Power Climber Wind BAP 360 User manual

Reference: 38741
Issue date: 2018-JUL-24
Revision: L
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BLADE ACCESS PLATFORM
TYPE: BAP 360°
OPERATION AND INSTALLATION INSTRUCTIONS
CONFORM TO THE
MACHINE DIRECTIVE 2006/42/EC
EN 1808 was used as guiding base for the design
WARNING:
All persons operating this equipment must read and completely understand this manual.
All persons must be thoroughly trained in the use of the equipment, it’s operational and
safety features, and they must also be capable of carrying out the daily checklist.
Only authorized and physically fit persons shall operate the equipment.
Any operation in violation of these instructions is at the operator’s own risk and may result
in serious injuries.
Keep this manual with the platform at all times.
Only use spare parts and steel wire rope from POWER CLIMBER WIND

Reference: 38741
Issue date: 2018-JUL-24
Revision: L
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1. General View ......................................................................................... 3
2. Specifications........................................................................................ 3
3. Rigging of the Steel Wires at the Nacelle............................................ 4
4. Assembly of the BAP 360°.................................................................... 5
5. Overview of Assembled Platform ...................................................... 21
6. Operation of the Blade Access Platform........................................... 23
7. Instructions & Precautions Before Starting and During Operation. 25
8. Hoist Specifications and Features..................................................... 28
9. Reeving of Steel Wires ....................................................................... 29
10. Maintenance...................................................................................... 31
11. Trouble shooting............................................................................... 32
12. Safety Features ................................................................................. 33
13. Steel Wire Specs and Inspection Criteria........................................ 35
14. General Caution And Precautions ................................................... 36
15. Daily Test........................................................................................... 37
Manufacturer:
Power Climber Wind b.v.b.a,
Satenrozen 7,
B-2550
Kontich BELGIUM
Phone: [phone]
Fax ; [phone]
Email: [e-mail]

Reference: 38741
Issue date: 2018-JUL-24
Revision: L
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www.powerclimberwind.com
1. General View
2. Specifications
Verification needs to be done to make sure that the size of the BAP platform is suitable for the
given blade parameters. Form with blade dimensions and parameters to be completed.
General Specifications
The platform is designed to inspect and to perform any necessary maintenance or repairs to the
blades of wind turbines.
The platform is built with Power Climber Wind Modulo Platform elements. Two Titan hoists Type
653-CE are used to power the platform. Attached to the bottom of the rectangular platform is an
aluminium sub frame. The sub frame is actuated with a manual winch to push the platform away
from the tower to access the blade. Double pneumatic castor rollers are used to engage the
tower and roll along during ascent and descent.
Subframe/
stabilization frame
Walk-through Stirrup
x2
Roller Stanchions x4
Winch Assembly
Modulo Platform

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Revision: L
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General Specifications
Total self-weight
1075 kg
Max. Payload
225 kg
Lifting capacity Titan hoists 2 x 650 kg
1300 kg
Max number of Persons
2
Lifting speed
8,5 m/min
Max Distance from Tower to Blade Tip
10,4 m
Min. Distance from Tower to blade
840 mm
Distance between suspension wires
2960 mm
Overall internal Dimensions L x W
4390 mm x 2200 mm
Total Height
2850 mm
Power Supply
3x400V/50 Hz ( 3Ph+N+E)
Power rating Titan hoists
2 x 1.8 HP
Max wind speed not continuously guided
10 m/sec
Max wind speed continuously guided with tag line
12,5 m/sec
3. Rigging of the Steel Wires at the Nacelle
Rigging of the steel wires may only be done by trained installers.
Rigging points must have a minimum rating of 3 x WLL = 3 x 650 kg
When using slings, use 1 sling for the safety wire and 1 sling for the suspension
wire.
Minimum rated load of slings is 2000 kg ( Green Slings)
Only steel wires recommended by Power Climber Wind may be used.
The top limit striker plates can be fixed to the suspension wires under the hook
before lifting the wire to the nacelle. This to avoid the need to install the top plate
from the platform.
The distance from the striker plates to the nacelle has to be carefully determined
so to limit the angle of the steel wires to maximum 15°. This distance has to be
calculated with the specific turbine parameters.

Reference: 38741
Issue date: 2018-JUL-24
Revision: L
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4. Assembly of the BAP 360°
NOTE: Length to be measured between the bottom holes of the sideframe.
A. Bill of Material
Before assembling the BAP 360° make sure following components are present:
For the MODULO®platform:
A. 4 x Corner section with 2 U frames attached ( PN 61054+2 x PN 61041 )
B. 2 x Deck section 1274 mm ( PN 61025-1274 )
C. 4 x Side frame 1274 mm ( PN 61027-1274 )
D. 4 x Guard rail 1274 mm ( PN 61026-1274 )
E. 2 x Deck section 2375 mm ( PN 61025-2375 )
F. 4 x Side frame 2375 mm ( PN 61027-2375 )
G. 4 x Alu Guard rail 2375 mm ( PN 61026-2375 )
H. 2x Extra U frame ( PN 61041 )
I. 2 x Deck 980 mm ( PN 61025-0980 )
J. 4x Side Frame 980 mm ( PN 61027-0980 )
K. 4 x guard rail 980 mm ( PN 61026-0980 )
L. 120 x SafeFix pins ( PN 61049 )
M. 2 x Walk-through Stirrup ( Assembly )
N. 8 x Soft Wall Roller ( PN 61046)
O. 2 x Titan Hoist ( PN 9091 3 phase unit )

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For the Sub-Frame:
A. 1 x BAP 360° Stabilization Frame
4 x Caster Assembly ( Assembly )
6 x Tubes 130x50x4 L = 2686mm (PN P-6360-019)
2 x Tubes 130x50x4 L = 1500mm (PN P-6360-084)
2 x Tubes 130x50x4 L = 3081mm (PN P-6360-087)
6 x Connection piece ( Assembly)
4 x Corner piece ( Assembly )
B. 4 x Roller support (Roller Stanchion) ( Assembly )
C. 1 x Winch Assembly with steel wires and 3 pulleys.
D. 1 x Anchor Assembly
D
C
B
A

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B. Assembly of the MODULO®platform with stirrup
General information on MODULO®platform assembly
The modular design of the MODULO®suspended platform allows you to modify the
configuration of the standard components to obtain the size platform required. These
components are secured together by using the patented SafeFix pin system, a one
step “insert and snap” method to assemble MODULO®platform components. The
slotted pin is fixed in place by a spring mounted on the stirrup or U-frame.
General information on SafeFix pins
To connect the platform components use the SafeFix Pins. Push the pins through the
holes, keeping the slot horizontal (Fig 1). In this position the pin is secured by a spring
catching in a groove of the pin. To remove the SafeFix pin, turn the pin 90° and push the
pin out. (Fig 2&3) The pins can be positioned with a screw driver and a mallet.

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Insertion of the SafeFix pin
Line the pin up with the hole, so that the slot at the base of the pin is
horizontal.
Push the pin in from outside until the spring clicks in the grooves on the shaft
of the pin. If required, rotate the pin till the slot is horizontal and the springs
are in place.
Make sure the pin is secured.
Fig 1
Removal of the SafeFix pin
Rotate the pin ¼ turn till the slot is vertical (and the springs are no
longer in the grooves) and pull the pin out.
Fig 2 Fig 3

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Assembly platform
Start assembling the platform according to the pictures below. Do this 2 times
Do not put the Alu Guard rail 2375 mm in place yet. This will be done after
mounting the stirrups.
Put the 2 elements on its side and assemble the roller support units to the corner
sections. Fix the units with 2 clams to the platform.
2x
2x

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Install support and put the platform-half up again.
Assemble the stirrups on the platform. Afterwards, the Guard rails can be installed.
Make sure that the stirrups on both platform halves are located at approximately the same
location
2x
Big roller on
tower side

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Mount the back support that hold the steel wire of the subframe.

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Mount the support with the winch

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Now start assembling the 2 pieces of the platform according to pictures below.
On the other side mount one side frame and guard rail where no supports are present. After that
remove the supports.
Finally assemble the last pieces of the platform.

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C. Assembly platform starting from trailer
On the picture below the platform is positioned that the front part of the trailer has the
part of the platform that needs to be positioned towards the tower. This can be
reversed that the rear of the trailer has the part of the platform that needs to face the
tower.

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First you need to mount the hoists on the stirrup. You can shear in the steel wires and use it to lift
the hoist to the proper positions. Make sure that on both stirrup sides, the black cover of the Titan
hoist is facing the tower.
Safety Wire
Suspension Wire

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After that the hoist are properly mounted and the wires are attached correctly you can start lifting
the platforms. Move one half of the platform to the side and put it on the ground. Lift the other half
up and remove the trailer.
Now position the half that is hanging in the air according to the pictures below.

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Now start assembling the pieces of the platform on the side where no supports are present.
On the other side mount one side frame and guard rail where no supports are present. After that
remove the supports.
Finally assemble the last pieces of the platform.

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D. Assembly of the subframe
Assemble the subframe on the platform that you get the result as in the general
overview. (see point 5) Depending on the size you want to build you will need different
tubes. See the bill of material in point 4a for the needed materials. Use the following
assembly guides to complete the subframe assembly.
Assemble the straight tubes together with the straight connection pieces and the
corner pieces to a straight tube and a cross tube by means of bolts M12x70.
Mount the tower roller assembly to the front tube using the connection plate, 4
spacers, 4 M12x90 bolts and M12 washers and nylock nuts.
Use the following tightening sequence and torque specifications.
Make sure that the rollers are perpendicular to the turbine’s tower.

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1) First tighten the four nuts without applying any force
2) Next tighten to 10Nm in the cross pattern sequence shown above
3) Finally torque down to 25Nm, also following the cross pattern above.
Mount the CCB on the crossbar of the platform.

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Fix 1 cable weight of 10 kg to the suspension wire and 2 cable weights to the safety wire.
Suspension wire need to be able to rotate freely.