushing the steel tap on the door into the red door lock switch The door is unlocked by pushing the black button on the red doo
46. ngth corresponding to 30 times the wire diameter Fig 17 Severe corrosion on the surface or inside Heat damage evident by the wire colour Reduction of the wire diameter by 5 or more compare to the nominal wire diameter Fig 18 page 29 Damage on the wire surface See fig 19 page 29 for most common examples of wire damage These examples do not however replace the relevant provisions laid down by ISO 4309 3 Check and ensure all wires are mounted at the top and ground level in accordance to the mounting instructions See Installation Manual section 2 1 2 3 and 2 6 page 38 ff Power cables Check and replace the supply and control cables if the cable jacket or cable connec tions are damaged O Wire guide wheels Ensure wires are lead round guide wheels in accordance to mounting instructions See Installation Manual section 2 5 page 43 Fig 17 Wire strand breaks Fig 18 Wire diameter 12 1 5 Overload limiter information signs Annual test Test switches as specified in User s Manual section 5 3 and 5 4 page 18 ff Perform overload test as specified in Installation Guide section 4 c page 48 Verify completeness and legibility of all rating plates and information signs Replace missing or illegible plates and signs Wire strap loop which cannot be unwound Loop knot forming when a wire loop is pulled tight Bends resulting from inappropriate treatment e
47. oaded with the admissible test load i e safe working load 25 Q IMPORTANT Before leaving for the tower make sure you bring the needed test load of 660 880 Lbs 300 400kg We recommend to weighing the person s who can climb into the work cage during the test procedure and bring enough weighed ballast sandbags similar 2 2 Exclusion of other causes Before modifying the overload limiter set tings check if the upwards travel stopping is caused by other reasons a If the cage is guided by wire ropes or lad der Check for obstructions on the guiding device s and remove them b Check trouble free wire rope guiding at diverter pulley or similar Is the rope nowhere blocked squeezed Do the pulleys freely rotate Check with the work cage set to ground with no load on the ropes or by a person from outside the cage when going up and down c When starting does the primary brake open You can hear the klick sound respectively feel a mechanical shock when putting your hand on the motor fan cover In the cases b and c have the trouble be cor rected repaired by a qualified person AppendixA 49 Fig 16 3 Overload limiter 3 1 Function Fig 16 The traction hoist wire rope under load 1 ac tivates the lever 8 by means of the deflection pulley 2 Under overload the limit switch 4 is activated which stops the upwards travel and on man riding installations act
48. oint Planks and stages are designed with rated working loads of 250 500 and 750 pounds 113 227 and 340 ko The total combined weight of each worker and all materials should not exceed the rated working load Do not overload Erect the plank or platform so that the work Ing or standing surface is level Support plank or platform ends by stirrups scaffold bearer members trusses or other equipment intended for this purpose Use guardrails midrails and toe boards as required by local state and federal regula tions Their use is recommended in all cases Do not allow unstable objects such as bar rels boxes loose brick tools and debris to accumulate on the work surface Do not use a ladder or other device on a plank or platform to gain greater heights Never climb onto a stage from a ladder unless both the stage and the ladder are secured from movement in all directions m Do not ride on a moving plank or platform Tools materials and equipment should not be stored on planks or platforms that are be ing moved n Do not apply impact loads to a plank or plat form o Do not use acids or other corrosive sub stances on a plank or platform without con sulting the plank or platform manufacturer for specific instructions p Scaffolds and tools shall not be allowed to contact unprotected energized electrical lines or equipment Maintain a minimum safe distance of at least 10 ft 8m Consult
49. ons Weight of lift L 242 Lbs kg 110 XL 265 Lbs kg 120 To the weight of the lift should be added the weight of the power supply cable approx 0 22 Lbs per foot 0 23 kg per m 99 82 O O O O O O O O O O O O O O O O O O Standing height Under spine 1980 mm Under Traction hoist 2100 mm 9999899 260808 09990 OOOSOSOSO 590909090 999999959999 O O Q 262252 90898089 OR O86 95 fe ele e fele e 09090 00596 Q Q Q Q Slide door opening X XL 550 mm Dimensions in mm Shark A B C D E F H FL 3 em ex 75 2000 _ Standard wire guide narrow wire guide Details p 46 14 AVANTI Work Cage for Wind Turbines Fig 3b Dimensions double door 90909 5059590 09090000 62695 09590 e 8586208085262 998090999999808080809099808080909099998080908090908080808080909080 9590908505959090909090 00905 0209090 eee O80 ele 050506
50. ounting If so use rigging screws as described in method 2 3 1 for mounting the guide wire to the steel beam 2 3 4 Tensioning of the guide wires 012 mm Tighten the wires by hand and mark with a water resistant marker Measure the distance to the floor e For 60 m long wires stretch the wire 40 mm e For 80 m long wires stretch the wire 50 mm e For 100 m long wires stretch the wire 60 mm For each additional 20 m stretch the wire by a further 10 mm Fig 8a Method 2 Tripod After some time it may be necessary to stretch 60 m wire by another 5mm and longer wire by a further 7 10 mm all wires stretches after some time ATTENTION This will tighten the wires to approxi mately 2000 4000 N Installation Manual 41 2 4 Electrical connections Connections 2 4 1 Power supply AN DANGER The electrical connection of the traction hoist must be made in accordance with EN 60204 1 The power supply must be protected by a fuse and an earth leak circuit breaker 30m4A Disconnect the main power supply before handling power units Verify that the rated grid and motor voltages are identical The three phase motor is normally supplied in a star connection configuration 3 5 1 5 kW 1 2 0 1 5 kW 400 V 3 phases gnd 480 V 3 phases gnd Control voltage 230 V 2 4 2 Supply cable a The lenoth of the cable depends on the height of the tower and the positioning of the power outlet The
51. possible to pull the safety wire upwards 1 Engage the safety brake by pressing the stop button the handle should jump to the position Fig 15 Should it nevertheless be possible to pull the safety wire upwards the safety brake must be replaced and sent to the supplier for testing Heopen the safety brake by pressing down on the lever On top of the lift pull up the safety wire with a quick jerk the safety brake should now engage auto matically if it does not replace it and return to the supplier for testing N f Repeat the control with the second safety brake g If guide wires are mounted using the tripod now tighten the tripod wire locking device 2 The results from this test must be recorded in writing and saved for later reference Appendix B page 47 f Appendix A Adjusting instructions for overload limiter CAUTION Avoid injuries by strictly following the instructions a Verification and or adjustment of the overload device on the work cage can only be done by a qualified person who must have been instructed by AVANTI to perform this task Verification and or adjustment must be per formed under the supervision of the site fore man respectively another person authorized by the manufacturer One copy of this instruction must be provided to the personnel and always be available d Other alterations modifications of the work cage than necessary for adjusting the over
52. possibly reduce load until in the connection cabinet buzzer stops B3 Limit stop UP DANGER Limit stop defective or not a Test the limit stop connection function connected Replace if necessary Operation limit stop was b Move work cage down until the Unplug the power activated limit stop switch is released supply before opening the power cabinet B4 A phase is missing Test fuses and power supply B5 Fault in UP control circuit Test and possibly repair connections in control box or traction hoist wiring and relays Motor hums C1 Overheating For descriptions of individual causes and how loudly remedy faults see page 24 under item A5 or wire ropes squeak C2 Wire ropes dirty ATTENTION If possible immediately replace Further use of work cage the traction hoist and return it for may result in damage to the test repair at AVANTI wire traction but the work cage can go both up and down User s Manual 25 Break down work cage will DANGER go up but not Irresponsible behaviour down threatens the system s safety D1 The work cage has encountered Carefully take the work cage up and or is stuck on an obstacle remove the obstacle Test the operational safety of affected platform components Inform the supervisor D2 Either of the two safety brake DANGER devices is holding the work cage on the wire Unplug the power supply before opening the power cabinet Excessive hoist speed a b Take
53. r lock switch From the outside the same button is reached through a hole 4 6 9 Limit stop switch 4 6 9 1 Top limit stop switch At the top of the cabin frame a top limit stop switch will stop upward travel when activated Fig 10 User s Manual 17 Downward travel will still be possible A top stop disc which activates the top stop switch is installed below the lifting wire attachment Fig 5 page 38 ATTENTION When the top limit stop switch is en gaged activate the DOWN switch until the top limit stop switch is released 4 6 9 2 EMERGENCY top limit stop switch Deactivates control if the top limit stop switch fails Fig 10 Manual downward travel is possible CAUTION Do not use the work cage until the top limit stop switch fault has been remedied 4 6 9 3 Bottom safety stop The bottom safety stop switch Fig 11 stops downward travel if the work cage encounters an obstacle or touches the ground Upward travel will be possible for instance to remove the obstacle In order to put the work cage on the ground the contact plate s opera tion can be bypassed with the key switch in the control box If it is possible to enter underneath the work cage a double button safety stop must be installed See installation manual page 31 Fig 10 Stop switch normal operation Emergency 1 A stop switch HIE PE TP re bets Pate Bid at arg Pato 18 AVANTI Work Cage for Wind Turbin
54. remove the obstacle Test the operational safety of affected building sections Inform the supervisor a Turn EMERGENCY STOP switch to the right until it is released b Find the cause and wait for the power to return c Have an electrician switch 2 phases in the plug d Test and possibly repair the supply cable guide wires fuses and or wiring from the control box a Manually take the lift up until the limit stop switch is released b Close the doors and test the limit stop switch a Test repair fuses supply and connection b Clean the hood c Measure voltage and power 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 a Supply braking coil or rectifier defective b Braking rotor closes 24 AVANTI Work Cage for Wind Turbines a Have an electrician test repair replace the supply braking coil and rectifier b Return traction hoist for repair Break down The work cage will A8 The HAND AUTOM Turn the HAND AUTOM switch back neither go up nor switch is on AUTOM to HAND down work cage goes DANGER down but not up Irresponsible behaviour Jeopardises system safety B1 work cage is stuck on Carefully move the work cage downwards and an obstacle remove the obstacle Test the operational safety of affected platform components Inform the supervisor B2 Overload Buzzer sounds Test and
55. ressing the safety brake stop button the handle should jump to position ON Fig 8 page 16 b Reopen the safety brake by pressing down on the lever the lever must engage c During operation regularly monitor the centrifugal force regulator relay s rotation by looking through the window 5 7 Wires and suspension a During operation Checking of the lifting and safety wires free passage through hoist and safety gripping device b When the lift is at the top landing inspect the wire attachment and all the building sec tions that suspend the lift 6 Operation lift transport Transportation of people in AUTOM mode is forbidden 6 1 Entry and exit To ensure safe entry and exit a Lower the work cage onto the access plat form until the contact plate is activated and the cabin stops or bring the lift to a height corresponding to the correct level for exiting from the wind turbine s platform b Open the door and exit enter the lift through the door over the cabin railing 6 2 Stop EMERGENCY STOP a Release the direction selector the work cage should stop If it does not b Push the EMERGENCY STOP switch and all controls should be disabled Open the door and enter exit the lift through the door over the cabin railing 6 3 Normal operation a Turn the red EMERGENCY STOP switch on the control box clockwise and the switch should pop out Fig 13 page 19 Do likewise with EMERGENCY STOP fixed
56. switch must be in HAND mode The wiring diagram is found in the Electrical control box O If the traction hoist does not start two phases in the supply connection have been switched around the built in pro tection against phase switching blocks the control Remedy Have an electri cian switch the two phases in the plug ig Fig 10a EMERGENCY STOP UP O DOWN IMPORTANT 2 5 Installation of drive and safety wire in work cage CAUTION Wear protective gloves when handling wires 2 5 1 Drive wire installation a Remove protection guard above rollers b Feed the wire through the roof into the trac tion hoist s wire inlet opening Right side seen from front of work cage c Push the UP button on the pendant control and feed wire through until the traction hoist starts pulling Ensure that the wire can exit without obstruction d Continue feeding the wire underneath round the front guide wheel over the back guide wheel and through the back panel e Let the lift wire pass through until it is slightly tightened f Replace roller protection guard g Feed wire through platform floor 2 5 2 Safety wire installation a Remove protection guard above rollers b Open the safety brake gripping device by pushing down the lever until it engages clicks Fig 16 page 23 Feed the safety wire through the roof hole above the safety brake and con tinue by feeding through the safety brake c
57. the indicated manufacturing locations in the near future Please note that Follow Up Services Procedures are sent to the manufacturers only unless the Applicant specifically requests this document Products that bear the UL Mark shall be identical to those that were evaluated by UL and found to comply with UL s requirements If changes in construction are discovered appropriate action will be taken for products not in conformance with UL s requirements and continued use of the UL Mark may be withdrawn Sincerely 227 SANDER RIEZEBOS Materials Engineer UL International Netherlands B V Reviewed by Edgar Wolff Klammer SANDER NIEUWENHUIJZEN EDGAR WOLFF KLAMMER Senior Project Engineer Principal Engineer UL International Netherlands B V Underwriters Laboratories Inc 34s QAR a NS fi Only trained people may use this work cage This manual must be available to staff at all times during installation and operation Additional copies available from the manufacturer upon request All measurements are indicative only and subject to change without notice Contents User s manual 1 Explanations of symbols used in this manual 2 Cautions 242422 eR a a 3 Instructions es POR EER EU m Xem E 9 3 x P 3 d Wm ee Es 4 Description of equipment 4 1 Purpose aede c Coe a A2 uec xw lt 2 22 Q S Q Ao
58. the lift the buzzer may sound brie y This is due to temporary load peaks occurring as the lift takes off The control box is designed not to activate the buzzer or stop the lift because of peak loads caused by the cabin swinging If the problem persists have an AVANTI expert adjust the overload limiter Appendix A page 49 Users Manual 21 7 Manual operation EMERGENCY If a power failure or an operation fault etc Fig 14 interrupts the lift a manual EMERGENCY descent is possible 7 1 EMERGENCY descent a Open the manhole by pushing the lid in the roof and operate the lift from above b On top of the lift insert the leaver into the break leaver hole in front of the Traction hoist Fig 14 1 Pull the leaver upwards The work cage moves downwards The build in centrifugal force brake limits the pace of descent d To stop simply loosen the leaver e After use replace leaver in roof hole O For emergency situation only 7 2 Manual ascent Fig 15 With the break open the work cage can be pulled upwards using the hand wheel Fig 15 a Remove the rubber cap b Mount the hand wheel 2 on the motor shaft and turn it counter clockwise with the brake 1 open c After use retract the hand wheel and leaver from the traction hoist and replace them in the roof holes Replace the rubber cap 22 AVANTI Work Cage for Wind Turbines 8 What to do if the safety gripping device en
59. the power company to shut off power or insulate relocate the line if working closer than 10 ft DANGER To avoid contact and shock hazard scaffolds and tools shall not be used in the vicinity of energized power lines or electrical lines q Before using refer to manufacturer s instruc tions r Use only appropriate duty rated ladders when using planks or platforms with ladder jacks S Never attempt to straighten a deformed side rail or decking member t Each end of a platform unit shall extend over its support centreline not less than 6 inches nor more than 18 inches User s shall not stand on the cantilevered portion of plat forms Users Manual 9 4 Description of equipment 4 1 Purpose The work cage described in this User s Manual serves the following purposes transportation of staff and material inside wind turbine systems lettuce towers for wind tur bines and telecommunication towers transportation for mounting inspection and repairs The work cage may be used for transportation of two persons plus their tools and equipment to the most convenient height for performing work on the tower The work cage is designed for permanent in stallation in one specific tower The lift is not designed for use in silos at drilling sites as a permanently installed facade lift as a crane lift in environments with explosion hazards 4 2 Function The work cage uses a traction hoist
60. to the color code All wires are secured using strips max 200mm between strips All bolts and nuts are stainless steel DANGER If it is possible to enter underneath the work cage a double buttom safety stop must be fitted See In stallation Manual page 32 34 Installation Manual 31 1 1 Parts list SHARK Sliding door 44 42 43 36 37 09 OcOcOcOc UREN 59880595589359995 83308 999999935 886559 58 6262626844 026269686 9000000 00599959590 9506060606 95500900 90959090909 0950000 090000095 99000060 050505050586 955009000 0500000 95500000 90000006 14 S86 Q EB 50650059506009596 96000000 OPOLO OLORO OLOLLO 5505000059506909 EGOO 6262626262 62626 555580 090909090590909090590905959 SOSOSOSOSSOSOSOSOSOSOSO SSD BOGOBOBOROSOROROROROBORO dLaQdkoPo2oR8a8oRXoR58o8 POGOSOSOSOSOGSOSOSOSOOSOO 5050606005059595959000 GOGOSOGOSOSOSOSOOOSSOSOOSS dLd252GL2oLoLo85252686 POGSOSOSOSOSOSOSOSOSOGSOO 5050606005059595959600 95500900 OCOLO OLOOTO OLOO dLd2626L6L5L5852696865 POG6OSOSOSOSOSOSOSOSOSOO SOGOSOSOSOSOSOSOSOSOSOS dLd
61. ttom limit stop switch key to the right and turn the direction selec tor towards DOWN until the cabin rests on 11 1 Parking the work cage the platform b After having removed the drive wire con Ascend the work cage until bottom safety stop tra weight turn the travel direction selector engages towards DOWN The wire now exits the traction hoist at the top c From above the traction hoist remove the 11 2 Wire ends wire by hand Beneath the access platform a Loosen and decoil all coiled and secured 11 4 Removing the safety wire wire ends b Remove the weight and the tightening spring a Keep safety brake open and manually pull out the wire b Pull out the wire on top of the work cage 12 Maintenance Time Performance Component Details on page Daily Attachment components Supervisor Traction hoist 19 20 Control box Safety brake Annually Expert Entire system 28 29 Annually User s Manual 27 12 1 Yearly inspection Have the entire system especially the traction hoist and the safety brake tested by an AVANTI trained expert at least once annually however more frequently if required depending on use and the conditions of use and operation The traction hoist and safety brake must be overhauled at an authorized work shop and fur nished with new certificate for every 250 hours of operation Time counter is found in the power cabinet Fig 20 page 29 ATTENTION If safety brake has engaged an
62. vel should be possible Switch in pendant control holder blocks operation e Push EMERGENCY STOP button on pendant control f Place pendant control in holder so it is opera tional from the outside g Leave cabin and close door h Deactivate EMERGENCY STOP button The work cage should stand still O j Push UP button The lift should travel upwards j Push EMERGENCY STOP button The lift stops k Turn EMERGENCY STOP button clockwise and push DOWN button The work cage should travel downwards until emergency stop bottom stops the work cage Remove pendant control from holder m Return HAND AUTOM button to HAND n Test that the UP and DOWN buttons works again o DO NOT try to activate the override auto matic operation switch FIG 13b Fig 13b Emergency stop button Override automatic operation switch 20 AVANTI Work Cage for Wind Turbines 5 5 Remote operation control Perform only this inspection if remote control is installed a On the electrical control box switch HAND AUTOM Switch to hand fig 7 b On top of the remote operation receiver switch the device on c Push upward arrow on remote operation transmitter The work cage should ascend d Push downward arrow on remote operation transmitter The work cage should descend e Once the test is complete switch the remote operation function off 5 6 Safety gripping device a Engage the safety brake by p
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