AVANTI SERVICE LIFT User’s, Installation and Maintenance Manual Model Service Lift Pegasus
Date of publication: 1st CE Edition: 05/2012 Revision 3: 15/11/12 Manufacturer: Avanti Wind Systems SL Poligono Industrial Centrovia Calle Los Angeles n°88 Nave 1 50198 La Muela (Zaragoza) Spain P: (+34) 976 149 524 F: (+34) 976 149 508 E: info@avanti-online.com I: www.avanti-online.com Avanti Wind Systems, Inc.
Only trained people may use this lift. This manual must be available to staff at all times during installation, maintenance and operation. Additional copies are available from the manufacturer upon request. All measurements are indicative only and subject to change without notice. Contents Page 1 Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 6.1 Maintenance planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 6.2 Daily inspection by the supervisor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 6.3 Yearly inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 Avanti service lift (“Product”) described in this Manual will be free from defects in material and workmanship under normal use and service when installed and operated in accordance with the provisions of this Manual.
2. Explanation of symbols used in this manual 2.1 Symbols used in this manual 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.
2.2 Cautions CAUTION! Avoid injury – follow all instructions! m) All tests/repairs of electrical installations may only be performed by qualified electricians. a) 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. n) All repairs to the motor group: gear box, centrifugal brake, motor brake and instead of supporting parts may be performed only be qualified fitters.
3. Description 3.1 Purpose 3.3 Exclusions The Service Lift described in this User’s Manual serves the following purposes: - Transportation of staff and material inside wind turbine systems. - Transportation for mounting, inspection and repairs. The service lift may be used to transport persons plus their tools and equipment to the most convenient height for performing work on the tower. Please read Cautions section for limitations and exclusions of the service lift operation of the service lift. 3.
3.4 Technical specifications 3.4.1 General specifications service lift 3.4.3 Cabin dimensions Service lift Cabin Cabin type Bucket type, front fence (1.1 m) with double door Service lift speed 19.4 m/min ± 10 % (50 Hz) Cabin weight 225 Kg Outer dimensions (W x D x H) 1060 x 715 x 2540 mm Inner dimensions (W x D x H) 990 x 525 (680) x 2200 mm Door opening (full) (W x H) 980 x 1120 mm Top hatch dimensions (W x D) 600 x 400 mm Bottom hatch dimensions (W x D) 600 x 400 mm 17.
3.5 Service lift overview 1 2 3 4 7 5 6 8 9 1. 2. 3. 4. 5. Top safety stop Top hatch Double door Main frame User control box 6. 7. 8. 9.
3.6 General arrangement of Pegasus lift inside a generic wind turbine tower 1 2 3 5 15 8 6 9 4 7 10 11 13 14 12 INTERMEDIATE ARM FOR ELECTRIC CABLE This bracket is screwed to one of the anchorages of the installation at a suitable height to allow the proper reeving of the electrical cable. 12 AVANTI Service Lift for Wind Turbines 1. User control box in top platform 2. Top platform 3. Top mechanical stop 4. Rest platform 5. Pegasus service lift 6. Anchorages 7. Junction box 8.
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3.8 Main frame The main frame is a welded steel structure. The traction and guiding system are bolted to the main frame. 2 1 6 7 5 3 1. 2. 3. 4. 5. 6. 7.
3.9 Controls 3.9.1 Bottom platform control box FAULT LIGHT (RED) Shines when there is an activated switch on the safety circuit i.e: Open door, emergency stop pressed, open hatch or the ON/ OFF buttons of the user control box is not in the ON position ON/OFF MAIN SWITCH UP/DOWN LIGHTS (GREEN) Shines when the lift is going up or down respectively. NOK DOWN BUTTON Press down button to call the lift to the bottom platform. OK READY LAMP (GREEN) Shines when the box has electric current.
3.9.3 Top platform control box UP/DOWN LIGHTS (GREEN) Shines when the lift is going up or down respectively. UP BUTTON Press continuously UP button to call cabin to top platform. NOK READY LAMP (GREEN) Shines when the box has electric current. OK FAULT LIGHT (RED) Shines when there is an activated switch on the safety circuit i.e: Open door, emergency stop pressed, open hatch or the ON/OFF buttons of the user control box is not in the ON position. EMERGENCY STOP Press to interrupt any control function.
3.10 Service lift doors Main access to the cabin is done through the double door system installed in the front. The system consists of two folding doors that open outwards. Each door has a door switch that monitors the closed function and stops or prevents any movement of the lift in case any of them is opened. The doors can be opened at any time and the switch door automatically interrupts the control and the movement of the cabin.
3.11 Top hatch The service lift has a top hatch made of two sheets with hinges. This ensures that the hatch can be opened in 2 steps minimizing the necessary space over the service lift top to get it opened. This hatch is used to evacuate the lift or access the top platform. TURN TO OPEN COMPLETELY The dimensions of the hatch are 600 x 400 mm. A switch with an independent actuator interrupts the control of any movement of the cabin if the hatch is open or not properly closed.
TOP HATCH TOP FLOATING FRAME TOP STRUCTURAL FRAME TOP FLOATING FRAME SWITCH 3.12 Bottom hatch The service lift has a bottom hatch made of one sheet which is opened inwards the cabin. It can be used in case of evacuation. (SEE APPENDIX A) BOTTOM HATCH SWITCH AND BOTTOM HATCH SWITCH ACTUATOR A switch ensures that the hatch is closed during operation. It interrupts the control of any movement of the cabin if the hatch is open or not closed properly. In this case the fault light shines.
3.14 Bottom safety stop The bottom safety stop will interrupt the up/ down movement if: 1) Encounters an obstacle. 2) Reaches the bottom mechanical stop installed on the bottom of the ladder. Upward travel will be possible from any user control box, for instance to remove the obstacle after necessary verifications. BOTTOM STOP SWITCHES BOTTOM SAFETY STOP BOTTOM MECHANICAL STOP 3.15 Emergency limit stop switch Emergency limit stop switch interrupts the control if top stop limit switches fail.
3.16 Top and bottom mechanical stops PINION Top and bottom mechanical stops including buffers are installed on top and bottom of the ladder to avoid derailment if the top stop/bottom stop and emergency limit stop switches fail. 3.17 Traction system The traction system is rack and pinion type. The system has two motor groups working on the same rack. They are installed on the main frame of the cabin. Each motor groups has a centrifugal brake, gear box, pinion and a brake motor.
3.19 Overload detection system FLOATING FLOOR Electronic equipment is installed inside the user control box. The overload detection system prevents any movement of the lift in the event of an overload. In case of an overload, the overload light (yellow) shines. This system consists of a floating floor with four load cells. The load cells send the load signal to the electronic equipment. Remove the overload restriction reducing the load. 3.
4. Lift Operation 4.1 Good use Aspects to consider for a good use of the service lift: A. No person on the ladder when the lift is in operation. B. The fall protection system is properly installed. C. The elevator is free of objects. D. No objects are located on the top of the cabin. E. When the door is open user(s) MUST BE attached with shock absorber to an anchor point. F. Electrical system is properly insulated. G. The manual, the evacuation procedure and quick guide must be accessible in the cabin. H.
4.8 Emergency stop Release the UP/DOWN buttons and the service lift should stop. If it does not, push the emergency stop, and all controls should be disabled. Turn / pull the emergency stop button to reset the control. 4.9 Manual operation In case of power failure or an operation fault, a controlled descent without power can be performed. To do so: Rest platforms must not be used unless necessary. For example if the service lift is out of service. 4.
6. Maintenance Pegasus Service lift maintenance is required and necessary: • To avoid premature wear • To prolong the lifetime of the machine • To maintain the level of safety which Pegasus was designed and manufactured to. 6.
6.3 Yearly inspection 6.3.1 Pinions Check carefully that the pinions are free from deterioration, damage or abrasion. A (nominal) 25.70 Wear limit: To evaluate the wear of the pinion, “A” dimension measured on the primitive line shall range between 24.41 and 25.7 mm (see figure) Pinion replacement criteria is shown on table below: DIMENSIONS (mm) NEW PINION (mm) CHANGE PINION ( mm) A 25.70 < 24.41 6.3.2 Ladder rack Check carefully that the rack is free from deterioration, damage or abrasion.
6.3.2.2 Looseness limit: To evaluate the looseness, check of control dimension “C” shall be between 57 and 59 mm. C (loose) C (nominal) F. Apply lubricant to top pinion from inside the cabin throughout ascend. G. Repeat lubrication throughout descend. H. If necessary clean excess of new lubricant off the rack. IMPORTANT! Clean and lubricate the rack every time you replace a section of the ladder. If use is made more severe, it will be necessary to lubricate more often.
6.3.5 Torques Assurance Check tightening torques of all screw connections with approved and calibrated torque wrench in the following cases: A. In tower factory, during assembly of ladder section to tower section. B. On site, pre-commissioning, and in each yearly inspection.
7. Repair in the event of breakdown 1. All tests and repairs to the electronic components should be performed by an authorised electrician only! The wiring diagram is placed in the traction hoist’s power cabinet. Breakdown The service lift will neither go up nor down! 2.
Breakdown Service lift goes down but not up Lift can go both up and down. Cause Solution B1 The service lift is stuck on an obstacle. Carefully move the service lift downwards and remove the obstacle. Test the operational safety of the affected platform components. Inform the supervisor. B2 TOP SAFETY STOP has been activated a) Check the springs b) Move the lift down until the top stop switches are released. B3 INDUCTIVE SENSOR has been activated a) Check section ladders.
9.1.4 Tower support brackets The ladder rack is attached to the tower structure at a distance of max 3000 mm. The tower support brackets must be so designed that the ladder rack anchorages can be mounted. The connection between the tower support brackets and the ladder rack anchorages is done with M12 bolts A2-70 tighten with a torque of 50 N•m in the tower factory but with a torque of 12 N•m on site once the tower has been erected and before the cabin is going up.
9.3 Previous considerations All installation process must be made according to the installation drawing supplied by AVANTI. C. Install the rest platforms approximately every 9 m according to the installation drawing as shown on figure below: Before starting installation, check the instructions and drawings. Verify that all the needed components and necessary tools are available. 9.4 Assembly in tower factory 9.4.1 Top tower section A.
B. Install the rest platforms approximately every 9 m according to the installation drawing as shown on figure below: 9.4.3 Bottom tower section C. Install the electric cable arm support like shown on the figure below according to the installation drawing. ! IMPORTANT! Not necessary for all intermediate sections. A. Follow same installation instructions as on points A and B for intermediate tower section. B. Position the cabin inside the bottom tower section. See figures below: C.
C. Take the service lift up to the first tower flange. Install one ladder section to join the lower tower section with the intermediate tower section. There will be a gap. Place the connection bolts but do not tighten them. See figures below: INTERMEDIATE TOWER SECTION LOWER TOWER SECTION D. Take the service lift down and loosen the anchorages screws to the tower of each ladder section. ! LOOSEN ALL THE ANCHORAGES AND SCREWS ATTENTION! Loosen the screws above the lift. E.
F. Go up with the service lift to the next tower section flange. Tighten all the ladder anchorage – ladder bracket screws M12 above the cabin with a torque of 12 N•m before the cabin is going up. ! B. Use cable strips to attach the fixed cable to the tower internal: ATTENTION! Tighten all the ladder anchorage tower bracket screws above the lift with a torque of 12 N •m. G. Repeat from C to F until all the tower sections are installed. H.
Appendix A: Safety measures when using AVANTI Pegasus lifts In general: The Service Lift is only to be used by personnel who has received instructions about how to operate the Service Lift in all predictable situations. These instructions can only be given by a person with the proper knowledge e.g Avanti Trainer or Trainer approved by Avanti.
Australia Avanti Wind Systems PTY LTD Unit 15 / 160 Lytton Road Morningside 4170 · Queensland P: +61 (0) 7 3902 1445 · F: +61 (0)7 3902 1252 China Avanti Wind Systems Building 4, No, 518, Gangde Road, XiaokunshanTown Songjiang District, 201614 Shanghai P: +86 21 5785 8811 · F: +86 21 5785 8815 Denmark Avanti Wind Systems A/S Høgevej 17-19 · 3400 Hillerød · Denmark P: +45 4824 9024 · F: +45 4824 9124 Germany Avanti Wind Systems GmbH Max-Planck-Str.
