AVANTI SERVICE LIFT User’s Manual and Installation Manual Model SHARK
Date of publication: 9th CE Edition: July 2010 Revision 3: 17/9/10 Manufacturer: AVANTI Wind Systems A/S Høgevej 19 3400 Hillerød Denmark P: +45 4824 9024 F: +45 4824 9124 E: info@avanti-online.com I: www.avanti-online.
Only trained people may use this lift. This manual must be available to staff at all times during installation and operation. Additional copies are available from the manufacturer upon request. All measurements are indicative only and subject to change without notice. Contents User’s manual 1. Limited warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. Explanations of symbols used in this manual . . . . . . . . . . 3. Cautions . . . . . . . .
6.6 Lifting force limiter . . . . . . . . . . . . . . . . . . . . . 7. Manual operation . . . . . . . . . . . . . . . . . . . . . . . . 7.1 EMERGENCY descent . . . . . . . . . . . . . . . . . . . 7.2 Manual ascent . . . . . . . . . . . . . . . . . . . . . . . . 8. What to do if the safety gripping device engages . . 9. Repair in the event of breakdown . . . . . . . . . . . . . 10. Out of service . . . . .
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 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.
3. Cautions CAUTION! Avoid injury – follow all instructions! 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. b) The personnel must be at least 18 years of age. The staff must be familiar with the relevant accident prevention instructions and must have received proper training in these. c) Personnel is obliged to read and understand this User’s Manual.
4. Description of equipment 4.1 Purpose 4.3 Service lift models The service lift described in this User’s Manual serves the following purposes: - transportation of staff and material inside wind turbine systems, lattice towers for wind turbines, and telecommunication towers. - transportation for mounting, inspection and repairs.
4.6 Components 4.6.1 Cabin overview Fig. 1a SHARK L sliding door Fig.
Fig. 1c SHARK L 4-door version Fig.
Fig. 1e SHARK L Half roller door Fig.
4.6.2 C abin with safety gripping device, traction hoist, electrical control box and pendant control Fig.
4.6.3 Technical data for the service lift M, L and XL Fig.
Fig. 3b Dimensions, double door Lifting capacity: • Motor X402P 240 kg • Motor M500 240 kg (max 2 persons) • Motor L502P 320 kg • Motor M500 320 kg (max 3 persons) M Weight of lift: L: kg 115 XL: kg 125 The weight of the power supply cable should be added to the weight of the lift (approx. 0.23 kg per m).
4.6.4 Drive system, safety gripping device and controls Fig. 4 Traction hoist M500 X402P 1 1 2 2 3 3 4 4 Fig. 5 Safety brake BSO 504E OSL500 1 Insertion point for brake lever 2 Motor 3 Wire traction w/overload protection 4 Drive system/ gearbox 7 6 Fig. 6 Electrical control box For M500 For X402P 12 11 7 6 8 Fig. 7 a Pendant control Fig.
4.7 Cabin safety devices 4.7.1 Safety brake Electromagnetic spring-loaded brake which engages automatically – on releasing the up/down push button and – following a power failure. 4.7.2 EMERGENCY STOP When the red EMERGENCY STOP (pendant control) switch is pushed in an emergency, all control is interrupted. After remedying the fault, control is reactivated by turning the switch clockwise, until it pops out again. 4.7.
by means of a switch. (Fig .9b) 4.7.10 Door stop switch 4.7.10.1 Sliding door: Sliding door is closed by pushing the actuator into the door guard locking switch. (Fig .15) The switch is unlocked by pushing the green button if the cabin is located at a height corresponding to a platform. In case of an emergency evacuation between platforms, the interlock is unlocked by pushing its emergency release red button from outside the cabin as well as using a M5 triangular key from inside the cabin. 4.7.10.
4.8.2 Trapped-key Interlock System The Trapped-key Interlock System uses a system of security locks installed on the fences. These locks can be opened by using a key placed into the lift. The key also activates the On/Off general switch placed into the service lift cabin. The key is linked to the lift by means of a wire rope, and can not be detached from it except using cutting tools.
5. Daily inspection by the supervisor If a safety device for fence doors is installed (see chapter 4.7 of the User’s manual), every platform fence door must be closed to be able to drive the cabin. 5.1 Service lift a) Before each operation, ensure that the traction hoist, the safety brake and all auxiliary components (stoppers, wire guide wheels, etc.) are mounted in accordance with the specifications and without any noticeable defects.
5.4 Automatic operation test Perform this inspection only if the AUTOMATIC function is installed. a) Press EMERGENCY STOP button on the pendant control. Turn the HAND/AUTOM. switch on the electrical control box to the right to activate automatic operation. (Fig. 13 page 20) b) Deactivate the EMERGENCY STOP button by turning the button clockwise. (Check the EMERGENCY STOP button fixed is deactivated.) The service lift should stand still. c) DO NOT try to activate the “automatic operation” switch.
6. Operation - lift transport If a safety device for fence doors is installed (see chapter 4.7 of the User’s manual), every platform fence door must be closed to be able to operate the cabin. Transportation of people in AUTOM. mode is forbidden. b) Press the EMERGENCY STOP switch on the pendant control. 6.1 Entry and exit c) Put the pendant control inside the holder. It should engage the automatic operation switch (fig.13b).
7. Manual operation (EMERGENCY) If a power failure or an operation fault etc. interrupts the lift, a manual EMERGENCY descent is possible. Fig. 14 1 7.1 EMERGENCY descent a) Open the manhole by pushing the lid in the roof and operate the lift from above. b) On top of the lift insert the lever into the break lever hole in front of the traction hoist (Fig. 14 (1)). c) Pull the lever upwards. The service lift moves downwards. The built-in centrifugal force brake limits the pace of descent.
8. What to do if the safety gripping device engages If the safety brake engages simply disengage by pushing down the lever (Fig. 16A) until it click. However this is not possible if the service lift is hanging on the wire - if so, see below. STOP Fig. 16 BSO DANGER! In the event of lift wire breaks or hoist fails, evacuate personnel from the service lift. The safety wire suspension and the attachment between the safety brake and the service lift are exposed to dynamic loads when a fall is blocked.
STOP DANGER! Avoid serious injuries: 9. Repair in the event of breakdown 1. All tests and repairs to the electronic components should be performed by an authorised electrician only! The power chart is placed in the traction hoist’s power cabinet. Breakdown The service lift will neither go up nor down! 2.
Breakdown The service lift will neither go up nor down Service lift goes down but not up DANGER! Unplug the power supply before opening the power cabinet. Motor hums loudly or wire ropes squeak, Cause Solution A8 The HAND/AUTOM. switch is on AUTOM. Turn the HAND/AUTOM. switch back to HAND. A9 The Trapped-key Interlock System for fences is installed. The Cabin switch of the system is in Off position. Turn On the trapped-key switch.
Breakdown Cause Service lift will go up but not down! Solution DANGER! STOP 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 safety brake device is holding the service lift on the wire. a) Excessive hoist speed b) Too low release speed on safety brake.
10. Out of service a) Securing the service lift: Bring the service lift all the way down, until the contact plate switch stops the cabin. b) S witch off the power supply to prevent inadvertent operation of the lift: Push in the EMERGENCY STOP button fixed – all controls are now blocked. Mark the lift “OUT OF SERVICE”. Contact the service technician for repair. 11. Removing wires for replacement CAUTION! Wear protective gloves when handling wires. 11.
12.1 Yearly inspection Have the entire system, especially the traction hoist and the safety brake tested by an AVANTI trained expert at least once annually however more frequently if required depending on use and the conditions of use and operation. The traction hoist and safety brake must be overhauled at an authorised workshop and furnished with new certificate for every 250 hours of operation. (Time counter is found in the power cabinet (Fig. 20 section 12.1.5).
Fig. 18 Wire diameter 12.1.5 Overload limiter/information signs Annual test: Test switches as specified in section 5.3 and 5.4 of the User’s Manual. Perform overload test as specified on page 54 of the Installation Guide. Verify completeness and legibility of all rating plates and information signs. Replace missing or illegible plates and signs! Fig. 19 Wire strap/loop, which cannot be unwound Fig.
13. Ordering spare parts 13.1 Wire/ropes 13.5 Rating plate/information signs In addition to the item number and name of the spare part, always state the traction hoist type, wire diameter and production number! Verify the completeness and legibility of all rating plates/information signs (see Fig. 21). Replace missing or illegible plates/signs! 13.
AVANTI Service Lift for Wind Turbines
Installation Manual Please familiarise yourself with these instructions and the User Manual (Model SHARK) before installing the service lift. Ensure that all specified parts are present before commencing installation. No warranty is provided against damage and injury resulting from not following this “User’s Manual and Installation Manual” i.e. reconstruction or modification of equipment or use of non-original parts which are not approved by the manufacturer. 1.
1.1 Part list - Shark L/XL Sliding door Fig. 1 37 11 39 38 40 39 17, 18 40 16 1 28 13 3 2 4 23 5 12 14 7 15 29 30 6 20 19 21 22 24 25 2 3 4 5 6 7 8 1 A B B C C D D E E Dimension: Edge: Material: Surface: Measure tolerance: Weight: Revsion note: AIP ApS Hogevej 19 DK-3400 Hillerod Denmark Proj: Constructor: Release Date: 1 2 3 4 5 ISO 2768-mK kg Sign: Stamp: Valid from: Replaces: Replaced by: Edit by: Title: F 6 ISO-E Scale: 7 Sheet no.
1.1 Part list - Shark L/XL Sliding door Pos. Item no.
1.1 Part list - Shark L/XL Sliding door Pos Part no. Part description Qty Reference 38 45303101 Top stop disc 1 Manual fig. 2 45541020 Quick-guide, English 1 Manual fig. 21 45541022 Quick-guide, Spanish 1 45541031 Label lift EN/ES 240 kg 1 45541007 Wall label UK/DE 1 45541025 Warning sign - hook on to anchor point 1 45541027 Serial number plate Shark lift 1 45512023 Counterweight 31 kg 1 45541009 Label lift EN/ES 320 kg 1 Manual fig. 21 Manual fig.
1.2 Part list - Shark L/XL Double door Fig.
1.2 Part list - Shark L/XL Double door Pos Part no.
1.2 Part list - Shark L/XL Double door Pos 36 Part no. Part description Qty Reference 45512010 Bracket for wire fix 70 10 Install. fig. 14 45303101 Top stop disc 1 Manual fig. 2 45541020 Quick-guide, English 1 Manual fig. 21 45541022 Quick-guide, Spanish 1 45541031 Label lift EN/ES 240 kg 1 Manual fig. 21 45541007 Wall label UK/DE 1 Manual fig. 21 45541027 Serial number plate Shark lift 1 Manual fig.
1.3 Part list - Shark L/XL Half Roller door Fig.
1.3 Part list - Shark L/XL Half Roller door Pos Part no.
1.3 Part list - Shark L/XL Half Roller door Pos Part no. Part description Qty Reference 45512003 Cable suspension 1 Install. fig 9 45512056 Snap hook, Galv. L=70mm 1 Install. fig 9 45511001 Wire fix 10 Install. fig. 14 45512010 Bracket for wire fix 70 10 Install. fig. 14 45541020 Quick-guide, English 1 Manual fig. 21 45541022 Quick-guide, Spanish 1 45541031 Label lift EN/ES 240 kg 1 Manual fig. 21 45541007 Wall label UK/DE 1 Manual fig.
1.4 Parts list - SHARK M Fig.
1.4 Parts list - SHARK M Pos. Item no. Part description Qty 1 45303300 Cabin right (Shark M) 1 2 45303301 Cabin left (Shark M) 1 3 45303312 Top (Shark M) 1 4 45303306 Bottom (Shark M) 1 5 45512007 Landing rubber feet 4 6 45303305 Sliding door fixture (Shark M) 1 7 45303302 Sliding door w.
1.4 Parts list - SHARK M Pos. Item no.
1.5 Parts list - SHARK M roller door Fig.
1.5 Parts list - SHARK M roller door Pos Part no. Part description Qty 1 45303326 Top Shark M roller door 1 2 45303107 Spine 1 Safety brake BSO 504E/BSO 1004E/OSL500.
1.5 Parts list - SHARK M roller door Pos Part no. Part description Safety wire / Drive wire ø8 Guide wire Ø12mm 45512005 Shackle, 2 tonnes 45303100 Tripod 45512060 Threaded rod, M16, FZV, L=330mm 45515001 Push spring for safety wire 45512011 Contra weight 11 kg for drive wire 45512001 Cable bucket Rubber cable 4G1.5 /5G1.5 Connector 690V/Connector 400V 45512003 Cable suspension 45512056 Snap hook, Galv.
Installation Manual 49
2. Fitting the wires 2.1 Tower top Wire lengths depend on the tower height and should be specified when ordering. The coils are marked with their length; check for accuracy prior to mounting. Do not pull wire over any edges. Uncoil correctly (Fig. 5a). ! Warning! Do not pull wire over edges. Important! Place all wire coils on the top platform when tower is raised or use the tower mounting crane to place the wires on the top platform before nacelle is mounted.
2.2 Wire positioning measurements Holes in the base platform in the tower for wire bushing are positioned as outlined below. Fig. 6 Minimum shaft clearance dimensions required for the service lift to run, and distance between the guide wires. Dimensions: Shark A B1) C D E S M 250 395/330 600 600 220 50 L 250 575/510 960 600 220 50 XL 350 575/510 960 800 320 50 1) Standard wire guide/narrow wire guide (details page 46). The holes are positioned with a tolerance of +/-5 mm.
2.3 Securing the guide wire - ground level IMPORTANT: Before feeding the guide wires through the platform, fit the correct number of wire fixes on the wire and feed through the wire guides (See Fig. 7 and Fig. 14 page 52). The wire fixes are fitted during the first run. Fig. 7 Wire fix Feed the guide wire through the 2 Ø60mm holes in the platform. Underneath the platform the guide wires are fastened and tightened using one of the following three methods. 2.3.
2.3.2 Method 2: Tripod Pull the guide wire through the platform and fasten with the tripod (See Fig. 8a.) 1) After feeding the guide wire through the platform continue feeding the wire through the tripod and the Ø16 mm x 1.5 mm aluminium tube. 2) Lock the aluminium tube, the wire, and the treated rod using a wire locking device. Make sure the tube is placed so no contact is made between the wire and treated rod. (See Fig 8a). 3) Tighten the bolts to 75 Nm 4) Mount the second wire.
2.4.2 Supply cable a) The length of the cable depends on the height of the tower and the positioning of the power outlet. The cable length is determined prior to ordering. The power cable is marked with its length; check for accuracy before installing. b) Minimum cross-sectional dimension of the supply cable. Important with increased distance between grid connection, generator, and traction hoist, respectively: Table 3 and Fig. 10a) clockwise to deactivate.
2.5 Installation of drive and safety wire in lift CAUTION! Wear protective gloves when handling wires. Fig. 12 Back side Drive wire Safety wire 2.5.1 Drive wire installation a) Remove protection guard above rollers b) Feed the wire through the roof into the traction hoist’s wire inlet opening. (Right side seen from front of lift). c) Push the UP button on the pendant control and feed wire through until the traction hoist starts pulling.
2.6 Securing the drive and safety wire The drive wire is fastened as described in point 2.6.1 below and the safety wire is fastened in one of three ways described in point 2.6.2, 2.6.3 and 2.6.4. 2.6.1 Drive wire contra weight An 11 kg weight is mounted approximately 300mm below the floor on the drive wire. Excess wire is coiled with at least 3 strips (See Fig. 13). IMPORTANT! Before fastening the safety wire carry out the safety brake test (See Installation Manual section 5 e) page 54). Fig.
2.6.3 S afety wire method 2: Push spring Underneath the platform the wire is fed through the two holes at each end of the push spring. The wire is then tightened as much as possible before being fastened with the wire locking device. If prior to mounting the spring was held tight by strips, cut them loose. If properly tightened, this will stretch the spring by approximately 15 mm (See Fig. 13b). Fig. 13b Safety wire method 2: Push spring 2.6.
2.7 Wire fix alignment Having mounted the service lift, the wires, and the power, the wire fix fittings are adjusted during the initial ascent. By means of the oblong holes in the wire fix fittings, adjust the fittings so that the two parts pass each other easily, when the lift passes. a) Perform the tests prescribed in section 5 of the User’s Manual (page 19). b) Install wires as shown in Fig. 14. Clic-on wire guide Clic-on wire fix Fig.
2.8 Adjustment of the safe-zone plates 2.9 Adjustment of top stop disc (Full open door lifts) The service lift door should be able to be opened whenever the cabin is in alignment with the platform (tolerance ± 100 mm). The safe-zone plate is adjusted in relation to the platform position switch fixed on the cabin (see Fig. 15). Fig.
5. Inspection before initial use An officially recognised expert must: a) Inspect the lift as specified in section 12.1 of the User’s Manual. b) Carry out a test run with the maximum rated load. c) Overload test: The test load depends on the lift motor. Load the cabin as follows: Motor L402P: load kg 320 (125% of lifting capacity + weight of power cable). Motor L502P: load kg 420. When an attempt is made to start the lift, the platform should stop, and the buzzer in the connection cabinet should sound.
Appendix A: Regulation of overload limiter CAUTION! Avoid injuriy by strictly following the instructions! a) Verification and/or adjustment of the overload device on the service lift can only be done by a qualified person, who must have been instructed by AVANTI to perform this task. b) Verification and/or adjustment must be performed under the supervision of the site foreman or another person authorised by the manufacturer.
Fig. 16 8 4 6 3 7 2 5 1 3 Overload limiter a) Place the service lift on the lowest travel point b) Apply the Setup load + 20 Kg from the table depending on the tower height. c) Push the UP button. If the lift can go up modify the adjustment of the overload system until it is no longer possible to go UP following the procedure below: 1. Loosen the set screw (7) in the casing cover with an Allen key (size 2) 2. Remove the cap (8).
Australia Avanti Wind Systems PTY LTD Unit 15 / 160 Lytton Road Morningside 4170 · Queensland P: +61 (0) 7 3902 1445 China Avanti Wind Systems Building 14 · Weishi Industrial Park No.
