Original instructions ® AVANTI SERVICE LIFT User’s, Installation and Maintenance Manual Model Service Lift PEGASUS
Date of publication: 2nd CE Edition: 06/2013 Revision 1: 14/06/13 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 Page Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1 2 Introduction . . . . . . . . . .
6.4 Yearly inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 6.4.1 Pinions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 6.4.2 Ladder rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 6.4.3 Guiding rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. Introduction 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 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 authorised 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.
3.4 Technical specifications 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) 992 x 717 x 2844 mm Inner dimensions (W x D x H) 976 x 481 x 2232 mm Door opening (full) (W x H) 920 x 1100 mm Top hatch dimensions (W x D) 640 x 400 mm Bottom hatch dimensions (W x D) Note: Optional feature. 600 x 400 mm 17.
3.5 Service lift overview 1 2 3 7 5 6 4 8 9 1. 2. 3. 4. 5. Top safety stop Top hatch Double door Main frame User control box 6. 7. 8. 9. 1) Fixed front Anchor point for PPE Bottom hatch Bottom safety stop Note: Optional feature.
3.6 General arrangement of Pegasus lift inside a generic wind turbine tower 2 1 4 6 11 7 3 8 9 5 10 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. 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. Intermediate platform 9.
2295 2850 1123 3.
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. 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 service lift is done through the double door system installed in 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. A mechanical lock is also installed to lock the doors together to the fixed front. From outside: turn the key clockwise to open the door, and anticlockwise to close it.
3.11 Top hatch The top hatch consists of a double hinged sheet, that minimizes necessary space to open it. This hatch is used to evacuate the service lift or to access the top platform. The dimensions of the clear opening are 640 x 403 mm. A switch interrupts control if the hatch is open or not properly closed. In this case the fault light illuminates. TOP HATCH SWITCH TOP HATCH SWITCH ACTUATOR The top hatch is mounted over a top floating frame.
3.12 Bottom hatch 3.15 Emergency limit stop switch The bottom hatch consists of a perforated sheet that opens inwards. It is used in case of evacuation. The emergency limit stop switch interrupts the control if top stop switches fail. To release the switch on the top plate: Perform manual descent some metres. This switch in triggered by the activation plates located on bottom and top platforms.
3.17 Traction system 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. 3.18 Guiding and anti-derailment system PINION GEAR BOX CENTRIFUGAL BRAKE It allows to descend with a controlled speed in case of emergency.
CELLS 3.19 Overload limiter FLOATING FLOOR Electronic equipment is installed inside the cabin control box. The overload detection system prevents any movement of the service lift in the event of an overload. In case of an overload, the overload light (yellow) illuminates. This system consists of a floating floor with four load cells. The load cells send the load signal to the electronic equipment. 3.
4. Instructions for use 4.1 Cautions Aspects to consider for a good use of the service lift: 1. No person is on the ladder when the service lift is in operation. 2. The elevator is free of objects. 3. No objects are located on the top of the cabin. 4. When the door is open user(s) MUST BE attached with shock absorber to an anchor point. 5. Electrical system is properly insulated. 6. The manual, the evacuation procedure and quick guide must be accessible in the cabin. 7.
4.8 Emergency stop button 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. Always wear all the PPE and attach the fall protection device in the fall protection rail system of the ladder. User(s) in a rest platform MUST ALWAYS BE attached safely to the fall protection system. 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. • Place cabin at bottom platform and disconnect power supply. • Use an electricity measuring tool when performing inspection of electrical components. 6.
2. Emergency stop: The service lift shall not move UP/DOWN. Release the emergency stop and drive the lift UP approximately 1 m. 3. Press UP/DOWN buttons on the control box. The lift should travel upwards or downwards. 6.3.3.2 CABIN CONTROL BOX: 1. ON/OFF button: Turn the ON/OFF button on the user control box to the OFF position. The green light shall be OFF. The service lift shall not run. Turn it ON; the green light shall be on. The service lift shall run. 2.
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 an authorised electrician only! epairs to the motor group and to the system’s R supporting components shall be performed by qualified installers only! 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 and descend but motor hums loudly. 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 is activated. a) Check the springs. b) Move the lift down until the top stop switches are released. B3 INDUCTIVE SENSOR is activated.
The components subjected to possible movement inside the tower may include, but are not limited to, dampers, wire ropes, cables, doors, hatches, etc. The service lift needs a gap of 500mm below the lowest landing area to accommodate the bottom buffers and power cable. 9.2 Cautions on site All installation process must be made according to the installation drawing supplied by AVANTI. Prior to installation, check the instructions and drawings.
9.3 Assembly in tower factory 9.3.1 Top tower section 4. Install the top mechanical stops and the top safety position 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 9.3.2 Intermediate tower sections 1.
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). 9.4 Assembly on site After the tower sections are erected: 1. Climb up to the second tower flange. 2.
9.5 Electrical connections on site 10. Disassembling Electrical connection of the system must be made in accordance with EN 60204-1. 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. 2. Use cable strips to attach the fixed cable to the tower internal (see Fig. 12). Fig. 12 3. Conect power supply cable.
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 OK Not OK ISSUE DESCRIPTION OK Not OK ISSUE DESCRIPTION 1.1 Travel zone is clear of obstacles. 2 CONTROL & SAFETY DEVICES 2.
6.7 The mid tower electric cable support is properly installed and tightened. 6.8 Bottom platform control box is free of damages. 6.9 Mid tower junction box is free of damages. 6.10 Top platform control box is free of damages. 7 TRACTION SYSTEM OK Not OK ISSUE DESCRIPTION OK Not OK ISSUE DESCRIPTION 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): 7.
Appendix C: Operation log sheet Date & time Date & time Type of inspection (before first use, annual or unscheduled) Type of inspection (before first use, annual or unscheduled) Overall result OK Not Ok Overall result OK Not Ok Hour counter Issue description & comments Name (in capital letters) & signature of competent Hour counter Issue description & comments Name (in capital letters) & signature of competent User’s, Installation and Maintenance Manual 37
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 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. AVANTI LIFT ANCHOR is tested and approved only to be installed on AVANTI lift.
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.
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.
