Avanti OCTOPUS L80 Manual

AVANTI SERVICE LIFT
Installation and Maintenance Manual
Model Service Lift OCTOPUS L80
Original instructions
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Date of publication:
1st Edition: 09/2017
Revision 3: 15/10/2018
Manufacturer:
AVANTI Wind Systems A/S
Rønnevangs Allé 6
3400 Hillerød Denmark
P: [phone]
F: [phone]
E: [email protected]
I: www.avanti-online.com
Sales & Service:
Australia Avanti Wind Systems PTY LTD P: [phone]
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, PL P: [phone]
Brazil Avanti Brazil Sistemas Eólicos. S.L. P: [phone]
Manufactured Under Process Patent NO.8,499,896.
® Registered in Europe
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4
AVANTI Service Lift for Wind Turbines
Contents
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 Service lift installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.4 Electrical connections on site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.5 Travelling cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.6 Traction wire rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.7 Safety wire rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.8 Travelling cable pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.9 Safe zone plates and top limit plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.10 Rescue guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.11 Inspection before first use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.12 Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1 Recommended planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.2 Alternative planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.3 Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.4 Annual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.5 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.6 Ordering spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5. Appendix A: Regulation of overload limiter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6. Appendix B: Inspection checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7. Appendix C: Inspection Log Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8. Appendix D: AVANTI lift anchor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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Maintenance and Installation Manual
1) Avanti service lift (“Product”)
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. 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 PARTICULAR
PURPOSE, NON-INFRINGEMENT, SATISFACTORY
QUALITY, COURSE OF DEALING, 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
WARRANTY 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 CUSTOMER. THIS
LIMITED WARRANTY GIVES CUSTOMER
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.
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AVANTI Service Lift for Wind Turbines
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. This manual, including, but not limited to,
measurements, procedures, components, descriptions, instructions, 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.
2.2 Symbols
Symbol Signal word Meaning Possible injury if not observed
Safety instructions
STOP
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
Order

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
Maintenance and Installation Manual.
Personnel shall wear PFPE (safety helmet, full body
harness, shock absorber, lanyard and slider) at all times.
A copy of the Maintenance and Installation 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.
Electrical connection of the system must be made
in accordance with EN 60204-1.
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 technician.
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 Certified
technicians before first use.
Service lift must be inspected at least once a year
by Certified technicians. In case of high operating
frequency or severe conditions of use, more
frequent inspection is required.
Service lift is designed for a lifetime of 20 years
with an operating frequency of approximately 12.5
h/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
weather, including wind speeds over 18 m/s.
Avoid injury – follow all instructions!

Owner must verify the need for third party 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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AVANTI Service Lift for Wind Turbines
3. Installation
3.1 WTG integration requirements
WTG component General integration requirements
Power supply
Power supply type 3 Phase + PE + N
Voltage (50 Hz) 400 V ± 5 %
Voltage (60 Hz) 400 V ± 5 %
Fuses 16 A
Protection Acc. To EN 60204 – 1
Location of power supply connection for service lift Over mid tower´s height
Platforms
Distance from rung center to platform outer edge for
platforms over mid tower 1035 mm 1)
Distance from rung center to platform outer edge for
platforms below mid tower 1105 mm 1)
Hole width 920 mm
Minimum clearance around service lift 60 mm
Basement Minimum height 600 mm 2)
Platform fences
Height 1.1 m
Compliant to requirements of standard EN 14122
Fence door interlock system Trapped key 4) / Guardlocking 4)
Max. total travel height 120 m (typical 140 m tower total height)
Safety ladder
Max. angle between ladder axis and vertical axis ± 3º 2)
Max angle variance between ladder sections ± 1º 2)
Max. distance between rung attachments 3360 mm 2) 3)
Forces capable to withstand by ladder brackets Upon request to AVANTI
Forces capable to withstand by ladder sections Upon request to AVANTI
Ladder width for Octopus 490 mm 2)
Standard stile profile dimensions 74 x 25 mm 2)
Rung dimensions 29 x 27 mm 2)
Top beam
Forces capable to withstand by top beam Upon request to AVANTI
Max. thickness of top beam for 2 Tn shackles (C shape) 20 mm
Min. distance between top platform and top beam shackle holes 3000 mm 2)
1) Depending of travel path, dimension may need to be larger in order to avoid collisions of travelling cable pulley with platforms.
2) Other dimensions are possible upon request and design verification by AVANTI.
3) In case of single rung brackets: 2240 mm. between the centers of brackets.
In case of double rung brackets: 3360 mm. between the centers of brackets. 4)Note: Optional feature.
A gap of 2 mm is demanded from each
side of the fishplate to the ladder.
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.
The Octopus service lift is designed for a lifetime of 20
years with a frequency of use of approximately 12.5 h
/ year or 250 h during life. In case frequency of use is
higher, service, inspections and replacement of
components might be more often, according to the
replacement criteria stated in the maintenance
instructions.
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Maintenance and Installation Manual
3.2 Cautions
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
elevating heavy weights.
• Use a cable clamp or grip when lowering traction
and safety wire ropes.
• Not work at different levels if tasks involve risk of
falling objects.
Installation shall be performed by certified technicians
At the end of the workday security measures must be
taken to put the service lift out of service and make
the ladder accessible.
3.3 Service lift installation

The WTG manufacturer shall
provide 3D drawings to ensure
that installation of lift on ladder is
possible.
3.3.1 After tower erection
The service lift is installed on to the ladder after
tower erection.
1. Mount safe zone plates, top limit plate and rest
platforms on ladder.
2. Fit the nuts and bolts to the shackles, and lock
with cotter pins.
3. Mount traction and safety wire ropes (Ø8 mm)
using the shackles supplied for the top beam at
the top of the tower.
4. Follow instructions from chapter “Electrical
connections on-site” onwards.
3.3.2 Before tower erection
Alternatively, the service lift can be installed on to
the ladder before tower erection. With the tower
section lying horizontally:
1. Mount safe zone plates, final limit activation
plates and rest platforms on ladder.
2. Fit the nuts and bolts to the shackles, and lock
with cotter pins.
3. Mount traction and safety wire ropes (Ø8 mm)
using the shackles supplied for the top beam at
the top of the tower.
4. Attach coiled wire ropes to top beam by means
of cable strips to prevent them from moving
during transport of tower section.
5. Position service lift on ladder at bottom platform,
by means of a crane and the lifting eyes.
6. Mount fixing set for transport to prevent lift
from moving during transport of tower section.
7. The tower sections shall be transported to the
wind farm.
8. Pre-tension the 8 mm wire ropes by acting
manually the motor of the hoist with a wrench, to
be able to free the fasten kit after tower erection.
9. After tower erection takes place, follow
instructions from chapter “Electrical connections
on-site” onwards.
3.4 Electrical connections on site
Before making any connection, disconnect
any power supply to the service lift and the
fence interlock system; and verify with WTG
responsible.
The electrical connection of the traction hoist 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.
Electrical system shall be properly insulated.
3.5 Travelling cable
1. Install power supply socket over mid tower´s
height platform; and install a cable relief on the
platform fence.
Platform fence
Support
Cable Relief
Travelling
Cable
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10
AVANTI Service Lift for Wind Turbines
2. Feed travelling cable through the cable relief,
without plugging it to power supply socket!
3. Uncoil the cable to the bottom platform.
The travelling cable must be evenly uncoiled
to prevent looping.
4. Plug travelling cable outlet directly to service lift
(provisional connection).
5. Plug travelling cable inlet to power supply
socket over mid tower´s height.
3.6 Traction wire rope
1. Uncoil both wire ropes to the bottom of the WTG.
All wire ropes must be evenly uncoiled to
prevent looping.
2. Check that traction and safety wire ropes are
not crossed.
3. Feed the traction wire rope through the roof into
the traction hoist inlet opening.
4. Push the UP button of cabin control box to
continue feeding wire rope through until the
hoist starts pulling.
5. Open maintenance cover and feed wire rope
through guide bushing of service lift.
6. Feed through guide bushing of travelling cable
pulley.
7. Feed through the platform hole.
8. Attach an 11 kg counterweight to it at least
600mm below the bottom platform.
9. Coil and fasten remaining wire rope with at
least 3 cable ties.
10.Check that wire rope and counterweight are
able to rotate freely.
3.7 Safety wire rope
1. Feed the safety wire rope through the roof into
the fall arrest device inlet opening.
2. Pull the wire rope through while turning the fall
arrest device release lever clockwise.
3. Open maintenance cover and feed wire rope
through guide bushing of service lift.
4. Feed through guide bushing of travelling cable pulley.
5. Feed through the platform hole.
6. Feed the wire rope through the compression spring.
7. Fasten cable ties to the compression spring,
and adjust them to compress the spring.
8. Pre-tension the safety wire rope by hand as
much as possible and fasten the wire lock.
9. Cut the cable ties that keep the spring
compressed. The spring will apply a tension of
approximately 40 kg to the safety wire rope.
3.8 Travelling cable pulley
1. Turn the override key of bottom obstruction
device switch.
2. Manually descend service lift until rubber feet
reach bottom platform floor.
3. Unplug travelling cable inlet from power supply
socket over mid tower´s height, leaving it
attached with the cable relief.
4. Unplug travelling cable outlet from service lift socket.
5. Demount plug head from cable and adjust
cable length by cutting off excess.
6. Feed cable through pulley until it is positioned
2cm. from service lift wire rope bushings.
7. Feed cable through cable relief, mount plug
and plug it back to service lift. Attach the cable
to the lift between the cable relief and the panel
inlet by means of plastic strips every 300 mm.
8. Plug travelling cable inlet from power supply
socket over mid tower´s height.
Cable
Relief
Travelling
cable
Bottom
platform floor
Traction
wire rope
Safety wire
rope
Rubber feet
Travelling cable
pulley
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