Avanti OCTOPUS L95 HD Manual

AVANTI SERVICE LIFT
Model: OCTOPUS L95 HD Service Lift
Installation and maintenance manual
Original instructions
AT00016129
English (EN)
Installation and maintenance Manual – Service Lift Model OCTOPUS L95 HD
3rd Edition: July 2019 — Revision 1: 30/07/2019

AVANTI SERVICE LIFT
Limited warranty
Avanti Wind Systems Technology, S.L. guarantees 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 ex-
clusive 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 pro-
cedures of Avanti.
This warranty does not apply if the Product (i) has been altered without the au-
thorization of Avanti or its authorized representative; (ii) has not been installed,
operated, repaired, or maintained in accordance with this Manual or other in-
structions 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 WARRAN-
TIES, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OR CON-
DITION 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 DIS-
CLAIMED BY AVANTI. IF, PURSUANT TO ANY APPLICABLE LAW, TO THE EX-
TENT 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 pur-
pose. In any cases of dispute the English original shall be taken as authoritative.
1)Avanti service lift ("Product")
Avanti Wind Systems Technology, S.L.
Calle Ángeles (Los), Num. 88
Pol. Industrial Centrovía
50198 Muela (La) - (Zaragoza) - Spain
P: [phone]
F: [phone]
E: [email protected]
www.avanti-online.com
Contact

Contents
i
1 Introduction ................................................................................3
1.3 Observations ........................................................................... 3
1.1 Symbols ................................................................................. 3
1.4 Cautions ................................................................................ 4
1.2 Terms and definitions .................................................................. 3
2 Transport .................................................................................. 6
2.1 General transport requirements....................................................... 6
1.5.1 Height and angle ........................................................... ......5
3 Installation ................................................................................. 6
3.1 Delivery
inspection...................................................................... 6
3.2 Storage ................................................................................. 6
3.2.1 General storage requirements...................................................... 6
3.3.1 Powe supply ...................................................................... 6
3.3.2 Cable management ............................................................... 7
3.4 Traction and safety wire ropes ........................................................ 7
3.4.1 Traction wire rope ................................................................ 7
1.5 WTG Integration requirements .... .................................................... 5
1.5.2 Liftway clearances ........ ............. ............ ............. ............. .. .5
1.5.3 Power supply .... .... .. ........... .......... .. .......... ... ....... ... ...... ...5
1.5.4 Beam ........ ............. ............ ...... ..................... ............. ..5
1.5.5 Fences ........ ....................... .............. ............. ............. ..5
1.5.6 Lighting ........ ... ................... ............ ............. ............. .....5
1.5.7 Other requirements ........ ............. ............ ............. .............. .5
3.3 Electrical connections................................................................. 6
3.4.2 Safety wire rope .................................................................. 8
3.5 Guiding system .
... ... ... .. ... ... ... ... ... ... ... .. ... ... .... ... .. ... ... .... ... .. 9
3.5.1 Guiding ladder ................................................................... 9
3.6 Top limit device ............ ............................................................ 9
3.8 Information signs and warnings . ... ... ... .. ... ... ... ... ... .... .. ... ... .... ... .. 10
3.8.1 Rescue guide ...... ............................................................. 10
3.9 Inspection before first use . ... .. . . .. .. .. . . .. . .. .. . . .. .. .. .. . ... .. . ... . . .. .. 10
3.10 Disassembling . ... .. . . .. .. .. . . .. . .. .. . . .. .. .. .. ... .. . . .. .. . .. .. . .. .. . .. .. 10
4 Maintenance . ................................... .. ................ ..
.. ......... ....... 11
4.1 Recommended planning ............. ................................................ 11
4.2 Alternative planning..................................................... ............. 11
4.3 Annual maintenance and inspection . . .. .. . . . . . . . . . . .. . . . .. . . .. .. .. .. . . .. .. 12
4.3.1 Overall . ..... ... ............................................ .....................12
4.3.2 Control and safety devices ...................................................... 13
3.2.2 Pre installation storage
....................................... ..................... 6
3.7 Landing interlock system .............................................................. 9
3.7.1 Trapped key system .............................................................. 9
3.7.3 Safe zone plates ............................. ....................................10
3.7.2 Guard locking system........................ .................................... 10

ii
4.3.3 Cabin ............................................................................ 13
4.3.4 Traction hoist .................................................................... 14
4.3.5 Fall arrest device ................................................................ 14
4.4 Repairs ................................................................................ 19
Installation and maintenance Log Sheet......................................................20
4.3.6 Cable management ............................................................. 14
4.3.7 Traction and safety wire ropes .................................................. 15
4.3.8 Guiding system . .................................................................18
4.3.9 Top limit device ..................................................................18
4.3.10 Landing interlock system ......... ............................... .............. 19
4.3.11 Overload check and adjustment ......... .................................. .... 19
4.3.12 Information signs and documents ......... ............................... ..... 19
4.5 Ordering spare parts .................. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. 19
4.6 Actions to temporarily put the lift out of service .................................... 19
Inspection and maintenance Checklist........................................................24
Adjustment of the overload detection device.................................................28
AVANTI lift anchor..............................................................................30
Changelog ..................... ................... .. ....... .............. ........... ......... 34

3
1 Introduction
1.1 Symbols
DANGER
Immediate or possibly imminent danger. Risk of injury
if not observed: Death or severe injury.
WARNING
Potentially hazardous situation. Risk of injury if not
observed: Minor injury or material damage.
CAUTION
Hazardous situation which, if not avoided, could result
in minor or moderate injury.
NOTICE
Useful tips for optimum working procedure.
Possible injury if not observed: None.
1.2 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
(Also manual no-
powerdescent)
Action performed to descend the lift at a
controlled speed without power supply by
manually opening the hoist electromagnetic
brake.
1.3 Observations
This lift must only be used by trained people.
Additional copies are available from the manufacturer upon
request.
This manual must always be available to the personnel
responsible for the installation, maintenance and
operation of the service lift.
This manual, including, but not limited to, measurements,
procedures, components, descriptions, instructions,
recommendations and requirements, is subject to change
without prior notice. Please see the manuals section in the
Avanti Website for the latest revisions of the manuals.
Any additional cost relate to or arising from any changes
in the manuals does not entitle the customer to any form
of compensation or other legal remedies.
NOTICE
The pictures and diagrams in this manual may not
reflect the exact appearance, colors or layout of the
product. This has no impact on its functionality or
safety.

1.4 Cautions
Personnel must be of legal age. Personnel must be
familiar with the relevant accident prevention instructions
and must have received appropriate occupational heath
and safety training.
The service lift must not be used by persons who are
under the influence of alcohol or drugs and who may
jeopardize working safety.
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 path is protected by fences at each platform.
•Walking way surfaces are dry and not slippery.
During installation tasks:
•Personnel must wear PPE (safety helmet, full
body harness, shock absorber, lanyard and slider) at all
times andcarry2waycommunicationsystemsdependingon
local regulation.
•Use a hand winch attachable to the ladder when
elevating 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.
The service lift is designed for a useful life of 20 years with
an approximate use frequency of 12.5 h/year (250 h in
total).
Installation and maintenance of the service lift must only be
performed by certified technicians. The service lift must be
inspected by a certified technician before its first use.
The service lift must be inspected at least once a year by a
certified technician. In case of high use frequency
or severe use conditions, more frequent
inspections are required.
If more than one person is entrusted with
installation, inspection or maintenance tasks, the
employer must appoint a supervisor in charge of
the operation.
Use and daily inspection of the service lift must only be
performed by persons who have received the relevant
training associated with the use and daily inspection of the
Avanti service lift and who are in possession of a valid (not
expired) certificate for the task.
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.
CAUTION
Avoid injury — follow all instructions.
If any damage or faults are found during
operation, or if circumstances arise which may
jeopardize safety: interrupt the work in progress
immediately and notify the supervisor or employer.
If required secure workplace.
The service lift must not be used in the event of
a fire in the tower.
The service lift must only be used when the
turbine is not generating power.
All wind farm regulations must be followed. The
service lift must not be used during severe
weather, including wind speeds over 18 m/s.
The customer must define the maximum allowable
wind speed ensuring safe installation.
If any supporting parts are repaired or replaced,
the operational safety of the system must be
tested and verified by a certified technician.
All test / repairs of electrical installations must only
be performed by a certified technician.
All repairs to the traction, braking and supporting
systems may only be performed by a certified
technician.
Only original fault-free parts must be used. Use of
non-original parts renders the manufacturer’s warranty
void and invalidates any type of approval.
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 that are not approved by the manufacturer.
In case self-locking nuts are used, these nuts must not
be used once it has become possible to loosen by hand
and in no case should they be reused, but must be
replaced.
During maintenance tasks, personnel shall:
•Wear at least the following PPE: 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.
•Use a cable grip when replacing travelling cable.
•Keep cabin doors closed when using a 3-step ladder.
NOTICE
The owner must verify the need for third-party service
lift inspections with the local authority and comply with
specified standards.
4

1.5 WTG Integration requirements
1.5.1 Height and angle
The service lift can be installed in towers up to 100
m high of travel path.
The maximum angle between hoist way and
vertical axis is of ±2º.
1.5.2 Liftway clearances
Depending of travel path inclination, gaps
may need to be large enough in order to avoid
collisions of lift elements with platforms.
The Octopus L95 HD service lift shall have an air
gap of at least 60 mm. around it along the
tower to avoid collision with tower components.
These gaps have considered not only the static
position but also considering possible
movement of components inside the tower as
a consequence of the towers way.
The components subjected to possible
movement inside the tower include, but are not
limited to, dampers, wireropes, cables, doors,
hatches, and travelling cable pulley (if installed).
1.5.3 Power supply
Electrical supply requirements
Power Supply Type 3 Phase + PE + N 3 Phase + PE
Voltage (50 Hz) 400 V 690 V
Protection Acc. To EN 60204 - 1
Voltage (60 Hz) 400 V 690 V
1.5.4 Beam
The top beam must be capable to withstand
the reaction loads transmitted by the traction and
safety wire ropes.
The required safety factors and load cases for the
top beam are according to EN1808 european
standards are required, check with the local authority.
1.5.5 Fences
Travel path must be protected by fences at
each platform. The platform fences consist of
structures, of different geometries depending
on the platforms where they are installed.
The platform fences must conform to EN
14122-3. They shall be equipped with a door
(sliding and/or swinging) monitored with a
trapped key system. Optionally, and apart from
the trapped key system, the platform fence
doors for the Octopus L95 HD service lift
could feature guard locking switch system, or
an electrical switch monitoring system.
The first one just allows the user to open the
fence door when the service lift cabin is at the
platform level. In case of an emergency situation,
users can open the fence door by acting the
emergency release of the guard locking
switch. From the moment the fence door is
open, power is removed so the service lift cannot
move.
The second system is an electrical
switch monitoring system. This interlocking
mechanism is comprised of a mechanical
locking unit and a switch unit. When the switch
is opened, the power is removed so the service
lift cannot move. In this case, the fence
doors must be self-closing doors, to avoid any
user could fall from a platform if the fence door is
left open.
1.5.6 Lighting
The platform control boxes shall be
properly illuminated (e.g. an illumination of at
least 50 lux according to EN 50308).
The loading side of the platform holes shall be
properly illuminated.
The landing platform shall be properly illuminated
The tower shall provide emergency lighting in case of
power failure (e.g. an illumination of at least 10 lux
according to EN 50308).
1.5.7 Other requirements
The WTG manufacturer must provide any other means
necessary to ensure the safe use of the service lift
according to AVANTI´s recommendations and its own
risk assessment for the integration that shall include
items which are not under AVANTI´s scope.
NOTICE
A detailed list of integration requirements is available
from AVANTI upon request.
5

2 Transport
2.1 General transport requirements
The transport conditions shall be agreed with the
customer. If special transport requirements are needed,
the customer must specify them to AVANTI prior to
delivery.
3 Installation
3.1 Delivery inspection
Check the delivery against shipping lists and look
for transport damages. Should there be any damage,
report it to the responsible transport insurance
company within 24 hours from the date of arrival of the
goods.
Other claims should be made to AVANTI
representative within the same period.
3.2 Storage
3.2.1 General storage requirements
The storage conditions shall be agreed with customer.
If special storage requirements are needed, customer
shall specify them to AVANTI prior to delivery.
3.2.2 Pre installation storage
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” onwards.
3.3 Electrical connections
3.3.1 Power supply
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.
WARNING
When plugging the service lift to the power supply,
ensure that supply phases are correct!
NOTICE
For CE versions: the electrical connection of the
system must be made in accordance with EN 60204-1.
WARNING
Before making any connection, disconnect any power
supply to the service lift and the fence interlock
system.
NOTICE
The WTG manufacturer shall provide 3D drawings to
ensure that installation of lift on ladder is possible.
6

3.4 Traction and safety wire ropes
3.4.1 Traction wire rope
3.4.1.1 Traction wire rope in suspension beam
The traction wire rope is attached to the suspension beam
on the available hole.
To install the traction wire rope on the suspension beam:
1) Mount the traction wire rope (ø 8 mm) using the shackles
supplied for the suspension beam at the top of the tower.
2) Fit the nuts and bolts on the shackles. Lock with cotter
pins.
3) Fit the top limit device1) on the traction wire rope leaving
at least 200 mm between top limit device1) 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 the traction wire rope to the bottom of the tower.
1)Described in the top limit device section.
DANGER
Do not pull wire rope over edges.
CAUTION
All wire ropes must be evenly uncoiled to prevent
looping.
3.4.1.2 Path of traction wire rope through the lift
1) Open the wire ropes maintenance cover inside the
cabin.
2) Feed the wire rope through the roof into the
traction hoist’s wire rope inlet opening.
3) Push the UP button of the cabin control box and
feed wire rope through until the traction hoist starts
pulling. Ensure that the wire rope can exit without
obstruction!
4) Feed the wire rope through the guide bushings of
service lift.
5) Feed the wire rope through the guide bushing of the
travelling cable pulley.
3.3.2 Cable management
3.3.2.1 Travelling cable
Travelling cable pulley is suspended on the cable and is
guided along the traction and safety wire ropes.
-Install the junction box on the first platform over
mid tower’s height.
-Cut the transport strips which hold the cable and
connect the cable inlet to the junction box.
-Uncoil the cable to the bottom platform.
-Connect the power cable outlet socket to the service
lift inlet plug as described on the travelling cable
adjustment.
Travelling cable ajustment:
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.
The travelling cable pulley should be adjusted to avoid
collision or hits with cabin when lift is resting on buffers.
The pulley also should not rest on the platform when the
lift is in the bottom platform.
1
2
3 4
Travelling cable
1
2
Travelling cable pulley
Travelling cable
Traction wire rope
Safety wire rope
3
4
7
Figure 1: Travelling cable