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AVANTI SERVICE LIFT
User’s Manual
Model Service Lift OCTOPUS L80
Original instructions
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Date of publication:
1st Edition: 09/2017
Revision 3: 15/10/2018
Manufacturer:
AVANTI Wind Systems A/S
Rønnevangs Allé 6
3400 Hillerød Denmark
P: +45 4824 9024
F: +45 4824 9124
E: info@avanti-online.com
I: www.avanti-online.com
Sales & Service:
Australia Avanti Wind Systems PTY LTD P: +61 (0) 3 9585 1852
China Avanti Wind Systems P: +86 21 5785 8811
Denmark Avanti Wind Systems A/S P: +45 4824 9024
Germany Avanti Wind Systems GmbH P: +49 (0) 41 21-7 88 85 – 0
Spain Avanti Wind Systems SL P: +34 976 149 524
UK Avanti Wind Systems Limited P: +44 0 1254 399923
USA Avanti Wind Systems, Inc P: +1 (262) 641-9101
India Avanti Wind Systems India (P) Ltd P: +91 95 00 173 492
Brazil Avanti Brasil Sistema Eólicos LTDA P: +55 85 9 9955-0090
Manufactured Under Process Patent NO.8,499,896.
® Registered in Europe
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AVANTI Service Lift for Wind Turbines
Contents
Page
1. Limited warranty ................................................................................................................................................................................. 5
2. Introduction ......................................................................................................................................................................................... 6
2.1 Observations .................................................................................................................................................................................. 6
2.2 Symbols ......................................................................................................................................................................................... 6
2.3 Cautions ......................................................................................................................................................................................... 7
2.4 Terms and definitions ..................................................................................................................................................................... 7
3. Description .......................................................................................................................................................................................... 8
3.1 Purpose .......................................................................................................................................................................................... 8
3.2 Scope ............................................................................................................................................................................................. 8
3.3 Exclusions ...................................................................................................................................................................................... 8
3.4 Technical specifications ................................................................................................................................................................. 8
3.5 Dimensions .................................................................................................................................................................................... 9
3.6 Components .................................................................................................................................................................................. 10
3.6.1 Overview ........................................................................................................................................................................... 10
3.6.2 Traction hoist..................................................................................................................................................................... 11
3.6.3 Fall arrest device ............................................................................................................................................................... 11
3.6.4 Traction and safety wire ropes .......................................................................................................................................... 11
3.6.5 Main control box ............................................................................................................................................................... 12
3.6.6 Control boxes ................................................................................................................................................................... 12
3.6.7 Platform fences ................................................................................................................................................................. 13
3.6.8 Main service lift door......................................................................................................................................................... 13
3.6.9 Ladder access door .......................................................................................................................................................... 13
3.6.10 Sliding window ................................................................................................................................................................ 14
3.6.11 Maintenance cover ......................................................................................................................................................... 14
3.6.12 Bottom hatches .............................................................................................................................................................. 14
3.6.13 Top hatches .................................................................................................................................................................... 14
3.6.14 Bottom obstruction device ............................................................................................................................................. 14
3.6.15 Top obstruction device ................................................................................................................................................... 15
3.6.16 Top normal limit switch ................................................................................................................................................... 15
3.6.17 Manual descent system .................................................................................................................................................. 15
3.6.18 Overload limiter ............................................................................................................................................................... 15
3.6.19 Internal light .................................................................................................................................................................... 16
3.6.20 Warning lights and buzzer .............................................................................................................................................. 16
3.6.21 Anchor points .................................................................................................................................................................. 16
3.6.22 Rescue pendant control.................................................................................................................................................. 16
3.6.23 Information signs and documents .................................................................................................................................. 17
3.6.24 Travelling cable pulley ..................................................................................................................................................... 17
3.6.25 Fasten kit ........................................................................................................................................................................ 17
4. Instructions for use ............................................................................................................................................................................... 18
4.1 Daily inspection.............................................................................................................................................................................. 18
4.2 Prohibited uses .............................................................................................................................................................................. 19
4.3 Entry and exit ................................................................................................................................................................................. 19
4.4 Stop/Emergency stop .................................................................................................................................................................... 19
4.5 Operation from inside the cabin .................................................................................................................................................... 19
4.6 Operation from outside the cabin .................................................................................................................................................. 19
4.7 Overload limiter .............................................................................................................................................................................. 20
4.8 Manual descent ............................................................................................................................................................................. 20
4.9 Fall arrest device ............................................................................................................................................................................ 20
4.10 Troubleshooting ........................................................................................................................................................................... 21
4.11 Out of service ............................................................................................................................................................................... 23
Appendix A: Daily Inspection Log ............................................................................................................................................................ 24
Appendix B: Stomp-test Instruction......................................................................................................................................................... 34
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User’s Manual
1)
Avanti service lift (“Product”)
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 Product
1)
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.
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.
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AVANTI Service Lift for Wind Turbines
2. Introduction
2.1 Observations
Only trained people may use this lift.
This manual must be available to staff at all times during installation, maintenance and operation.
Additional copies are available from the manufacturer upon request.
This manual, including, but not limited to, measurements, procedures, components, descriptions,
instructions, recommendations and requirements, is subject to change without prior notice. Please check
Avanti website/manuals for the latest revisions of the manuals.
Any additional cost related to or arising from any changes in the manuals does not entitle Customer to any
form of compensation or other legal remedies.
!
The pictures and sketches in this manual may not reflect the product aesthetics, colours, arrangement precisely.
This has no impact on the function or safety.
2.2 Symbols
Symbol Signal word Meaning Possible injury if not observed
Safety instructions
STOP
DANGER!
IMMEDIATE or possibly
imminent danger:
Death or severe injury!
DANGER!
IMMEDIATE or possibly
imminent danger of
hazardous voltage:
Death or severe injury!
CAUTION!
Potentially hazardous
situation:
Light injury or material damage.
Additional instructions
!
ATTENTION!
Potentially dangerous
situation:
Damage to equipment or workplace
IMPORTANT!
Useful tips for optimum
working procedure
None
Order
Reference to written
specification/documentation
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User’s Manual
2.3 Cautions
Use and daily inspection of the service lift shall only
be performed by person who has gone through the
relevant training associated with the Avanti service lift
use and daily inspection and is in possession of a
valid (non expired) certificate for the task. Installation
and maintenance of the service lift shall only be
performed by Certified technicians.
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 PFPE (safety helmet, full
body harness, shock absorber, lanyard and slider)
at all times.
A copy of the User’s Manual must be handed out
to the personnel and must always be available for
reference.
If more than one person is entrusted with one of
the above tasks, the employer shall appoint a
supervisor in charge of the operation.
Electrical conection of the system must be made in
accordance with EN 60204-1.
Self-locking nuts must be used at all times. The
screw must extend from the nut by at least half of
the thread diameter. The nut may not be used once
it has become possible to loosen by hand!
If any damage or faults are found during operation,
or if circumstances arise which may jeopardize
safety: immediately interrupt the work in progress
and notify the supervisor or employer!
All tests/repairs of electrical installations may only
be performed by Certified technicians.
All repairs to the traction, braking and supporting
systems may only be performed by Certified
technicians.
If any supporting parts are repaired or replaced,
the operational safety of the system must be tested
and verified by Certified technicians.
Only original fault-free parts may be used. Use of
non-original parts will render the manufacturer’s
warranty void and any type approval invalid.
No modification, extension or reconstruction of the
service lift is allowed without AVANTI’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 AVANTI.
Service lift must be inspected by Certified
technicians before first use.
Service lift must be inspected at least once a year
or after 12,5 h. of use (whichever occurs first) by
Certified technicians.
Service lift is designed for a lifetime of 20 years
with an operating frequency of approximately 12,5
h/year (250 h in total).
Service lift may not be used by persons who are
under the influence of alcohol or drugs which may
jeopardize working safety.
The service lift shall not be used in case of fire in
the tower.
Service lift shall ONLY be used when the turbine is
not generating power.
All wind farm site specific rules must be followed.
Service lift shall not be used during inclement
weather, including wind speeds over 18 m/s.
Avoid injury – follow all instructions!
Owner must verify the need for third party
service lift inspections with the local authority
and comply with the standards specified.
2.4 Terms and definitions
Terms Definitions
Certified technician
Person who has gone through the relevant training associated with the scheduled task from Avanti
or from a certified trainer and is in possession of a valid (non expired) certificate for the task.
User
Person who has gone through the relevant training associated with the Avanti service lift use and
daily inspection and is in possession of a valid (non expired) certificate for the task.
Manual descent
Action performed to descend the lift at a controlled speed without power supply by manually
opening the hoist electromagnetic brake. (Also manual no-power descent)
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AVANTI Service Lift for Wind Turbines
3. Description
3.1 Purpose
The service lift purpose is to transport persons
plus their tools and equipment to the most
convenient height for performing work in wind
turbine generators (WTG).
Its use is limited to certified technicians. The
access to the WTG and consequently to the
service lift is controlled and forbidden to public
access.
The service lift is used primarily to transport
technicians, their tools and spare parts from the
bottom platform (or lowest accessible point) to the
top platform (or highest accessible point). It is also
used to access intermediate platforms where
inspection and service of WTG connecting bolts
and other equipment is made.
3.2 Scope
The Octopus L80 service lift system consists of
the following subsystems:
• Cabin.
• Traction and fall arrest systems.
• Guiding system.
• Control, safety and power systems
(including an interlock system on platform fence
doors1)).
• A rescue pendant control (only mandatory if
rescue route of service lift can be somehow
blocked).
Each of the subsystems listed above and their
components are described in detail throughout
the document.
3.3 Exclusions
The service lift shall not be used outdoor or in
potentially explosive atmospheres.
The service lift is not designed to carry a person
on its top.
The wind turbine manufacturer is responsible of
integrating the service lift and ensuring compliance
with the essential health and safety requirements
following AVANTI´s recommendations.
This will require supply of interface components,
including but not limited to:
• Ladder system.
• Brackets for ladder sections.
• Platform fences with doors.
• Power supply protection.
The wind turbine manufacturer shall also provide
any additional relevant warning, instruction and /
or training specific to the integration of the service
lift necessary for its safe and correct installation.
Tower manufacturer’s risk assessment
shall include a service lift integration
study.
3.3 Technical specifications
Service lift
Main door type Full sliding door
Main door interlock system Trapped key 1) / Guard locking
1)
Service lift speed 18 m / min ± 10 % (50 Hz)
21 m / min ± 10 % (60 Hz)
Rated load 240kg
Max. nº persons 2 persons
Max. travelling height (L80) 120 m
Operating temp (normal version) -15ºC to +60ºC
Survival temperature (normal version) -25ºC to +80ºC
Operating temp (Low temp version) -25ºC to +40ºC
Max. noise level 80 dB (A)
1)
Note: Optional feature.
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3.5 Dimensions
2750192
1040
2680
800
975
1)
1)
Platform level switch location may be
different due to wind turbine design.
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AVANTI Service Lift for Wind Turbines
3.6 Components
3.6.1 Overview
1 Traction system
2 Fall arrest device
3 Cabin light
4 Anchor points
5 Maintenance cover
6 User control box
7 Bottom obstruction device
8 Guide ladder
9 Guiding rollers
10 Main control box
11 Hour counter
12 Ladder access door
13 Full sliding door
14 External controls
15 Top obstruction device
16 Safety wire rope
17 Traction wire rope
18 Travelling cable pulley
15
17
16
18
11
14
13
10
8
9
2
12
7
6
5
4
3
1
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User’s Manual
Traction system Fall arrest device
3.6.2 Traction system
Service Lift Hoist
Lifting
capacity
Wire rope
speed
Power
Rated
current
Traction
wire rope Ø
Unit weight
approx.
Version Traction system type Kg m/min kW A mm Kg
Octopus L80 M508 / 400V 50Hz
500 18 1.5 4.1 8.4 50
Octopus L80 M508 / 400V 60Hz
500 21 1.8 4.9 8.4 50
3.6.3 Fall arrest device
Service Lift Fall arrest device Lifting capacity
Safety
wire rope Ø
Unit weight
approx.
Version Type Kg (lbs) mm Kg (lbs)
Octopus L80 ASL 508
500 (1100) 8.4 7 (15.4)
3.6.4 Traction and safety wire ropes
Service Lift Version Wire rope type
Wire rope
diameter
Surface
Treatment
Mark/
feature
Min. break
resistance
Attached
with
Octopus L80 M508 / ASL 508
8.4 mm, 5x19 HDG no 55 kN 2 t shackle
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AVANTI Service Lift for Wind Turbines
3.6.5 Main control box
Hour counter
3.6.6 Control boxes
3.6.6.1 Cabin control box
Trapped key switch
1)
(Optional feature. Not
applicable when
guardlocking
1)
system
is installed)
Internal emergency stop button
Platform
level lamp
OK
lamp
Fall arrest device
triggered lamp
Internal
UP button
(for manual
function)
Internal
DOWN button
(for manual
function)
External UP
button (for
send function)
External
emergency
stop button
External
DOWN button
(for send
function)
Override key of bottom
obstruction switch
Overload/Warning buzzer
3.6.6.2 Bottom platform electrical protection box
Main switch
1)
Note: Optional feature.
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User’s Manual
3.6.7 Platform fences
They must conform to EN 14122, be 1,1 m high
and be equipped with doors. These are monitored
with a trapped key system1) that permits fence
door to be opened only when service lift is present.
Trapped key1) is attached to cabin by means of a
wire rope, preventing loss of key.
Optionally, the platform fences can be equipped
with a guard locking system1) keeping the door
locked while the service lift is not at the platform.
The door is unlocked when the service lift is at the
platform with the lift detection switch activated.
The ready light is ON when the door is closed.
During emergency use, for example, power cut,
need of evacuation or rescue, the door guard
locking switch can be unlocked by acting the
mechanical Door Manual Release system from
outside the fence, or from inside the fence.
3.6.8 Main service lift door
Main access to the cabin is done through the full
sliding door installed on the front.
The full sliding door opening dimensions are
2070 x 500 mm.
It features a guard locking system that:
• Prevents service lift to travel if the door is open.
This opening condition is monitored by the guard
locking switch.
• Permits door to be opened only when service lift is
levelled with a platform. This levelling condition is
monitored by the platform level switch which is
triggered by the safe zone plates.
It is possible to manually release guard locking
system in order to open main door between
platforms for maintenance tasks or installation of
WTG parts.
External manual release
of guard locking.
Internal manual release
of guard locking.
3.6.9 Ladder access door
Ladder access door consists of two hinged sheets
that fold up when opened, thus optimizing space.
In case of evacuation, the ladder access door
permits direct access to ladder and ladder rail.
A safety switch interrupts control when door is open.
Safe zone plate
(on all platforms)
1)
Note: Optional feature.
1)
Platform
level switch
1)
Platform level switch location may be
different due to wind turbine design.
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AVANTI Service Lift for Wind Turbines
3 6.10 Sliding window
It consists of 2 perforated sheets that slide
horizontally.
The sliding window can be opened at any time. If the
window is opened, a safety switch that monitors
the closed function will stop the service lift.
1. Perforated sheets
2. Window switch
1 2
STOP
The sliding window shall not be used for
accessing or exiting the cabin!
STOP
During the manual descent, the doors,
window and hatches of the lift shall be kept
closed. Don not extend body parts outside
the cabin during travel.
3.6.11 Maintenance cover
Maintenance cover allows safe and fast inspection
of traction and safety wire ropes from inside the
cabin while travelling.
3.6.12 Bottom hatches
Bottom hatches can be opened from both sides,
thus allowing egress and ingress from underneath.
Bottom cabin hatch opens inwards, and bottom
obstruction device hatch opens outwards.
Each of them has a safety switch that interrupts
control when hatch is opened.
Once top hatches and ladder access door are
open, clear area is at least 500 x 500 mm, and
ladder becomes totally accessible.
Direct evacuation to ladder is possible at any
position along the WTG.
3.6.13 Top hatch
Top hatch can be opened from both sides, thus
allowing egress and ingress from above.
It has a safety switch that interrupts control when
hatch is opened.
Top obstruction device hatch opens outwards.
Once top hatches and ladder access door are
open, clear area is at least 500 x 500 mm, and
ladder becomes totally accessible.
3.6.14 Bottom obstruction device
Bottom obstruction device interrupts descent if:
• It encounters an obstacle.
• It reaches the bottom platform.
Ascent will still be possible, for instance to remove the
obstacle. In order to put the service lift on the ground,
the contact plate functionality can be bypassed with the
override bottom obstruction device switch located on
the cabin control box. To do so, turn the override bottom
obstruction switch key while pressing the down button.
Release the DOWN button as soon as the
rubber bumpers hit the floor. Otherwise
the service lift or the installation may get
damaged.
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User’s Manual
A mechanical bottom obstruction device switch
permits the bottom obstruction device to be still
operational during manual descent. Manual descent
will be stopped if an obstacle is encountered.
Guiding shaft &
supporting wire
Bottom
obstruction
switches
Bottom
obstruction
device (plate)
Guiding shaft &
supporting wire
Mechanical bottom
obstruction device
switch
3.6.15 Top obstruction device
Top obstruction device interrupts ascent if it
encounters an obstacle. Descent will still be
possible, for instance to remove the obstacle.
When the top obstruction device switches
are engaged, press the down button until
it disengages.
!
Do not use the service lift until the top
obstruction device switch fault has been
rectified.
Guiding shafts
with spring (x4)
Top obstruction
switches
Top obstruction
device (plate)
3.6.16 Top limit switch
Top limit switch interrupts ascent if it is triggered
by the top plate.
Emergency top limit switch is triggered in case the
top limit switch fails to engage. It cuts off power
supply, so only manual descent will be possible.
These switches are located on the top of the cabin,
beside safety and traction wire ropes.
Top limit plate is mounted attached to traction and
safety wire ropes.
Top limit plate
3.6.17 Manual descent system
The service lift features a manual descent system
that can be used in case of emergency.
To activate it, push the manual descent actuator
fully upwards. The electromagnetic motor brake is
released.
The service lift descends with a controlled speed
limited by means of a centrifugal brake installed
between the motor shaft and the gear box.
3.6.18 Overload limiter
An overload limiter is built into the traction hoist. In
case of an overload, it will prevent the upward
travel and a buzzer will sound, until overload
condition is eliminated.
STOP
Attempting to run in an overloaded lifif is
prohibited!
Performing a manual descent in case of an
overloaded lift is prohibited!
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AVANTI Service Lift for Wind Turbines
3.6.19 Internal light
The service lift is equipped with a light inside the
cabin. When service lift is connected to power
supply, this light illuminates at all times.
The internal light is battery packed in order to
illuminate the inside of the cabin in case of a power
failure. When fully charged, it will last at least for 90
minutes.
3.6.20 Warning lights and buzzer
A set of warning lights is mounted on the top and
on the bottom of the service lift. The flashes warn
that the service lift is moving.
When actuating the external UP or DOWN buttons,
response of cabin is delayed while the warning
lights are flashing and the warning buzzer sounds,
in order to warn personnel in the surroundings that
cabin is going to move.
Overload/Warning buzzer
3.6.21 Anchor points
The service lift features two anchor points inside
the cabin.
STOP
Each anchor point may only be used by one
user simultaneously.
During operation personnel must hook themselves
up to the anchor points inside the cabin, in order to
prevent falling risks. In case of need of evacuation,
the evacuation procedure will be followed.
3.6.22 Rescue pendant control
Rescue pendant control is only mandatory if
rescue route of service lift can be somehow
blocked. A blocked rescue route is an event where:
• A person is unconscious inside the service lift,
blocking the bottom hatch,
• the rescuer is below service lift, and
• the service lift is stopped halfway through a
platform hole, blocking rescue route since
platform has no extra hatch.
!
There shall be one rescue pendant control
per WTG; and it shall be stored in the
WTG bottom platform. A clearly visible
sign shall indicate its exact location.
It features three buttons: UP, DOWN and
emergency stop button. When necessary, pendant
control is plugged to cabin bottom socket. It has a
4 m long cable that permits service lift to be
powered up/down that same distance. When
plugged, pendant control does not override any
safety switch. If any of them is triggered, no running
will be possible; including the obstruction device
switches. Therefore, there is no risk of moving
service lift hitting rescuer. Pendant control
overrides cabin control box, and service control
box if installed.
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User’s Manual
3.6.23 Information signs and documents
The manual and quick guide are accessible from
inside the cabin. The following documents, signs
and labels are supplied with the service lift and
shall always be available.
A rescue pendant control emergency sign shall be
present at the bottom platform, clearly indicating
storage location of rescue pendant control.
Location Document
Cabin
Serial number plate
Manual documents inside blue bag
Quick guide document
Use of PFPE label sign
Working load limit / Nº persons label
Manual descent label
Fall arrest deactivation label
Fall arrest activation label
Main door guardlocking labels
No standing on top prohibition label
Fasten kit sticker
For one person only sticker (anchor
point)
Remove eye nuts stickers
Pull to open sticker (ladder door)
Evacuation guide
Main control box
Wiring diagram
Electrical hazard warning label
Bottom platform
Rescue pendant control emergency sign
3.6.24 Travelling cable pulley
Travelling cable is connected from power supply
socket over mid tower´s height platform to service
lift socket and it is provided with a cable relief on
each end. A travelling cable pulley is suspended
on the cable and is guided along the traction and
safety wire ropes.
Traction
wire rope
Travelling
cable
Travelling
cable pulley
Safety wire rope
The travelling cable pulley straightens the cable at
all times.
3.6.25 Fasten kit
The service lift features an special tool, called
Fasten kit, for mechanically blocking the lift in
order to perform installation/maintenance tasks
below the suspended cabin. This kit is located
inside the cabin.
It consists in a M16 screwed rod, that must be
inserted through a hole of the top rollers assembly
and along a rung of the guiding ladder, and finally
blocked with a M16 nut.
Fasten
kit
M16 nut
M16 screwed rod
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AVANTI Service Lift for Wind Turbines
4. Instructions for use
4.1 Daily inspection
Daily inspection of the service lift shall
only be performed by the user. If there is
more than one user, the employer shall
appoint a supervisor in charge of the daily
inspection.
4.1.1 Overall
Visual Inspection:
a) Check that the cabin has no damages.
b) Check that the top and bottom obstruction
devices are free of damages.
c) Check that the traction and safety wire rope
ropes are correctly fed and guided.
d) Record the hour counter reading on the “Daily
Inspection Log” Appendix.
4.1.2 Travel zone
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.
4.1.3 Control and safety devices
4.1.3.1 Cabin control from inside the cabin
a) Close the doors. Press the EMERGENCY
STOP button.
The lift should remain still when the UP/DOWN
button is pressed. To restart, pull the
EMERGENCY STOP button.
b) Test the EMERGENCY top limit switch:
During upward travel, press the switch manually,
and the service lift shall stop immediately. Neither
upward nor downward travel should now be
possible.
c) Bottom obstruction device. Lower the lift; It
shall stop before the rubber feet of the cabin
reach the tower ground level.
d) Door switch:
Open the door – it shall not be possible to move
the lift upwards or downwards.
Place the cabin at a height no corresponding to
platform – it shall not be possible to open the
door.
The door is only able to open by turning the
emergency release lever up.
e) Key switch ON/OFF (if installed):
Turn the key to OFF – it shall not be possible to
move the lift upwards or downwards.
f) Top obstruction device:
activate device by pressing it down. The service
lift shall not move up until device is released.
STOP
If any faults occur during work,
- stop working,
- if required secure the workplace and
- rectify the fault!
!
Make sure that nobody is exposed to danger
below the service lift, for instance from
falling parts.
g) Fall arrest device. Activate the fall arrest device
by pulling down the red locking handle. Press and
hold the DOWN button of the cabin control box.
The service lift should not descend. Try to
perform manual descent. The service lift should
not descend. Press and hold the UP button of the
cabin control box. The service lift should ascend.
Unlock the fall arrest device by pulling down the
black unlocking handle.
There is a supplementary method to check the
FAD functionality, called ‘Stomp Test’. The
procedure is explained in the ‘Stomp-test
Instruction’ Appendix.
4.1.3.2 Cabin control from outside of the cabin
– Automatic send
The automatic mode function is only available
from the control buttons outside of the cabin and
shall be checked as follows:
a) Press the UP button. The warning lights start
flashing and the warning buzzer will sound. Once
the delay time response of cabin is finished, the
service lift should travel upwards.
b) Press the EMERGENCY STOP button on the
control box. The lift stops.
c) Pull the EMERGENCY STOP button and press
the DOWN button. The warning lights start
flashing and the warning buzzer will sound. Once
the delay time response of cabin is finished, the
service lift should travel downwards until the
bottom obstruction device engages.
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User’s Manual
4.2 Prohibited uses
STOP
The consequences of not following below
prohibitions are extremely hazardous to the
physical integrity of the users.
When using the service lift it is prohibited to:
• Use the service lift beyond its intended purpose.
• Operate the service lift without following the
safety warnings and operating instructions.
• Overload the service lift more than its rated load.
• Try to repair machine components. Only certified
technicians are allowed to perform service on the
machine.
• To use the ladder while service lift is being used.
• To use the ladder, unless service lift is out of
service, or in case of evacuation or rescue.
• To manipulate switches and safeties.
• To place objects on service lift roof.
• To travel on service lift roof.
• To use the emergency manual release of the
guard locking of door lift or fence doors
1)
during
normal use.
• To disattach trapped key
1)
from wire rope.
• To have a second trapped key 1).
4.3 Entry and exit
To ensure safe entry and exit:
a) Lower the service lift onto the access platform
until the bottom obstruction device 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.
4.4 Stop/Emergency stop
a) Release the Up or Down button; the service lift
should stop.
If it does not:
b) Push the EMERGENCY STOP button, and all
controls should be disabled.
4.5 Operation from inside the cabin
a) Close the door
b) The key switch ON/OFF should be ON (if available)
c) To go up or down, push and hold the Up or
Down button.
d) To place the service lift on the floor after the
bottom obstruction device has stopped the lift.
- Turn the override bottom obstruction device
switch clockwise and hold.
- Press the DOWN button until the service lift
rests on the floor, then release.
4.6 Operation from outside the cabin
(automatic send configuration)
Transportation of people is forbidden if the
operation is controlled from outside the cabin
Operation by means of the user control box:
a) The key switch ON/OFF should be ON (if
available).
b) Close the door.
c) Press the UP or DOWN button respectively
and the cabin starts ascending/descending.
STOP
Transportation of people is forbidden if the
operation is controlled from outside the
cabin
!
When actuating the external UP or DOWN
buttons, response of cabin is delayed while
the warning lights are flashing and the
warning buzzer sounds, in order to warn
personnel in the surroundings that cabin is
going to move.
STOP
Before closing the lift door, ensure that your
equipment (i.e.lanyards) do not get trapped/
tangled with the closing door and/or with
surrounding elements.
STOP
To prevent the lanyards from tangling with
surrounding elements, keep them properly
attached to your body harness.
STOP
To prevent the lanyards from tangling with
the moving service lift, do not get close to
the hoistway.
1)
Note: Optional feature.
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AVANTI Service Lift for Wind Turbines
4.7 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
Attempting to run in an overloaded lift is
prohibited!
Performing a manual descent in case of an
overloaded lift is prohibited!
b) Remove enough of the load to make the
buzzer stop and enable upward travel.
!
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 overload limiter 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 a certified
technician adjust the overload limiter (Refer
to “Regulation of overload limiter” Appendix
in Installation and Maintenance Manual).
4.8 Manual descent
If a power failure or an operation fault etc.
interrupts the hoist, a manual descent is possible
from inside the cabin.
1. The lever is attached underneath the cabin top.
Turn it down.
2. Push the lever upwards the full way. The service
lift moves downwards. The built-in mechanical
overspeed limiter limits the pace of descent.
3. To stop, simply loosen the lever.
4. After manual descent, the system must be
5. checked by a certified tecnician.
STOP
During the manual descent, the doors,
window and hatches of the lift shall be kept
closed. Don not extend body parts outside
the cabin during travel.
!
During manual descent if the bottom
obstruction device hits an obstacle, the
brake release lever is mechanically
disengaged so the further descent is
disabled. The system is automatically reset
once the obstacle is removed.
4.9 Fall arrest device
To lock the fall arrest device in an emergency:
• Pull down the red handle.
If the fall arrest device engages, simply disengage
it from inside the cabin until the fall arrest device
is unlocked by:
• Pulling the black handle downwards.
• However, this is not possible if the safety wire rope
is under tension. If this is the case:
1. Remove the load on the safety wire rope by
pushing the UP button taking the lift upwards a
few centimetres.
2. Manually open the fall arrest device until the fall
arrest device is unlocked by:
• Pulling the black handle downwards.
In case of no power and the fall arrest device is
locked with the safety wire rope under tension
evacuate the lift according to the “Evacuation
guide”.
Brake release lever.
PULL TO
UNLOCK (Black)
PULL TO
LOCK (Red)
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User’s Manual
STOP
Breakdown Cause Solution
The service lift
will neither go up
nor down!
DANGER!
Attempting to use the lift will jeopardize work safety.
A1 The fixed EMERGENCY STOP
button has been activated.
Deactivate the button in question by pulling
it until it pops out.
A2 Wire rope loop on traction hoist.
Damaged or defective wire rope or
wire rope outlet causes problems.
Stop work immediately!
Ask the supplier or manufacturer for help.
A3 The fall arrest device is
holding the service lift on the
safety wire.
a) Lift wire rope breakage
b) Hoist failure
a) + b) Evacuate the service lift according to
the “Evacuation guide”.
A4 The service lift is stuck on
an obstacle.
Carefully remove the obstacle.
Test the operational safety of affected tower
sections. Inform the supervisor.
A5 Power failure
a) Control not switched on or
deactivated.
b) Grid voltage interrupted.
c) Supply between grid connection
and control interrupted.
d) Phase control relay tripped due to
wrong phase sequence.
a) Turn EMERGENCY STOP button to the
right until it is released.
b) Find the cause and wait for the power
to return.
c) Test and if necessary repair the supply
cable, fuses, and/or wiring from the
control box.
d) Check and correct phase lay at power
supply.
A6 Safety switch is triggered
a) EMERGENCY top limit switch
was pressed.
b) Door switch is not properly
closed or is defective.
c) Ladder access door switch is
activated.
d) A top or bottom hatch switch is
triggered.
a) Perform manual descent until the
emergency top limit switch is released.
b) Close the door and test the door switch.
c) Close the door.
d) Close the hatch.
A7 Protection switch on
overheating
a) A phase is missing
b) Motor is not cooling
c) Voltage too high/low
a) Test/repair fuses, supply and connection.
b) Clean the hood.
c) Measure voltage and power consumption
on the loaded motor. If voltage deviates
from specifications, use cable with
increased dimensions.
A8 Brake does not open
(no click on on/off)
a) Supply, braking coil or
rectifier defective.
b) Braking rotor closes.
a) Have a certified technician, repair/replace
the supply, braking coil and rectifier.
b) Return traction hoist for repair.
4.10 Troubleshooting
1. All tests and repairs to the electronic
components should be performed by certified
technicians only! The wiring diagram is
placed in the power cabinet.
2. Repairs to the traction hoist, the fall arrest
device and to the system’s supporting
components should be performed by
certified technicians only!
DANGER!
Unplug the power
supply before
opening the power
cabinet.
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AVANTI Service Lift for Wind Turbines
!
Breakdown Cause Solution
The service lift will
neither go up
nor down
A9 The key switch ON/OFF
has not been activated
(if installed).
Turn the key to ON.
A10 The main switch is in the
OFF position.
Turn the main switch ON.
A11 Rescue pendant control
is plugged.
- Use rescue pendant control in case of
rescue event.
- Otherwise, unplug pendant control.
Service lift goes
down but not up
Irresponsible behaviour
jeopardizes system
safety!
B1 The 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.
B3 Top obstruction /
top limit switch:
a) Top obstruction / top limit switch
is defective or not connected
properly
b) Top obstruction / top limit switch
is activated.
a) Test the top obstruction / top limit switch
connection/function. Replace it if
necessary.
b) Descend the service lift until the top
obstruction / top limit switch is released.
B4 A phase is missing
Test fuses and power supply.
B5 Fault in UP control circuit
in control box or traction system
Test and possibly repair connections,
wiring and relays.
Motor hums
loudly or wire
ropes squeak,
but the lift can
go both up and
down.
C1 Wire ropes dirty
WARNING!
Further use of lift may result
in damage to the wire rope
traction.
If possible, immediately replace
the traction system and return it for
test/repair at AVANTI.
STOP
DANGER!
Unplug the power
supply before
opening the power
cabinet.
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User’s Manual
Breakdown Cause Solution
Service lift will
go up but not
down!
Irresponsible behaviour
jeopardizes system
safety!
D1 The 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.
D2 The fall arrest device is
holding the service lift on
the wire rope.
a) Excessive hoist speed
b) Too low release speed on fall arrest
device.
A defective fall arrest device
will threaten the safety of
the service lift!
Replace immediately!
a) + b) Take the service lift upwards to
relieve the safety wire rope.
Unlock the fall arrest device by
turning the unlocking lever, 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.
D3 Fault in down controller
circuit on traction system
Insert brake lever into the traction system
and lower lift manually.
Test, and if necessary have connections,
wiring, and relays repaired.
D4 Bottom obstruction switch:
a) Bottom obstruction switch is
defective or not connected
properly.
b) Bottom obstruction switch is
activated.
a) Test the bottom obstruction switch
connection/function. Replace if
necessary.
b) Move lift up until the bottom obstruction
switch is released.
OK lamp not lit
although operation
is normal.
E A lamp is defective
Have an electrician replace it.
Loud noise and / or
smoke coming from
hoist motor
F Brake closed or partially closed
WARNING ! Damage of hoist brake
leading to brake function lost
Stop work immediately!
Call supervisor for advice and potential
repair of hoist
If these steps do not identify the cause and rectify the fault:
Consult a certified technician or contact the manufacturer.
4.11 Out of service
1. Securing the service lift:
Bring the service lift all the way down, until
the bottom obstruction device stops the
cabin.
2. Turn off the main switch to prevent
inadvertent operation of the lift:
Turn the main switch to the OFF position
Power supply is now interrupted. Mark the
lift “OUT OF SERVICE”. Contact the service
technician for repair.
STOP
STOP
DANGER!
Unplug the power
supply before
opening the power
cabinet.
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AVANTI Service Lift for Wind Turbines
Appendix B: Stomp-test Instruction
Supplementary way to inspect the ASL during Daily Inspection before Operation
Purpose
This instruction is a supplementary part of the Daily
Lift Checking to be used by authorized users and
Certified technicians. The information describes a
recommended and supplementary way of how to
check the over speed triggering and arresting
function in the Avanti Safety Fall Arrest Device
model ASL. Second, the test also documents that
the Safety Brake maintains its grip on the Safety
Wire after engagement. This extra testing we name
the “Stomp-test”. This stomp-test-method is
supplementary to the given daily obligation in your
manual explaining “to descend the lift, manually
engage the FAD (Fall Arrest Device), verification by
short no-powerdescent, unloading the FAD again
by ascending and observing centrifugal weigh unit
through the window during lift use”. With the
“Stomp-test” we test the ability of the FAD to trigger
in case of over speed and arrest the load.
Tools: None
Measurement Equipment: None
Validity
It is applicable for testing the installed Safety Fall
Arrest Device (ASL) on-site. The test must only be
performed by trained users/Certified technicians
and always with respect of all the relevant safety
regulations.
Cautions
Be aware that the instruction only explains the
steps of how to execute the “Stomp test” in the lift
installation; it doesn’t guide any safety precautions
and the necessary use of safety equipment.
Therefore, Avanti strongly recommends you to
read and understand what the physical work steps
in the “Stomp-test” are, and then execute your
own Risk and Hazard Assessment according to
the valid safety working procedures in your own
organisation before starting the test.
1. Test Preparation
The cabin (with 1 person inside) is ascended with
a service lift user inside, and the cabin bottom is
positioned (“parked”) in a height of app. 3 m/10 ft.
above the bottom landing floor platform.
2. Test Step
With the cabin in “parked” position app. 3 m/10 ft.
above the bottom landing floor, the user starts
descending by electrical power using the push
down button. When the cabin starts descending
the user executes a hard stomp with one foot in the
cabin floor – The hard stomp is executed by lifting
one foot, so the lower leg is positioned with a knee
angle of 90 degrees – Then immediately after the
foot is stomped in the cabin floor
- The user must make sure to have a solid footing
during the foot stomp!
The foot stomp should engage the ASL and arrest the
electrical descent of the cabin, the red light (if existing
in the control box) should turn “on” and the cabin load
should be hanging on the FAD/Safety Wire.
If the ASL doesn’t arrest at the first trial, then reestablish the cabin in the position described in the
preparation part mentioned above and execute the
“Step” once again stomping a little harder.
3. Test Result
If the ASL activates properly after the stomp, the
ASL will now hold the cabin on the Safety Wire.
In order to ensure important maintaining grip by the
Safety Brake, the user then activates the manual
descent function and result shall be a Safety Fall
Arrest Device ASL holding the cabin fixed on the
Safety Wire (manual descending is not possible).
- If the activated ASL fixes the cabin on the Safety
Wire while manual descent is activated, the
Safety Fall Arrest Device (ASL) is in good and
operational condition.
In order to release the activated ASL push the
ascent button up a little before releasing the ASL
by the unlocking handle.
- If the ASL can´t activate after first or second
“Stomp-test”, or can´t fix the cabin in activated
position
- User must immediately bring the cabin down
and park it at the bottom landing platform floor.
- Lock Out the installation from use and contact
Avanti for further approach!
- Document the execution of the above described
procedure in the Daily Inspection Log Appendix.
Any doubts regarding above instruction, please do
not hesitate to contact Avanti’s local representative
for help.
- www.avanti-online.com
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User’s Manual
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AVANTI Service Lift for Wind Turbines
Australia
Avanti Wind Systems PTY LTD
Unit 7 / 109 Tulip Street, Cheltenham Melbourne VIC 3192
P: +61 (0) 3 9585 1852
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. 8 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) 1254 399923
USA
Avanti Wind Systems, Inc.
11311 West Forest Home Ave. Franklin, Wisconsin 53132
P: +1 (262) 641-9101 · F: +1 (262) 641-9161
India
Avanti Wind Systems India (P) Ltd.
Old No. 28, New No. 41,
Vellala Street, Aiyanambakkam
Chennai 600095 · Tamil Nadu
P: +91 95 00 173 492
Brazil
Avanti Brasil Sistema Eólicos LTDA.
Rua João Paulo II, 131 Autódromo
Eusébio, Ceará 61760-000
P: +55 85 9 9955-0090
I: www.avanti-online.com · E: info@avanti-online.com
AT00014735 – Octopus L80 User’s manual, EN
1st Edition: 09/2017
Revision 3: 15/10/2018
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