Avanti DOLPHIN A-V164 User manual

AVANTI SERVICE LIFT
Installation and Maintenance Manual
Model Service Lift DOLPHIN A-V164
Original instructions
®
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Certificate of Dolphin A-V164
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Date of publication:
1st CE Edition: 09/2017
Revision 4: 11/06/2018
Manufacturer:
AVANTI Wind Systems A/S
Rønnevangs Allé 6
3400 Hillerød Denmark
P: [phone]
F: [phone]
E: [e-mail]
I: www.avanti-online.com
Sales & Service:
Australia Avanti Wind Systems PTY LTD P: [phone] 9585
China Avanti Wind Systems P: [phone]
Denmark Avanti Wind Systems A/S P: [phone]
Germany Avanti Wind Systems GmbH P: [phone] – 0
Spain Avanti Wind Systems SL P: [phone]
UK Avanti Wind Systems Limited P: [phone]
USA Avanti Wind Systems, Inc P: [phone]
India Avanti Wind Systems India (P) Ltd P: [phone]
Brazil Avanti Brasil Sistema Eólicos LTDA P: [phone]
Manufactured Under Process Patent NO.8,499,896.
® Registered in Europe
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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. Installation ....................................................................8
3.1 WTG integration requirements ..................................................8
3.2 Cautions ...................................................................9
3.3 Freight kit ..................................................................9
3.4 Electrical connections ....................................................... 9
3.4.1 Power cable............................................................10
3.4.2 Guard locking system ...................................................10
3.5 Guiding, traction and safety wire ropes..........................................10
3.5.1 Top platform ...........................................................10
3.5.2 Bottom platform .......................................................10
3.6 Wire rope fix. ...............................................................12
3.7 Danger zone sticker..........................................................13
3.8 Rescue guide ...............................................................13
3.9 Inspection before first use ................................................... 13
4. Maintenance ..................................................................14
4.1 Recommended planning ......................................................14
4.2 Alternative planning..........................................................14
4.3 Cautions ...................................................................15
4.4 Daily inspection .............................................................15
4.5 Annual inspection ...........................................................16
4.5.1 Cabin .................................................................16
4.5.2 Traction hoist ..........................................................16
4.5.3 Fall arrest device .......................................................16
4.5.4 Traction, safety and guiding wire ropes .....................................16
4.5.5 Guiding system.........................................................18
4.5.6 Electrical cables ........................................................18
4.5.7 Overload check and adjustment ...........................................18
4.5.8 Information signs and documents..........................................18
4.6 Repairs ....................................................................18
4.7 Ordering spare parts ........................................................18
Appendix A: Adjustment of the overload limiter ........................................19
Appendix B: Inspection Checklist ....................................................21
Appendix C: Inspection Log Sheet ...................................................25
Appendix D: AVANTI lift anchor . .....................................................29
Contents
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5
Maintenance and Installation Manual
1) Avanti service lift (“Product”)
Avanti Wind Systems A/S warrants that com-
mencing 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. 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 PAR-
TICULAR PURPOSE, NON-INFRINGEMENT,
SATISFACTORY QUALITY, COURSE OF DEAL-
ING, 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 WARRAN-
TY 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 CUSTOM-
ER. THIS LIMITED WARRANTY GIVES CUS-
TOMER 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.
1. Limited Warranty
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6
AVANTI Service Lift for Wind Turbines
2.2 Symbols
2.1 Observations
2. Introduction
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, instruc-
tions, 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.
!
STOP
!

Symbol Signal word Meaning Possible injury if not observed
Safety instructions
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
Reference to written
specification/documentation
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Maintenance and Installation 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.
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 a certified technician.
All repairs to the traction, braking and supporting
systems may only be performed by a certified techni-
cian.
If any supporting parts are repaired or replaced,
the operational safety of the system must be tested
and verified by a certified technician.
Only original fault-free parts may be used.
Use of non-original parts will render the manufac-
turer’s warranty void and any type approval invalid.
No modification, extension or reconstruction of the
service lift is allowed without the manufacturer’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
the manufacturer.
Service lift must be inspected by a certified techni-
cian before first use.
Service lift must be inspected at least once a year
by a certified technician. In case of high operating
frequency or severe conditions of use, more frequent
inspection is required.
Service lift is designed for a lifetime of 25 years with
an operating frequency of approximately 10h/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 weath-
er, including wind speeds over 25 m/s (55.5 mph).
Avoid injury – follow all instructions!
Owner must verify the need for third par-
ty 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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8
AVANTI Service Lift for Wind Turbines
3. Installation
3.1 WTG integration requirements
WTG
component
General integration requirements
Service lift Dolphin A-V164
Power supply Type 3 Phase + PE + N1)
Voltage (50 Hz) 400 V/ 690 V
Voltage (60 Hz) 400 V/ 690 V
Fuses 16 A
Protection According to EN
60204-1
Platforms Minimum clearance
around service lift
50 mm 2)
Evacuation
way
Means of evacuation
shall be provided
with a maximum
distance of
1100 mm
Platform
fences
Minimum height 110 0 mm
Compliant to
requirements of
standard
EN 14122-3
Fence door inter-
lock system
Trapped key or
guard locking
Hoistway Maximum total
travel height
See note (3)
Maximum angle
between hoistway
and vertical axis
±5,3º
Top beam Forces capable to
withstand
Upon request
from AVANTI
1) Note: Neutral applies only to 400 V.
2) Note: Up to a minimum value of 40 mm. after evaluation
and approval by Avanti
3) Note: With all options: 135 m. / Standard design: 160 m.
Depending on travel path, dimensions may need to be
larger in order to avoid collisions of travelling cable pulley
with platforms. Other dimensions are possible upon
request and design verification by AVANTI.
The WTG manufacturer shall put in place any other
means necessary to ensure the safe use of the service
lift according to AVANTI recommendations and its own
risk assessment for the integration that shall include
items which are not under AVANTI´s scope.
In the event of installation procedure divided into two
different stages and extension of travel path is needed
(e.g.: offshore configuration):
There is a first assembled onsite at harbor stage were
some of the lift components are preassembled by the
tower manufacturer. All the wire ropes have to be
tightened at provisional bottom platform and the extra
length coiled up in a secure manner to prevent damages
in them since they have to be used for the final exten-
sion. Half bushings must be installed to protect wire
ropes (traction, safety and guiding) before travelpath
extension.
The assembly of the tower to the offshore foundation
extending the operation of the service lift to the transition
piece (TP) will be undertaken in the second stage.
In this second stage, TP bottom platform will be the final
low travel end of the lift, and therefore when the tower is
located over the TP, the Control Box previously mounted
on first stage provisional bottom platform will be
disassembled and re-mounted on the TP Bottom
Platform.
When the travel path of the cabin is extended to TP
bottom platform, travelling cable and wire ropes need to
be longer, for this reason, these are previously ready
coiled on the first stage.
Half bushings
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Maintenance and Installation Manual
3.2 Cautions
Please familiarise yourself with these instruc-
tions and the User’s Manual before installing the
service lift. Ensure that all specified parts are
present before commencing installation.
No warranty is provided against damage and injury result-
ing from not following this “User’s, Maintenance and
Installation Manual” i.e. reconstruction or modification of
equipment or use of non-original parts which are not
approved by the manufacturer.
Prior to installation, ensure that:
• Building sections involved will be able to withstand the
service lift loads.
• All parts are available and fully functional.
• Travel zone is protected by fences at each platform.
• Walking way surfaces are dry and not slippery.
The customer must define the maximum allowable
wind speed ensuring safe installation.
During installation tasks, personnel shall:
• Wear at least the following PFPE: fall arrest
equipment if falling height is higher than 2 m, hand
gloves, helmet, safety glasses, working gear.
• Use a hand winch attachable to the ladder when elevat-
ing heavy weights.
• Use a wire rope clamp or grip when lowering wire ropes,
in order to avoid the risk of personnel losing the wire
rope, and wire rope getting damaged or person being
hit. The clamp shall be secured to a platform anchor
point. The diameter of the clamps or grips shall match
the diameter of the wire ropes.
• Not work at different levels if tasks involve risk of falling
objects.
3.3 Freight kit
The service lift shall be transported to destination
inside a box.
1. Open the box.
2. Turn the service lift from horizontal to vertical
position by means of the freight kit.
3. By means of carabiners and slings, attach the
lifting machinery (i.e. forklift, chain hoist, crane,
etc.) to the lifting eye.
4. Use the lifting machinery to lift the service lift
over the pallet level. One person is needed to
ensure the lifting process is being done properly.
5. In the picture below you can see the detail of
where the lift must lay during the lifting.
6. Place the lift inside the lift shielding at bottom
platform.
7. Remove the freigth kit.
3.4 Electrical connections
Before making any connection, disconnect any
power supply to the service lift and the fence
interlock system.
The electrical connection of the system must be made in
accordance with EN 60204-1.
The power supply must be protected by a fuse and
against indirect contacts according to local regulations.
Verify that the rated grid and motor voltages are
identical.
When plugging the service lift to the power supply,
ensure that supply phases are correct!

Transportation
bracket
Bottom
corner
protections
Lifting eye
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10
AVANTI Service Lift for Wind Turbines
3.4.1 Power cable
3.4.1.1 Tr avellin g Cable
-Install power supply socket
over mid tower´s height platform.
-Cut the transport strips
which hold the cable and
connect the cable inlet to the
power supply socket.
-Uncoil the cable to the
bottom platform.
-Connect the power cable
outlet socket to the service
lift inlet plug as described
on 3.5.2.4.
3.4.2 Guard locking system 4)
- Install the guard locking control box on the bottom
platform fence.
- Install the guard locking switch and its actuator on
the fence door using the supplied hardware
- Install the lift detection switch on its bracket on the
bottom fence toeboard and connect to the socket on
the guard locking control box.
- Connect the power cable power inlet plug to the
guard locking control box outlet.
1)Note: An interlock system (trapped key or
guard locking) is mandatory for CE versions if
platform fences are equipped with doors.
3.5 Guiding, traction and safety wire
ropes
3.5.1 Top platform
Guiding, traction and safety wire ropes are attached
to the suspension beam on the available holes.
To install them on the suspension beam:
1)Mount the guiding wire ropes (12 mm) and the traction
and safety wire ropes (8 mm) using the shackles
supplied for the suspension beam at the top of the tower,
with the guide wire rope outermost on either side.
2)Fit the nuts and bolts on the shackles. Lock with cotter
pins.
3)Fit the top limit device 2) on the traction wire rope
leaving at least 200 mm between top limit device 2) and
shackle. Adjust the final position during first run so that
the service lift is levelled with the top platform when it
stops.
4)Uncoil all wire ropes to the bottom of the tower.
3.5.1.1 Top limit device (bar) 2)
3.5.2 Bottom platform
3.5.2.1 Guiding wire ropes:
1) Feed the guiding wire ropes through the wire
guides on the service lift.
2) Fit the correct number of wire rope fixes on the
wire rope and feed through the wire rope guides.
The wire rope fixes must be installed and adjusted
during the first run.
Bottom platform hole arrangement
Safety wire rope Traction wire rope
Guiding wire rope Guiding wire rope
All wire ropes must be evenly uncoiled
to prevent looping.
Do not pull wire rope over edges.
!
STOP
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Maintenance and Installation Manual
3) Pull the guiding wire rope through the bottom
platform and fasten it with the tensioning system.
The tensioning system may vary depending on the
tower configuration.
4) Attach the wire ropes to the tensioner:
a) Feed the wire ropes through the tensioning
system.
b) Attach the wire rope to the tensioning system
using the wire rope grips to allow for the first run.
c) Make a mark on the wire rope to ensure no sliding
occurs at the wire rope grips and to use as a refer-
ence for checking stroke if necessary.
5) Perform final tension adjustment after first run:
a) Tension the wire ropes by turning the supplied nut
until the desired tension is shown on the graduated
scale (7000N).
b) Use the second nut to lock the assembly.
3.5.2.2 Traction wire rope
1) Open the maintenance cover on the back of the
service lift.
2) Remove protection guard above rollers.
3) Feed the wire rope through the roof into the
traction hoist’s wire rope inlet opening.
4) Push the UP button of the user control box and
feed wire rope through until the traction hoist starts
pulling. Ensure that the wire rope can exit without
obstruction!
5) Continue feeding the wire rope around the pulleys
to the back of the lift.
6) Feed the wire through the guide bushings (includ-
ing pulley ones when using travelling cable).
7) Feed the wire rope through the platform holes.
Traction
wire rope
Tensioning methods and tension values may vary depending on
specific tower configurations
If the applied tension to the guiding wire ropes is below the
stated values, the cabin sway may be high enough to prevent
the power cable to coil properly.
Bipod tensioner
Set
Tensioner Set
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12
AVANTI Service Lift for Wind Turbines
Aluminium
two-pieces
wirefix
8) Secure the 11 kg counterweight on the traction
wire rope at least 600 mm below the bottom platform
(See figure below). The remaining wire rope must be
coiled and fastened with at least 3 strips. The counter-
weight and the excess of wire rope shall be able to
rotate freely.
If the wire rope is not installed in accordance with the
stated procedure, it can get damaged, deformed or
show other critical defects.
Traction wire rope
Bottom platform
Traction wire rope-
counterweight
Free rotation
Safety wire rope
3.5.2.3 Safety wire rope
1) Open the maintenance cover on the back of the
service lift.
2) Remove protection guard above rollers.
3) Feed the wire rope through the roof into the fall
arrest device’s wire inlet opening.
4) Pull the wire rope through the fall arrest device
while turning the release lever clockwise.
5) Continue feeding the wire rope around the pulleys
tothe back of the lift.
6) Feed the wire rope through the guide bushings
of the cabin.
7) Feed the wire rope through the guide bushings of
the travelling cable pulley.
8) Feed the wire rope through the platform holes.
9) Feed the compression spring through the safety
wire rope.
10) Pre-tension the safety wire by
hand as much as possible before fastening the
wire locks.
11) Cut the mounting strips that keep the spring
compressed. This will apply a tension of approxi-
mately 40 kg to the safety wire rope.
3.5.2.4 Travelling cable adjustment
1. Guide the travelling cable through the travelling
cable pulley.
2. Connect the outlet socket of the travelling cable
to the inlet plug of the service lift using a cable
stocking. Attach the schacle to the eyebolt on the
back of the service lift.
3. Attach the travelling cable to the cabin by
means of cable ties.
3.6 Wire rope fix
Wire rope fixes are installed and adjusted during
the first run so that the centres of the wire rope
fixes are in the centre of the service lift wireguides.
Wire rope fixes must be installed on each platform
and as required along the tower (MAX. 30 m) to
improve guiding to avoid collision with tower ele-
ments.
Use the oblong holes on the wirefix
brackets to align and adjust the wire rope fix
position.
Dolphin A-V164 service lift is guided along the
guiding wire ropes by means of roller guides.
These roller guides have rubber parts that allow
them to adapt to deviations on the trajectory of
the guiding wire ropes.
Wirefixes are made of aluminium material, which
results in an improved durability. In addition, the
wirefixes are made of two symmetric parts. These
two-piece concept allows the wirefix to be
installed at any moment, without having to
introduce it through the bottom end of the wire
rope.
Safety
wire rope
Rollerguide
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Maintenance and Installation Manual


Wire rope fixes are installed and adjusted during the
first run so that the centres of the wire rope fixes are
in the centre of the service lift roller guides.
Additional wire rope fixes could be installed if
necessary to allow boarding upright. This extra wire
rope fixes are installed on a structure so that the
lower and upper wire rope fixes are aligned
vertically. This way, the landing angle on the lift in
platform will be reduced.
3.7 Danger zone sticker
Mount the “Danger Zone” sticker in the front door of
the bottom platform fence. Make sure that the fence
is clean and dry before attaching the sticker.
3.8 Rescue guide
Place the “Rescue guide” in the front door of the
bottom platform fence by using plastic flanges
to attach it to the perforated sheet.
3.9 Inspection before first use
Certified technicians must carry out an
inspection before first use following the
“Inspection checklist” Appendix.
The inspection before first use must be
recorded for future reference filling the
“Inspection Log Sheet” Appendix.
Aluminium
two-piece
wirefix
Aluminium
two-piece
wirefix
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14
AVANTI Service Lift for Wind Turbines
4. Maintenance
All the inspections / maintenance operations (periodical or extraordinary) must be logged in the appropriate
Inspection Appendix.
All inspections and service tasks made to the hoist and fall arrest device must be carried out by certified
technicians. The relevant maintenance instructions are provided to each person during the training.
4.1 Recommended planning
Avanti recommends the following maintenance planning:
Frequency Performed by Components
Daily User
Overall / Travel zone
Control and safety devices
Fall arrest device
Annually Certified Technician
Overall / Travel zone
Control and safety devices
Cabin
Traction hoist
Fall arrest device
Overload limiter
Traction and safety wire ropes
Guiding system
Electrical system
Information signs and documents
Doors and hatches
User control box
Safety switches
Interlock system
Platforms
Every two years Certified Technician Fall arrest device
Every five years or 50 hours (whatever occurs first) Certified Technician Traction hoist
Every 20 years or 250 hours of operation (whatever occurs first) At Avanti Workshop Traction hoist
Fall arrest device
4.2 Alternative planning
Owners who strictly follow the maintenance program and the daily inspections, and can document it could
decide with taking over the responsibility as well to provide the following alternative planning:
Frequency Performed by Components
Daily User
Overall / Travel zone
Control and safety devices
Fall arrest device
Annually Certified Technician
Overall / Travel zone
Control and safety devices
Cabin
Traction hoist
Fall arrest device
Overload limiter
Traction and safety wire ropes
Guiding system
Electrical system
Information signs and documents
Doors and hatches
User control box
Safety switches
Interlock system
Platforms
Every ten years or every 125 hours of operation (whatever occurs first) Certified Technician Traction hoist
Fall arrest device
Every 20 years or 250 hours of operation (whatever occurs first) At Avanti Workshop Traction hoist
Fall arrest device
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Maintenance and Installation Manual
4.3 Cautions
Before any maintenance task, ensure that walking
way surfaces are dry and not slippery.
Before any maintenance operation, check that
the service lift is properly out of service.
In case of a fault, do not use the service lift until it
is solved. If required secure workplace.
During maintenance tasks, personnel shall:
• Wear at least the following PFPE: fall arrest
equipment (when falling height is more than 2
m), hand gloves, helmet, safety glasses and working
gear.
• Place cabin at bottom platform and disconnect
power supply.
• Use an electricity measuring tool when performing
inspection of electrical components.
• Use a hand winch attachable to the ladder when
handling big/ heavy loads and shall be performed at
least by 2 persons.
• Panel parts shall be removed to facilitate access to
confined spaces.
• Guiding rollers shall be replaced one by one.
• Use a cable grip when replacing travelling cable.
• Keep cabin doors closed when using a 3-step
ladder.
Only certified technicians shall perform electrical
installation tasks.
When plugging the servivice lift to the power
supply, ensure that supply phases are correct!
4.4 Daily inspection
Travel zone:
Ensure that there are no obstacles in the travel zone
which may obstruct the travel of the service lift.
Service lift:
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 and safety wire ropes are not
damaged or jammed.
3. Check that the safety devices are in place and
working:
3.1 Main switch: Turn the main switch on the
interlock control box to the OFF position. The green
light must be OFF. The service lift must not run. Turn it
ON, the light shall be ON.
3.2 Green light (Ready) – Service lift: Close and lock the
bottom platform gallery door and the service lift door.
Turn the trapped key to the ON position. The green light
must be ON. It should not be possible to remove the
trapped key unless it is switched OFF again.
3.3 Emergency stop button: Press the emergency
stop button on the user control box. The service lift
should not move UP / DOWN. Release the emergen-
cy stop and drive the lift UP approximately 1 meter.
3.4 Service lift door: Pull the door to open. The door
should not open. Unlock the top sliding door from the
bottom sliding door and pull to open. The top sliding
door should open, the green light must be OFF and
the lift must not move UP / DOWN. Close the top
sliding door and apply the lock to the bottom sliding
door.
3.5 Ascend lift electrically a few centimeters and
observe centrifugal weight during this. Activate the
fall arrest device by turning the lock lever counter
clock wise. Press and hold the DOWN button of the
user control box. The service lift should not descend.
Try to perform manual descent and observe centrifu-
gal weight during this. The FAD should hold the load
(if not, leave the lift and tag it out). Ascend electri-
cally again to unload the FAD. Unlock the fall arrest
device by turning the unlock lever clockwise. There is
an alternative method to check the FAD functionality,
called ‘Stomp Test’. The procedure is explained in the
‘Stomp-test Instruction’ Appendix.
3.6 Perform a manual descent test for a meter. The
lift should descend and the buzzer should sound.
3.7 Drive the service lift down until the Bottom
obstruction device hits the bottom platform. The
service lift should stop before the rubber bumpers hit
the bottom platform. The service lift door and the
fence door should be unlocked.
3.8 Top obstruction device: activate top stop by
pressing it down. The service lift should not ascend
until top obstruction device is released.
4.When the lift is at the top platform, check the wire
rope fastenings.
5. Record the hour meter reading in the
“Inspection log sheet” Appendix.
Cabin control from outside of the cabin-
Automatic:
The automatic mode function is only available from
the control buttons outside of the cabin and shall
be checked as follows (one technician inside the
cabin/one technician outside):
1. Press the UP button on the control box. The lift
should ascend.
2. Press the emergency stop button on the control
box. The lift stops.
3. Pull the emergency stop button and press the
DOWN button. The service lift should descend until
the bottom obstruction device engages.
!
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.
STOP
STOP
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STOP
AVANTI Service Lift for Wind Turbines
4.5 Annual inspection
Have the entire system tested by a cerified techni-
cian at least once a year, especially the traction
hoist and the fall arrest device. However, it may be
required more frequently depending on use and
the conditions of use and operation. The traction
hoist and fall arrest device must be inspected
according to intervals included in the sections 4.1
or 4.2 tables (see above). Hour counter is
found in the main control box.
A certified technician must carry out the annual
inspection following th appropriate Inspection
Appendix.
Owner must ensure that the results of all annual
and extraordinary inspections are logged in the
appropriate Inspection Appendix.
In case of replacement of hoist, Fall Arrest De-
vice and/or 8 mm. wire ropes, the operation/s
and the related total hours of use of this/these
component/s, must be logged in the appropriate
Inspection Appendix.
4.5.1 Cabin
Inspect the cabin structure, joints, attachments
and accessories.
4.5.2 Traction hoist
The traction hoist shall be maintained according to
maintenance planning (please see sections 4.1 or
4.2). Relevant maintenance instructions are
provided to each person during the training. These
maintenance inspections must be only carried out
by a certified technician.
4.5.3 Fall arrest device
The fall arrest device shall be maintained accord-
ing to maintenance planning (please see sections
4.1 or 4.2).
Relevant maintenance instructions are provided to
each person during the training.
These maintenance inspections must be only
carried out by a certified technician.
If fall arrest device has engaged due to a
dynamic fall, a certified technician must verify the
safety of the fall arrest device, the wire rope, and
wire rope fastenings.
After FAD has engaged, if the FAD damper has
moved downwards, the FAD unit must be replaced
by a certified technician.
!
!

4.5.4 Traction, safety and guiding wire ropes
The inspection of the wire ropes can be carried out from inside
the cabin. To do so, open the maintenance cover. The cabin
panel has a white sticker attached to it. This sticker makes the
wire ropes´ silhoutte stand out and therefore facilitates the
inspection of the wire ropes.
Carry out the following inspections and adjust if
necessary:
1. Inspect all the wire ropes along their entire length.
2. Pay special attention to the wire rope ends, parts of
the wire ropes running over sheaves and wire ropes
under frictional wear by external components.
3. When inspecting the wire ropes, consider the follow-
ing points: type and number of wire breaks, position and
time sequence of wire breaks, decrease of the wire rope
diameter during operation, corrosion, abrasion, deforma-
tion, influence of heat, and operating time.
4. Check that the traction and safety wire ropes are fed
correctly around the 2 wire rope guide wheels.
5. Check that the wire rope ends are coiled separately
under the bottom platform and tied with at least 3 cable
ties.
6. Check that the guiding wire rope tensioning system is
correctly installed and that the wire rope locks and fixes
are properly fastened.
7. Check that the compression spring on the safety wire
rope is correctly installed and that the wire rope locks
are properly fastened.
8. Check that the counterweight on the traction wire rope
is properly fastened. The traction wire rope coil and
counterweight shall be able to rotate freely. Do not
attach them to a fixed part.
9.Check that the guiding wire ropes are correctly
tensioned.
Record any visible change of the condition of the wire
ropes on the appropriate Inspection Appendix, and
monitor closely throughout time.
4.5.4.1 Lubrication of the traction and
safety wire ropes
Traction / safety wires are lubricated by supplier and should
keep their lubrication during operation. When touched you
should find little grease on finger tip. To ensure this, the
storage of the wires MUST be adequate and without any
harmful conditions as for example dust, water, etc.
1. Position the lift at the bottom platform.
2. Open the maintenance cover by unscrewing its
screws.
3. Apply lubricant on the traction and safety wire ropes
by means of a spray can.
4. While applying the lubricant, use the second hand to
place and hold a cloth around both wire ropes. This way,
the lubricant will be distributed uniformly on both wire
ropes.
5. While the first user uses the spray can and the cloth, a
second user presses and holds the UP button from
inside the lift. This way, while the service lift ascends, the
lubricant is applied along the complete length of the two
wire ropes.
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Maintenance and Installation Manual
6. After applying the lubricant, leave the maintenance
cover open and carry out a descent back to the bottom
platform.
7. While descending, check that the two wire ropes have
been properly and uniformly lubricated.
8. Once the service lift is at the bottom platform, clean off
any lubricant accidentally applied on the cabin panels.
9. Finally, close the maintenance cover by screwing back
its screws.
Only use specialised wire rope lubricants. Do not use
lubricants based on lithium soap grease or bitumen.
Do not use disulphide-containing lubricants like
Molycote ®.
Apply lubricant using a spray can, brush, drip
applicator or pressurized device.
Pay special attention to sections of the wire rope
where dehydration or denaturation of the lubricant
can be seen.
Re-lubricate the wire ropes before they show signs of
corrosion or run dry, and taking in mind that:
• A poor lubrication leads to corrosion and to a
quick wear of components.
• An excessive lubrication leads to dirt
agglomeration on the wire rope surface. As a
result, this can lead to quick wear of wire rope,
sheaves and drum.
• A correct lubrication keeps the efficiency factor
of the wire rope, protects against corrosion, helps
to elongate their lifetime significantly and ensures
a safe operation.
4.5.4.2 Measuring of the wire rope diameter
When measuring the diameter of the wire ropes, use a
digital calliper with broad measuring faces.
In general, measure the diameter of the wire rope at
each WTG tower platform, and under the service lift,
where the wire rope is less loaded. Specifically, if a
wire rope wear is detected, measure on the affected
area.
Rotate the calliper around the wire rope to
measure the minimum and maximum wire
rope diameter at each measurement point.
4.5.4.3 Discard criteria
The discard criteria of the wire ropes should
be based on ISO 4309: Cranes - Wire ropes -
Care and Maintenance, inspection and discard.
Determine and eliminate the cause before
installing a new wire rope.
AVANTI recommends to replace the traction and safety wire
ropes after 250 hours of operation corresponding with the
refurbishment of the traction hoist and fall arrest device.
Please check with your local authority regulations if it’s
mandatory in your case.
Check and replace the respective wire rope(s) if one of
the following defects is found:
• For traction and safety wire ropes, if there are more
than one 4-wire strand break on a wire rope length of 250
mm.
• For guiding wire ropes, if there are more than one
8-wire strand break on a wire rope length of 360 mm.
• If there is severe corrosion on the surface or the
inside.
• If there is heat damage, evident by the wire rope
colour.
• For traction and safety wire ropes, if the wire rope
diameter is less than 7,6 mm.
• For guiding wire ropes, if the wire rope diameter is
less than 11,4 mm.
• If there is damage on the wire rope surface (see
following figures for most common examples of wire
rope damage).
!
!
Wire rope strap/
loop,
which cannot be
unwound
Kinks resulting
from counterweight
of traction wire rope
not being able to
rotate freely.
Loop knot forming
when a wire loop is
pulled tight
Bends resulting from
inappropriate treatment
(e.g. securing the load
with the wire)
Damage resulting from
crushing, squeezing,
running over, etc.
Wire bags
Loop formation
!
!
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AVANTI Service Lift for Wind Turbines
4.5.5 Guiding system
Check all the wirefixes are free of cracks, dents and
disparities on each platform and proceed to lubricate
them.
1.Position the lift at the bottom platform.
2.Ascend to the top platform.
3.Once located on top platform, exit the service lift
and using the fence’s windows apply lubricant to
wirefixes by using a brush.
4.Descend and perform the same lubrication
operation of all the wirefixes on each platform.
The type of grease shall be LUBERKRAFFT KL.
In case of using an equivalent grease, it must be
previously verified by AVANTI.
The wirefixes must be replaced in case of damage.
4.5.6 Electrical cables
Check and replace the power supply and control
cables if the cable jacket or cable connections are
damaged.
4.5.7 Overload check and adjustment
Annual test: Test switches and perform overload
test as specified in the “Adjustment of the
overload limiter” Appendix.
4.5.8 Information signs and documents
Verify availability and legibility of all data plates and
information signs. Replace missing or illegible
plates and signs!
4.6 Repairs
Repairs to traction hoist equipment must ONLY be
performed by AVANTI, and only using original
spare parts. If the gearbox oil needs to be replaced,
use one of the lubricants specified below, corre-
sponding to the temperature range in which the
traction hoist equipment is used.
• Amount required: 1,5 l
• Traction hoist: M508
• Oil: Mobil SHC 632.
Each oil has to be verified by AVANTI.
4.7 Ordering spare parts
Only use original parts. Spare part lists are available
from AVANTI. Please indicate lift model when re-
questing a spare part list.
!
!
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Maintenance and Installation Manual
Appendix A: Adjustment of the overload limiter
For the tests, test weights shall be needed.
One turn of the tool (2) represents a
change of approximately 40 kg of the
triggering limit of the overload limiter.
The adjustment of the overload limiter of the service lift shall be carried out only by a certified technician.
Travel
distance (m)
Setup load (1) (kg)
Dolphin A-V164
From 61 to 80 300
From 81 to 100 309
From 101 to 120 318
From 121 to 140 327
From 141 to 160 336
WLL of lift (4) (kg)
Dolphin A-V164
240
The overload limiter complies with EN18088.3.5.5 1)
since it will trigger before reaching a load of 1,25
times the working load limit of the hoist. In case
that a third party inspector requests this test to be
done, the load to be introduced in the cabin is as
follows.
Overload test load = WLL hoist x 1,25 – Weight of
lift, counterweight, traction wire rope and power
cable for Dolphin A-V164 = 440 kg
1) The EN1808 test load is only applicable to CE
versions.
Overload adjustment tool (2)
with security Torx 40
Hole (3)
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AVANTI Service Lift for Wind Turbines
Can the service lift ascend?
Can the service lift ascend?
Does the overload limiter engage dur-
ing the ascent of the complete tower?
No
No
Yes
Yes
Yes
No
1. Place the service lift on the lowest travel point without touching the floor
2. Insert the setup load (1) (from the table depending on the WTG height) in the cabin
3. Press and hold the UP button
1. Remove 20 kg from the setup load (1)
2. Press and hold the UP button
1. Insert the working load limit of the lift (4) in the cabin
2. Press and hold the UP button.
1. The overload limiter is correctly set!
2. Fill in the “Appendix: Inspection log sheet”
Review the setup load (1)
that has been used
1. Insert the tool (2) through the hole (3)
2. Turn the tool (3) clockwise to increase the trigger limit of the overload limiter
3. Remove the tool (2) from the hole (3)
1. Insert the tool (2) through the hole (3)
2. Turn the tool (3) anti-clockwise to decrease the trigger limit of the overload limiter
3. Remove the tool (2) from the hole (3)
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