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

Original instructions
®
AVANTI SERVICE LIFT
User’s, Installation and Maintenance Manual
Model SHARK
Date of publication:
13th CE Edition: July 2015
Revision 2: 22/12/2015
Manufacturer:
AVANTI Wind Systems A/S
Rønnevangs Allé 6
3400 Hillerød Denmark
P: +45 4824 9024
F: +45 4824 9124
E:[email protected]
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 1706 356 442
P: +1 (262) 641-9101
P: +91 95 00 173 492
P: +55 85 9671 6336
Only trained people may use this lift.
This manual must be available to staff at all times during installation and operation.
Additional copies are available from the manufacturer upon request.
All measurements are indicative only and subject to change without notice.
Contents
User’s manual
1. Limited warranty . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. Description of equipment . . . . . . . . . . . . . . . . . . . . .
4.1Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Service lift models . . . . . . . . . . . . . . . . . . . . . . .
4.4Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6Components . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.1 Cabin overview . . . . . . . . . . . . . . . . . . . . .
4.6.2 Cabin with fall arrest device, traction hoist,
power cabinet and pendant control . . . . . . .
4.6.3 Technical data for the service lift M, L and XL
4.6.4 Drive system, fall arrest device and controls .
4.6.5 Drive wire, safety wire, and guide wire . . . . .
4.7 Cabin safety devices . . . . . . . . . . . . . . . . . . . . . .
4.7.1 Electromagnetic motor brake . . . . . . . . . . .
4.7.2 EMERGENCY STOP . . . . . . . . . . . . . . . . .
4.7.3 EMERGENCY STOP fixed (Optional) . . . . . . .
4.7.4 Automatic operation switch . . . . . . . . . . . . .
4.7.5 Overload limiter . . . . . . . . . . . . . . . . . . . .
4.7.6 Fall arrest device . . . . . . . . . . . . . . . . . . . .
4.7.7 Drop down safety beam (Optional) . . . . . . . .
4.7.8 Yellow flash (Optional) . . . . . . . . . . . . . . . .
4.7.9 Emergency light (Optional) . . . . . . . . . . . . .
4.7.10 Door stop switch . . . . . . . . . . . . . . . . . . . .
4.7.10.1 Sliding door: . . . . . . . . . . . . . . . . .
4.7.10.2 Double door: . . . . . . . . . . . . . . . .
4.7.10.3 Half roller door: . . . . . . . . . . . . . . .
4.7.11 Trapped-Key interlock system (Optional): . . .
4.7.12 Limit stop switch . . . . . . . . . . . . . . . . . . . .
4.7.12.1 Top limit stop switch . . . . . . . . . . .
4.7.12.2 EMERGENCY top limit stop switch . .
4.7.12.3 Bottom safety stop . . . . . . . . . . . .
4.7.12.4 Top safety stop (Optional) . . . . . . . .
4.8 Safety devices for fences with door . . . . . . . . . . . .
4.8.1 Guard Locking System . . . . . . . . . . . . . . . . .
4.8.2 Trapped-key Interlock System . . . . . . . . . . . .
5. Daily inspection by the supervisor . . . . . . . . . . . . . .
5.1 Service lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Operating area . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Control functions . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Automatic operation test . . . . . . . . . . . . . . . . . . .
5.5 Remote operation control . . . . . . . . . . . . . . . . . .
5.6 Fall arrest device . . . . . . . . . . . . . . . . . . . . . . . .
5.7 Wires ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.8 Wires ropes after an unusual event . . . . . . . . . . . .
6. Operation - lift transport . . . . . . . . . . . . . . . . . . . . .
6.1 Entry and exit . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Stop/EMERGENCY STOP . . . . . . . . . . . . . . . . . .
6.3 Normal operation . . . . . . . . . . . . . . . . . . . . . . . .
6.4Automatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5 Remote operation . . . . . . . . . . . . . . . . . . . . . . . .
6.6 Overload limiter . . . . . . . . . . . . . . . . . . . . . . . . .
4 AVANTI Service Lift for Wind Turbines
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6.6 Override of the bottom obstruction device . . . . . . . . . . .
7. Manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 EMERGENCY descent . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 Manual ascent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8. Fall arrest device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9. Repair in the event of breakdown . . . . . . . . . . . . . . . . . . .
10. Out of service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11. Removing wires for replacement . . . . . . . . . . . . . . . . . . .
11.1 Parking the service lift . . . . . . . . . . . . . . . . . . . . . . . . .
11.2 Wire ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.3 Removing the lifting wire . . . . . . . . . . . . . . . . . . . . . . .
11.4 Removing the safety wire . . . . . . . . . . . . . . . . . . . . . . .
12.Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.1 Yearly inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.1.1 Traction hoist . . . . . . . . . . . . . . . . . . . . . . . . . .
12.1.2 Fall arrest device . . . . . . . . . . . . . . . . . . . . . . . .
12.1.3 Service lift . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.1.4Suspension/wires/cables . . . . . . . . . . . . . . . . . .
12.1.5 Overload limiter/information signs . . . . . . . . . . . .
12.2Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13. Ordering spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13.1Wire/rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13.2Motor and brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13.3 Electric control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13.4 Fall arrest device . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13.5 Rating plates and information signs . . . . . . . . . . . . . . . .
14. Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation manual
1. Assembling SHARK cabin . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 Part list - Shark L/XL Sliding door . . . . . . . . . . . . . . . .
1.2 Part list - Shark L/XL Double door . . . . . . . . . . . . . . . . .
1.3 Part list - Shark L/XL Half Roller door . . . . . . . . . . . . . .
1.4 Parts list - SHARK M sliding door . . . . . . . . . . . . . . . . .
1.5 Parts list - SHARK M Roller door . . . . . . . . . . . . . . . . . .
2. Fitting of wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Tower top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Wire positioning measurements . . . . . . . . . . . . . . . . . .
2.3 Securing the guide wire - ground level . . . . . . . . . . . . . .
2.3.1 Method 1: Wedge anchor . . . . . . . . . . . . . . . . . . .
2.3.2 Method 2: Tripod . . . . . . . . . . . . . . . . . . . . . . . .
2.3.3 Method 3: Steel beam . . . . . . . . . . . . . . . . . . . . .
2.3.4 Tensioning of the guide wires Ø12 mm . . . . . . . . . .
2.4 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.1 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.2 Supply cable . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.3 Power connection . . . . . . . . . . . . . . . . . . . . . . . .
2.5 Installation of drive and safety wire in lift . . . . . . . . . . . . .
2.6 Securing the drive and safety wire . . . . . . . . . . . . . . . .
2.6.1 Drive wire contra weight . . . . . . . . . . . . . . . . . . . .
2.6.2 Safety wire method 1: Wedge anchor with spring . . .
2.6.3 Safety wire method 2: Push spring . . . . . . . . . . . . .
2.6.4 Safety wire method 3: Steel beam with spring . . . . .
2.7 Wire fix alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8 Adjustment of the safe-zone plates . . . . . . . . . . . . . . . .
2.9 Adjustment of top stop disc . . . . . . . . . . . . . . . . . . . . .
3. Danger zone! sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. Inspection before initial use . . . . . . . . . . . . . . . . . . . . . . . .
Appendix A: Regulation of overload limiter . . . . . . . . . . . . . . .
Appendix B: Safety measures when using AVANTI SHARK lifts .
Appendix C: Inspection checklist . . . . . . . . . . . . . . . . . . . . . .
Appendix D: Inspection log sheet . . . . . . . . . . . . . . . . . . . . . .
Appendix E: Avanti Lift Anchor . . . . . . . . . . . . . . . . . . . . . . . .
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5
User’s Manual
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)
6
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 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
!
Order
Reference to written
specification/documentation
User’s Manual
7
3. Cautions
Installation and/or maintenance and/or operation of
the service lift and its suspension may be performed
only by qualified personnel, hired by the employer for
the job at hand.
The personnel must be at least 18 years of age.
The staff must be familiar with the relevant accident
prevention instructions and must have received
proper training in these.
Personnel are obliged to read and understand this
User’s Manual.
Personnel shall wear PPE (safety helmet, full body
harness, shock absorber, lanyard and slider) at all
times.
No modification, extension or reconstruction of the
service lift is allowed without the manufacturer’s prior
written consent.
No warranty is provided against damage resulting
from reconstruction or modification of equipment or
use of non-original parts which are not approved by
the manufacturer.
Before using the lift an inspection by the authorized
inspection organisation must be carried out.
Service lift must be inspected at least once a year by
an expert trained by AVANTI. In case of high operating frequency or severe conditions of use, more
frequent inspection is required.
A copy of the User’s Manual must be handed out
to the personnel and must always be available for
reference.
Service lift is designed for a lifetime of 20 years with
an operating frequency of approximately 12.5 h/year
(250 h in total).
If more than one person is entrusted with one of
the above tasks, the employer shall appoint a
supervisor in charge of the operation.
Service lift may not be used by persons who are
under the influence of alcohol or drugs which may
jeopardize working safety.
Electrical connection of the system must be made
in accordance with EN 60204-1.
Service lift shall ONLY be used when the turbine is
not generating power.
Self-locking nuts must be used at all times. The
screw must extend from the nut by at least half
of the thread diameter. The nut may not be used
once it has become possible to loosen by hand!
If any damage or faults are found during operation,
or if circumstances arise which may jeopardize
safety: immediately interrupt the work in progress
and notify the supervisor or employer!
All wind farm site specific rules must be followed.
Service lift shall not be used during inclement
weather, including wind speeds over 18 m/s. All tests/repairs of electrical installations may only
be performed by qualified electricians.
All repairs to the traction, braking and supporting
systems may only be performed by qualified installers.
If any supporting parts are repaired or replaced,
the operational safety of the system must be tested
and verified by an expert.
Only original fault-free parts may be used.
Use of non-original parts will render the manufacturer’s warranty void and any type approval invalid.
8
AVANTI Service Lift for Wind Turbines
Avoid injury – follow all instructions!
The tower owner must verify the need for third party service lift inspections with the local authority and comply with the standards specified.
4. Description of equipment
4.1 Purpose
4.3 Service lift models
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 User’s Manual and Installation Manual
describe the following models:
Its use is limited to authorized personnel by
AVANTI holding the relevant training certificates.
The access to the WTG and consequently to the
service lift is controlled and forbidden to public
access.
The service lift is used primarily to transport
technicians, their tools and spare parts from the
bottom platform (or lowest accessible point) to the
top platform (or highest accessible point).
It is also used to access intermediate platforms
where inspection and service of WTG connecting
bolts and other equipment is made.
4.2 Function
The service lift uses a traction hoist for ascending
and descending on a wire secured to the building.
A fall arrest device secures the service lift to a
separate safety wire.
Upward and downward travel is controlled from
inside the service lift in manual mode, from the
remote control transmitter in remote mode
(optional), or from the outside in the automatic
mode (optional).
An overload limiter prevents upward travel in the
event of an overload of the traction hoist.
Two guide wires on either side of the service lift
prevent the lift from swivelling/tilting.
•SHARK M sliding door and roller door
with 240 kg lifting capacity
•SHARK L sliding door, double door, 4-door and
half-roller door with 240/320 kg lifting capacity
•SHARK XL sliding door and double door
with 320 kg lifting capacity.
4.4 Temperature
Operating temperature
-15ºC - +60ºC.
Survival temperature
-25ºC - +80ºC.
Low temperature kit is also available.
Operational temperature for low temperature kit
-25ºC - +40ºC.
4.5 Accessories
In order to fulfil the essential health and safety
requirements from the regulations the design of
the wind turbine and its components shall complement the safety systems supplied on the service
lift making the ensemble safe as a whole.
A detailed evaluation of compliance to the EHSR
and a risk assessment shall be completed. Avanti
shall verify the compliance to such requirements
prior to installation. Systems that may be considered to complement the service lifts are:
4.5.1 Fences & guards
The service lift hole must be adequately protected
to prevent people from falling or being injured by
the movement of the service lift. The fences and
guards design shall comply with the relevant
standards and local regulations.
4.5.2 Safety system for landing access doors
The service lift hole must be adequately protected
to prevent risk of falling. When the service lift is not
at the landing, access doors shall not be able to
open. Such function may be achieved by using
interlock systems on access doors linked to the
position of the service lift.
User’s Manual
9
4.6 Components
4.6.1 Cabin overview
Fig. 1a SHARK L sliding door
Fig. 1b SHARK L double door
3
1Cabin
2 Sliding door
3 Drive and safety wires
4 Guide wire
5 Wire guides
6 Bottom safety stop
10 AVANTI Service Lift for Wind Turbines
3
2
1
1
2
4
4
5
5
6
6
1Cabin
2 Double door
3 Drive and safety wires
4 Guide wire
5 Wire guides
6 Bottom safety stop
7
6
5
4
F
C
Fig. 1c SHARK L 4-door version
Fig. 1d SHARK M sliding door
3
3
2
2
1
1
4
4
5
5
6
1Cabin
2 4 door
3 Drive and safety wires
4 Guide wire
5 Wire guides
6 Bottom safety stop
6
1Cabin
2 Sliding door
3 Drive and safety wires
4 Guide wire
5 Wire guides
6 Bottom safety stop
D
User’s Manual 11
Fig. 1e SHARK L Half roller door
Fig. 1f SHARK M Roller door
3
1
2
2
1
4
5
6
3
1 Cabin
2 Roller door
3 Drive and safety wires
4 Guide Wire
5Wire guides
6 Bottom safety stop
12 AVANTI Service Lift for Wind Turbines
1
2
3
Cabin
Roller door
Bottom safety stop
4.6.2 Cabin with fall arrest device, traction hoist, electrical control box and
pendant control
Fig. 2
2
3
4
5
12
6
8
7
10
9
13
14
1
11
1
2
3
4
5
6
Cabin
Traction hoist
Electrical control box
Anchor point
Fall arrest device
Cable connection (behind the lift)
7EMERGENCY STOP button fixed
(Inside cabin optional)
8 Pendant control
9Override automatic operation switch (Inside cabin optional)
10 Door stop switch
11 Bottom safety stop
12Shackle
13 Operation limit stop switch
14 EMERGENCY limit stop switch
User’s Manual 13
4.6.3 Technical data for the service lift M, L and XL
Fig. 3a Dimensions, sliding door
Shark M lifting capacity:
•Motor X402P 240 kg
•Motor M500/M508 240 kg
(max 1 person)
H
Shark L lifting capacity:
•Motor X402P 240 kg
•Motor M500/M508 240 kg
(max 2 person)
•Motor L502P 320 kg
•Motor M500/M508 320 kg
(max 2 person)
Shark XL lifting capacity:
•Motor X402P 240 kg
•Motor M500/M508 240 kg
(max 2 person)
•Motor L502P 320 kg
•Motor M500/M508 320 kg
(max 3 person)
Weight of lift:
M:
kg 90
L:
kg 110
XL:
kg 120
F
The weight of the power
supply cable should be
added to the weight of the lift
(approx. 0.23 kg per m).
B
A
Standing height:
Under spine: 1980 mm
Under traction hoist: 2100 mm
D
C
Sliding door opening:
M:
500 mm
L - XL: 550 mm
E
N
G
Noise level emitted: max. 75 dB(A).
Dimensions in mm:
Shark
A
B
C
D
E
F
G1)
N
H
M
380
600
600
650
400
75
790/660
630
3000
L
380
960
600
650
475
75
1150/1020
990
3000
XL
480
960
800
850
475
75
1150/1020
990
3000
1) Standard wire guide/narrow wire guide. (Details p. 52)
14 AVANTI Service Lift for Wind Turbines
Fig. 3b Dimensions, double door
Lifting capacity:
•Motor X402P 240 kg
• Motor M500/M508 240 kg
(max 2 persons)
• Motor L502P 320 kg
•Motor M500/M508 320 kg
(max 3 persons)
M
Weight of lift:
L:
kg 115
XL:
kg 125
The weight of the power
supply cable should be added
to the weight of the lift
(approx. 0.23 kg per m).
Fence
Standing height:
Under spine: 1980 mm
Under
traction hoist: 2100 mm
B
A
D
C
E
N
G
Dimensions in mm:
Shark
A
B
C
D
E
G1)
M
N
L
380
960
600
650
475
1150/1020
1900
990
1) Standard wire guide/narrow wire guide. (Details p. 52)
User’s Manual 15
4.6.4 Drive system, fall arrest device and controls
Fig. 5 Fall arrest device
BSO
OSL500/ASL508
Fig. 4 Traction hoist
M500/M508
Tirak
1
1
2
2
3
3
4
4
5
5
9
7 6
7 6
8
Fig. 6 Electrical control box
For M500/M508
For Tirak
12
11
5
6
Fig. 7 a
Pendant control
12
11
10
Fig. 7 b
Remote control
13
14
1Insertion point for
brake lever
2Motor
3Wire traction
w/overload
protection
4Drive system/
gearbox
5Control handle/
brake lever
6Fall arrest device
stop button
7Connection cable
8Window
9Wire
10
Overide bottom
limit stop switch
11 Ready lamp
12HAND/AUTOM
13EMERGENCY
STOP button
14UP
15DOWN
15
10
Table 1. Traction hoist
Traction
Unit weight Measures/dimensions
hoist wire Ø
approx.
a
b
c
Lifting
capacity
Wire speed
Effect
Rated
current
Traction hoist type
Kg
m/min
kW
A
mm
Kg
mm
mm
mm
X402P/400V
400
18
1.5
3.5
8.3
35
485
250
250
X402P/690V
400
18
1.5
2.0
8.3
35
485
250
250
L502P/400V
500
18
1.5
3.5
8.3
35
485
250
250
L502P/690V
500
18
1.5
2.0
8.3
35
485
250
250
M500-M508/400V
500
18
1.5
4.5
8.3
39
447
244
279
M500-M508/690V
500
18
1.5
3
8.3
39
447
244
279
Hoist
Table 2. Fall arrest device
Fall arrest device
Fall arrest type
BSO 504 E
BSO 1004 E
1)
OSL500/ASL508
1)
Lifting capacity
To max. wire
speed
Traction hoist
wire Ø
Unit weight
approx.
kg
m/min
mm
400
18
500
500
Measures/dimensions
a
b
c
kg
mm
mm
mm
8.3
4.7
214
121
131
18
8.3
4.7
251
140
131
18
8.3
7
269
176
101
Motor L502P must be installed with BSO 1004 E
Table 3. Drive wire, safety wire and guide wire
Wire type
X402P / BSO504 E
L502P / BSO1004 E
Guide Wire
M500 / OSL500/
ASL508
Wire
diameter
8mm, 4x26
or 5x19
12mm
8.3mm, 5x19
Surface
treatment
galvanised
galvanised
galvanised
16 AVANTI Service Lift for Wind Turbines
Mark/
feature
1 red string
/ cord
Min. break
resistance
-
55 kN
Shackle,2t
51.5 kN
2 t shackle,
Form C
none
55 kN
Attached
with
2 t shackle,
Form C
Anchoring
Tighten
to
-
-
Min. every
35m
2 to 4 kN
-
-
4.7Cabin safety devices
4.7.1Electromagnetic motor brake
Electromagnetic spring-loaded brake which
engages automatically
–on releasing the up/down push button and
– following a power failure.
4.7.2 EMERGENCY STOP
When the red EMERGENCY STOP (pendant
control) switch is pushed in an emergency, all
control is interrupted. After remedying the fault,
control is reactivated by turning the switch clockwise, until it pops out again.
b) Hoist failures.
The fall arrest device can also be engaged manually in an emergency by pressing the Emergency
stop button. The window is used to monitor the
function of the centrifugal force mechanism during
operation.
Fig. 9
Fig. 8
Emergency stop
Fall arrest device
BSO
OSL500/ASL508 and bottom stop
switch
Fixed
Emergency
stop button
4.7.3EMERGENCY STOP fixed (optional)
Only in service lifts with an AUTOMATIC function
installed. A backup switch to the pendant control
EMERGENCY STOP switch is situated on one of
the side panels inside the lift (Fig. 9).
4.7.4Automatic operation switch
A switch situated inside the pendant control
holder. It prevents the lift from being controlled
from the inside when the control is in automatic
mode.
4.7.5 Overload limiter
The overload limiter is built into the wire traction
system and will prevent upward travel in the event
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 service lift is overloaded or
- the service lift encounters an obstacle during
upward travel.
Operator intervention:
-R
educe 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.
Automatic
operation
switch
Window
Stop
button
ON/Locked
OFF/Open
4.7.7 Drop-down safety beam (optional)
This device can be installed in sliding door lifts. It
provides protection against accidental falls when
the door is opened during work between platforms. The beam remains in closed position by
means of a latch. The beam is opened by actuating the latch and lifting the beam up slightly (Fig.
9c).
See 4.6.10.1 Guard locking switch for information
on how to open the sliding door between platforms.
Fig. 9a
Fig. 9b
Fig. 9c
4.7.6 Fall arrest device
Service lifts for personnel transportation must be
equipped with a fall arrest device which will
prevent the load from falling.
Fall arrest device type BSO + OSL + ASL
The fall arrest devices BSO + OSL + ASL are
opened manually (Fig. 8).
The speed of the safety wire
passing through the device is continuously
monitored, and the jaws automatically close in the
event of sudden excessive speed.
This protects the lift from
a) Traction wire rope breaks and
4.7.8 Yellow flash (optional)
An optional set of flashes can be mounted on the
top and at the base of the lift. The flashes indicate
when the lift is in movement (Fig 9a).
4.7.9 Emergency light (optional)
An emergency light can be installed to provide
illumination inside the lift with and without electric
supply.
User’s Manual 17
The operation modes can be selected
by means of a switch (Fig. 9b).
4.7.10 Door stop switch
4.7.10.1 Sliding door:
The sliding door is closed by pushing the actuator into
the door guard locking switch (Fig. 15). The switch is
unlocked by pushing the green button if the cabin is
located at a height corresponding to a platform. In
case of an emergency evacuation between platforms,
the interlock is unlocked by pushing its emergency
release red button from outside the cabin as well as
using an M5 triangular key from inside the cabin.
4.7.10.2 Double door:
A switch (Fig. 12) will interrupt control if the door is not
closed properly.
4.7.10.3 Half roller door:
A switch will interrupt control if the door is not closed
properly.
4.7.11 Trapped-key interlock system (optional):
Control is interrupted by turning the trapped-key
switch to OFF. The key can then be removed. The key
allows the user to open the platform fence doors. See
the Trapped-Key Interlock System Manual for further
information.
Fig. 15
1 Green push button
1
2 Emergency release red push button
3 Emergency release M5 triangular key
3
2
4.7.12 Limit stop switch
4.7.12.1 Top limit stop switch
At the top of the cabin frame a top limit stop switch will
stop upward travel when activated (Fig. 10). Downward travel will still be possible. A top stop disc which
activates the top stop switch is installed below the
traction wire attachment (Fig. 5 section 2 of the
installation manual ).
!
ATTENTION!
When the top limit stop switch is engaged,
activate the DOWN switch until the top limit
stop switch is released.
4.7.12.3 Bottom safety stop
The bottom safety stop switch (Fig. 11a or Fig. 11b
which shows an optional configuration) stops downward travel if the service lift
encounters an obstacle or touches the ground.
Upward travel will be possible, for instance to remove
the obstacle. In order to put the service lift on the
ground, the contact plate’s operation can be bypassed with the key switch in the control box.
4.7.12.4 Top safety stop (optional)
The top safety stop switch stops upward travel if the
lift:
- Type 1: encounters an obstacle (fig. 13).
- Type 2: the switch also works as a top limit stop
switch. A top stop end bar is installed bellow the
guiding wire attachment and activates the top safety
stop. In this case the top stop end bar replaces the top
stop disc (Fig. 14).
Downward travel will be possible, for example, to
remove the obstacle.
4.8 Safety devices for fences with
doors
Safety devices for fences include devices to prevent
people from accessing the service lift area, unless the
service lift is safe to be accessed. The device also
guarantees that the service lift does not when the
protective fence doors are open. There are two types
of safety devices for fences:
4.8.1 Guard Locking System
The Guard Locking System uses a system of security
locking switches installed on the fences. Another
position switch detects the correct position of the
service lift on the protected platform. The service lift
cannot operate until all the protected fences are
closed and locked.
Main Switch Disconnector
Ready Lamp
WARNING!
4.7.12.2 EMERGENCY top limit stop switch
Deactivates control if the top limit stop switch fails
(Fig. 10). Manual downward travel is possible.
18 AVANTI Service Lift for Wind Turbines
OFF
Switch ON only when the wind turbine generator has been
stopped.
Switch OFF before start up of the wind turbine generator.
Conectar: Sólo con turbina parada.
Desconectar: Antes del arranque de turbina.
45741006
CAUTION!
Do not use the service lift until the top limit stop switch fault has been rectified.
ON
45741006 Control box U5 UL ENES.indd 1
2/16/2012 9:49:26 AM
The fences remain closed and locked until the service
lift is stopped and properly positioned on the platform,
actuating the position switch of the platform. In this
position, the guard locking can be unlocked while
pressing the green light button.
Locking
switch
The interlock 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.
Consult the AVANTI Guard Locking System Manual
for further information.
4.8.2 Trapped-key Interlock System
The Trapped-key Interlock System uses a system of
security locks installed on the fences. These locks can
be opened by using a key placed into the lift.
The key also activates the On/Off general switch
placed into the service lift cabin. The key is linked to
the lift by means of a wire rope, and cannot be
detached from it except using cutting tools.
The key cannot be taken out from the On/Off general
switch in the lift, unless it is in Off position, and
therefore, the lift is stopped. In the same way, the key
cannot be taken out from the fence lock unless the
fence door is closed, and the door actuator is put into
the door lock.
The fences remain closed and locked until the service
lift is stopped on the platform, and the key is transferred from the lift cabin to the fence lock.
Consult the AVANTI Trapped-key Interlock System
Manual for further information.
Key
Green Light
access button
Fence latch
with actuator
Position switch
Fig. 10
Stop switch,
normal
operation
Emergency
stop switch
Fig. 11a
Bottom safety stop
Fig. 11b
Fig. 12
EMERGENCY
STOP button
Security lock on fence
Door limit stop switch
(In door frame)
Fig. 13
Actuator
Trapped-key switch
Fig. 14
User’s Manual 19
5. Daily inspection by the supervisor
If a safety device for fence doors is installed (see
chapter 4.7 of the User’s manual), every platform
fence door must be closed to be able to drive the
cabin.
5.1 Service lift
a)Before each operation, ensure that the traction
hoist, the Fall arrest device and all auxiliary
components (stoppers, wire guide wheels, etc.)
are mounted in accordance with the specifications
and without any noticeable defects.
b)Check whether the drive, and safety wires are fed
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
in at least 3 places.
d)Check lifting capacity: (see the rating plate or
section 4.5.3) – the extra load (persons and
materials!) must not exceed the maximum rated
lifting capacity.
5.2 Operating area
a)Ensure that there are no obstacles within the
service lift’s operating area which may obstruct
the travel of the cabin or cause the cabin to 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 from falling objects.
5.3 Control function
a)Close the doors. Press the EMERGENCY STOP
button. The lift should remain still when the UP/
DOWN button is pressed. To restart, turn the
EMERGENCY STOP button clockwise. If a FIXED
EMERGENCY STOP button is installed (Fig. 9)
test as above.
b)Test the top limit stop switch:
During upward travel, press the switch manually,
and the service lift should stop immediately.
Pressing the limit stop switch should enable the lift
to travel down again.
c)Test the EMERGENCY top limit stop switch:
During upward travel, press the switch manually,
and the service lift should stop immediately.
Neither upward nor downward travel should now
be possible.
d)Bottom safety stop. Lower the lift;
it should stop before the rubber feet of the cabin
20 AVANTI Service Lift for Wind Turbines
reach the tower ground level. When the “bypass
switch” is activated, it should be possible to lower
the lift all the way to the ground.
e)Door stop switch:
Open the door - it should not be possible to move
the lift upwards or downwards.
Sliding door service lift: Move the cabin at a height no corresponding to a platform - it should not be possible to open the door. The door will be only able to be opened by pushing the emergency release red button from outside the cabin as well as using a M5 triangular key from inside the cabin.
f)If the optional AUTOMATIC function is installed.
Set the HAND/AUTOM. selector to AUTOM. When
holding the handle, the lift should remain still when
the UP or DOWN buttons are activated.
g)
If the Trapped-Key interlock system is installed.
Turn the trapped-key switch to OFF - it should be not possible to move the lift upwards or downwards. See the Trapped-Key Interlock System Manual for further information.
!
Warning! If any faults occur during work,
- stop working,
- if required secure the workplace and
- rectify the fault!
DANGER!
Make sure that nobody is exposed to danger below the service lift, for instance from falling parts. Suitable measures: Pent roof or barriers.
Fig. 13
STOP
Electrical control box
Tirak
M500 / M508
HAND/
AUTOM.
(Optional)
Ready lamp
“ON”
Override
bottom
safety stop
Pendant control
EMERGENCY STOP
UP
DOWN
5.4 Automatic operation test
Perform this inspection only if the AUTOMATIC
function is installed.
a)Press EMERGENCY STOP button on the
pendant control. Turn the HAND/AUTOM.
switch on the electrical control box to the right
to activate automatic operation.
b)Deactivate the EMERGENCY STOP button by
turning the button clockwise. (Check the
EMERGENCY STOP button fixed is deactivated.) The service lift should stand still.
c)DO NOT try to activate the “automatic operation” switch.
d) If the trapped-Key interlock system is installed, turn the trapped-key switch to ON. With the doors closed, press the UP and DOWN buttons. Neither upward nor downward
travel should be possible (Switch in pendant
control holder blocks the operation).
e)Press the EMERGENCY STOP button on the
pendant control.
f)Place the pendant control in its holder so it is
operational from the outside.
g)Leave the cabin and close the door.
h)Deactivate the EMERGENCY STOP button.
The service lift should stand still.
i)Press the UP button. The lift should travel
upwards.
j)Press the EMERGENCY STOP button. The lift
stops.
k)Turn the EMERGENCY STOP button clockwise
and press the DOWN button. The service lift
should travel downwards until the EMERGENCY STOP bottom stops the service lift.
Fig. 13b
Emergency
stop button
Automatic
operation
switch
l)Remove the pendant control from holder.
m)Return the HAND/AUTOM. button to HAND.
n)Check that the UP and DOWN buttons work
again.
5.5 Remote operation test
Perform this inspection only if the remote control
function is installed.
a)Set the electrical control box switch HAND/
AUTOM to AUTOM (fig 7 a).
b)On top of the remote operation receiver switch
the device on (fig 7 b).
c)Press the up arrow on the remote operation
transmitter. The service lift should ascend.
d)Press the down arrow on the remote operation
transmitter. The service lift should descend.
e)Once the test is complete, switch the remote
operation function off.
5.6 Fall arrest device
a)Engage the Fall arrest device by pressing
the fall arrest device stop button - the handle
should jump to the “ON” position (Fig. 8
section 4.7).
b)Reopen the fall arrest device 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 Wire ropes
a) Follow the 3 steps below to check that the
traction and safety wire ropes are not tangled with
tower internals.
a.1) Open the top hatch and look upwards in
search of any unusual trajectory deviation of the
traction and safety wire ropes.
a.2) Close the top hatch and ascend with the
service lift to the following platform.
a.3) Repeat steps a.1) and a.2) until the complete
length of the wire ropes is inspected.
a.4) If any wire rope is found tangled, climb up the
ladder and untangle the wire rope by hand. Then,
inform AVANTI.
b) During operation, check that the traction and
safety wire ropes pass freely through the traction
hoist and the fall arrest device.
User’s Manual 21
c) Once the lift is at the top platform, inspect the top
tower beam and the wire rope attachments.
d) Check that the length (L) between the top end of
each wire rope and its ferrule is equal to or more than
0 mm.

L ≥ 0 mm
Thimble
Ferrule
X
5.8 Wire ropes after an unusual event
STOP
After any unusual event (such as a tower
jerk due to the wind turbine going into
emergency mode) check that the traction
and safety wire ropes have not got tangled
with tower internals.
5.8.1 At the bottom platform
If the service lift is placed at the bottom platform
when the unusual event occurs, follow the steps
below.
a.1) Open the top hatch and look upwards in search
of any unusual trajectory deviation of the traction and
safety wire ropes.
a.2) Close the top hatch and ascend with the service
lift to the following platform.
a.3) Repeat steps a.1) and a.2) until the complete
length of the wire ropes is inspected.
a.4) If any wire rope is found tangled, climb up the
ladder and untangle the wire rope by hand. Then,
inform AVANTI.
22 AVANTI Service Lift for Wind Turbines
5.8.2 At the top platform
If the service lift is at the top platform when the
unusual event occurs, follow the steps below.
a) From the platform look downwards through the
platform hole in search of any unusual trajectory
deviation of the traction and the safety wire ropes.
b) Enter the lift and descend to the following platform.
c) Exit the lift and repeat steps a) and b) until the
complete length of the wire ropes is inspected.
e) If any wire rope is found tangled, climb down the
ladder and untangle the wire rope by hand. Then,
contact AVANTI.
6. Operation - lift transport
If a safety device for fence doors is installed (see chapter 4.7 of the User’s manual), every platform fence
door must be closed to be able to operate the cabin.
Transportation of people in AUTOM. mode is
forbidden.
6.1 Entry and exit
To ensure safe entry and exit:
a)Lower the service lift onto the access platform 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 UP/DOWN push button; the service lift
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
6.3.1 Without trapped key system
If the trapped key system is not provided, follow the
steps below.
d) Close the platform and lift doors.
e) Turn the emergency stop button of the pendant
control clockwise until it pops out.
f) Do likewise with the emergency stop button fixed in
the cabin (Fig. 9).
g) Press and hold the UP or DOWN button to ascend
or descend respectively.
6.4 Automatic operation
Only in service lifts with the AUTOMATIC function
installed.
a) If the trapped-key interlock system is installed, the
trapped-key switch should be ON in order to drive the
lift.
b) Press the EMERGENCY STOP switch on the
pendant control.
Turn the HAN/AUTOM switch on the power cabinet to
activate the automatic operation.
c) Put the pendant control inside the holder. It should
engage the automatic operation switch (fig.13b).
d)Close the door
e) Turn the EMERGENCY STOP switch on the pendant
control clockwise and the switch should pop out.
a) Close the platform and lift doors.
f) Press the UP or DOWN button respectively and the
cabin starts ascending/descending.
b) Turn the emergency stop button of the pendant
control clockwise until it pops out.
6.5 Remote operation
c) Do likewise with the emergency stop button fixed in
the cabin (Fig. 9).
d) Press and hold the UP or DOWN button to ascend
or descend respectively.
6.3.2 With trapped key system
If the trapped key system is provided, follow the steps
below.
a) Extract the trapped key from key hole of the
platform fence.
a)Set the electrical control box switch to AUTOM
(fig.6).
b)On top of the remote operation receiver switch the
device on (fig.7b).
c)For ascending press the up arrow on remote
operation transmitter.
d)For descending press the down arrow on remote
operation transmitter.
e)Once the operation is complete, switch the remote
operation function off.
b) Insert the trapped key in the key hole of the cabin
control box.
c) Turn the trapped key to ON position.
User’s Manual 23
6.6 Overload limiter
a)In case of an overload, the lift’s upward travel
should be blocked, and a buzzer should sound in
the connection cabinet.
STOP
DANGER!
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 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.
If the problem persists have an AVANTI expert adjust
the overload limiter (Appendix A).
6.7 Override of the bottom obstruction
device
For maintenance tasks only, it is possible to override
the bottom obstruction device by means of a key on
the cabin control box.
a) Descend the service lift until the the bottom
obstruction device reaches the floor.
b) Turn the override key of the cabin control box (fig. 6
section 4.6.4) clockwise and hold.
c) Press and hold the DOWN button until the service
lift feet rest on the floor.
24 AVANTI Service Lift for Wind Turbines
7. Manual operation (EMERGENCY)
If a power failure or an operation fault etc. interrupts
the lift, a manual EMERGENCY descent is possible.
Fig. 14a Tirak
1
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 lever into the break
lever hole in front of the traction hoist (Fig. 14 [1]).
c)Pull the lever upwards. The service lift moves
downwards. The built-in centrifugal force brake
limits the pace of descent.
d) To stop, simply loosen the leaver.
e)After use, replace the lever in roof hole.
Fig. 14b M500 / M508
For emergency situation only
2
1
7.2 Manual ascent for Tirak only
It is not possible for the M500 / M508 to manually ascend.
With the brake open, the service lift 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 anticlockwise with the brake [1] open.
c)After use, retract the hand wheel and lever from
the traction hoist and replace them in the roof
holes. Replace the rubber cap.
User’s Manual 25
8. Fall arrest device
If the fall arrest device engages simply disengage
by pushing the lever down (Fig. 16A) until it clicks.
However, this is not possible if the service lift is
hanging on the wire - if so, see below.
STOP
Fig. 16
BSO
Safety
wire
DANGER!
In the event of breakages in the wire
ropes or failure of the service lift,
evacuate personnel from the service lift.
The safety wire suspension and the attachment
between the fall arrest device and the service lift
are exposed to dynamic loads when a fall is
blocked.
If the fall arrest device has locked and the
service lift is hanging on the wire, ascending is
blocked. Do as follows:
a)Remove the load on the safety wire by taking
the service lift upwards a few centimetres by
pushing the UP button.
– In the event of a power failure, evacuate the
lift.
b)Manually open the fall arrest device by pressing
the lever down (Fig. 16A) until the device
disengages. On ground level perform test as
specified in section 5. e) of the Installation
Manual section and 5.6 of the User’s Manual
before resuming normal operation.
26 AVANTI Service Lift for Wind Turbines
OSL500 / ASL508
A
!
ATTENTION!
When the service lift has returned to
ground level, test the fall arrest device
function
CAUTION!
eplace any defective fall arrest device
R
components and return them for repair
to the manufacturer.
CAUTION!
In case of no power and the fall
arrest device is locked with the
safety wire rope under tension,
evacuate the service lift according
to the evacuation procedure.
LOCK
9. Repair in the event of breakdown
1.All tests and repairs to the electronic components should be performed by an authorised
electrician only! The power chart is placed
in the traction hoist’s 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
fitters only!
Cause
STOP
DANGER!
Attempting to use the lift will jeopardize work safety
A1The fixed EMERGENCY STOP
button is activated.
Turn this button clockwise until it moves
out to deactivate it.
A2Wire loop on traction hoist.
Damaged or defective wire or wire
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) Traction wire rope breakage
b) Hoist failure
A4The service lift is stuck on an
obstacle.
DANGER!
Unplug the power
supply before
opening the power
cabinet.
Solution
A5Power failure
a) The control is not set to ON.
b)Grid voltage interrupted
c)Supply between grid connection and
control interrupted
A6Limit stop switch functions
a)EMERGENCY limit stop switch is
pressed.
b)Door limit stop switch is
blocked or is defective.
A7Protection switch on
overheating
a) A phase is missing
b) Motor is not cooling
c) Voltage too high/low
a) + b)Evacuate the service lift and
follow the directions in section 8
Carefully remove the obstacle.
Test the operational safety of affected
building sections. Inform the supervisor.
a)Turn EMERGENCY STOP switch
clockwise until it is released
b) Find the cause and wait for the power
to return
c)Test and if necessary repair the supply
cable, guide wires, fuses, and/or wiring
from the control box
a)Manually take the lift down 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
does not obey the 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.
a)Have an electrician test, repair/replace
the supply, braking coil and rectifier.
b) Return the traction hoist to the
manufacturer for repair.
User’s Manual 27
Breakdown
The service lift will
neither go up
nor down
Service lift goes
down but not up
DANGER!
Unplug the power
supply before
opening the power
cabinet.
Motor hums
loudly or wire
ropes squeak,
Cause
Solution
A8The HAND/AUTOM.
switch is on AUTOM.
Turn the HAND/AUTOM. switch back
to HAND.
A9 The Trapped-key Interlock
System for fences is installed.
The Cabin switch of the system is in
Off position.
Turn On the trapped-key switch.
Consult the AVANTI Trapped-key Interlock
System Manual for further information.
A10 The Guard Locking System
for fences is installed. The
general On/Off switch of the Guard
Locking System Control Box at the
bottom platform is Off.
Turn On the general On/Off switch of the
Guard Locking System Control Box at the
bottom platform. Consult the AVANTI Guard
Locking System Manual for further information.
A11 The Guard Locking System
for fences is installed. At least
one of the protected fences is open.
Close all the protected fence doors. Consult
the AVANTI Guard Locking System Manual
for further information.
DANGER!
STOP Irresponsible behaviour
jeopardizes system
safety!
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.
B2 Overload - Buzzer sounds
in the connection cabinet.
Test and possibly reduce load until
buzzer stops.
B3Limit stop UP:
a)Limit stop defective or not
connected.
b)Operation limit stop was
activated.
a)Test the limit stop connection/function.
Replace if necessary.
b)Move lift down until the limit stop switch
is released.
B4A phase is missing
Test fuses and power supply.
B5Fault in UP control circuit
in control box or traction hoist
Test and possibly repair connections,
wiring and relays.
C1Overheating
For descriptions of individual causes and
how to rectify faults
!
C2Wire ropes dirty
but the lift can
go both up and
down.
WARNING!
Further use of lift may
result in damage to the
wire traction.
28 AVANTI Service Lift for Wind Turbines
If possible, immediately replace
the traction hoist and return it for
test/repair at AVANTI.
Breakdown
Cause
Service lift will
go up but not
down!
Solution
DANGER!
STOP
Irresponsible
behaviour
jeopardizes system
safety!
D1The service lift has
encountered or is stuck
on an obstacle.
Carefully take the service lift up and
remove the obstacle.
Test the operational safety of affected
platform components.
Inform the supervisor.
D2The fall arrest device
is holding the
service lift on the wire.
a) Excessive hoist speed
b)Too low release speed on
fall arrest device.
a) + b)Take the service lift upwards to
relieve the safety wire.
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!
DANGER!
D3Fault in down controller circuit
on traction hoist
Pull the lever upwards.
The service lift moves
downwards.
(See details in section 7)
Test, and if necessary
have connections,
wiring, and relays
repaired.
Green lamp
not lit although
operation is
normal
E The lamp is defective
Have an electrician replace the bulb.
Hoist goes down
when up button is
pressed and up
when down button
is pressed.
F Two phases changed
in the supply
Have an electrician switch the two
phases in the plug
Unplug the power
supply before
opening the power
cabinet.
If these steps do not identify the cause and rectify the fault:
Consult a qualified electrician or contact the manufacturer.
User’s Manual 29
10. Out of service
WARNING!
a) Securing the service lift:
Bring the service lift all the way down, until the
contact plate switch stops the cabin.
ON
OFF
b) Disconnect the lift to prevent
inadvertent operation:
Mark the lift “OUT OF SERVICE” and padlock as necessary.
Contact the service technician for repair.
Switch ON only when the wind turbine generator has been
stopped.
Switch OFF before start up of the wind turbine generator.
45741006
Conectar: Sólo con turbina parada.
Desconectar: Antes del arranque de turbina.
45741006 Control box U5 UL ENES.indd 1
2/16/2012 9:49:26 AM
11. Removing wires for replacement
CAUTION!
Wear protective gloves when handling
wires.
11.1 Parking the service lift
Lower the lift until bottom safety stop engages.
11.2 Wire ends
Beneath the access platform:
a)Loosen and uncoil all coiled and secured wire
ends.
b)Remove the weight and the tightening spring.
11.3 Removing the lifting wire
a)Turn the “override bottom limit stop switch” key
to the right and push the DOWN button until
the cabin rests on the platform.
b)After having removed the drive wire counter
weight turn the DOWN button. The wire now
exits the traction hoist at the top.
c)From above the traction hoist remove the wire
by hand.
11.4 Removing the safety wire
a)Keep the fall arrest device open and manually
pull out the wire.
b)Pull out the wire on top of the lift.
12. Maintenance
Time (Performance)
Component
Daily:
(Supervisor)
Attachment components
traction hoist
Control box
Fall arrest device
Annually:
(Expert)
Wires
Electrical cable
Annually:
(Expert)
Entire system
Annually, however at least
every 250 hours of operation:
(Expert)
Traction hoist
Fall arrest device
30 AVANTI Service Lift for Wind Turbines
12.1 Annual inspection
Have the entire system, especially the traction
hoist and the fall device, tested by AVANTI or
qualified personnel authorised by AVANTI at least
once a year. However, more frequent inspections
may be required, depending of the use and the
conditions of use and operation. The traction
hoist and fall arrest device must be overhauled at
an authorised workshop and furnished with new
certificates for every 250 hours of operation. The
time counter is found in the main control box (see
Fig. 20).
!
If the fall arrest device has engaged, AVANTI or
qualified personnel authorised by AVANTI must
verify the safety of the fall arrest device, the
wire rope, and the wire rope attachment.
4. Check that the tension of the guiding wire
ropes has not decreased over time.
5. Ensure that all wire ropes are mounted at the
top and bottom platforms in accordance with the
Installation Manual (section 2.1, 2.3, and 2.6).
6. Ensure that the wire ropes are led round the
guide wheels in accordance with the Installation
Manual (section 2.5).
Perform the inspections filling in the “Appendix
B: Inspection checklist” and the “Appendix C:
Inspection log sheet”.
12.1.1 Traction hoist
When cleaning the traction hoist, always ensure
sufficient air supply.
1. Ensure that no visual defects have appeared.
2. Test emergency descent function
(See User´s Manual section 7.1)
12.1.2 Fall arrest device
Keep free from dirt.
1. Test the fall arrest device stop button.
2. Test the fall arrest device stop button reset.
3. Release the safety wire bottom attachment in
tower and perform the wire rope acceleration
test by hand.
12.1.3 Service lift
Inspect the service lift as specified in section 5 of
the User Manual.
12.1.4 Traction, safety and guiding wire ropes
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.
!
!
Record any visible change of the condition
of the wire rope on the “Appendix C: Inspection log sheet”, and monitor closely throughout time.
12.1.4.1 Cleaning
1. Open the top lift hatch to access the wire ropes
from inside the service lift.
2. Use a cloth to wipe off the old grease from the
wire ropes.
3. Close the top lift hatch and ascend the service
lift 1 or 2 m.
4. Repeat steps 1 to 3 until the entire length of the
wire ropes is clean.
Always keep the traction, safety and guiding wire
ropes clean and slightly greasy.
Only use mechanical means to clean the dirty
wire ropes, i.e. a cloth or a hand brush. Do not
use solvents or other detergents.
12.1.4.2 Lubrication
If the distance between platforms is more than 20
m perform the following procedure:
1. Ascend the service lift 20 m.
2. Open the top lift hatch.
3. Through the top lift hatch and with a spray can,
apply lubricant on the wire ropes.
4. Close the top lift hatch and ascend the service
lift 1 or 2 m.
5. Repeat steps 1 to 4 until the entire length of the
wire ropes is lubricated.
6. Finally, perform two complete ascends and
descends in order to distribute the new lubricant
evenly along the wire ropes.
If the distance between platforms is equal or less
than 20 m perform the following procedure:
1. A first person ascends in the service lift several
meters so that the wire ropes are accessible from
the platform.
2. From the platform and with a spray can, a
second person applies lubricant on the wire
ropes.
3. Both persons ascend in the service lift to the
next platform.
4. One person egresses to the next platform.
5. Repeat steps 1 to 4 on each platform until the
entire length of the wire ropes is lubricated.
User’s Manual 31
6. Perform two complete ascends and descends in
order to distribute the new lubricant evenly along the
wire ropes.
!
!
!
!
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.
!
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.
Check and replace the respective wire rope(s) if
one of the following defects is found:
•
For traction and safety wire ropes, there are
more than one 4-wire strand break on a wire
rope length of 250 mm (see Fig. 18).
Fig. 18
Re-lubricate the wire ropes before they show signs
of corrosion or run dry.
•
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.
•
12.1.4.4 Discard criteria
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.
12.1.4.3 Measuring of the wire rope diameter
When measuring the diameter of the wire
ropes, use a digital calliper with broad
measuring faces.
Fig. 17
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.
32 AVANTI Service Lift for Wind Turbines
• For guiding wire ropes, there are more than
one 8-wire strand break on a wire rope length
of 360 mm (see Fig. 18).
•
Severe corrosion on the surface or the inside.
•
Heat damage, evident by the wire rope colour.
•
For traction and safety wire ropes, the wire
rope diameter is less than 7,6 mm.
•
For guiding wire ropes, the wire rope
diameter is less than 11,4 mm.
• Damage on the wire rope surface (see Fig. 19
for most common examples of wire damage).
Fig. 19
Kinks resulting
from counterweight
of traction wire rope
not being able to
rotate freely.
Fig. 20
X402/L502
Wire rope strap/
loop,
which cannot be
unwound
Loop knot forming
when a wire loop is
pulled tight
M500 / M508
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
owever, these examples do not replace the
H
relevant provisions laid down by ISO 4309!
12.1.5 Electrical cables
Check and replace the power supply and control
cables if the cable jacket or cable connections are
damaged.
12.1.6 Overload limiter/information signs
Test switches as specified in section 5.3 and 5.4 of
the User’s Manual. Perform overload test as
specified in the Installation Guide.
12.1.7 Information signs
Verify the completeness and the legibility of all rating
plates and information signs. Replace missing or illegible
plates and signs!
12.2 Repairs
Repairs to traction hoist equipment may ONLY be
performed by the manufacturer or a hoist service centre,
and only using original spare parts.
If the gearbox oil needs to be replaced, use one of the
lubricants specified in the following table, corresponding
to the temperature range in which the traction hoist
equipment is used.
Amount required:
• traction hoist X402P: 1.4 l.
• traction hoist L502P: 1.4 l.
• traction hoist M500 / M508: 1.5 l.
Table 4
Temperature
range
-15ºC to 80ºC
-35ºC to 40ºC
Synthetic oil
API specification CLPPG or
Oil specification
CLPPG or
PGLP ISO VG 4601)
PGLP ISO VG 100
Klübersynth
GH6 460
Klübersynth
GH6 100
Use of other synthetic oil only with
approval by AVANTI.
1)
Standard filling
Traction hoist:
Specification:
M500 / M508
MSHC 632 VG320
User’s Manual 33
13. Ordering spare parts
13.1 Wire/ropes
13.5 Rating plate/information signs
In addition to the item number and name of the
spare part, always state the traction hoist type, wire
diameter and production number!
Verify the completeness and legibility of all
rating plates/information signs (see Fig. 21).
Replace missing or illegible plates/signs!
13.2 Motor and brake
Rating plate on
the service lift Spine
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 on the connection cabinet. There is a wiring chart in the
connection cabinet and in the motor terminal box.
13.4 Fall arrest device
Information signs
In addition to the item number and name of the
spare part, always state the fall arrest device type,
the wire diameter and lift serial no.
Please observe
the
STOP
following safe
ty precaution
s:
CAUTION !
Only person
nel trained
may operate to use the service lift
the system.
When using
the system
bring commu
nication equ ,
ipment.
Max. 2 perso
ns.
Max. Load:
240 kg.
A spare parts list is available from the
supplier or directly from AVANTI.
Bitte folgend
e Sicherheits
maßnahmen
einhalten:
STOP
ACHTUNG !
Nur für Service
lift
dürfen diese ausgebildete Personen
Anlage bedien
en.
Bei Ben
Kommunika utzung der Anlage
tionsmittel mit
bringen.
Fig. 21
Max. 2 perso
ns.
Max. Belastun
g: 240 kg.
Operating instructions inside the lift
STOP
Quick Guide – Service lift SHARk
• Only personnel trained to use the service lift may operate this system.
• Before using the lift, carefully read and observe all operating instructions.
Quick Guide
– Service lift
SHARk
Pendant control
• Only perso
nnel trained to us
e the service lift m
• Before usin
g the lift, carefully
ay operate this s
read and observ
ystem.
e all operating in
structions.
Service
lift SHARK Slidin
g door
Brake leaver
Up
Down
Wire guide
To open the brake
1. Losen the Safety brake
wire by taking lift up.
2. Press down Safety brake
leaver until brake
disengages.
Stop button
Inspection window
STOP
Bottom safety
stop bar
Traction hoist
Bottom safety
stop switch
Manual operation
Brake leaver
insertion point
Insert brake
leaver into
insertion point and
pull upwards for
descent.
Hand wheel
For taking lift up
manually.
Emergency
stop
(For details, see
User’s Manual
and Installation
45541020 – Quick guide EN
Safety wire
Drive wire
Do not enter
during lift operation!
Flywheel must turn during lift
operations.
Guide wire
Emergency
top limit STOP
switch
Top limit STOP
switch
DANGER ZONE!
Safety brake
Emergency
stop
Service lift SHAR
K Double door
WARNING!
(For details, see User’s Manual and Installation Manual)
Manual)
34 AVANTI Service Lift for Wind Turbines
ACHTUNG!
Down
1. Losen the Safety brake.
2. Insert brake leaver into
break leaver insertion point
and loosen motor brake by
slowly pulling upwards.
Up
1. Mount hand wheel on top
of the traction hoist.
2. Losen motor brake
using the brake leaver
(see above) while turning
the hand wheel counter
clockwise.
GEFAHRENBEREICH!
Wärend des Betriebes
nicht betreten!
14. Transport and storage
Depending on the transport and storage conditions that
were agreed with the customer, the following methods are
standard ways for the transport of the cabin with the
installation accessories:
• Land transport: Rear support over pallet.
Non stackable.
• Sea transport: Package using wooden box and
plastic shrink on a pallet.
Non stackable.
Storage conditions:
• Keep the service lift in its original packaging until it is mounted in the tower section.
• Keep stored in a dry place.
• Storage temperature between -25 º C and 80 º C (survival temperature).
• Non stackable.
User’s Manual 35
Installation Manual
Please familiarise yourself with these instructions and the User Manual (Model SHARK) 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 Manual 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, all parts must be tested to
ensure their completeness and full functionality.
!
Prior to installation of the suspension system,
ensure that the building sections involved will
be able to carry the load.
1. Assembling the SHARK cabin
Assemble the SHARK service lift close to its final
place of installation. Assemble both versions,
sliding doors and double doors, as follows:
Installation holes have been pre-drilled. Bolts, nuts
etc can be found in the plastic bags supplied.
9.Bring the cabin to its upright position.
10.Mount the doors on the cabin. On the Double
door version - remember to install the ground
wire at the top hinge.
11. Mount the steps and handle inside the cabin.
1.Assemble the right, left and bottoms sections
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 fall arrest device
to the spine.
12.Feed the power cable through the rear hole
and fit the socket to the back using the strips.
13.Mount the bottom safety stop switch and
adjust. Connect the switch cables to the power
cabinet according to the colour code. All wires
are secured using strips (max 200mm between
strips).
All bolts and nuts are stainless steel.
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 including
the wires that hold the bottom safety stop
beam.
36 AVANTI Service Lift for Wind Turbines
STOP
DANGER!
If it is possible to enter underneath the
service lift a double button safety stop
must be fitted.
1.1 Parts list - Shark L/XL sliding door
29 29 29
29 29 29
26 26 26
27 27 27
24 24 24
28 28 28
14 14 14
7
7
7
28 28 283
3
3
5
5
5
25 25 25
4
4
4
30 30 30
22 22 22
13 13 13
30 30 30
8
8
8
19 19 19
20 20 20
6
23 23 23
2
2
6
6
8
8
8
8
8
8
1
1
1
18 18 18
2
11 11 11
17 17 17
15 15 15
16 16 16
9
9
9
12 12 12
Installation Manual 37
10 10 10
21 21 21
1.1 Parts list - Shark L/XL sliding door
Pos.
Item no.
Part description
Qty
45303105 / 45303180
Cabin, right: Shark L / Shark XL
1
45303106 / 45303181
Cabin, left: Shark L / Shark XL
1
45303111 / 45303178
Bottom: Shark L / Shark XL
1
9
45303117
Hatch (Shark)
1
24
45511002
Wire guide
4
45502004/45502045
Plug 690V/Plug 400V
1
45512194
Anchor point
2/3
45303119
Bracket for top switches
1
45502035
Top stop swich (S1)
1
45502036
Emergency top stop switch (S13)
1
10
45303118
Pendant control holder (Shark)
1
19
45502038
Emergency stop box
1
20
45502062
Automatic operation switch
1
21
45502111
Pendant control
1
8
45303116
Step (Shark)
3
25
45512009
Handle for cabin, black
2
4
45303113
Front for Shark sliding door
1
45303114
Center door for Shark L w/slide
1
45303115
Right door for Shark L w/slide
45303125
Guide 1 for sliding door, Shark L, bottom
1
45303126
Guide 2 for sliding door, Shark L, top
1
22
45502217/45502218
Sliding door limit stop switch, left/right
1
23
45502219
Platform position switch
1
13
45303421
Sliding door handle - Interlock
1
79999562
Eye nut, M8, FZV
1
45303123
Angle for wirebush
1
45512006
Guide for wirebush
2
45303128
Bottom stop bar (Shark)
1
45512064
Wire Ø2.3mm, coated
0.62
45502034
Bottom limit stop switch
1
29
Safety wire / Drive wire ø8
2
30
Guide wire Ø12mm
2
45512005
Shackle, 2 tonnes
2
45303100
Tripod
2
45512060
Threaded rod, M16, FZV, L=330mm
2
45515001
Push spring for safety wire
1
45512011
Counterweight 11 kg for drive wire
1
45512001
Cable bucket
1
Rubber cable 4G1.5/5G1.5/5G2.5
1
Connector 690V/Connector 400V
1
45512003
Cable suspension
1
45512056
Snap hook, Galv. L=70mm
1
45511001
Wire fix
10
45512010
Bracket for wire fix 70
10
28
11
18
38 AVANTI Service Lift for Wind Turbines
1.1 Parts list - Shark L/XL sliding door
Pos
Part no.
Part description
Qty
2
35410095
Landing rubber feet
1
1
35410001
Bolts for wire support bracket
1
6
35710001
Set platform position plate
1
45303101
Top stop disc
1
45541020
Quick-guide, English
1
45541022
Quick-guide, Spanish
1
45541031
Label lift EN/ES 240 kg
1
45541007
Wall label UK/DE
1
45541025
Warning sign - hook on to anchor point
1
45541027
Serial number plate Shark lift
1
45512023
Counterweight 31 kg
1
45541009
Label lift EN/ES 320 kg
1
12
45303112 / 45303175
Top: Shark L / Shark XL
1
5
45303107 / 45303177
Spine: Shark L / Shark XL
1
Fall arrest device BSO 504E/BSO 1004E.
1
45303121 / 45303176
Guard small for Spine: Shark L / Shark XL
1
45303120 / 45303179
Guard large for Spine: Shark L / Shark XL
1
Traction hoist, X402P/L502P
1
45570001
Roller 1 for spine (Shark)
2
45547002
Roller 2 for spine (Shark)
2
5
45303397
Spine M500 Shark L
1
12
45303398
Top M500 Shark L
1
14
45408001
M500 690V CE
1
45408012
M508 400V CE 50Hz
1
45408013
M508 690V CE 50Hz
1
35412013
Rollers Assy M500 Shark L
1
45303400
Cover spine M500 Shark L
1
45108043 / 45408006
OSL500 / ASL508
1
45303401
Bracket OSL500 Shark L
1
45303402
Support OSL500 Shark L
1
45511006
Click on wire fix
45511007
Click on wire guide
35499287
Roller wire guide
4
45502142
Remote control transmitter
1
45502140
Remote control receiver
1
16
45502008
Grey connection box
1
17
45502016
Transformer 400 V - 230 V
1
45502001/55020011
Safety light top
1
45502002
Safety light bottom
1
35499074/35499075
Drop down safety beam Standard/Reverse
1
35499010 / 35499021
Double button stop: Shark L / Shark XL
1
26
35499012/35499022
Top safety stop: Shark L/XL
1
27
45512174
Top safety stop Switch
1
45502146
Emergency light
1
7
14
3
3
7
15
Installation Manual 39
1.2 Parts list - Shark L/XL double door
28
28
20
26
26
28
20
28
28
28
20 19
19
19
26
24
24
24
15
25
6
6
29
25
6
29
27
7
7
7
29
29
29
15
5
15
5
27
3 27
3
6
8
6
8
12
13
8
21
22
22
8
13
1
2
9
4
10
10
10
23
23
23
8
8
8
8
8
8
3
21
22
12
8
2
27
4
8
21
13
27
4
29
6
12
27
5
25
2
9
9
11
11
11
16
16
16
17
17
17
18
18
18
14
14
14
40 AVANTI Service Lift for Wind Turbines
1
1
1.2 Parts list - Shark L/XL double door
Pos
Part no.
Part description
Qty
45303105 / 45303180
Cabin, right: Shark L / Shark XL
1
45303106 / 45303181
Cabin, left: Shark L / Shark XL
1
45303111 / 45303178
Bottom: Shark L / Shark XL
1
9
45303117
Hatch (Shark)
1
24
45511002
Wire guide
4
45502004/45502045
Plug 690V/Plug 400V
1
45512004/47870006
Anchor point, yellow/Spine Anchor
1
45303119
Bracket for top switches
1
19
45502035
Top stop swich (S1)
1
20
45502036
Emergency top stop switch (S13)
1
10
45303118
Pendant control holder (Shark)
1
23
45502111
Pendant control
1
21
45502038
Emergency stop BOX
1
22
45502062
Automatic operation switch
1
8
45303116
Step (Shark)
4
25
45512009
Handle for cabin, black
2
2
35410095
Landing rubber feet
1
12
45303156
Front fence top
1
13
45303157
Front fence bottom
1
6
45303109
Double door right
1
7
45303110
Double door left
1
45502033
Double door limit stop switch
1
45502007
Cable 1,5Q Flex yellow/green
0.55
79999562
Eye nut, M8, FZV
1
45303123
Angle for wirebush
1
45512006
Guide for wirebush
2
35410001
Bolts for wire support bracket
1
45512023
Counterweight 31 kg
45541009
Label lift EN/ES 320 kg
45303128
Bottom stop bar, (Shark)
1
45512064
Wire Ø2.3mm, coated
0.62
45502031
Bottom limit stop swich
1
Safety wire / Drive wire ø8
2
Guide wire Ø12mm
2
45512005
Shackle, 2 tonnes
2
45303100
Tripod
2
45512060
Threaded rod, M16, FZV, L=330mm
2
45515001
Push spring for safety wire
1
45512011
Counterweight 11 kg for drive wire
1
45512001
Cable bucket
1
Rubber cable 4G1.5/5G1.5/5G2.5
1
Connector 690V/Connector 400V
1
45512003
Cable suspension
1
45512056
Snap hook, Galv. L=70mm
1
45511001
Wire fix
10
13
1
11
28
29
Installation Manual 41
1.2 Parts list - Shark L/XL double door
Pos
Part no.
Part description
Qty
45512010
Bracket for wire fix 70
10
45303101
Top stop disc
1
45541020
Quick-guide, English
1
45541022
Quick-guide, Spanish
1
45541031
Label lift EN/ES 240 kg
1
45541007
Wall label UK/DE
1
45541027
Serial number plate Shark lift
1
Driving system X402P/L502P-BSO504E/BSO1004E
14
45303112 / 45303175
Top: Shark L / Shark XL
1
4
45303107 / 45303177
Spine: Shark L / Shark XL
2
Fall arrest device BSO 504E/BSO 1004E
3
45303121 / 45303176
Guard small for Spine: Shark L / Shark XL
4
45303120 / 45303179
Guard large for Spine: Shark L / Shark XL
5
Traction hoist, X402P/L502P
11
45570001
Roller 1 for spine (Shark)
14
45547002
Roller 2 for spine (Shark)
15
5
14
3
Driving system M500-OSL500 / M508-ASL508
4
45303397
Spine M500 Shark L
2
14
45303398
Top M500 Shark L
1
15
45408001
M500 690V CE
11
45408012
M508 400V CE 50Hz
1
45408013
M508 690V CE 50Hz
1
35412013
Rollers Assy M500 Shark L
3
45303400
Cover spine M500 Shark L
5
45108043 / 45408006
OSL500 / ASL508
45303401
Bracket OSL500 Shark L
45303402
Support OSL500 Shark L
1
Optional
45511006
Click on wire fix
45511007
Click on wire guide
35499287
Roller wire guide
4
45502142
Remote control transmitter
1
45502140
Remote control receiver
1
45502001
Safety light top
1
17
45502008
Grey connection box
1
18
45502016
Transformer 400 V - 230 V
1
45502002
Safety light bottom
1
35499011
Safety bar for sliding door
1
35499010 / 35499021
Double button stop: Shark L / Shark XL
26
45512173
Top safety stop premounted
1
38
45512174
Top safety stop Switch
1
45502146
Emergency light
1
16
42 AVANTI Service Lift for Wind Turbines
1.3 Parts list - Shark L/XL half roller door
6
32 32
32
28 28
28
6
6
32 32
32
31 31
31
31 31
31
23 23
23 22
22
22
18 18
30 30
29 29
18
17 17
17
30
8 8
8
29
3
5
5
9
5
9
32
12
25 25
14
2
2
7
7
7
24
25
12 12
15
2
1
21 21
16 16
4
4
10
24 24
15 15
4
3
12 12
14 14
30
9
10 10
32 32
3
30 30
16
21
11 11
19 19
19
20 20
20
17 17
11
1
12
13 13
13
27 27
27
26 26
26
12 12
12
12 12
12
1
32 32
32
17
Installation Manual 43
1.3 Parts list - Shark L/XL half roller door
Pos
Part no.
Part description
Qty
9
45303105 / 45303180
Cabin, right: Shark L / Shark XL
1
10
45303106 / 45303181
Cabin, left: Shark L / Shark XL
1
11
45303111 / 45303178
Bottom: Shark L / Shark XL
1
16
45303321
Hatch for half roller door
1
28
45511002
Wire guide
4
45502004/45502045
Plug 690V/Plug 400V
1
45303369
Top stop switch bracket
1
30
45512194
Anchor point
2/3
16
45303119
Bracket for top switches
1
22
45502194
Top stop swich (S1)
1
23
45502036
Emergency top stop switch (S13)
1
13
45303118
Pendant control holder (Shark)
1
24
45502038
Emergency stop BOX
1
26
45502111
Pendant control
1
2
35410095
Landing rubber feet
1
25
45502062
Automatic operation switch
1
12
45303116
Step (Shark)
4
29
45512009
Handle for cabin, black
2
5
35499272
Set half roller door
1
14
45303156
Front fence top
1
15
45303157
Front fence bottom
1
27
45502150
Switch for half roller door
1
79999562
Eye nut, M8, FZV
1
45303123
Angle for wirebush
1
45512006
Guide for wirebush
2
1
35410001
Bolts for wire support bracket
1
7
35499357 / 35499317
Bottom stop full cover Shark L/Shark XL
1
33
45502170
Bottom limit stop switch
1
31
Safety wire / Drive wire ø8
2
32
Guide wire Ø12mm
2
45512023
Counterweight 31 kg
45541009
Label lift EN/ES 320 kg
45512005
Shackle, 2 tonnes
2
45303100
Tripod
2
45512060
Threaded rod, M16, FZV, L=330mm
2
45515001
Push spring for safety wire
1
45512011
Counterweight 11 kg for drive wire
1
45512001
Cable bucket
1
Rubber cable 4G1.5/5G1.5/5G2.5
1
Connector 690V/Connector 400V
1
44 AVANTI Service Lift for Wind Turbines
1.3 Part lists - Shark L/XL half roller door
Pos
Part no.
Part description
Qty
45512003
Cable suspension
1
45512056
Snap hook, Galv. L=70mm
1
45511001
Wire fix
10
45512010
Bracket for wire fix 70
10
45541020
Quick-guide, English
1
45541022
Quick-guide, Spanish
1
45541031
Label lift EN/ES 240 kg
1
45541007
Wall label UK/DE
1
45541027
Serial number plate Shark lift
1
Driving system X402P/L502P-BSO504E/BSO1004E
17
45303112 / 45303175
Top: Shark L / Shark XL
1
4
45303107 / 45303177
Spine: Shark L / Shark XL
2
Fall arrest device BSO 504E/BSO 1004E.
3
45303121 / 45303176
Guard small for Spine: Shark L / Shark XL
4
45303120 / 45303179
Guard large for Spine: Shark L / Shark XL
5
Traction hoist, X402P/L502P
11
45570001
Roller 1 for spine (Shark)
14
45547002
Roller 2 for spine (Shark)
15
7
17
2
Driving system M500-OSL500 / M508-ASL508
4
45303397
Spine M500 Shark L
2
17
45303398
Top M500 Shark L
1
18
45408001
M500 690V CE
11
45408012
M508 400V CE 50Hz
11
45408013
M508 690V CE 50Hz
11
35412013
Rollers Assy M500 Shark L
3
45303400
Cover spine M500 Shark L
8
45108043 / 45408006
OSL500 / ASL508
45303401
Bracket OSL500 Shark L
45303402
Support OSL500 Shark L
3
Optional
45511006
Click on wire fix
45511007
Click on wire guide
45502142
Remote control transmitter
1
45502140
Remote control receiver
1
20
45502008
Grey connection box
1
21
45502016
Transformer 400 V - 230 V
1
45502001
Safety light top
1
45502002
Safety light bottom
1
35499011
Safety bar for sliding door
1
35499010 / 35499021
Double button stop: Shark L / Shark XL
35499287
Roller wire guide
35499296
Top limit stop for top floating stop Shark L/XL
1
35499295/35499318
Top floating stop premounted Shark L/Shark XL
1
19
6
Installation Manual 45
1.4 Parts list - Shark M sliding door
8
8
12
12
12
7
7
7
8
8
8
8
7
7
7
27
27
27
26
26
26
14
23
23
6
20
6 13
6
31
20
14
14
23
13
13
9
9
15
15
4
4
31 9
31
17
30
17
17
15
30
4
19
5
19
22
30
16
16
16
32
32
32
25
25
25
19
5
18
29
30
20
30
5
30
29
22
10
10
10
10
10
10
18
18
3
3
3
2
2
2
1
1
1
21
21
21
29
22
28
28
28
11
11
11
24
24
24
28
28
28
46 AVANTI Service Lift for Wind Turbines
1.4 Parts list - Shark M sliding door
Pos.
Item no.
Part description
Qty
18
45303300
Cabin right (Shark M)
1
19
45303301
Cabin left (Shark M)
1
23
45303312
Top (Shark M)
1
21
45303306
Bottom (Shark M)
1
29
45512007
Landing rubber feet
4
20
45303305
Sliding door fixture (Shark M)
1
45303302
Sliding door w. hinge (SharkM)
1
45303303
Sliding door middle (Shark M)
1
45303304
Sliding door extreme (Shark M)
1
45303314
Slide for Sliding door
4
45303307
Bottom door guide (Shark M)
1
45303308
Top door guide (Shark M)
1
45512008
Hinge for double door
3
45502037
Sliding door limit stop swich, Shark L,S19.3,3500mm
1
45303124
Sliding door handle,Shark L
1
45303310
Bottom stop (Shark M)
1
45303311
Bottom stop holder(Shark M)
1
45512006
Guide bush for pulling wire
2
11
45303057
Hatch for Shark M
1
13
45303107
Spine
1
13
45303121
Small cover for spine
1
17
45303168
Large cover for spine
1
30
45512194
Anchor point
2
31
45512256
Spacer for anchor point
2
6
Traction hoist
1
9
fall arrest device BSO504E / OSL500 / ASL508
1
26
Top stop switch, Shark M,(S1)
1
5
22
27
45502041
Emergency top stop switch, Shark M,(S13)
1
14
45303119
Bracket for limit stop switch
1
10
45303005
Step for Shark L
2
28
45511003
Wire guide, low
4
Control box
1
Door handle
1
Key switch door
1
4
16
32
45303124
Installation Manual 47
1.4 Parts list - Shark M sliding door
Pos.
Item no.
Part description
Qty
12
45303101
Top stop disc
1
24
45502034
Bottom limit stop switch Shark L,1S2,3000mm
1
2
45502038
Emergency stop box
1
“Automatic operation” switch
1
1
3
45303118
Cover for pendant control
1
25
45502111
Pendant control
1
Traction/safety wire rope Ø8mm
2
Guide wire Ø12mm
2
45502004
Female connector 690V
2
45502026
Insulated terminal 1,5Q, black
1
45512001
Cable collect bin
1
Rubber cable 4G1,5 78m 3 phases + ground 690V
1
45541019
Quick guide multiple language
1
45512060
Threaded rod,M16x330mm FZV
2
45515001
Safety wire push spring
1
45303100
Tripod
2
45512005
Shackle 2T
4
45512011
Motor wire contra weight,11kg
1
45540005
CE conformaty declaration
1
45541020
Quick guide UK
1
45541022
Quick guide ES
1
45541008
Wall label UK/ES
1
45541025
Label Use Fall Protection
1
7
Optional
45511006
Click on wire fix
45511007
Click on wire guide
45502142
Remote control transmitter
1
45502140
Remote control receiver
1
45502001
Safety light top
2
45502002
Safety light bottom
2
35499010
Double button stop
48 AVANTI Service Lift for Wind Turbines
4
1
3
2
2
1
1
1
ELE CTD
Control Box 4
1
2
Guide wire 3
Traction wire 2
1
1
Safety wire 1
ELE CT
1.5 Parts list - SHARK M roller door
21
1
3
2
3
2
1
3
3
3
31
24
31
31
30
30
30
6
6
6
9
9
9
24
32
32
36
36
37
18
32
35
36
3
13
13
1
4
4
4
36
37
37
10
35
36
32
32
18
18
16
16
27
32
10
10
16
27
15
15
15
33
27 33
33
20
19
22
22
19
20
7
20
20
19
22
21
19
11
11
11
11
11
11
11
11
11
21
21
19
17
34
14
5
23
23
26
26
26
38
28
29
14
12
17
38
28
29
12
12
8
25
25
17
5
32
23
34
29
8
32
2
19
5
32
20
7
25
Installation Manual 49
28
1.5 Parts list - SHARK M roller door
Pos
Part no.
Part description
Qty
45303326
Top Shark M roller door
1
13
45303107
Spine
1
10
45108031 / 45108042
Fall arrest device BSO 504E/BSO 1004E
1
15
45303121
Small cover for spine
1
16
45303168
Large cover for spine
1
21
45303331
Cabin right Shark M GE
1
22
45303332
Cabin left Shark M GE
1
23
45303333
Door switch bottom protection
1
14
45303117
Top hatch Shark M roller door
1
32
45511002 / 45511003
Wire guide long / Wire guide low
6
Traction hoist
1
9
35
45512188
Roller door (Shark M)
1
36
45512194
Anchor point
2
45570001
Roller 1 for spine (Shark)
2
45512256
Spacer for anchor point
2
45547002
Roller 2 for spine (Shark)
2
45303340
Top stop switch bracket roller door
1
30
45502165
Top stop switch S1
1
31
45502166
Top limit switch S13
1
45303333
Door switch bottom protection
1
34
45512183
Landing rubber feet 70x70
1
28
45502162
Roller door switch
1
11
45303005
Step
4
17
45303324
Roll.D. switch actuator support
1
38
45702002
Actuator for switch
1
33
45512009
Handle for cabin, black
1
79999562
Eye nut, M8, FZV 1
1
45303123
Angle for wirebush 1
1
45512006
Guide for wirebush 2
1
26
45303337
Bottom stop Shark M
1
29
45502164
Bottom limit switch S2
1
45502163
Hatch switch
1
12
45303101
Top stop disc
5
35410001
Bolts for wire support bracket
37
50 AVANTI Service Lift for Wind Turbines
1
1.5 Parts list - SHARK M roller door
Pos
Part no.
Part description
Qty
1
Safety wire / rope Ø8mm
1
2
Traction wire rope Ø8mm
1
3
Guide wire Ø12mm
2
4
Control box
45512005
Shackle, 2 tonnes
45303100
Tripod
45512060
Threaded rod, M16, FZV, L=330mm
45515001
Push spring for safety wire rope
45512011
Counterweight 11 kg for traction wire rope
45512001
Cable bucket
2
Rubber cable 4G1.5 /5G1.5
Connector 690V/Connector 400V
45512003
Cable suspension
45512056
Snap hook, Galv. L=70mm
45511001
Wire fix
45541020
Quick-guide, English
45541031
Label lift EN
45541007
Wall label UK/DE
45541025
Warning sign - hook on to anchor point
45541027
Serial number plate Shark lift
Optional
45511006
Click on wire fix
45511007
Click on wire guide
45502142
Remote control transmitter
45502140
Remote control receiver
45502001
Safety light top
45502002
Safety light bottom
45502146
Lift emergency light
27
35499280
Top safety stop premoun. Shark M
8
35499285
Top stop end Shark M
20
45303330
Tool shelf support
4
7
35499278
Tool shelf premounted
1
19
45303329
Tool shelf reinforcement sheet
2
25
45303336
Top safety frame Shark M
1
24
45303335
Top stop bracket 2 Shark M
2
6
35499035
BSO-holder UL pre mounted
1
Installation Manual 51
2. Fitting the wires
2.1 Tower top
Wire lengths depend on the tower height and
should be specified when ordering. The coils are
marked with their length; check for accuracy prior
to mounting. Do not pull wire over any edges.
Uncoil correctly (Fig. 5a).
!
Warning!
Do not pull wire over edges.
1)Mount the Ø12 mm guide wire and the Ø8 mm
drive and safety wires using the shackles
supplied for the suspension beam at the top of
the tower, with the guide wire outermost on
either side.
2) Fit the nuts and bolts. Lock with cotters.
3)Fit the top stop disc on the suspension wire
leaving at least 200mm between disc and
shackle (See Fig. 5).
4)Feed all wires to the bottom of the tower (See
Fig. 5).
Important!
Place all wire coils on the top platform
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 Ø8 (fall arrest device)
Drive wire Ø8 (traction hoist)
Shackle, 2t
Top stop disc
Guide wire
Ø12mm
Fig. 5a
IMPORTANT!
All wires are evenly uncoiled
as shown in Fig. 5a to prevent
looping.
52 AVANTI Service Lift for Wind Turbines
2.2 Wire positioning measurements
Holes in the base platform in the tower for wire
bushing are positioned as outlined below.
Fig. 6
Minimum shaft clearance dimensions required for the service lift to
run, and distance between the
guide wires.
Traction Wire
Safety Wire
Guiding Wire
Guiding Wire
Power Cable
Minimun safety
gap “S” all
around the
service lift:
50 mm
Dimensions:
Shark
A
B1)
C
D
E
S
M
250
395/330
600
600
220
50
L
250
575/510
960
600
220
50
XL
350
575/510
960
800
320
50
The holes are positioned with a tolerance of
+/-5 mm. Holes with diameter Ø200 mm are fitted
with rubber edging.
!
Warning!
Ensure that no obstacles are in the way
of the service lift.
STOP
DANGER!
Ensure that lift evacuation to the tower
ladder is possible.
Installation Manual 53
2.3 Securing the guide wire - ground level
Fig. 7 Wire fix
IMPORTANT:
Before feeding the guide wires through the
platform, fit the correct number of wire fixes on the
wire and feed through the wire guides. The wire
fixes are fitted during the first run.
Feed the guide wire through the outer Ø20mm
holes in the platform. Underneath the platform the
guide wires are fastened and tightened using one
of the following three methods.
2.3.1 Method 1: Wedge anchor
Mount wire as shown in Fig. 8 following procedure
below.
1)Drill 2 Ø16x75mm holes in the floor underneath
the outer Ø20mm 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, fasten the rigging screw 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.
5)Excess wire is coiled and hung by means of
wire strips. Use at least 3 strips.
6) Mount the second wire.
Fig. 8 Method 1: Wedge anchor
Coiled guide wire
Guide wire
Wire grips
Thimble
Rigging screw
Lifting eye bolt
Wedge anchor
2.3.2 Method 2: Tripod
Pull the guide wire through the platform and fasten
with the tripod (See Fig. 8a.)
!
1)After feeding the guide wire through the platform
continue feeding the wire through the tripod and
the Ø16 mm x 1.5 mm aluminium tube.
2)Lock the aluminium tube, the wire, and the
treated rod using a wire locking device. Make
sure the tube is placed so no contact is made
between the wire and treated rod. (See Fig 8a).
3)Tighten the bolts to 75 Nm
4) Mount the second wire.
ATTENTION!
Check the distance between the wires so that the
wire fix and wires are in the centre of the wire guides
(See Fig. 6 section 2.2).
Tighten the wire locking device after the first run.
54 AVANTI Service Lift for Wind Turbines
Fig. 8a Method 2: Tripod
2.3.3 Method 3: Steel beam
There may be a steel beam beneath the platform
intended for lift mounting. If so, use rigging screws
as described in method 2.3.1 for mounting the
guide wire to the steel beam.
2.3.4 Method 4: Tensioner
Mount the guiding wire ropes as shown in following figures and as explained in procedure below.
Fig. 8b Installation of tensioner - Phase 1
Bottom platform floor
Guiding wire rope
Base tube
Indicating dial
Spring tensioner
Threaded shaft
2.3.5 Tensioning the guide wires Ø12 mm
Tighten the wires by hand and mark with a waterresistant marker. Measure the distance to the floor.
• For 60 m long wires, stretch the wire 60 mm.
• For 80 m long wires, stretch the wire 80 mm.
• For 100 m long wires, stretch the wire 100 mm.
Graduated tube
Indentations
1. Mount the preassembled tensioner underneath the
bottom platform floor.
2. Place the threaded shaft in the toppest position
(see Fig. 8b).
3. Feed the guiding wire rope by hand through the
threaded shaft.
4. Stretch the wire rope pulling downwards.
5. Install the wire rope grips.
6. While locking the threaded shaft with a spanner in
the shaft indentations, turn the tensioning nut until
dial indicates 2KN – 4KN (see Fig. 8c).
7. Fasten the locking nut.
8. Mount the second tensioner.
Tensioning Nut
Wire rope grips
Fig. 8c Installation of tensioner - Phase 2
For each additional 10 m, stretch the wire by a further
10 mm.
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 approximately
2000-4000 N.
2.4 Electrical connections
2.4.1 Power supply
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 (30mA).
Indicating dial
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:
Locking Nut
400 V,
690 V,
3 phases + t 0 + gnd. I = 3.5 A
3 phases + gnd.
I = 2.0 A
1.5 kW
1.5 kW
Control voltage: 230 V / 240 V
Necessary equipment to comply with EN60204-1
can be supplied by Avanti as an option.
Installation Manual 55
2.4.2 Supply cable
a)The length of the cable depends on the height
of the tower and the positioning of the power
outlet. The cable length is determined prior to
ordering. The power cable is marked with its
length; check for accuracy before installing.
b) Minimum cross-sectional dimension of the
supply cable. Important with increased distance
between grid connection, generator, and
traction hoist, respectively:
Table 3
h)Turn the EMERGENCY STOP button (Fig. 10
and Fig. 10a) clockwise to deactivate.
i)The power is turned on and the green indicator
on the electrical control box lit. In order for the
service lift to be operational the door must be
locked and the HAND/AUTOM switch must be
in HAND mode.
The wiring diagram is found in the electrical control
box.
For cable lengths up to...
190 m
1 hoist
1.5
Cable-cross sectional dimension [mm2]
Tensioning
system
c)Use heavy rubber cable ducts for fastening live
wire to service lift.
d)An installed generator will have to provide at
least 2.5 times the output of the traction hoist.
Fig. 9
Cable
suspension
Power
cable
outlet socket
Spring
safety wire
Fig. 9b
Power cabinet
Tirak M500/M508
Cable
collect bin
suspension
straps
Cable
stocking
Cable
collect bin
Power cable
inlet plug
2.4.3 Power connection
a)Push the EMERGENCY STOP button
b)Check that the various stop switch cables and
fall arrest device cable are connected to the
power cabinet according to colour code.
c)Place or hang the cable collect bin underneath
the Ø200 mm hole in the platform.
d)If possible hang the bucket in the full length of
the webbing. Keep the webbing as long as
possible (Fig. 9c).
e)Cut the transport strips and tape which hold
the wire inside the bin and connect the cable
suspension (Fig. 9) to the eyebolt underneath
the service lift floor.
f)Connect the socket to the lift plug on the back
of the lift.
g)Connect the power cable plug to the grid: 400V
/ 3Ph + 0 + gnd. / 50 Hz
680V / 3Ph + gnd. / 50 Hz Pre-fuse: 16 A.
56 AVANTI Service Lift for Wind Turbines
Counterweight
traction wire
Fig. 10
Fig. 10a
EMERGENCY
STOP
UP
DOWN
Important:
If the traction hoist does not start, two
phases in the supply connection might
have been switched around the phase
protection relay. Remedy: Have an electrician check the phase lay.
2.5 Installation of drive and safety wire ropes through lift
CAUTION!
W
ear protective gloves
when handling wires.
Fig. 12 Back side
Drive wire
Safety wire
2.5.1 Drive wire installation
a) Remove protection guard above rollers
b)Feed the wire through the roof into the traction
hoist’s wire inlet opening. (Right side seen from
front of lift).
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 fall arrest device by pushing down
the lever until it engages/clicks (Fig. 16 Appendix A). Feed the safety wire through the roof
hole above the fall arrest device and continue
by feeding through the fall arrest device.
c)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 lift pull the safety wire to
tighten it.
e) Replace roller protection guard.
f)Feed wire through platform floor.
Ensure that the
wires can exit freely!
Fig. 11
BSO
OSL500/ASL508
Drive wire contra
weight
Safety wire push
spring
ON/Locked
OFF/Open
Installation Manual 57
2.6 Securing the traction and
safety wire ropes
2.6.2 Safety wire rope method 1:
Wedge anchor with spring
The traction wire rope is fastened as described in
point 2.7.1 below and the safety wire rope is
fastened in one of three ways described in point
2.7.2, 2.7.3 and 2.7.4.
As in point 2.3.1 above the wire is fastened
using a rigging screw with spring (See Fig. 13a).
Mounting the safety wire without the spring will
cause the fall arrest device to block frequently.
Excess wire is coiled with at least 3 strips.
Before fastening the safety wire rope, leave
the service lift hanging from the safety wire
rope for a while so that wire rope stretches.
Before fastening the safety wire rope, carry
out the fall arrest device test (See Installation
Manual section).
2.6.1 Counterweight of the traction wire rope
•At a wire length of 60 m, tighten the rigging
screw so the wire stretches 9 mm.
•At a wire length of 100 m, tighten the rigging
screw so the wire stretches 15 mm.
This will tighten the wire to approximately
400-500 N (40-50 kg).
1. Mount an 11 kg counterweight on the traction
wire rope (see Fig. 13).
Fig. 13
Fig. 13a
Safety wire
Wire lock,
2 pieces
Thimble
Spring
Rigging screw
fork/fork
2. If the basement is less than 1500 mm high,
place the counterweight approximately 300 mm
below the floor.
3. If the basement is more than 1500 mm high,
place the counterweight approximately 300 mm
below the cable bin.
4. Coil the excess of the wire rope and fix with at
least 3 cable ties.
The traction wire rope shall be able to
rotate freely.
58 AVANTI Service Lift for Wind Turbines
Eye bolt
Wall anchor
2.6.3 Safety wire rope method 2: Push spring
Fig. 13b
1. Feed the safety wire rope through the bottom platform
hole.
2. Ascend the service lift 50 cm.
3. Activate the fall arrest device.
4. Perform manual descent so that the weight of the
service lift is transmitted to the safety wire rope.
5. Compress the spring to 40 mm and fix with cable ties.
6. Feed the safety wire rope through the compressed
spring.
7. Pull the safety wire rope downwards by hand as much
as possible.
8. Place and fasten the wire rope grip.
9. Cut the cable ties so that the spring decompresses to
55 mm.
2.6.4 Safety wire method 3:
Steel beam with spring
There may be a steel beam beneath the platform
intended for lift mounting. If so, use wire screws as
described in method 2.6.2 for mounting the safety wire
to the steel beam.
Installation Manual 59
2.7 Wire fix alignment
Having mounted the service lift, the wires, and the
power, the wire fix fittings are adjusted during the
initial ascent.
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 lift passes.
a) Perform the tests prescribed in section 5 of the
User’s Manual.
b) Install wires as shown in Fig. 14.
Click-on wire guide
Click-on wire fix
Fig. 14
Wire guide
Standard wire guide
Narrow wire guide
Wire fix
Bracket
platform
(optional)
Roller wire guide
CAUTION!
Wire fixe must be mounted on
guide wires on all platforms with max.
30 m between each wire fix.
60 AVANTI Service Lift for Wind Turbines
!
!
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 the safe-zone plates 2.9 Adjustment of top stop disc
(Full open door lifts)
The service lift door should be able to be opened
whenever the cabin is in alignment with the
platform (tolerance ± 100 mm).
The safe-zone plate is adjusted in relation to the
platform position switch fixed on the cabin (see
Fig. 15).
The top stop disc is adjusted so the top limit stop
switch stops the lift in alignment with the top
landing platform, however at least 200 mm before
contact with the wire thimble.
The emergency limit stop switch is a backup. It is
adjusted so it stops the lift in case the operation
limit stop switch fails.
Fig. 15
The emergency limit stop shuts off the control, just
like an emergency stop. If the emergency limit stop
is activated, lowering can only be done manually
as described in the User’s Manual. Manual
lowering will activate the lift again.
3. Danger zone! sticker
Mount the “Danger Zone” sticker in the tower
behind the lift and the yellow marking ribbon on
the floor. Make sure the wall and platform are
clean and dry before attaching the sticker and
ribbon.
STOP
DANGER!
Make sure that nobody is exposed to
danger below the service lift, for
instance from falling parts.
Suitable measures: Pent roof or barriers.
The service lift is now ready for use.
Prior to use, however, carry
out the inspection specified
in Installation Guide section 5!
4. Disassembling
Disassemble in reverse order and dispose in
accordance with local authority regulations.
Installation Manual 61
5. Inspection before initial use
An officially recognised expert must:
a)Inspect the lift as specified in section 12.1 of
the User’s Manual.
b)Carry out a test run with the maximum rated
load.
c)Overload test: The test load depends on the lift
motor. Load the cabin as follows:
Motor L402P: load kg 320 (125% of lifting
capacity + weight of power cable). Motor
L502P: load kg 420. When an attempt is made
to start the lift, the platform should stop, and
the buzzer in the connection cabinet should
sound.
– If not, see Appendix A: “Adjusting instructions
for overload limiter” .
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.
e)Testing of the fall arrest device:
Important!
Before testing, the tightening spring beneath the access platform must be removed. Remember to secure it again after
testing!
STOP
Fig. 15
BSO
OSL500/ASL508
Safety wire
ON
OFF
Emergency
Stop
Window
Fall arrest
device
62 AVANTI Service Lift for Wind Turbines
DANGER!
If the fall arrest device is engaged, it
must not be possible to pull the safety
wire upwards!
1) Engage the fall arrest device by pressing the
stop button – the handle should jump to the
“ON” position (Fig. 15).
Should it nevertheless be possible to pull the
safety wire upwards, the fall arrest device
must be replaced and sent to the supplier
for testing.
2) Reopen the fall arrest device by pressing
down on the lever. On top of the lift, pull up
the safety wire with a quick jerk – the fall
arrest device should now engage automatically; if it does not, replace it and return to
the supplier for testing.
f)If guide wires are mounted using the tripod,
tighten the tripod wire locking device.
The results from this test must be
recorded in writing and saved for later
reference (Appendix C).
Appendix A:
Regulation of overload limiter
CAUTION!
Avoid injury by strictly following the
instructions!
a)Verification and/or adjustment of the overload
device on the service lift can only be done by a
qualified person, who must have been instructed by AVANTI to perform this task.
b)Verification and/or adjustment must be performed under the supervision of the site
foreman or another person authorised by the
manufacturer.
c)One copy of this instruction must be provided
to the personnel and must always be available.
d)Alterations/modifications of the service lift
other than those necessary for adjusting the
overload device are not permitted, unless the
manufacturer has agreed in writing.
e)AVANTI assumes no liability for damage due to
retrofitting/alterations to equipment or where
non-original spare parts are used, which have
not been approved by the company in writing.
This particularly applies to the specified
traction hoist wire rope.
f)The manufacturer of the service lift assumes no
liability for damage due to retrofitting or
alterations to equipment or where non-original
spare parts are used, which have not been
approved by the company in writing. In the
event of violation, the CE certification approval
becomes invalid.
g)The result of the verification/adjustment of the
overload device must be written down in the
“Annual inspection test report” and 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 is possible that the overload limiter inside the
traction hoist of the service lift stops upwards
travel even through the service lift is not overloaded.
Where other causes can be excluded by following
the instructions of section 2.2, the overload limiter
must be adjusted according to section 3.2.
2 Instructions for adjustment
2.1 Preparation
Tools/materials required:
- Allen keys, size 2 and 4 1) - X402P & L502
- Security TX40 - M500 / M508
- Ballast for applying the test load;
Note! Before driving to the service lift
make sure that the service lift can be loaded with
the permissible test load, i.e. “safe working
load” + weight of power cable + 25%.
IMPORTANT!
Before leaving for the tower, make sure
that you have the required test load of
300-400kg.
We recommend:
-w
eighing personnel who may climb into the
lift during the test procedure,
and
- taking suitable weighed ballast (sandbags
or similar).
2.2 Exclusion of other causes
Before modifying the overload limiter settings
check if the upwards travel stop is caused
by other reasons:
a)Check for obstructions on the guiding
device(s) and remove them.
b)Check that the wire rope moves freely at
the diverter or similar:
- Is the rope blocked/pinched at any point?
-D
o the pulleys rotate freely? (check with the
service lift 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 should hear a “click” or feel a
mechanical shock when putting your hand on
the motor fan cover.
In the case of b) or c), the problem must be
corrected/repaired by a qualified person.
1) With older hoists you may need an allen key size 6.
Appendix 63
Fig. 16
8
4
6
3
7
2
5
1
3 Overload limiter
a) Place the service lift on the lowest travel point
b) Apply the Setup load + 20 Kg from the table depending on the tower height.
c) Push the UP button. If the lift can go up modify the adjustment of the overload system until it is no longer possible to go UP following the procedure below:
1. Loosen the set screw (7) in the casing cover with an Allen key (size 2)
2. Remove the cap (8). Place an Allen key (size 41, 150 mm long) into the adjusting screw (6)
3. Turn the adjusting screw (6) clockwise, until the test load can be lifted.
4.Gradually reduce the trigger point of the limit switch (4) by means of the adjusting screw (6), until the test load can no longer be lifted: 1) Turn the adjusting screw by 1/4 turn
anticlockwise to reduce the trigger point; 2) Press the UP-button.
d) Apply Setup load. Push the UP button and verify the lift can go up. If not, return to b) until the lift is able to go UP with Setup load but is not able to go UP with Setup load + 20 Kg
e) Apply Lift WLL and verify that it can perform the travel to the top without triggering the overload limit. If it is not possible verify loads used and return to b), otherwise continue with f)
f) Go back to the lowest point and apply
overload test load.
g) Press the UP button and verify the overload is triggered. If it is not triggered verify test loads and return to b), otherwise continue with h)
h) Tighten the set screw (7).
i) Remove the tools.
j) Insert the cap (8) into the casing hole.
k) Fill in the “Annual inspection test report” check point 5.9 and sign.
64 AVANTI Service Lift for Wind Turbines
OVERLOAD TABLE
LOAD CAPACITY = 240 Kg
LIFT WLL
240
Kg
CABIN WEIGHT
110
Kg
CABLE AND WIRE
0,45
Kg/m
400
Kg
ROPE
HOIST WLL
WTG HEIGHT (m)
SETUP LOAD (KG)
OVERLOAD TEST
LOAD (KG)
67
290
370
78
295
370
100
305
370
LOAD CAPACITY = 320 Kg
LIFT WLL
320
Kg
CABIN WEIGHT
120
Kg
CABLE AND WIRE
0,51
Kg/m
500
Kg
ROPE
HOIST WLL
WTG HEIGHT (m)
SETUP LOAD (KG)
OVERLOAD TEST
LOAD (KG)
67
374
485
78
380
485
100
391
485
SETUP LOAD = WLL Lift + WTG height x Wire rope linear weight
+ Tolerance Overload device < 1,25 x (WLL Hoist - CABIN WEIGHT)
OVERLOAD TEST LOAD1 = WLL Hoist x 1,25 - CABIN WEIGHT
- TOLERANCE OVERLOAD device
NOTE 1: Acc. To EN1808 8.3.5.5
Tolerance overload device = 20 Kg
Appendix B: Safety measures
General: The Service Lift/Work Cage is only to be used by
personnel who has received instructions in operating the Lift/
Cage 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.
The following precautions and procedures are to be followed
during operation of, and if the Lift/Cage stops and the manual
emergency descend cannot be performed.
Operating the Lift/Cage: Anyone going in the Lift/Cage
must at all times wear PPE (safety helmet, full body harness,
shock absorber, lanyard and fall protection system on the
ladder)
EVACUATION of personnel from the Lift/Cage is only necessary in extreme situations. If necessary Avanti
recommends the following procedures:
1. User(s) attaches shock absorber to the yellow anchor
point(s) inside the cabin and open the door.
(See Fig.1)
4.User(s) climbs to the other side of the ladder with proper
safety technique and attaches runner/slider to the present fall
protection system on the ladder. ( See Fig.4)
2. User(s) climbs on the ladder and establishes suitable
safety with the shock absorber in the ladder area.(See Fig.2)
5. User(s) can now climb safely up or down the ladder (See
Fig.5)
3. After safe anchoring in the ladder area, user(s) releases his
anchor in the Cabin/Cage. (See Fig.3)
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
RESCUE of personnel from the Lift/Cage is only necessary in extreme situations.
If necessary Avanti recommends the following procedures:
1. User is on the work side of the ladder with attached
runner/slider to the present fall protections system on the
ladder at the same level as the Service lift/Work Cage.
2. User attaches suitable safety with one of the shock
absorber hook in the ladder area. After safe anchoring
to the ladder area, the runner is released from the Safety
Rail. (See Fig 1)
3. User climbs to the other side of the ladder using the
proper safety technique, opens the door (See Fig 2-3) and
attaches the other shock absorber hook to the yellow point
inside the Lift/Cage. (See Fig 4)
4. Check that the person to rescue is conscious or
unconscious. (See Fig 5)
5. User transfers to the Lift/Cage with proper safety
technique. When user is safe inside the cabin release his
anchor from Safety ladder. (See Fig 6)
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
The way to proceed and what to do in case of evacuation or rescue are unique and here described in general terms so
do not depend on the type of Shark that you have as it does not depend on the type of door. Consequently, we have
chosen the most representative photos of the model as an example
Appendix 65
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!
70 AVANTI Service Lift for Wind Turbines
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.
E.3 Marking
Serigraphy Detail (1:1)
Marking on Lift Anchor plate:
EN 795 A1: 2000



MAXIMUM 1 USER


European/American
standard number
Item number
04
Material and Capacity rating
Unique identification number
100
C
ISOMETRI

AVANTI product name
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.
B
150°
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.
A
50
A
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.
Before installing the AVANTI LIFT ANCHOR in heights, 4. Fill in “Installation form”.
assure to be proper secured against fall from height by
using relevant fall arrest equipment.
5. Carry out yearly inspection by following
the procedure in the section “Inspection”.
A
Set of QC measuring points: A B C D
Material: AISI 304
Sheet 5 mm
Dimension:
Edge: Deburred
YELLOW Measure
Surface: Powder coating RAL 1003 SIGNAL
Appendix 71
Weight:
Revsion note: Updated reference to AS/NZS 1891.4:2009
AIP ApS
Rønnevangs Allé 6
Valid from:
2014-05-30
Stamp:
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.
72 AVANTI Service Lift for Wind Turbines
Australia
Avanti Wind Systems PTY LTD
203 Blackburn Rd, MT Waverley, VIC 3149
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
45540024 – Shark Lift manual CE - EN
13th CE Edition: July 2015
Revision 2: 22/12/2015
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, India
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: [email protected]