Avanti OCTOPUS L95 User manual

AVANTI SERVICE LIFT
Installation and Maintenance Manual
Model Service Lift OCTOPUS L95
Original instructions
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CE certificate for Octopus L95 :
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Date of publication:
2nd CE Edition: 09/2017
Revision 2: 18/10/2018vision 3: 12/06/14
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] 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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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 Activation plates ............................................................10
3.10 Inspection before first use....................................................10
3.11 Disassembling .............................................................10
4. Maintenance .................................................................11
4.1 Recommended Planning . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..11
4.2 Alternative planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . 12
4.3 Cautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........12
4.4 Annual inspection ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.5 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....................15
4.6 Ordering spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...........15
Appendix A: Regulation of overload limiter .............................................16
Appendix B: Inspection checklist .....................................................18
Appendix C: Operation log sheet .....................................................21
Appendix D: AVANTI lift anchor ......................................................22
Appendix E: Service tool kit .........................................................26
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Installation and Maintenance Manual
* 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
Order
Reference to written
specification/documentation
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Installation and Maintenance 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.
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 Certified techni-
cians 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 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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AVANTI Service Lift for Wind Turbines
3.1 WTG integration requirements
WTG
component General integration requirements
Power supply
Power supply type 3 Phase + PE + N
Voltage (50 Hz) 400 V / 690 V ± 5 %
Voltage (60 Hz) 400 V / 480 V / 690 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 for L95 1070 mm
Minimum clearance around service lift 60 mm
Basement Minimum height 600 mm 2)
Height 1.1 m
Platform fences Compliant to requirements of standard EN 14122
Fence door interlock system See note 3)
Max. total travel height for L95 125 m (typical 140 m tower total height)
Safety ladder
Max. angle between ladder axis and vertical axis ± 2º 2)
Max angle variance between ladder sections ± 1º 2)
Max. distance between rung attachments 2240 mm 2)
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 L95 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) For Octopus L95 trapped key or guard locking or electrical switch monitoring system.
3. Installation
The WTG manufacturer shall put in place any other
means necessary to ensure the safe use of the ser-
vice 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.
A gap of 2 mm is demanded from each
side of the fishplate to the ladder.
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Installation and Maintenance 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 a certified technician. 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 plat-
forms 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 connec-
tions 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 mov-
ing 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 respon-
sible.
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.
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 (provi-
sional connection).
5. Plug travelling cable inlet to power supply socket over
mid tower´s height.

Platform fence
Support
Cable
Relief
Travelling
Cable
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AVANTI Service Lift for Wind Turbines
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.
In L95 version , the cable relief is located at
the bottom of the back panel
3.9 Safe zone plates and top limit plate
Adjust the final position of the safe zone plate on each
platform, so that the service lift floor is levelled with the
platform floor when it stops.
Adjust the final position of the top limit plate so that the
service lift floor is levelled with the top
platform floor when it stops.
3.10 Inspection before first use
A service lift inspector must carry out an inspection before
first use following the Annual inspection procedure and
filling in the Inspection checklist.
Inspection shall only be carried out by
a certified technician,
following the Annual inspection procedure.
And filling in the Inspection checklist for future
possible reference.
Owner must ensure that the results of this
inspection before first use are logged in the
Operation log sheet.
3.11 Disassembling
In accordance with local authority regulations
disassemble in reverse order and dispose.



Cable
relief
Travelling
cable
Bottom
platform
floor
Traction wire rope Safety wire rope
Rubber feet
Travelling cable
pulley
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Installation and Maintenance Manual
4 Maintenance
All the inspections / maintenance operations (periodical or extraordinary) must be logged in the appropriate Inspec-
tion 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
Cabin 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
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AVANTI Service Lift for Wind Turbines
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
Cabin 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
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.
Entire system shall be tested by a certified technician
at least once a year, nevertheless local regulations
may require more frequent inspections instead of
every year.
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.
• 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 Annual inspection
Have the entire system tested by a certified
technician 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 Device 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.
!
!
!

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Installation and Maintenance Manual
4.4.1 Cabin
Inspect the cabin structure, joints, attachments and
accessories.
4.4.2 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.
4.4.3 Fall arrest device
The fall arrest device 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.
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.
4.4.4 Traction and safety wire ropes
Perform 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 following
points:
• type and number of wire breaks,
• position and time sequence of wire breaks,
• decrease of the wire rope diameter during operation,
• corrosion, abrasion, deformation,
• 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 compression spring on the safety wire
rope is correctly installed and that the wire rope locks are
fastened
7. Check that the counterweight on the traction wire rope
is properly fastened. The traction wire rope coil and coun-
terweight
shall be able to rotate freely. Do not attach it to a
fixed part.
Record any visible change of the condition
of the wire rope on the “Operation log
sheet”, and monitor closely¡ throughout time.
4.4.4.1 Cleaning
1. Open the maintenance cover to access the wire ropes
from inside the service lift.
2. Use a cloth to wipe off the old grease from the wire
ropes.
3. Close the maintenance cover and ascend the service
lift 1 or 2 m.
4. Repeat steps 1 to 3 until the entire length of the wire
ropes is clean.
Always keep the traction, safety and guiding wire
ropes clean and slightly greasy.
Only use mechanical means to clean the dirty wire
ropes, i.e. a cloth or a hand brush. Do not use
solvents or other detergents.
4.4.4.2 Lubrication
If the distance between platforms is more than 20 m
perform
the following procedure:
1. Ascend the service lift 20 m.
2. Open the maintenance cover.
3. With a spray can, apply lubricant on the wire ropes.
4. Close the maintenance cover and ascend the service
lift 1 or 2 m.
5. Repeat steps 1 to 4 until the entire length of the wire
ropes is lubricated.
6. Finally, perform two complete ascends and descends
in order to distribute the new lubricant evenly along the wire
ropes.
If the distance between platforms is equal or less than 20
m perform the following procedure:
1. A first person ascends in the service lift several meters
so that the wire ropes are accessible from the platform.
2. From the platform and with a spray can, a second
person applies lubricant on the wire ropes.
3. Both persons ascend in the service lift to the next plat-
form.
4. One person egresses to the next platform.
5. Repeat steps 1 to 4 on each platform until the entire
length of the wire ropes is lubricated.
6. Perform two complete ascends and descends in order
to distribute the new lubricant evenly along the wire ropes.
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.

STOP
!
!
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14
AVANTI Service Lift for Wind Turbines
Damage resulting from
crushing, squeezing,
running over, etc.
Wire strap/loop,
which cannot be
unwound
Loop knot forming
when a wire loop is
pulled tight
Bends resulting from
inappropriate treatment
(e.g. securing the load
with the wire)
Wire bags
Loop formation
Kinks resulting
from counterweight
of traction wire rope
not being able to
rotate freely.
Re-lubricate the wire ropes before they show signs of
corrosion or run dry.
• 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 life-
time significantly and ensures a safe operation.
4.4.4.3 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.
4.4.4.4 Discard criteria
The discard criteria of the wire ropes should be based
on ISO 4309: Cranes - Wire ropes - Care and Mainte-
nance, 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 lo-
cal 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, there are more than
one 4-wire strand break on a wire rope length of 250 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.
• If there is damage on the wire rope surface (see following
figures for most common examples of wire rope damage).
4.4.5 Guiding system
Perform the following inspections and adjust if
necessary:
1. Check that the guiding ladder does not show
breaks, damages or corrosion, that is correctly
installed and that the locks and fixes are properly
fastened.
2. Check that outer surface of guiding rollers is
uniform and free of damage, and are properly
installed. Check if wear of surface of guiding
rollers is not be bigger than 1 mm.
4.4.6 Electrical cables
Check and replace the power supply and control
cables if the cable jacket or cable connections are
damaged.
!
!

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Installation and Maintenance Manual
4.4.7 Overload check and adjustment
Annual test:
Test switches and perform overload test as specified
in the “Regulation of overload limiter” Appendix.
4.4.8 Information signs and documents
Verify availability and legibility of all data plates
and information signs. Replace missing or
illegible plates and signs!
4.5 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, corresponding 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.
4.6 Ordering spare parts
Only use original parts.
Spare part lists are available from AVANTI. Please
indicate lift model when requesting a spare part list.
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AVANTI Service Lift for Wind Turbines
Appendix A:
Regulation of overload limiter
Avoid injury by strictly
following the instructions!
Required tools/material:
• Security Torx 40.
• Test weights for applying the test load.
To modify the lifting load limit:
1. Insert the overload adjustment tool in the
adjustment screw through the hole as shown in
the figure.
2. Turn the tool clockwise to increase the lifting
load limit.
3. Turn the tool counter-clockwise to decrease the
lifting load limit.
One turn on the adjustment screw repre-
sents a change of approximately 40 Kg of
the lifting load limit.
To adjust the lifting load limit proceed as follows:
Verification and/or adjustment of the overload device on the service lift can only be done by a certified
technician, who must have been instructed by AVANTI to perform this task.
Overload adjustment tool.
The overload limiter complies with EN 1808
8.3.5.5 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 -Tolerance overload device
(20 kg).
For Octopus L95 = 385 kg.
Travel distance Setup load L95 (kg)
125 to 135 m -
115 to 125 m 325
105 to 115 m 320
95 to 105 m 315
85 to 95 m 310
75 to 85 m 310
65 to 75 m 305
55 to 65 m 300
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Installation and Maintenance Manual
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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22
AVANTI Service Lift for Wind Turbines
AVANTI LIFT ANCHOR is an anchor point used for
protection against falls from heights intended for use
with a full body harness approved according to EN
361 or Z359.1:2007 as applicable. Connection to the
LIFT ANCHOR is only allowed by using self-closing
connectors according to EN 362 or Z359.1:2007 as
applicable.
Use in connection with other equipment than
specified, may be potentially dangerous. User shall
be equipped with a means of limiting the maximum
dynamic forces exerted on the user during the arrest
of a fall to a maximum of 6kN. In case of doubt, please
contact AVANTI.
The maximum load that can be transmitted in service
from the anchor device to the structure is 22.2 kN in
±15º vertical direction. The maximum deflection of the
anchor point that can occur in service is 10mm.
AVANTI LIFT ANCHOR is tested and approved only
to be mounted on AVANTI lifts. This manual always
needs to be represented in language of sale and
provided for use by all technicians. Activities at height
are dangerous and may lead to severe injury or even
death.
Gaining an adequate apprenticeship in appropriate
techniques and methods of protection is important
and is your own responsibility.
Users are obliged to read and understand this User
Manual. Further they need to be proper equipped and
instructed with the use of the necessary fall arrest
equipment and emergency procedures in case of
injury or sudden illness.
Users going to install AVANTI LIFT ANCHOR need to
be familiar with the installation section of this manual.
It’s essential to the safety, that the user always attach
the energy absorber as high as possible above his/her
position, to minimize the fall distance most possible in
case of a fall.
The position of the anchor point is crucial for fall
arrest – the height of the fall, elongation of lanyard and
energy absorber or pendulum movement of the user
should be considered in order to minimize the risk of
impact in obstacles in case of a fall. It’s prohibited for
the user to do many modifications or use non original
Avanti components when assembling AVANTI LIFT
ANCHOR.
Re-use of demounted AVANTI LIFT ANCHORS or
parts is not allowed. Any changes or other uses
beyond this manual are strictly forbidden.
Any changes or other uses beyond this manual are
strictly forbidden. This documentation must be kept
in the service lift for the purpose of subsequent
examinations of the anchor device.
The AVANTI LIFT ANCHOR is for the use of one
person only. It is strictly forbidden to carry out work
if the person is in unfit mental or physical condition.
Climbing and working under the influence of alcohol,
drugs or any medication which can interfere with the
safety are also much prohibited.
If there are any doubts to the safety of the AVANTI
LIFT ANCHOR, or it isn’t proper fixed, deform or
damaged with cracks or similar incompatible harms it
may never be used – Please contact the manufacture
immediately. In case of corrosion the anchor
immediately needs to be removed.
Observations:
Only to be used by instructed workers!
Instructed workers must be aware,
instructed and prepared to utilize site
rescue plans.
Only to be used for preventing vertical
fall!
Only to be used for fall arrest, not to
hoist or hang in goods or similar!
Before attaching in the ANCHOR the
user needs to check it is sitting fixed
and screws are sitting tight and proper.
If AVANTI LIFT ANCHOR has arrested
a fall it may never be used again. Part
must be removed from service imme-
diately.
D.2 Danger
D.1 Caution
Appendix D: AVANTI lift anchor
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Installation and Maintenance Manual
Marking on Lift Anchor plate:
After installation, marking shall be completely accessible;
otherwise additional marking near the anchor device will
be necessary.
The installation must be performed by a certified
technician following the instructions of this manual.
AVANTI LIFT ANCHOR is tested and approved only
to be installed on AVANTI lift. AVANTI LIFT ANCHOR
made from AISI 304 Steel has to be screwed with two
bolts DIN 933 A2-70 M12 mm, 4 washers DIN 125A
A4 and self locking nuts DIN 985 A4 M12. In case of
doubt, please contact AVANTI.
Before installing the AVANTI LIFT ANCHOR in heights,
assure to be proper secured against fall from height by
using relevant fall arrest equipment.
AVANTI LIFT ANCHOR:
1. Fix the anchor point to the structure using
the supplied hardware as shown in the
picture below.
2. Torque the nuts with 15 N·m (11 lb·ft).
3. Make sure the Anchor is fully seated and
properly tightened.
4. Fill in “Installation form”.
5. Carry out yearly inspection by following
the procedure in the section “Inspection”.
D.4 Installation
D.3 Marking
Item
number
European/
American
standard
number
Material
and Capacity
rating
Unique
identification
number
AVANTI
product
name
AS/NZS 1891.4:2009
Unique
identification
number
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AVANTI Service Lift for Wind Turbines
After installation:
An inspection must be carried out by a certified
technician following the inspection form in this
manual.
Before use:
Each time using the AVANTI LIFT ANCHOR the
user inspects the ANCHOR visual and manually by
twisting / pulling. Check the parts are properly fixed
and free of deformities, damages, cracks or similar
unacceptable defects.
Periodical examination:
A periodic examination at least
every 12 month is essential for the safety of the
AVANTI LIFT ANCHOR. The examination must be
performed by a certified technician following the
inspection form in this manual.
For the AVANTI LIFT ANCHOR the certified
technician only needs to be trained in any metallic
component covered by the European/American
standard norms for fall arrest equipment.
If the AVANTI LIFT ANCHOR is found not OK, it must be removed / replaced by a new AVANTI LIFT ANCHOR! The result of the
periodic examination must be recorded in the Registration form of anchor.
PFPE Anchor:
Manufacturer: Avanti
Type / Model: Lift Anchor
Identification no.:
Fixing structure:
Lift serial no.:
Lift model:
Wind farm / WTG no.:
Installed by:
Installation company:
OK not OK
1. Lift structure does not show any deterioration.
2. Anchor locking screws are fully inserted and tightened with 15 N·m.
3. Anchor does not show cracks, deformities, corrosion or other damages.
4. Anchor installed on the lift structure according to the instructions.
5. Anchor marking is clearly readable.
Is the Anchor in good condition to be used?
Yes No (Replace)
Signature of competent:
Name of competent in
capital letters:
Date:
D.6 Inspection form
D.5 Inspection
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