Original instructions AVANTI SERVICE LIFT User’s, Maintenance and Installation Manual

Original instructions AVANTI SERVICE LIFT User’s, Maintenance and Installation Manual
Original instructions
®
AVANTI SERVICE LIFT
User’s, Maintenance and Installation Manual
Model Service Lift DOLPHIN
Certificate of Dolphin V CE 240 and 350 versions
Certificate of Dolphin A CE 240 version
Certificate of Dolphin V AECO 240 version
Date of publication:
5th CE Edition: 04/2015
Revision 3: 5/1/2016
Manufacturer:
AVANTI Wind Systems A/S
Rønnevangs Allé 6
3400 Hillerød Denmark
P: +45 4824 9024
F: +45 4824 9124
E:info@avanti-online.com
I:www.avanti-online.com
Sales & Service:
Australia
Avanti Wind Systems PTY LTD China
Avanti Wind Systems Denmark
Avanti Wind Systems A/S Germany
Avanti Wind Systems GmbH Spain
Avanti Wind Systems SL UK
Avanti Wind Systems Limited USA
Avanti Wind Systems, Inc India
Avanti Wind Systems, PL Brazil
Avanti Brazil Sistemas Eólicos. S.L. Manufactured Under Process Patent NO.8,499,896.
® Registered in Europe
P: +61 (0) 7 3902 1445
P: +86 21 5785 8811
P: +45 4824 9024
P: +49 (0) 41 21-7 88 85 – 0
P: +34 976 149 524
P: +44 0 7930 272 270
P: +1 (262) 641-9101
P: +91 44 6455 5911
P: +55 85 9671 6336
Contents
Page
1. Limited warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Observations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3 Exclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.4 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.5 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.6 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.6.1 For Dolphin V CE and AECO versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.6.2 For Dolphin A version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.7 Traction system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.8 Fall arrest device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.9 Traction, safety and guiding wire ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.10 Main control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.11 Cabin control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.11.1 For Dolphin V CE and AECO versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.11.2 For Dolphin A CE version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.12 Bottom platform control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.12.1 For Dolphin V CE versions with guard locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.12.2 For Dolphin V CE versions with trapped key and for AECO version . . . . . . . . . . . . . . 17
3.12.3 For Dolphin A CE version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.12.3.1 Call only configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.12.3.2 Send and call configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.13 Intermediate and top platform control box for Dolphin A CE version . . . . . . . . . . . . . . . . . . 17
3.13.1 Call only configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.13.2 Send and call configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.14 Platform fences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.14.1 Fences for Dolphin V and A CE versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.14.2 Fences for Dolphin V AECO version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.15 Service lift door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.16 Emergency top limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.17 Top obstruction device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.18 Bottom obstruction device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.19 Manual descent system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.20 Fall arrest device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.21 Overload limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.22 Slack rope sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.23 Warning light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.24 Acoustic buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.25 Anchor points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.26 Internal light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.27 Lateral removable windows for Dolphin A version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.28 Front fixed window for Dolphin A version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.29 Travelling cable pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.30 CCV sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.1 WTG integration requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.2 Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.3 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.3.1 Power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.3.2 Guard locking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.4 Guiding, traction and safety wire ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.4.1 Top platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.4.2 Bottom platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.5 Wire rope fix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.6 Danger zone sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.7 Inspection before first use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5. Instructions for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.1 Prohibited uses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.2 Operation from inside the cabin (manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
5.3 Operation from outside the cabin (automatic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.3.1 Bottom platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.3.2 Top platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.4 Operation from the platform control boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.5 Fall arrest device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.6 Manual descent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.7 Lateral removable windows for Dolphin A version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.9 Out of service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.1 Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.2 Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.3 Daily inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.4 Annual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.4.1 Cabin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.4.2 Traction hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.4.3 Fall arrest device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.4.4 Traction, safety and guiding wire ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.4.5 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.4.6 Overload check and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.4.7 Wire guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.5 Information signs and documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.6 Ordering spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Appendix A: Adjustment of the overload limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Appendix B: Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Appendix C: Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Appendix D: Inspection Log Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Appendix E: AVANTI lift anchor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1. 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
Product1) 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 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.
1)
8
Avanti service lift (“Product”)
AVANTI Service Lift for Wind Turbines
Except as specifically set forth in this Limited
Warranty,
ALL EXPRESS OR IMPLIED CONDITIONS,
REPRESENTATIONS AND WARRANTIES,
INCLUDING, BUT NOT LIMITED TO, ANY
IMPLIED WARRANTY OR CONDITION OF
MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, NON-INFRINGEMENT,
SATISFACTORY QUALITY, COURSE OF DEALING, LAW, USAGE OR TRADE PRACTICE ARE
HEREBY EXCLUDED TO THE MAXIMUM
EXTENT PERMITTED BY APPLICABLE LAW
AND ARE EXPRESSLY DISCLAIMED BY
AVANTI. IF, PURSUANT TO ANY APPLICABLE
LAW, TO THE EXTENT AN IMPLIED WARRANTY CANNOT BE EXCLUDED AS PROVIDED IN
THIS LIMITED WARRANTY, ANY IMPLIED
WARRANTY IS LIMITED IN TIME TO THE SAME
DURATION AS THE EXPRESS WARRANTY
PERIOD SET FORTH ABOVE. BECAUSE SOME
STATES DO NOT PERMIT LIMITATIONS ON
THE DURATION OF IMPLIED WARRANTIES,
THIS MAY NOT APPLY TO A GIVEN CUSTOMER. 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.
In any cases of dispute the English original shall
be taken as authoritative.
2. Introduction
2.1 Observations
Only trained people may use this lift.
This manual must be available to staff at all times during installation, maintenance and operation.
Additional copies are available from the manufacturer upon request.
All measurements are indicative only and subject to change without notice.
!
The pictures and sketches in this manual may not reflect the product aesthetics, colours,
arrangement precisely. This has no impact on the function or safety.
2.2 Symbols
Symbol
Signal word
Meaning
Possible injury if not observed
IMMEDIATE or
possibly imminent
danger:
Death or severe injury!
Safety instructions
STOP
DANGER!
DANGER!
CAUTION!
IMMEDIATE or
possibly imminent
danger of hazardous
voltage:
Death or severe injury!
Potentially hazardous
situation:
Light injury or material damage.
ATTENTION!
Potentially dangerous
situation:
Damage to equipment or workplace
IMPORTANT!
Useful tips for optimum
working procedure
None
Additional instructions
!
VERSION!
Differentiation between CE
versions and AECO version.
Reference to written
specification/documentation
User’s, Maintenance
and Installation Manual
9
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 performed by qualified personnel authorised by a trainer
authorised by AVANTI.
Personnel must be at least 18 years of age.
The staff must be familiar with the relevant accident
prevention instructions and must have received
proper training in these.
Personnel are obliged to read and understand this
User’s Manual.
Personnel shall wear PPE (safety helmet, full body
harness, shock absorber, lanyard and slider) at all
times.
A copy of the User’s Manual must be handed out
to the personnel and must always be available for
reference.
If more than one person is entrusted with one of
the above tasks, the employer shall appoint a
supervisor in charge of the operation.
Self-locking nuts must be used at all times. The
screw must extend from the nut by at least half
of the thread diameter. The nut may not be used
once it has become possible to loosen by hand!
If any damage or faults are found during operation,
or if circumstances arise which may jeopardize
safety: immediately interrupt the work in progress
and notify the supervisor or employer!
service lift is allowed without the manufacturer’s prior
written consent.
No warranty is provided against damage resulting
from reconstruction or modification of equipment or
use of non-original parts which are not approved by
the manufacturer.
Service lift must be inspected by AVANTI or by qualified 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 conditions of use, more frequent inspection is required.
Service lift is designed for a lifetime of 20 years with
an operating frequency of approximately 12.5 h/year
(250 h in total).
Service lift may not be used by persons 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 weather, including wind speeds over 25 m/s (55.5 mph).
Personnel of Dolphin AECO version
shall be equipped with a wired or wireless two way communication device
connected to a location staffed by
authorized personnel.
Avoid injury – follow all instructions!
All tests/repairs of electrical installations may only
be performed by AVANTI or qualified personnel authorised by AVANTI.
All repairs to the traction, braking and supporting
systems may only be performed by AVANTI or qualified 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 authorised by AVANTI.
Only original fault-free parts may be used.
Use of non-original parts will render the manufacturer’s warranty void and any type approval invalid.
No modification, extension or reconstruction of the
10 AVANTI Service Lift for Wind Turbines
The tower owner must verify the need for
third party service lift inspections with the
local authority and comply with the
standards specified.
3. Description
3.1 Purpose
The service lift purpose is to transport persons plus
their tools and equipment to the most convenient
height for performing work in wind turbine generators
(WTG).
This will require supply of interface components,
including but not limited to:
• Platform fences.
• Power supply protection.
• An evacuation way (e.g. ladder)
Its use is limited to AVANTI or personnel authorised
by AVANTI holding the relevant training certificates.
The access to the WTG and consequently to the
service lift is controlled and forbidden to public
access.
The service lift is used primarily to transport 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 connecting
bolts and other equipment is made.
3.2 Scope
This manual contains instructions for four
different versions of the Dolphin lift:
• Dolphin V CE 240 version.
• Dolphin V CE 350 version.
• Dolphin A CE 240 version.
• Dolphin V AECO 240 version.
The Dolphin V CE and Dolphin A CE
versions are CE certified to the Machinery
Directive 2006/42/EC.
The Dolphin V AECO version is AECO
certified to ASME A17.7/CSA B44-7.
The product details are described along this manual.
The product 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, wire
fixes attached to the tower, and guides on the
service lift.
3.3 Exclusions
The service lift shall not be used outdoor or in
potentially explosive atmospheres. The service lift is
not designed to carry a person on its top.
The wind turbine manufacturer is responsible of
integrating the service lift and ensuring compliance
with the essential health and safety requirements as
stated on the 2006/42/EC Machinery Directive and
the applicable harmonized standards following
AVANTI´s recommendations.
3.4 Technical specifications
A third party approval of the final
integration might be required depending
on the national regulations.
The wind turbine manufacturer shall also provide any
additional relevant warning, instruction and / or
training specific to the integration of the service lift
necessary for its safe and correct installation.
Tower manufacturer’s risk assessment shall
include a service lift integration study.
Service
Dolphin V
Dolphin V
Dolphin A
Dolphin V
lift
CE 240
CE 350
CE 240
AECO 240
Service lift
165 kg
180 kg
165 kg
165 kg
Service lift
10 or 18 or 21 m/
18 m/min ± 10%
18 m/min ± 10%
10 or 21 m/min ±
speed
min ± 10 %
Working load
240 kg / 2
350 kg / 2
240 kg / 2
240 kg / 2
limit /
Persons
Persons
Persons
Persons
Operating
-15ºC to +60ºC
-15ºC to +60ºC
-15ºC to +60ºC
-15ºC to +60ºC
temperature
(5ºF to +140ºF)
(5ºF to +140ºF)
(5ºF to +140ºF)
(5ºF to +140ºF)
weight
10 %
Nº persons
(max)
Survival
-25ºC to +80ºC
-25ºC to +80ºC
-25ºC to +80ºC
-25ºC to +80ºC
temperature
(-13ºF to +176ºF)
(-13ºF to +176ºF)
(-13ºF to +179ºF)
(-13ºF to +176ºF)
Max. Noise
80 dB (A)
80 dB (A)
80 dB (A)
80 dB (A)
Wire rope
Shackle 2T
Shackle 2T
Shackle 2T form
Shackle 2T
fastenings
form C
form C
C with safety pin
with safety pin
with safety pin
level
Power supply
form C
with safety pin
3 Phase 400V
3 Phase 400V
3 Phase 400V
3 Phase 400V /
/ 480V / 690V,
/ 690V, 50Hz /
/ 690V
480V, 60Hz
50Hz / 60Hz
60Hz
50Hz / 60Hz
Power
Dolphin V
Dolphin V
Dolphin A
Dolphin V
cable
CE 240
CE 350
CE 240
AECO 240
Type
5G1.5 (400V) /
5G1.5 (400V) /
12G2.5 (400V
5G1.5 (400V) /
5G1.5 (480V) /
4G1.5 (690V)
/ 690V)
5G1.5 (480V)
0.16 kg/m
0.53 kg/m
0.16 kg/m
4G1.5 (690V)
Weight (ap-
0.16 kg/m
prox.)
User’s, Maintenance 11
and Installation Manual
3.5Dimensions
2102
2670
2909
2510
1)
675
737
Note: The top obstruction device is optional for CE versions if platform fences are
not railing type. Mandatory for CE versions
if railing type is installed. Mandatory for
AECO versions.
1)
960
1150
12 AVANTI Service Lift for Wind Turbines
3.6 Components
3.6.1 For Dolphin V CE and AECO versions
17
2
18
1
16
3
4
5
6
7
8
20
10
9
21
11
12
13
14
15
19
1. Emergency top limit stop switch
2. Top limit switch
3. Safety wire rope
4. Traction wire rope
5. Guiding wire ropes
6. Internal Light
7. Main control box
8. Hour counter
9. Anchor points
10. Top sliding door
11. External controls
12. Cabin control box
13. Bottom sliding door
14. Maintenance cover
15. Bottom obstruction device
16. Traction hoist and fall arrest device
17. Top obstruction device 1)
18. Top stop bar 1)
19. Travelling cable pulley 1)
20. External anchor point (optional)
21. Warning lights 1)
1) Note: Optional for CE versions. Mandatory for AECO version.
User’s, Maintenance 13
and Installation Manual
3.6.2 For Dolphin A version
1
2
3
6
4
7
8
5
9
4
15
16
10
10
17
11
18
12
12
20
13
19
14
10
10
21
22
1. Top obstruction device
2. Safety wire rope
3. Traction wire rope
4. Guiding wire rope (2x)
5. Traction hoist
6. Top obstruction switch
7. Emergency top limit switch (S13)
8. Fall arrest device
9. Travelling cable
10. Wire rope guide (4x)
11. Anchor point (2x)
12. Lateral removable window (2x)
14 AVANTI Service Lift for Wind Turbines
13. Maintenance cover
14. Folding step
15. Main control box
16. Hour counter
17. Front fixed window
18. Top sliding door
19. Bottom sliding door
20. Cabin control box
21. Bottom obstruction device
22. Travelling cable pulley
Traction system
Fall arrest device
3.7 Traction system
Service Lift
Hoist
Lifting
capacity
Wire rope
speed
Effect
Version
Traction system type
Kg
m/min
kW
Dolphin CE
M500-M508/400V
500
18
Dolphin CE
M500-M508/690V
500
18
Dolphin AECO
M508/400V
500
21.4
Dolphin CE 350
M508 / 400V 50Hz/60Hz
600
Dolphin CE 350
M508 / 690V 50Hz/60Hz
600
Rated
Traction
Unit weight
current wire rope Ø approx.
A
mm
Kg
1.5
4.1
8.4
50
1.5
2.3
8.4
50
1.8
4.9
8.4
50
18
2
4.4 / 5.3
8.4
55
18
2
2.6 / 3.2
8.4
55
3.8 Fall arrest device
Service Lift
Fall arrest device
Lifting capacity
Triggering
speed
Safety
wire rope Ø
Unit weight
approx.
Version
Type
Kg (lbs)
m/min (ft/min)
mm
Kg (lbs)
Dolphin CE
OSL 500 - ASL 508
500 (1100)
30 (100)
8.4
7 (15.4)
Dolphin AECO
ASL 508
500 (1100)
30 (100)
8.4
7 (15.4)
Dolphin CE 350
ASL 508
600 (1320)
30 (100)
8.4
7 (15.4)
3.9 Traction, safety and guiding wire ropes
Service Lift Version
Wire rope type
Wire rope
diameter
Surface Mark/ Min. break
Treatment feature resistance
Dolphin CE
M500 / OSL 500
8.4 mm, 5x19
HDG
no
55 kN
2 t shackle
Dolphin CE & AECO
M508 / ASL 508
8.4 mm, 5x19
HDG
no
55 kN
2 t shackle
Dolphin CE 350
M508 / ASL 508
8.4 mm, 5x19
HDG
no
59 kN
2 t shackle
ALL
Guiding wire rope
12 mm
HDG
no
53 kN
2 t shackle
Attached with
User’s, Maintenance 15
and Installation Manual
3.10 Main control box
Emergency top limit switch
Fall arrest
device switch
Manual
descent buzzer
Top obstruction
switch
Door guard locking
switch
Bottom
obstruction switch
Manual descent
switch
User control box
connector
Hour counter
Green light (Ready)
On if the lift is ready to use,
no safety devices engaged.
3.11 Cabin control box
3.11.1 For Dolphin V CE and AECO versions
1
1
1. Emergency stop button. Press it to interrupt any control
function. Pull to reset the control after necessary verifications.
22
2. Trapped key switch 1). Insert and turn the key to the ON
position to enable control of the lift. The key is now trapped and
cannot be removed until it is turned back to the OFF position.
Turn and remove the key to interrupt control of the lift. Then use
the key to open the trapped key lock of the top platform fence.
3. UP/DOWN buttons (hold to run)
33
66
55
44
4. UP/DOWN buttons (automatic send). Press it to send the lift
all the way to the top or bottom of the tower. The automatic
DOWN button is only operational from the top platform and the
automatic UP button is only operational from the bottom
platform.
5. Overload buzzer. It sounds when the cabin is overloaded.
3.11.2 For Dolphin A CE version
6. Bottom obstruction override switch
11
34
7. Platform light (green).
8. Overload light (yellow).
33
7
7
88
10
10
11
11
22
9. OK light (green)
99
10. ASL light (red).
11. Fault light (red).
6
6
16 AVANTI Service Lift for Wind Turbines
Note: An interlock system (trapped key or guard locking) is mandatory for the CE versions if platform fences are
equipped with doors. Optional for the AECO version.
1)
3.12 Bottom platform control box
The control box is installed at the bottom platform
fence. The control box has a main switch. Turn the
switch to the OFF position to cut the power to the
service lift. The main switch must be set to OFF
when the lift is not in use, when leaving the wind
turbine and while the wind turbine is running. It must
be set to OFF before starting an electrical generator.
3.12.1 For Dolphin V CE versions with guard
locking
1. CCV sticker (if applicable)
2. DOWN light (green)
3. DOWN button (black)
4. Main switch
5. UP light (green)
6. Fault light (red)
7. OK light (green)
8. Emergency stop button
9. UP button (white)
3.12.3.2 Send and call configuration
4
Main
switch
5
1
Green light
(Ready)
Power inlet
(from WTG)
Power outlet
Connector
(to lift)
Interlock switch
3.12.2 For Dolphin V CE versions with trapped
key and for AECO version
9
6
3
7
2
8
3.13 Intermediate and top platform
control box for Dolphin A CE
version
3.13.1 Call only configuration
9
5
6
2
7
8
3.12.3 For Dolphin A CE version
3.12.3.1 Call only configuration
3.13.2 Send and call configuration
4
5
9
5
3
2
6
1
2
6
7
3
7
8
8
User’s, Maintenance 17
and Installation Manual
3.14 Platform fences
3. Fixed perforated sheets.
The platform holes shall be protected with platform fences.
The platform fences consist of structures, with or without
perforated sheets, of different geometries depending on the
platforms where they are installed.
3.14.1 Fences for Dolphin V and A CE versions
The platform fences shall conform to EN 14122-3.
The following types of fences are possible as long as the
following points are fulfilled:
1. The doors shall be monitored with an interlock system:
either trapped key or guard locking.
2. The fixed fences shall only be installed in infrequently
accessed platforms (access to platform maximum once
per year).
3. The railing type fence is only possible if the service lift is
equipped with a top obstruction device.
1. Fixed railing.
4. Perforated sheets with door.
2. Railing type with door.
Trapped Key
Actuator
Trapped
Key Lock
18 AVANTI Service Lift for Wind Turbines
5. Perforated sheet type of 2,4m high, and with door
equipped with guard locking.
3.14.1.1 Trapped key system 1)
3.14.2 Fences for Dolphin V AECO version
The platform fence door is fitted with a
trapped key lock keeping the door locked while
the service lift is not at the platform. The door can
be unlocked by using the trapped key on the user
control box and opening the trapped key lock. The
key will get trapped until the door is closed and
locked again.
The platform fences shall comply with ASME
A17.1.5.11.
Fence of bottom platform
Trapped
key lock
Trapped
key lock
actuator
3.14.1.2 Guard locking system 1)
The platform fence door is fitted with an interlock
system keeping the door locked while the service lift
is not at the platform. The door is unlocked when the
service lift is at the platform with the lift detection
switch activated. The green light is ON when the door
is closed.
Fence of intermediate platform
Fence of top platform
Lift detection switch
Guard locking
switch actuator
Guard locking switch
Guard locking switch
emergency release button
Note: An interlock system (trapped key or
guard locking) is mandatory for the CE
versions if platform fences are equipped
with doors. Optional for the AECO version.
1)
User’s, Maintenance 19
and Installation Manual
3.15 Service lift door
The top sliding door is closed by pushing the
actuator into the door switch. The control will be
interrupted if the door is not closed properly or
opened while the lift is moving.
The bottom sliding door is closed by pushing
the actuator into the guard locking switch. The
guard locking switch is automatically unlocked
when the cabin is located on the top or the
bottom platform.
Optionally, the service lift can be equipped with
a platform switch (S18), 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.
In case of power cut, need of evacuation
between platforms or need to access intermediate 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.
Top sliding door
actuator
Top sliding
door switch
Guard locking
switch of bottom
sliding door
Guard locking actuator
of bottom sliding door
Emergency release
button of bottom sliding
door
20 AVANTI Service Lift for Wind Turbines
Lock
Sliding door
3.16 Emergency top limit switch
3.18 Bottom obstruction device
At the top of the cabin a top limit switch 1) 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 1) interrupts the control if
the top limit switch 1) fails. Manual descent is
possible.
The bottom obstruction switch stops descent if the
service lift:
• encounters an obstacle
• touches the ground
!
When the top limit switch 1) is engaged,
press the DOWN button until the top limit
switch 1) is released
Do not use the service lift until the top limit
switch 1) fault has been rectified.
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 bottom obstruction override switch while pressing the
DOWN button.
Release the DOWN button as soon as the
rubber bumpers hit the floor. Otherwise the
lift or the installation may get damaged.
Note: Top limit switch, or top obstruction switch if top
obstruction device is supplied.
Emergency top
limit switch
Top limit switch 1)
1)
3.17 Top obstruction device 2)
The top obstruction device switch stops ascent if the
service lift:
• encounters an obstacle
• touches the top limit device
Descent will be possible, for instance to remove the
obstacle.
Bottom
obstruction device
Note: Top limit switch, or top obstruction switch if
the top obstruction device 2) is supplied.
1)
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.
2)
Top
obstruction device 2)
User’s, Maintenance 21
and Installation Manual
3.19 Manual descent system
The service lift is provided with a lever allowing
manual release of the electromagnetic motor brake.
Once the motor brake is released, the service lift
descends with a controlled speed limited by a
centrifugal brake installed between the motor shaft
and the gear box. When the manual descent actuator
is pushed upwards, the brake release switch is
activated. The brake release switch will interrupt any
control function. The manual descent buzzer will
sound while the service lift descends.
Lift with knobs:
- To engage the fall arrest device: Pull the red knob
downwards (stop lever will turn counter clockwise)
- To release the fall arrest device: Pull the black
knob downwards (release lever will turn clockwise)
PULL DOWN TO UNLOCK
Fall arrest device
PULL DOWN TO LOCK
Lever extension
tube
Brake release
switch
Manual descent
actuator
PUSH UPWARDS TO
PERFORM MANUAL DESCENT
Manual descent
actuator holder
3.20 Fall arrest device
Fall arrest device
unlocking knob
(black)
Lift without knobs:
- A foldable step is provided for access to the fall
arrest device levers. The user must observe all safety
precautions and check that the lift doors are closed
before climbing on it.
- To engage the fall arrest device: Turn the stop
lever counter clockwise.
- To release the fall arrest device: Turn the release
lever clockwise.
The service lift is equipped with a fall arrest device
which will be triggered in case of an overspeed
condition. The speed of the safety wire rope passing
through the device is continuously monitored, and the
jaws are automatically closed in the event of sudden
excessive speed.
STOP
Fall arrest device
locking knob (red)
Fall arrest device
Tightness of safety wire rope must be
frequently inspected to ensure full
functionality of fall arrest device!
This device protects the service lift against traction
wire rope breakages or traction system failures. The
fall arrest device can also be engaged or disengaged
manually by pulling downwards knobs on the back of
the lift, or by acting directly on the fall arrest device
levers.
Foldable step
STOP
22 AVANTI Service Lift for Wind Turbines
BEFORE CLIMBING on foldable step, CHECK that
required PPEs are used, both doors are closed and
personnel is hooked to anchor points inside cabin
3.21 Overload limiter
3.25 Anchor points
A lifting force limiter is built into the wire rope
traction system and will prevent upward travel in
the event of overload. In case of overload, the
lift’s upward travel will be blocked, and a buzzer
will sound in the user control box. The buzzer
will stop only when the cause of the overload
has been removed.
• Reduce the load to below the overload limit.
• Lower the lift until it is free of the obstacle
and remove the obstacle before using the lift
again
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.
!
STOP
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 stop the lift because of peak
loads caused by the cabin swinging.
Attempting to run an overloaded lift is
prohibited!
3.22 Slack rope sensor 1)
Installed on the top of the service lift, over the
traction hoist, when engaged it interrupts
descent. It detects slack traction wire rope.
3.26 Internal light 3)
The service lift is equipped with a light inside the
cabin. The light is on when the lift is powered.
Optionally this light can be battery packed in
order to illuminate inside cabin without
electric supply (once charged).
3.27 Lateral removable windows
for Dolphin A version
The cabin has two lateral windows that are
removable to facilitate maintenance tasks on the
tower from inside the lift.
These windows shall be used only in special cases
such as corrective maintenance and installation of
tower components. These windows shall not to be
used for preventive or normal maintenance tasks.
3.23 Warning light 1)
An optional set of warning lights can be mounted on the top and at the base of the lift. The
flashes warn that the lift is moving.
3.24 Acoustic buzzer 2)
An optional audible signal can be installed with
the same warning function.
1)
Note: Optional for V CE version. Not
available for A CE version. Mandatory for
AECO version.
2)
Note: Optional for V CE version. Not
available for A CE version. Optional for
AECO version.
3)
Note: Optional for V CE version.
Mandatory for A CE version. Mandatory
for AECO version.
User’s, Maintenance 23
and Installation Manual
3.28 Front fixed window for
Dolphin A version
The front fixed window is transparent to enable
users look outside without the need to open the
door. This window cannot be removed.
3.29.2 For Dolphin A version
The travelling cable pulley has two arms attached to the guiding wire ropes. This way, the
guiding of the pulley improves.
Pulley
Front fixed
window
3.29 Travelling cable pulley 1)
A travelling cable pulley is suspended on the
power cable and is guided along the traction
and safety wire ropes. The pulley straightens the
power cable at all times.
Arms
Guiding wire
rope
Guiding wire
rope
3.30 CCV sticker
The Cold Climate Version sticker indicates the
temperature range wherein the CCV service lift
may be operated.
3.29.1 For Dolphin V CE and AECO versions
Front fixed Pulley
Traction wire rope
Safety wire rope
24 AVANTI Service Lift for Wind Turbines
Note: Optional for Dolphin V CE versions. Mandatory for Dolphin A version and for Dolphin V
AECO version.
1)
4. Installation
4.1 WTG integration requirements
WTG
component
General integration requirements
Power supply
Type
3 Phase + PE + N
Voltage (50 Hz)
400 V/ 690 V
Voltage (60 Hz)
400 V/ 690 V
Fuses
16 A
Protection
According to EN
60204-1
Platforms
Minimum clear- 60 mm
ance around
service lift
Evacuation
way
Means of evac- 1100 mm
uation shall be
provided with
a minimum
distance of
Platform
fences
Minimum
height
1100 mm
Compliant to
EN 14122-3
requirements of
standard
Hoistway
Top beam
Fence door interlock system
Trapped key or
guard locking
Maximum total
travel height
180 m
Maximum
angle between
hoistway and
vertical axis
±1.5º
Forces capable Upon request
to withstand
from AVANTI
Depending on travel path, dimensions may need to be
larger in order to avoid collisions of travelling cable pulley with platforms. Other dimensions are possible upon
request and design verification by AVANTI.
The WTG manufacturer shall put in place any other
means necessary to ensure the safe use of the service
lift according to AVANTI recommendations and its own
risk assessment for the integration that shall include
items which are not under AVANTI´s scope.
4.2Cautions
Please familiarise yourself with these instructions and the User’s Manual before installing the
service lift. Ensure that all specified parts are
present before commencing installation.
No warranty is provided against damage and injury resulting 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:
• Building sections involved will be able to withstand the
service lift loads.
• All parts are available and fully functional.
• Travel zone is protected by fences at each platform.
• 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:
• Wear at least the following PPE: fall arrest
equipment if falling height is higher than 2 m, hand
gloves, helmet, safety glasses, working gear.
• Use a hand winch attachable to the ladder when elevating heavy weights.
• Use a wire rope clamp or grip when lowering wire ropes,
in order to avoid the risk of personnel losing the wire
rope, and wire rope getting damaged or person being
hit. The clamp shall be secured to a platform anchor
point. The diameter of the clamps or grips shall match
the diameter of the wire ropes.
• Not work at different levels if tasks involve risk of falling
objects.
4.3
Electrical connections
Before making any connection, disconnect any
power supply to the service lift and the fence
interlock system.
For CE versions: the electrical connection of the system
must be made in accordance with EN 60204-1.
The power supply must be protected by a fuse and
against indirect contacts according to local regulations.
Verify that the rated grid and motor voltages are
identical.
When plugging the service lift to the power supply,
ensure that supply phases are correct!
User’s, Maintenance 25
and Installation Manual
4.3.1 Power cable
4.3.1.1 Cable bin 1)
- Hang the cable collect bin underneath the power
cable hole of the bottom platform using the straps
supplied. Attach the straps on the holes.
- Cut the transport strips and tape holding the cable
inside the bin and connect the cable stocking to the
eyebolt underneath the service lift floor
- Connect the power cable outlet socket to the service
lift inlet plug attaching the cable to the cabin with cable
ties.
4.3.1.3 V164 cable guiding system 3)
The lift is equipped with a Power Cable Support from
which the power cable exits the cabin.
Tensioning
system
Power cable
outlet socket
Cable
stocking
Spring of safety
wire rope
Cable collect bin
suspension
straps
Cable collect
bin
Power cable
inlet plug
Counterweight of
traction wire rope
4.3.1.2 Travelling cable 2)
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 as described on 4.4.2.4.
The cable bin is installed vertically aligned with the
Power Cable Set outlet when the lift is on P0.
Cable Guides are added to the platforms:
The system must be installed so that the Power
Cable Set travels through the Cable Guides with no
metal to metal contact.
1)
Note: Optional for Dolphin V CE versions.
Not available for Dolphin A version and for AECO version.
2)
Note: Optional for Dolphin V CE versions. Mandatory for Dolphin A version and for AECO version.
3)
Note: Only for Dolphin V CE versions for V164 WTG
26 AVANTI Service Lift for Wind Turbines
4.4.1.1 Top limit device 1) (disc)
4.3.2 Guard locking system 4)
- 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.
Guiding
wire ropes
Traction
wire rope
Safety
wire rope
Top limit
device 1) (disc)
4)
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.
4.4.1.2 Top limit device 1) (bar)
4.4 Guiding, traction and safety wire
ropes
4.4.1 Top platform
Guiding, traction and safety wire ropes are attached to
the suspension beam on the available holes.
To install them on the suspension beam:
1) Mount the guiding wire ropes (12 mm) and the traction
and safety wire ropes (8 mm) using the shackles
supplied for the suspension beam at the top of 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 1) on the traction wire rope
leaving at least 200 mm between top limit device 1) and
shackle. Adjust the final position during first run so that
the service lift is levelled with the top platform when it
stops.
4) Uncoil all wire ropes to the bottom of the tower.
Note: Top limit device (disc) is mandatory for CE versions if top
obstruction device is not present. Top limit device (bar) is mandatory
for CE versions if top obstruction device is present. Top limit device
(bar) is mandatory for AECO version.
1)
4.4.2 Bottom platform
Bottom platform hole arrangement
Safety wire rope
Guiding wire rope
!
STOP
Traction wire rope
Guiding wire rope
Power cable 2)
All wire ropes must be evenly uncoiled
to prevent looping.
Do not pull wire rope over edges.
4.4.2.1 Guiding wire ropes:
1) Feed the guiding wire ropes through the wire
guides on the service lift.
2) Fit the correct number of wire rope fixes on the
wire rope and feed through the wire rope guides.
The wire rope fixes must be installed and adjusted
during the first run.
Note: Power cable hole is only necessarywhen cable bin is installed.
2)
User’s, Maintenance 27
and Installation Manual
3) Pull the guiding wire rope through the bottom
platform and fasten it with the tensioning system.
The tensioning system may vary depending on the
tower configuration.
4.4.2.2 Traction wire rope
1) Open the maintenance cover on the back of the
service lift.
2) Remove protection guard above rollers.
3) Feed the wire rope between the two bushings of
the slack rope sensor.
4) Feed the wire rope through the roof into the
traction hoist’s wire rope inlet opening.
5) Push the UP button of the cabin control box and
feed wire rope through until the traction hoist starts
pulling. Ensure that the wire rope can exit without
obstruction!
6) Continue feeding the wire rope around the pulleys
to the back of the lift.
Link Tensioner /
Anchor Bolt
Bipod tensioner
Set
4) Attach the wire ropes to the tensioner:
a) Feed the wire ropes through the tensioning
system.
b) Attach the wire rope to the tensioning system
using the wire rope grips to allow for the first run.
c) Make a mark on the wire rope to ensure no sliding
occurs at the wire rope grips and to use as a reference for checking stroke if necessary.
5) Perform final tension adjustment after first run:
a) Tension the wire ropes by turning the supplied nut
until the desired tension is shown on the graduated
scale (4000N by default, 7000N for V164).
b) Use the second nut to lock the assembly.
Tensioning methods and tension values
may vary depending on specific tower
configurations
28 AVANTI Service Lift for Wind Turbines
Traction
wire rope
7) Feed the wire through the guide bushings (including 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 platform
(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.
Safety wire rope
Traction wire rope
Bottom platform
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 approximately 40 kg to the safety wire rope.
4.4.2.4 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 travelling cable to the cabin by
means of cable ties.
4.5 Wire rope fix
Wire rope fixes are installed and adjusted during the
first run so that the centres of the wire rope fixes are
in the centre of the service lift wireguides.
Wire rope fixes must be installed on each platform
and as required along the tower (MAX. 30 m) to
improve guiding to avoid collision with tower elements. Use the oblong holes on the wirefix brackets
to align and adjust the wire rope fix position.
Traction wire ropecounterweight
4.4.2.3 Safety wire rope
1) Open the maintenance cover on the back of the
service lift.
2) Remove protection guard above rollers.
3) Feed the wire rope through the roof into the fall
arrest device’s wire inlet opening.
4) Pull the wire rope through the fall arrest device
while turning the release lever clockwise.
5) Continue feeding the wire rope around the pulleys
tothe back of the lift.
Wire rope fix
bracket
Wire
rope fix
Wire rope
guide
4.6 Danger zone sticker
Safety
wire rope
6) Feed the wire rope through the guide bushings
of the cabin.
7) Feed the wire rope through the guide bushings of
the travelling cable pulley.
8) Feed the wire rope through the platform holes.
9) Feed the compression spring through the safety
wire rope.
Mount the “Danger Zone” sticker in the front door of
the bottom platform fence. Make sure that the fence
is clean and dry before attaching the sticker.
4.7 Inspection before first use
AVANTI or qualified personnel authorised 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 C: Inspection log sheet”).
User’s, Maintenance 29
and Installation Manual
5. Instructions for use
5.1 Prohibited uses
STOP
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:
• Use the service lift beyond its intended purpose.
• Operate the service lift without following the safety
warnings and operating instructions.
• Overload the service lift
• Try to repair machine components. Only personnel
from AVANTI or qualified personnel authorised by
AVANTI are allowed to perform service on the machine.
• To use the ladder, unless service lift
is out of service, or in case of
evacuation or rescue.
• To manipulate switches and safeties.
• To place objects on service lift roof.
• To descend on service lift roof.
5.2 Operation from inside the cabin
(manual)
1. Turn the main switch of the platform control box to
the ON position
2. Enter the service lift and close the bottom / top
fence door
3. Turn the trapped key switch ON
4. To go up or down, push and hold the UP or DOWN
button as needed
STOP
In the event of traction wire rope breaks or
traction hoist fails, evacuate the service lift.
5.3 Operation from outside the cabin
(automatic send)
STOP
Transportation of people is forbidden if the
operation is controlled from outside the service lift.
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
30 AVANTI Service Lift for Wind Turbines
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
5.4 Operation from the platform control
boxes
1. Turn the trapped key switch to ON.
2. Close the door of the cabin and of the platform
fence.
3. Press and hold the UP or DOWN button to
ascend or descend the cabin.
!
STOP
When the UP or DOWN button of a platform control
box is pressed and held, the response of the cabin is
delayed 5 seconds. During this delay, an acoustic
signal will sound. This way, any personnel in the
surroundings are warned of the imminent movement
of the service lift.
Transportation of people is forbidden if the operation
is controlled from a platform control box.
5.5 Fall arrest device
If the fall arrest device engages simply disengage it by
pulling downwards the black knob on the back of the
lift or by turning the “Unlock” lever clockwise 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 or by turning the “Unlock”
lever clockwise until the fall arrest device is unlocked.
In case of power failure and the fall arrest device is
locked with the safety wire rope under tension evacuate the lift according to the evacuation procedure.
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.
5.6 Manual descent
In case of power failure, a manual descent without
power can be performed. To do so:
1. Verify that the fall arrest device is unlocked
2. Check that there are no obstacles or persons in
the travel zone.
3. Take the manual descent actuator from its holder
and insert it on the lever extension tube.
4. Push the manual descent actuator upwards. The
service lift will start descent and a buzzer will sound.
5. To stop the manual descent, stop pushing
upwards.
During the manual descent, the door and
hatches of the lift shall be kept closed.
STOP
Always look through the perforated floor of the
cabin to see if anyone is standing on the
ladder.
Use the walkie-talkie to report about the
manual descent.
During the manual descent, stop the service lift
just before reaching the bottom platform floor.
This way, the bottom obstruction device will
not get damaged.
The manual descents shall be of maximum 30
m. Between two consecutive manual descents, the user shall wait minimum 10 minutes
for the centrifugal brake to cool down. This
way, the premature wear of the centrifugal
brake will be prevented.
5.7 Lateral removable windows for
Dolphin A version
To open the windows:
1. Press the emergency stop button of the cabin
control box.
2. Remove the lateral windows from the cabin lateral
panels by unscrewing its riveted screws with a Torx
screwdriver.
To close the windows:
1. Install the lateral windows by screwing its riveted
screws back on the cabin lateral panels with a Torx
screwdriver.
2. Press and turn the emergency stop button of the
cabin control box.
STOP
The lateral removable windows shall only be
used by AVANTI or qualified personnel
authorised by AVANTI.
The lateral removable windows shall only be
used for maintenance tasks.
User’s, Maintenance 31
and Installation Manual
5.8 Troubleshooting
1.All tests and repairs to the electronic components 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!
2.Repairs to the traction hoist, the fall arrest
device and to the system’s supporting components should be performed by qualified
personnel only!
Cause
A1The fixed EMERGENCY STOP
button has been activated.
Reset the button in question by pulling or
turning it
A2Wire 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.
A3The fall arrest device is
holding the service lift on the
safety wire.
a) Lift wire rope breakage
b) Hoist failure
A4The service lift is stuck on an
obstacle.
STOP
DANGER!
Attempting to
use the lift will
jeopardize
work safety
Solution
A5Power failure
a) Main switch is OFF
b) Grid voltage interrupted
c) Supply between grid connection
and control interrupted
a) + b)Evacuate the service lift
Carefully remove the obstacle.
Test the operational safety of affected
tower sections. Inform the supervisor.
a) Turn the main switch ON
b) Find the cause and wait for the power
to return.
c) Test and if necessary repair the supply
cable, fuses, and/or wiring from the
control box.
A6A safety switch is triggered:
a) Emergency top limit switch
is activated.
b) Top and/or bottom sliding door is
open.
c) Manual descent switch is activated
a) Perform manual descent until the
limit stop switch is released.
b) Close the top and/or bottom sliding
door.
c) Adjust manual descent switch so that
it is not involuntarily activated.
A7Protection switch on
overheating
a) A phase is missing
b) Motor is not cooling
c) Voltage too high/low
a) Test/repair fuses, supply and
connection.
b) Clean the motor cover.
c) Measure voltage and power
consumption on the loaded motor. If
voltage deviates from specifications,
use cable with increased dimensions.
A8Brake does not open
(no click on on/off)
a)Supply, braking coil or
rectifier defective.
b) Braking rotor closes.
A9 If trapped key system is provided: 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.
32 AVANTI Service Lift for Wind Turbines
a)Have an authorized person, repair/
replace the supply, braking coil and
rectifier.
b) Return traction hoist for repair.
Insert the key and turn it to the ON
position
Test / Repair defective components.
Breakdown
Cause
Solution
A11 The service lift is stuck on
an obstacle below it.
a) Evacuate the service lift
b) Inform the supervisor
c) Check the Bottom obstruction device
connection/function. Replace if necessary.
A12 Service lift is overloaded
(buzzer sounds).
Test and/or reduce load until buzzer stops.
Not applicable to CE versions.
Only applicable to AECO version.
Service lift goes
down but not up
B1The service lift is stuck on
an obstacle.
Carefully move the service lift downwards
and remove the obstacle. Test the operational safety of affected platform components. Inform the supervisor.
B2Service lift is overloaded
(buzzer sounds).
Test and possibly reduce load until buzzer
stops.
Only applicable to CE versions.
Not applicable to AECO version.
B3Top limit switch 1):
a) Top limit switch 1) is defective or
not connected.
b) Top limit switch 1) is activated.
a) Test the top limit switch 1) connection/
function. Replace it if necessary.
b) Descend the service lift until the top limit
switch 1) is released.
Note: Top limit switch, or top
obstruction switch if top obstruction
device is supplied.
1)
Service lift can
ascend but cannot
descend.
B4A phase is missing
Test fuses and power supply.
B5Fault in UP control circuit
Test and possibly repair connections,
wiring and relays.
C1 Slack rope sensor1) is engaged
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.
Note: Optional for CE version.
Mandatory for AECO version.
1)
Motor hums loudly
or wire ropes
squeak, but the lift
can go both up and
down.
D1Wire ropes are dirty.
If possible, immediately replace the traction
hoist and return it for test/repair at AVANTI.
Further use of lift may
STOP result in damage to the
traction wire rope.
User’s, Maintenance 33
and Installation Manual
Breakdown
Service lift will
go up but not
down!
Cause
D2The service lift has encountered 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.
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.
DANGER!
STOP A defective fall arrest device
will threaten the safety of
the service lift! Replace
immediately!
D4Fault in down controller circuit
Insert brake lever into the traction hoist
and lower lift manually.
Test, and if necessary have connections, wiring, and relays repaired.
D5 The slack rope sensor is
holding the service lift on the
traction wire rope.
a) The slack rope sensor has engaged:
move the service lift upwards to
disengage the device.
b) The sensor is not properly installed:
have a competent technician adjust
the device correctly.
c) The sensor is defective: replace it
and return it for test/repair at
AVANTI.
D5 Bottom stop switch:
a) Bottom stop switch is defective
or not connected.
b) Bottom stop switch is activated.
a) Test the bottom stop switch connection/ function. Replace if necessary.
Button lamp
not lit although
operation is
normal
E The lamp is defective
Have an authorised person replace it.
Service lift descends when UP
button is pressed
and ascends when
DOWN button is
pressed.
F If a phase control relay is not
provided: two phases changed
in the supply
Have an authorised person switch the 2
phases in the plug.
b) Descend service lift until bottom stop
switch is released.
If these steps do not identify the cause and rectify the fault:
Consult a qualified authorised person or contact the manufacturer.
34 AVANTI Service Lift for Wind Turbines
5.9 Out of service
1. Securing the service lift:
Bring the service lift all the way down, until the bottom stop switch stops the cabin.
6.Maintenance
2. T
urn 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 necessary. Contact the service technician for repair.
6.1 Planning
Time (Performance)
Component
Daily (User)
Operating area and service lift visual inspection
Service lift controls and safety devices
Annually (Expert)
Wire ropes
Electrical cable
Annually (Expert)
Entire system
Annually, at least every 250 hours of operation
(Expert)
Traction hoist
Annually (Expert)
Fall arrest device
V164 only: Annually, at least every 125 hours of
operation (Expert)
Wire guide replacement
6.2 Cautions
6.3 Daily inspection
Before any maintenance task, ensure that walking
way surfaces are dry and not slippery.
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 components
2. Check that the traction and safety wire ropes are
not damaged or jammed
3. Check that the safety devices are in place and
working:
3.1 Main switch: Turn the main switch on the
interlock control box to the OFF position. The green
light must be OFF. The service lift must not run.
Turn it ON, the light shall be ON.
3.2 Green light (Ready) – Service lift: Close and
lock the bottom platform gallery door and the
service lift door. Turn the trapped key to the ON
position. The green light must be ON. It should not
be possible to remove the trapped key unless it is
switched OFF again.
3.3 Emergency stop button: Press the emergency
stop button on the cabin control box. The service
lift should not move UP / DOWN. Release the
emergency stop and drive the lift UP approximately
1 meter.
User’s, Maintenance 35
During maintenance tasks, personnel shall:
• Wear at least the following PPE: fall arrest equipment (when falling height is more than 2 m),
hand gloves, helmet, safety glasses and working
gear.
• Place cabin at bottom platform and disconnect
power supply.
• Use an electricity measuring tool when performing inspection of electrical components.
• Use a hand winch attachable to the ladder when
handling big/ heavy loads and shall be performed at least by 2 persons.
• Panel parts shall be removed to facilitate access
to confined spaces.
• Use a cable grip when replacing travelling cable.
• Keep cabin doors closed when using a 3-step
ladder.
When plugging the service lift to the
power supply, ensure that supply phases
are correct!
and Installation Manual
3.4 Service lift door: Pull the door to open. The
door should not open. Unlock the top sliding door
from the bottom sliding door and pull to open.
The top sliding door should open, the green light
must be OFF and the lift must not move UP /
DOWN. Close the top sliding door and apply the
lock to the bottom sliding door
3.5 Activate the fall arrest device by pulling down
the red locking knob. Press and hold the DOWN
button of the cabin control box. The service lift
should not descend. Try to perform manual
descent. The service should not descend. Press
and hold the UP button of the cabin control box.
The service lift should ascend. Unlock the fall
arrest device by pulling down the black unlocking
knob.
3.6 Perform a manual descent test for a meter.
The lift should descend and the buzzer should
sound.
3.7 Drive the service lift down until the Bottom
obstruction device hits the bottom platform. The
service lift should stop before the rubber bumpers
hit the bottom platform. The service lift door and
the fence door should be unlocked.
3.8 Top obstruction device 1): activate top stop by
pressing it down. The service lift should not
ascend until top obstruction device is released.
3.9 Slack rope sensor1): Activate the slack rope
sensor by manually pulling the traction wire rope
upwards. Descent should not be possible.
4. When the lift is at the top platform, check the
wire rope fastenings.
5. Record the hour meter reading in the
“Appendix D: Inspection log sheet”.
STOP
STOP
6.4 Annual inspection
Have the entire system tested by an AVANTI
trained expert at least once a year, especially the
traction hoist and the fall arrest device. However, it
may be required more frequently depending on
use and the conditions of use and operation.
The traction hoist and fall arrest device must be
overhauled at AVANTI workshops and furnished
with new certificate for every 250 hours of operation. Hour counter is found in the main control
box.
!
If fall arrest device has engaged, an expert
must verify the safety of the fall arrest device,
the wire rope, and wire rope fastenings.
The tower owner must ensure that the results
of all annual and extraordinary inspections are
logged in the “Appendix D: Inspection log
sheet”.
6.4.1 Cabin
Inspect the cabin structure, joints, attachments
and accessories.
6.4.2 Traction hoist
The traction hoist is largely maintenance free.
Clean only when very dirty. During cleaning
always ensure sufficient air supply.
Annual test (only by authorized persons):
a) Ensure that no visual defects have appeared.
b) Check that air gap “a” between brake and disc
is 0.3 mm using a thickness gauge.
If any faults occur during work,
- stop working,
- if required secure the workplace and
- rectify the fault!
Make sure that nobody is exposed to
danger below the service lift, for instance
from falling parts.
Cabin control from outside of the cabinAutomatic:
The automatic mode function is only available
from the control buttons outside of the cabin at
the bottom platform and top platform. It shall be
checked as follows:
1. Press the UP button on the control box. The lift
should ascend.
2. Press the emergency stop button on the control
box. The lift stops.
3. Pull the emergency stop button and press the
DOWN button. The service lift should descend
until the bottom obstruction device engages.
36 AVANTI Service Lift for Wind Turbines
c) Test manual descent function.
d) Test speed and current should match the
service lift data plate.
e) Check that sound and behaviour are normal.
Note: Optional for CE versions.
Mandatory for AECO version.
1)
6.4.3 Fall arrest device
The fall arrest device is largely maintenance free.
Clean only when very dirty. Keep free from dirt
and lubricate often. Using too much oil will not
harm the equipment or the gripping function.
Annual test (only by authorized persons):
a) Test the fall arrest device stop lever by pulling
down the red locking knob.
b) Test the fall arrest device stop lever reset, by
pulling down the black unlocking knob.
c) Release safety wire rope bottom attachment in
the tower and pull the safety wire rope with a jerk.
The overspeed device should trigger the fall arrest
device automatically.
d) Ensure that no visual defects have appeared
6.4.4 Traction, safety and guiding wire
ropes
The inspection of the wire ropes can be
carried out from inside the cabin. To do so,
open the maintenance cover. The cabin
panel has a white sticker attached to it. This
sticker makes the wire ropes´ silhoutte stand
out and therefore facilitates the inspection of
the wire ropes.
Carry out the following inspections and adjust if
necessary:
1. Inspect all the wire ropes along their entire
length.
2. Pay special attention to the wire rope ends,
parts of the wire ropes running over sheaves and
wire ropes under frictional wear by external
components.
3. When inspecting the wire ropes, consider the
following points:
type and number of wire breaks,
position and time sequence of wire breaks,
decrease of the wire rope diameter during operation,
corrosion, abrasion, deformation,
influence of heat, and
operating time.
4. Check that the traction and safety wire ropes
are fed correctly around the 2 wire rope guide
wheels.
5. Check that the wire rope ends are coiled
separately under the bottom platform and tied
with at least 3 cable ties.
6. Check that the guiding wire rope tensioning
system is correctly installed and that the wire rope
locks and fixes are properly fastened.
7. Check that the compression spring on the
safety wire rope is correctly installed and that the
wire rope locks are properly fastened
8. Check that the counterweight on the traction
wire rope is properly fastened. The traction wire
rope coil and counterweight shall be able to rotate
freely. Do not attach them to a fixed part.
9. Check that the guiding wire ropes are correctly
tensioned.
Record any visible change of the
condition of the wire ropes on the
“Appendix C: Inspection log sheet”,
and monitor closely throughout time.
6.4.4.1 Lubrication of the traction and
safety wire ropes
1. Position the lift at the bottom platform.
2. Open the maintenance cover by unscrewing its
screws.
3. Apply lubricant on the traction and safety wire
ropes by means of a spray can.
4. While applying the lubricant, use the second
hand to place and hold a cloth around both wire
ropes. This way, the lubricant will be distributed
uniformly on both wire ropes.
5. While the first user uses the spray can and the
cloth, a second user presses and holds the UP
button from inside the lift. This way, while the
service lift ascends, the lubricant is applied along
the complete length of the two wire ropes.
6. After applying the lubricant, leave the maintenance cover open and carry out a descent back
to the bottom platform.
7. While descending, check that the two wire
ropes have been properly and uniformly lubricated.
User’s, Maintenance 37
and Installation Manual
8. Once the service lift is at the bottom platform,
clean off any lubricant accidentally applied on the
cabin panels.
9. Finally, close the maintenance cover by screwing
back its screws.
Only use specialised wire rope lubricants. Do not
use lubricants based on lithium soap grease or
bitumen. Do not use disulphide-containing lubricants like Molycote ®.
Apply lubricant using a spray can, brush, drip
applicator or pressurized device.
Pay special attention to sections of the wire rope
where dehydration or denaturation of the lubricant
can be seen.
Re-lubricate the wire ropes before they show signs
of corrosion or run dry, and taking in mind that:
A poor lubrication leads to corrosion and to a quick
wear of components.
An excessive lubrication leads to dirt agglomeration
on the wire rope surface. As a result, this can lead to
quick wear of wire rope, sheaves and drum.
A correct lubrication keeps the efficiency factor of
the wire rope, protects against corrosion, helps to
elongate their lifetime significantly and ensures a
safe operation.
6.4.4.2 Measuring of the wire rope diameter
When measuring the diameter of the wire
ropes, use a digital calliper with broad
measuring faces.
In general, measure the diameter of the wire rope at
each WTG tower platform, and under the service lift,
where the wire rope is less loaded. Specifically, if a
wire rope wear is detected, measure on the affected
area.
!
Rotate the calliper around the wire rope to
measure the minimum and maximum wire
rope diameter at each measurement
point.
6.4.4.3 Discard criteria
!
!
The discard criteria of the wire ropes shall
be according to ISO 4309: Cranes - Wire
ropes - Care and Maintenance, inspection
and discard.
Determine and eliminate the cause before
installing a new wire rope.
AVANTI recommends to replace the
traction and safety wire ropes after 250
hours of operation (approximately every 5
years) corresponding with the refurbishment of the traction hoist and fall arrest
device. Please check with your local
authority regulations if it’s mandatory in
your case.
Check and replace the respective wire rope(s) if one
of the following defects is found:
• For traction and safety wire ropes, if there are
more than one 8-wire strand break on a wire rope
length of 250 mm.
• For guiding wire ropes, if there are more than one
8-wire strand break on a wire rope length of 360
mm.
• If there is severe corrosion on the surface or the
inside.
• If there is heat damage, evident by the wire rope
colour.
• For traction and safety wire ropes, if the wire rope
diameter is less than 8 mm.
38 AVANTI Service Lift for Wind Turbines
• For guiding wire ropes, if the wire rope diameter
is less than 11,4 mm.
• If there is damage on the wire rope surface (see
following figures for most common examples of
wire rope damage).
Kinks resulting
from counterweight
of traction wire rope
not being able to
rotate freely.
Wire rope strap/
loop,
which cannot be
unwound
Loop knot forming
when a wire loop is
pulled tight
Bends resulting from
inappropriate treatment
(e.g. securing the load
with the wire)
Damage resulting from
crushing, squeezing,
running over, etc.
Wire bags
Loop formation
On AECO service lifts, according to A17.1
5.11, traction and safety wire ropes must
be replaced after 250 hours of operation
or 5 years whichever occurs first, corresponding with the refurbish­ment of the
traction system.
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.
• Amount required: 1,5 l
• Traction hoist: M500 / M508
• 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 specified in the “Appendix A: Regulation of overload
limiter”.
6.4.7 Wire guides
For the V164 WTG, the wire guides must be replaced every 125h maximum.
Depending on the type of wire guide, this may
require uninstalling the guide wires, following the
steps on 4.4.2.1 in reverse order. After replacing the
wire guides the steps on 4.4.2.1 must be followed for
reinstalling and tensioning the guide wires.
6.5 Information signs and documents
Verify availability and legibility of all data plates and
information signs. Replace missing or illegible plates
and signs!
6.6 Ordering spare parts
Only use original parts.
Spare part lists are available from AVANTI. Please
indicate lift model when requesting a spare part list.
User’s, Maintenance 39
and Installation Manual
Appendix A: Adjustment of the overload limiter
The adjustment of the overload limiter of the service lift shall be carried out only by AVANTI or by qualified
personnel authorised by AVANTI.
For the tests, test weights shall be needed.
One turn of the tool (2) represents a
change of approximately 40 kg of the
triggering limit of the overload limiter.
Hole (3)
Travel
distance (m)
Overload adjustment tool (2)
with security Torx 40
Setup load (1) (kg)
For Dolphin For Dolphin
240
350
From 61 to 80
315
425
From 81 to 100
330
440
From 101 to 120
340
-
From 121 to 140
350
-
WLL of lift (4) (kg)
For Dolphin
240
For Dolphin
350
240
350
The overload limiter complies with EN 1808 8.3.5.5 1)
since it will trigger before reaching a load of 1,25
times the working load limit of the hoist. In case that a
third party inspector requests this test to be done,
the load to be introduced in the cabin is as follows.
Overload test load = WLL hoist x 1,25 – Weight of lift,
counterweight, traction wire rope and power cable
For Dolphin 240 = 440 kg
For Dolphin 350 = 550 kg
The EN1808 test load is only applicable to CE
versions. Not applicable to AECO version.
1)
40 AVANTI Service Lift for Wind Turbines
1. Place the service lift on the lowest travel point without touching the floor
2. Insert the setup load (1) (from the table depending on the WTG height) in the cabin
3. Press and hold the UP button
1. Insert the tool (2) through the hole (3)
2. Turn the tool (3) clockwise to increase the trigger limit of the overload limiter
3. Remove the tool (2) from the hole (3)
1. Insert the tool (2) through the hole (3)
2. Turn the tool (3) anti-clockwise to decrease the trigger limit of the overload limiter
3. Remove the tool (2) from the hole (3)
Can the service lift ascend?
Yes
No
1. Remove 20 kg from the setup load (1)
2. Press and hold the UP button
No
Can the service lift ascend?
Yes
Review the setup load (1)
that has been used
1. Insert the working load limit of the lift (4) in the cabin
2. Press and hold the UP button.
Yes
Does the overload limiter engage during the ascent of the complete tower?
No
1. The overload limiter is correctly set!
2. Fill in the “Appendix: Inspection log sheet”
User’s, Maintenance 41
and Installation Manual
Appendix B: Safety measures
General: Only use service lift if you have received
instructions in operating the service lift in all predictable
situations. These instructions can only be given by a
person 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.
Operating the service lift: Wear your PPE at all times
(safety helmet, full body harness, shock absorber, lanyard and
runner fitting the fall protection system on the ladder).
Rescue of lift from the ladder is only necessary in extreme situations.
If necessary AVANTI recommends the following procedures:
1. Position yourself on the work side of the ladder with
attached runner to the present fall protection system on the
ladder and at the same level as the service lift (see fig. 1).
2. Hook up one of the shock absorbers to the yellow anchor
point which is on the ladder stile.
After safe anchoring to the ladder area, release runner from
the Safety Rail (see fig. 2).
Fig. 1
Fig. 2
42 AVANTI Service Lift for Wind Turbines
3. Climb to the other side of the ladder using the proper
safety technique and open the sliding door.
Note: Hook up the second shock absorber to the external
anchor point (if installed).
Then hook up the other shock absorber to the yellow anchor
point inside the service lift (see fig. 3).
4. Enter the service lift using the proper technique. Once
located in safe area, release shock absorber from outside
the cabin (see fig. 4).
Fig. 3
Fig. 4
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.
Users are obliged to read and understand this User
Manual. Further they need to be proper equipped and
instructed with the use of the necessary fall arrest
equipment and emergency procedures in case of
injury or sudden illness.
Users going to install AVANTI LIFT ANCHOR need to
be familiar with the installation section of this manual.
It’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.
Use in connection with other equipment than
specified, may be potentially dangerous. User shall
be equipped with a means of limiting the maximum
dynamic forces exerted on the user during the arrest
of a fall to a maximum of 6kN. In case of doubt, please
contact AVANTI.
The position of the anchor point is crucial for fall
arrest – the height of the fall, elongation of lanyard and
The maximum load that can be transmitted in service
energy absorber or pendulum movement of the user
from the anchor device to the structure is 22.2 kN in
should be considered in order to minimize the risk of
±15º vertical direction. The maximum deflection of the impact in obstacles in case of a fall. It’s prohibited for
anchor point that can occur in service is 10mm.
the user to do many modifications or use non original
Avanti components when assembling AVANTI LIFT
AVANTI LIFT ANCHOR is tested and approved only
ANCHOR.
to be mounted on AVANTI lifts. This manual always
needs to be represented in language of sale and
Re-use of demounted AVANTI LIFT ANCHORS or
provided for use by all technicians. Activities at height parts is not allowed. Any changes or other uses
are dangerous and may lead to severe injury or even
beyond this manual are strictly forbidden.
death.
Any changes or other uses beyond this manual are
Gaining an adequate apprenticeship in appropriate
strictly forbidden. This documentation must be kept
techniques and methods of protection is important
in the service lift for the purpose of subsequent
and is your own responsibility.
examinations of the anchor device.
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!
If there are any doubts to the safety of the AVANTI
LIFT ANCHOR, or it isn’t proper fixed, deform or
damaged with cracks or similar incompatible harms it
may never be used – Please contact the manufacture
immediately. In case of corrosion the anchor
immediately needs to be removed.
Only to be used for fall arrest, not to
hoist or hang in goods or similar!
Before attaching in the ANCHOR the
user needs to check it is sitting fixed
and screws are sitting tight and proper.
If AVANTI LIFT ANCHOR has arrested
a fall it may never be used again. Part
must be removed from service immediately.
User’s, Maintenance 49
and Installation Manual
E.3 Marking
Marking on Lift Anchor plate:
AVANTI product name
European/American
standard number
Material and Capacity rating
Unique identification number
Item number
After installation, marking shall be completely accessible;
otherwise additional marking near the anchor device will
be necessary.
E.4 Installation
The installation must be performed by a competent
person following the instructions of this manual.
AVANTI LIFT ANCHOR is tested and approved only
to be installed on AVANTI lift. AVANTI LIFT ANCHOR
made from AISI 304 Steel has to be screwed with two
bolts DIN 933 A2-70 M12 mm, 4 washers DIN 125A
A4 and self locking nuts DIN 985 A4 M12. In case of
doubt, please contact AVANTI.
Before installing the AVANTI LIFT ANCHOR in heights,
assure to be proper secured against fall from height by
using relevant fall arrest equipment.
50 AVANTI Service Lift for Wind Turbines
AVANTI LIFT ANCHOR:
1. Fix the anchor point to the structure using
the supplied hardware as shown in the
picture below.
2. Torque the nuts with 15 N·m (11 lb·ft).
3. Make sure the Anchor is fully seated and
properly tightened.
4. Fill in “Installation form”.
5. Carry out yearly inspection by following
the procedure in the section “Inspection”.
E.5 Inspection
After installation:
An inspection must be carried out by a competent
person following the inspection form in this manual.
Before use:
Each time using the AVANTI LIFT ANCHOR the
user inspects the ANCHOR visual and manually by
twisting / pulling. Check the parts are properly fixed
and free of deformities, damages, cracks or similar
unacceptable defects.
Periodical examination:
A periodic examination at least
every 12 month is essential for the safety of the
AVANTI LIFT ANCHOR. The examination must be
performed by a competent person following the
inspection form in this manual.
For the AVANTI LIFT ANCHOR the competent
person (authorized in writing by AVANTI) only needs
to be trained in any metallic component covered
by the European/American standard norms for fall
arrest equipment.
E.6 Inspection form
PPE Anchor:
Manufacturer:
Avanti
Type / Model:
Lift Anchor
Identification no.:
Lift serial no.:
Fixing structure:
Lift model:
Wind farm / WTG no.:
Installed by:
Installation company:
OK
not OK
1. Lift structure does not show any deterioration.
2. Anchor locking screws are fully inserted and tightened with 15 N·m.
3. Anchor does not show cracks, deformities, corrosion or other damages.
4. Anchor installed on the lift structure according to the instructions.
5. Anchor marking is clearly readable.
Is the Anchor in good condition to be used?
Yes
Needs Repair Replace
Signature of competent:
Name of competent in
capital letters:
Date:
If 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 51
and Installation Manual
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
Rønnevangs Allé 6 · DK-3400 Hillerød
P: +45 4824 9024 · F: +45 4824 9124
Germany
Avanti Wind Systems GmbH
Max-Planck-Str. 10 25335 Elmshorn
P: +49 (0) 41 21-7 88 85 – 0 · F: +49 (0) 41 21- 7 88 85-20
Spain
Avanti Wind Systems SL · Poligono Industrial Centrovia
Calle Los Angeles No 88 nave 1 · 50198 La Muela
P: +34 976 149524 · F: +34 976 149508
UK
Avanti Wind Systems Limited
Unit 2, Cunliffe Court Clayton-Le-Moors
Accrington BB5 5JG
P: +44 0 7930 272 270
45540046 – Dolphin Lift manual, EN
5th CE Edition: 4/2015
Revision 3: 5/1/2016
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 Eólicos. S.L.
Rodovia BR-116 · Km21
Fortaleza · Ceará
P: +55 85 9671 6336
I: www.avanti-online.com · E: info@avanti-online.com
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