Original instructions ® AVANTI SERVICE LIFT User’s, Installation and Maintenance Manual Model Service Lift PEGASUS
CE certificate of Pegasus CE versions:
AECO certificate of Pegasus AECO version:
Date of publication: 3rd CE Edition: 04/2014 Revision 2: 9/05/14 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.
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 1 2 3 Page Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Introduction . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 6.1 Maintenance planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 6.2 Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
2. Introduction 2.1 Observations Only trained people may use this lift. This manual must be available to staff at all times during installation, maintenance and operation. Additional copies are available from the manufacturer upon request. All measurements are indicative only and subject to change without notice. ! The pictures and sketches in this manual may not reflect the product aesthetics, colours, arrangement precisely. This has no impact on the function or safety. 2.
2.3 Cautions Use and daily inspection of the service lift shall only be performed by AVANTI or personnel authorised by AVANTI, hired by the employer for the job at hand. Installation and maintenance of the service lift shall only be performed by AVANTI or qualified personnel authorised by AVANTI, hired by the employer for the job at hand. Additionally, these tasks may be performed by qualified personnel authorised by a trainer authorised by AVANTI. warranty void and any type approval invalid.
3. Description 3.1 Purpose 3.3 Exclusions 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 personnel authorised by AVANTI holding the relevant training certificates. The access to the WTG and consequently to the service lift is controlled and forbidden to public access.
3.4 Technical specifications Service lift Cabin type Service lift speed Working load limit / Nº persons (max) Travelling height Operating Standard temperature1) Low Survival temperature 1) Traction system type Max.noise level Power supply IP protection / NEMA type 1) Control voltage CE versions Bucket type 2), front fence (1.1 m) with double door Full sliding door 19.4 m/min ± 10 % (50 Hz) 17.
3.5 Service lift overview 3.5.1 Bucket type 1) 1 2 3 7 5 6 4 8 9 1. Top obstruction device (frame) 1) 2. Top hatch 3. Double door 4. Main frame 5. Cabin control box 1) 2) 6. Fixed front 7. Anchor points for PPE (x2) 8. Bottom cabin hatch 9. Bottom obstruction device 10. Internal light 2) 11. Warning lights (x2) 2) Optional for CE versions. Not available for AECO version. Optional for Pegasus CE versions. Mandatory for AECO version.
THIS DOCUMENT AND ITS CONTENTS ARE PROPRIETARY TO AIP ApS AND PROTECTED BY COPYRIGHT. THEY ARE CONFIDENTIAL AND MAY CONTAIN LEGALLY PRIVILEGED INFORMATION. COPYING, SUBMITTING TO THIRD PARTIES OR USE IN ANY FORM AND FOR ANY PURPOSE OTHER THAN THAT ORIGINALLY INTENDED IS PROHIBITED WITHOUT THE EXPRESS PREVIOUS WRITTEN CONSENT OF AIP ApS. A 3.5.2 Full sliding door 1) 1 2 9 10 B 11 C 3 6 5 D 4 7 E 8 1. Top obstruction device (roof) 2. Top hatch 3. Full sliding door 4. Main frame 5.
3.6 General arrangement of Pegasus lift inside a generic WTG 2 1 4 6 11 7 3 9 8 5 10 INTERMEDIATE ARM FOR ELECTRIC CABLE This bracket is screwed to one of the anchorages of the installation. It is installed above the middle of the tower height, in order to allow the proper reeving of the electrical cable. 14 AVANTI Service Lift for Wind Turbines 1. Top platform 2. Top mechanical stop 3. Rest platform 4. Pegasus service lift 5. Anchorages 6. Junction box 7. Intermediate arm for electric cable 8.
3.7 Service lift dimensions 2642 2295 2850 1123 3.7.1 Bucket type 1) 598 777 768 996 Optional for CE versions. Not available for AECO version.
2 3.7.2 Full sliding door 1) 3 4 564 A 2) 2295 2850 2642 1988 2295 1123 B C D 996 989 E Optional for CE versions. Mandatory for AECO version. 996 777 750 1) 598 If top obstruction device (frame) 3) is installed, height is 2850 mm. 2) Optional for CE versions. Not available for AECO version.
3.8 Main frame The main frame is a welded steel structure. The traction and guiding systems are bolted to the main frame. 2 1 6 7 5 4 3 1. Main frame 2. Guiding rollers top 3. Guiding rollers bottom 4. Evacuation ladder 5. Traction system/ 2 Motor groups 6. Anti- derailment brackets 7.
3.9 Controls 3.9.1 Bottom platform control box CE Call only configuration: CE Send 1) and call configuration: 1 1 6 5 5 2 2 8 6 3 1 4 2 7 3 3 4 5 6 4 A 7 7 8 9 DIMENSIONS AECO configuration: B Rivet Nut M6 1 Rivet Nut M6 5 6 2 7 THIS DOCUMENT AND ITS CONTENTS ARE PROPRIETARY TO AIP ApS AND PROTECTED BY COPYRIGHT. THEY ARE CONFIDENTIAL AND MAY CONTAIN LEGALLY PRIVILEGED INFORMATION.
1) All components must fulfil CE, UL, CCC Standards 2) Parts in complience with RoHs 3) See electric diagram ED00101 4) Cold climate version: operational -25ºC / survival -30ºC Gray marking ISOMETRIC VIEW ( 1 : 5 ) 3.9.2 Cabin control box Description Article STB206012, STB Wall mounted enclosure IP66 200x600x120 57.504.9055.0 Earth terminal WK 4 SL/ U /V0 GREEN - YELLOW Cabin control box inside the cabin has control priority over control boxes at platforms. 57.904.5355.0 Fuse holder WK4 4MM2 8MM PRF. GR.
1 2 31 A 42 53 64 A DIMENSIONS DIMENSIONS 3.9.
3.10 Service lift doors 3.10.1 Double door 1) Main access to the service lift is done through the double door system installed on the front. The system consists of two hinged doors that open outwards. This door can be opened at any time. A safety switch monitors the closed function and interrupts control if the door is opened. If the doors are not closed properly, the fault light illuminates. The steps inside the cabin are provided with non-slip surface in order to prevent the risk of falling.
THIS DOCUMENT AND ITS CONTENTS ARE PROPRIETARY TO AIP ApS AND PROTECTED BY COPYRIGHT. THEY ARE CONFIDENTIAL AND MAY CONTAIN LEGALLY PRIVILEGED INFORMATION. COPYING, SUBMITTING TO THIRD PARTIES OR USE IN ANY FORM AND FOR ANY PURPOSE OTHER THAN THAT ORIGINALLY INTENDED IS PROHIBITED WITHOUT THE EXPRESS PREVIOUS WRITTEN CONSENT OF AIP ApS. 1 2 3 2 3 1) 4 3.10.2 Full sliding door A It consists of two perforated sheets that slide horizontally.
3.12 Lateral windows 1) TOP HATCH SWITCH Optionally, the service lift can be equipped with lateral windows 1). These windows facilitate service tasks of tower internals from inside the cabin. In order to open a window, the cabin trapped key must be removed and the window trapped key must be used. Both trapped keys are attached to the same wire rope, this way service lift cannot travel if a window is open.
3.15.1 Frame configuration The top obstruction device (frame) interrupts ascent if: 1. It encounters an obstacle. 2. It reaches the top platform. Descent is still possible; i.e. to remove the obstacle. 1) 1 TOP MECHANICAL STOP 2 3 TOP OBSTRUCTION SWITCHES (x2) 1) A TOP OBSTRUCTION DEVICE (FRAME) 1) 3.15.2 Roof configuration 2) The top obstruction device (roof) 2) interrupts control if it encounters an obstacle. The top limit switch 2) interrupts ascent if the service lift reaches top platform.
3.19 Traction system 3.21 Overload limiter The traction system is rack and pinion type. The system has two motor group working on the same rack. They are installed on the main frame of the cabin. Each motor groups has a centrifugal brake, a gear box, a pinion and a brake motor. Each motor brake includes a manual release lever allowing a manual descent in absence of electric current. The overload detection system prevents any movement of the service lift in the event of an overload.
3.24 Anchor points for PPE 3.26 Internal light 1) The service lift is equipped with two anchor points inside the cabin in bucket type version and three anchor points in full sliding door versions. In case of evacuation, the evacuation procedure must be followed (see “Appendix A: Safety measures”). 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.
(If MANUAL/AUTO selector 1) on cabin control box is provided) After using service lift and before exiting the WTG, the MANUAL/AUTO selector of cabin control box shall be turned to the AUTO position. This way it will be possible to call the lift from top platform if necessary. STOP 4.2 Prohibited uses The following prohibitions shall be observed when using the service lift. The consequences of not following them are extremely hazardous to the physical integrity of the users. It is prohibited to: 1.
To exit the cabin: 1. Attach the shock absorber to the cabin anchor point. 2. Open the hatch. 3. Climb out of the cabin using the handles 1) and the cabin main frame ladder as support. 4. Attach to the fall protection system or attach the shock absorber to a tower anchor point. 5. Release the shock absorber on the cabin anchor point. 6. Close the hatch. WTG manufacturer must ensure that access to the top platform or nacelle can be done safely to avoid risk of falling. 4.
6. Maintenance A maintenance is required and necessary: • To avoid premature wear • To prolong the lifetime of the machine • To maintain the level of safety which the service lift was designed and manufactured to. 6.2 Cautions STOP Before any maintenance operation check that the service lift is out of service. 6.
6.3.2 Visual inspection 1. Check that the service lift components are mounted in accordance with the specifications and without any noticeable defects or missing components. 2. Check that the traction system (ladder rack & pinion) is not damaged or jammed. 3. Check that the guided system is not damaged or jammed. 4. Check that the two motor groups are in good conditions and not damaged. measured on the primitive line shall range between 24.41 and 25.7 mm. A (loose) 24,41 A (nominal) 25.
6.4.2.3 Lubricate the rack Check status of old lubricant on rack and pinions. If maintenance required proceed as follows: 1. Place lift at bottom platform and disconnect power supply. 2. Clean old lubricant off the rack and pinions. 3. Use a grease gun and a zipper sleeve to lubricate low pinion through lubricating nipple. 6.4.3 Guiding rollers Check that the outer surface of the rollers is uniform and free from damage.
6.4.5 Torques Assurance Check tightening torques of all screw connections with approved and calibrated torque wrench in the following cases: 1. In tower factory, during assembly of ladder section to tower section. 2. On site, pre-commissioning, and in each annual inspection.
7. Troubleshooting ll tests and repairs to the electric components shall A be performed by AVANTI or qualified personnel authorised by AVANTI. epairs to the motor group and to the system’s R supporting components shall be performed by AVANTI or qualified personnel authorised by AVANTI. The wiring diagram is placed in the traction hoist’s power cabinet. Breakdown The service lift cannot ascend nor descend. STOP DANGER! Attempting to use the lift will jeopardize work safety.
Breakdown The service can descend but cannot ascend. The service lift can ascend but cannot descend. Cause Solution B1 The service lift is stuck under an obstacle. a) Carefully move the service lift downwards and remove the obstacle. b) Test the operational safety of the affected platform components. c) Inform the supervisor. B2 TOP OBSTRUCTION DEVICE is activated. a) Check the springs. b) Move the lift down until the top obstruction switches are released. B3 INDUCTIVE SENSOR is activated.
10. Storage The storage conditions shall be agreed with customer. If special storage requirements are needed, customer shall specify them to AVANTI prior to delivery. The following conditions shall be considered. 10.1 Before installation of service lift on WTG tower section Keep the service lift in its original packaging until it is mounted on the WTG tower section. Avoid direct contact of package with floor by placing a pallet under it. Position the pallet on a stable ground.
The gaps on the loading side of the service lift shall conform to applicable requirements of 5.11 of ASME A17.1-2013/CSA B44-13 1). Service lift 11.1.4 WTG electrical supply requirements Electrical supply requirements Version CE AECO Power Supply Type 3 Phase +PE + N 3 Phase + PE Voltage 400 V ± 5 % 400 V ± 5 % Frequency 50 / 60 Hz 60 Hz Fuses 16 A 16 A Protection Acc. To EN 60204 - 1 UL 508A Less than or equal to 65 mm (2.5 in.) Between 90 mm (3.5 in.) and 150 mm (6 in.
11.3 Assembly in tower factory 11.3.1 Top tower section 4. Install the top mechanical stops and the top limit plate (see Fig. 4 and installation drawing). Use 15 N·m torque for M8 and 50 N·m for M12. 1. Install and adjust upper ladder section at the top of the top tower section (see Fig. 1 and installation drawing). Use 15 N·m torque for M8 and 50 N·m for M12. Fig. 4 11.3.2 Intermediate tower sections 1. Install and adjust upper ladder section at the top of the intermediate tower section (see Fig.
2. Install the rest of the ladder sections from top to bottom (see Fig. 2). 3. Install the rest platforms approximately every 9 m (see Fig. 3 and installation drawing). 4. Position the cabin inside the bottom tower section ensuring that bottom guiding rollers are aligned with a ladder support (see Fig. 6). 11.4 Assembly on site After the tower sections are erected: 1. Climb up to the second tower flange. 2.
11.5 Electrical connections on site Electrical connections must be made in accordance with EN 60204-1 for CE versions and in accordance with UL 508A for AECO version. 12. Disassembling In accordance with local authority regulations disassemble in reverse order and dispose. 1. Install the top and bottom platform control boxes and connect the cable connections and the electrical boxes. Mandatory for CE bucket type version. Not available for CE full sliding door version. Optional for AECO version. 1) 2.
Appendix A: Safety measures In general: Only use service lift if you have 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. The following precautions and procedures are to be followed during operation of Service Lift, and if the Service Lift stops and the manual descent cannot be performed.
Appendix B: Inspection checklist Date: Serial nº traction system: Name of competent: Serial nº traction system 2: Lift nº: Total hours of operation: Tower nº: Address of installation: Serial nº ladder rack: 1 TRAVEL ZONE OK Not OK ISSUE DESCRIPTION OK Not OK ISSUE DESCRIPTION OK Not OK ISSUE DESCRIPTION OK Not OK ISSUE DESCRIPTION 1.1 Is the travel zone clear of obstacles? 2 CONTROL & SAFETY DEVICES 2.1 Is the cabin control box without dents, cracks and disparities? 2.
4.7 Are the connecting screws between the ladder sections and the ladder rack anchorages properly tightened? 4.8 Is the rack of each ladder section free of damages and within allowed wear limits? 4.9 Is the rack properly lubricated? 4.
11 PLATFORMS Does the service lift pass freely through all platform openings without hitting the WTG flanges, platform floors and platform fences? OK Not OK ISSUE DESCRIPTION OK Not OK ISSUE DESCRIPTION OK Not OK ISSUE DESCRIPTION Name of competent(s) in capital letters: Signature of competent(s): 11.1 11.2 Do platform fences fulfil specifications for proper mounting? 11.
Appendix C: Operation log sheet TYPE OF OVERALL RESULT INSPECTION Date & time (BEFORE FIRST USE, ANNUAL OR OK NOT OK UNSCHEDULED) 44 AVANTI Service Lift for Wind Turbines HOUR COUNTER ISSUE DESCRIPTION & COMMENTS NAME (IN CAPITAL LETTERS) & SIGNATURE OF COMPETENT
Appendix D: AVANTI lift anchor D.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.
D.3 Marking Marking on Lift Anchor plate: AVANTI product name European/American standard number ANSI Z359. l:2007 AS/NZS 1891.4:2009 Material and Capacity rating Unique identification number Item number After installation, marking shall be completely accessible; otherwise additional marking near the anchor device will be necessary. D.4 Installation The installation must be performed by a competent person following the instructions of this manual.
D.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.
D.7 Registration form of anchor Identification no.: Avanti Wind Systems A/S DK-3400 Hillerød Tel:+45 48 24 90 24 Fax: +45 48 24 91 24 www.avanti-online.com Avanti lift Anchor Date of purchase: Date first put into service: Periodic examination and repair history Date Reason for entry (per.
Appendix E: Service tool kit 1) E.1 Description E.2 Technical specifications <25 kg A B C F E D The service tool kit is an optional portable tool that allows a user Service tool kit DOCUMENT AND ITS CONTENTS ARE PROPRIETARY TO AIP ApS AND PROTECTED BY COPYRIGHT. THEY ARE CONFIDENTIAL AND MAY CONTAIN LEGALLY PRIVILEGED INFORMATION. to ride on THIS top of theTOservice installation and IS PROHIBITED WITHOUT THE EXPRESS PREVIOUS WRITTEN CONSENT OF AIP ApS.
THIS DOCUMENT AND ITS CONTENTS ARE PROPRIETARY TO AIP ApS AND PROTECTED BY COPYRIGHT. THEY ARE CONFIDENTIAL AND MAY CONTAIN LEGALLY PRIVILEGED INFORMATION. COPYING, SUBMITTING TO THIRD PARTIES OR USE IN ANY FORM AND FOR ANY PURPOSE OTHER THAN THAT ORIGINALLY INTENDED IS PROHIBITED WITHOUT THE EXPRESS PREVIOUS WRITTE B E.6 Information signs and documents The following information signs and documents are supplied with the service tool kit and shall always be available.
E F A ( 1:5 ) Reinforcement for installation of service tool kit Fixing bolts B A 1 C 2 Lifting Eyes D ARY TO AIP ApS AND PROTECTED BY COPYRIGHT. THEY ARE CONFIDENTIAL AND MAY CONTAIN LEGALLY PRIVILEGED INFORMATION. ANY FORM AND FOR ANY PURPOSE OTHER THAN THAT ORIGINALLY INTENDED IS PROHIBITED WITHOUT THE EXPRESS PREVIOUS WRITTEN CONSENT OF AIP ApS. D THIS DOCUMENT AND ITS CONTENTS ARE PROPRIETARY TO AIP ApS AND PROTECTED BY COPYRIGHT.
E.11 Instructions for use at intermediate and top platforms To egress to intermediate and top platforms from service tool kit: 1. Level service lift roof with platform floor. 2. Attach second fall arrest equipment to guiding ladder. 3. Release first fall arrest equipment from service anchor point. 3. Climb over service tool kit fence and overpass platform fence as specified by manufacturer. 4. Release fall arrest equipment from guiding ladder.
E.14 Troubleshooting Breakdown # The service tool kit cannot ascend nor descend. A1 Service tool kit can descend but cannot ascend. B1 Cause Solution It overrides cabin control box. Use service control box. Service emergency top limit switch (S13r) is activated. Perform manual descent from inside the cabin until switch is released. Service top limit switch (S1.1r) is activated. Descend service tool kit until switch is released. E.15 Inspection checklist 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.
Australia Avanti Wind Systems PTY LTD Unit 15 / 160 Lytton Road Morningside 4170 · Queensland P: +61 (0) 7 3902 1445 · F: +61 (0)7 3902 1252 China Avanti Wind Systems Building 4, No, 518, Gangde Road, XiaokunshanTown Songjiang District, 201614 Shanghai P: +86 21 5785 8811 · F: +86 21 5785 8815 Denmark Avanti Wind Systems A/S Rønnevangs Allé 6 · DK-3400 Hillerød P: +45 4824 9024 · F: +45 4824 9124 Germany Avanti Wind Systems GmbH Max-Planck-Str.
