Power Climber Wind BAP 360, Operation And Installation Instructions Manual

Page 1: ...etely 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...

Page 2: ...orm 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 32 3 451 05 ...

Page 3: ...ssary 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 r...

Page 4: ...g 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 to...

Page 5: ...4 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 ...

Page 6: ...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 ...

Page 7: ...ing 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 catch...

Page 8: ...izontal 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 turn till the slot is vertical and the springs are no longer in the grooves and pull the pin out Fig 2 Fig 3 ...

Page 9: ... 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 ...

Page 10: ...37 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 ...

Page 11: ...Reference 38741 Issue date 2018 JUL 24 Revision L Page 11 of 37 Mount the back support that hold the steel wire of the subframe ...

Page 12: ...Reference 38741 Issue date 2018 JUL 24 Revision L Page 12 of 37 Mount the support with the winch ...

Page 13: ...ge 13 of 37 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 ...

Page 14: ...tarting 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 ...

Page 15: ...f 37 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 ...

Page 16: ...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 ...

Page 17: ...of 37 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 ...

Page 18: ... 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 tighte...

Page 19: ... Page 19 of 37 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 ...

Page 20: ...Reference 38741 Issue date 2018 JUL 24 Revision L Page 20 of 37 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 ...

Page 21: ...Reference 38741 Issue date 2018 JUL 24 Revision L Page 21 of 37 5 Overview of Assembled Platform ...

Page 22: ...Reference 38741 Issue date 2018 JUL 24 Revision L Page 22 of 37 GENERAL DIMENSIONS ...

Page 23: ... Plug To operate the platform upwards press the UP button Both Titan hoists will start simultaneously Buttons are of the dead man type See Picture 1 To operate the platform down press the down button In Case of Emergency the Emergency stop will cut the power to the hoists The control Box is provided with an automatic Levelling device becoming active when the inclination exceeds 6 The system will c...

Page 24: ...cted Note On the right hand site of the CCB there is a selector switch to control the platform from a Pendant control When the selector is in horizontal position control from the Central box and from the pendant are enabled When the selector is in vertical position only controls from the central box are enabled The Pendant controlled is wired into the circuit after the automatic level control so i...

Page 25: ...n the blade As long as the platform is over the blade there is no problem In case the platform needs to be operated down at least one tag line is required fixed on the safety hook attachment point at the rear of the platform on the wind side and lowered to the ground for the ground team to give the relevant amount of pulling force to keep the 2 rollers in contact with the turbine tower Therefore a...

Page 26: ...de use the winch to bring the blade in the middle of the opening in the platform If needed the platform can be pushed side wards When going higher on the blade make sure that the blade is only in contact with the rollers or the cushioning Use the winch to keep the platform centric round the blade ...

Page 27: ...op plate which has been fixed to the steel wire during installation will activate the Top limit switch and the UP and DOWN direction will be cut To reset the lower the hoist a bit by pulling on the yellow brake lever on the Titan hoist Once the top plate is not in contact with the activating bar of the Top limit switch the system is reset The loading on the platform should be uniformly distributed...

Page 28: ...tart current 7 5 A Power 1 8 HP SWR breaking force 52 kN Climbing speed 8 0 m min Noise up 60 dBA Noise down 64 dBA IP rate IP 55 Hoist self weight 45 kg Safety rope Suspension rope Motherboard under the cover Top limit switch Power plug 10Pole Slack rope lever Carrying handle No Power emergency descent lever Nameplate serial no Lower carrying handle Electric motor ...

Page 29: ...ye of the slack rope lever and into the hoist until it stops 2 Push the up button on the Control panel and the steel wire rope passes through the hoist automatically The end of the rope will come out from the bottom of the hoist Make sure the outlet is free and the wire rope can come out Tip If there is any difficulty reeving the suspension rope it helps to put a small bend in the end of the rope ...

Page 30: ...e launching the platform E Install Top Limit Switch Striker Plates The striker plate activates the top limit switch and must be clamped on the safety wire at a distance of min 20cm from the talurit clamp IMPORTANT Clamp the striker plate to the safety rope ONLY so that the suspension rope passes freely through the slot in the plate REMOVING the steel wire rope from the TITAN hoist Tip Remove the s...

Page 31: ...s noted and action taken Hour meter reading of the hoist ANNUAL MAINTENANCE to be carried out by an authorized service centre or level 3 trained person 1 Completely strip the hoist clean and inspect all parts for wear and damage Replace worn parts when necessary 2 Clean lubricate and re assemble the hoist Particular attention must be given to the slack rope safety device 3 Place the hoist on a tes...

Page 32: ... down direction RED warning light ON Top limit switch has been activated Check for obstruction E g hitting the striker plate Lower by manual brake release Hoist hums starts slowly or is sluggish or fails to lift the loaded platform Serious voltage drop Check the power supply and the specifications of the power supply cable Single phase hoist only Start capacitor is defective Hoist to be checked by...

Page 33: ...descent In the event of a power failure the platform can be lowered at a controlled speed Approx 6 m min by pulling the No Power descent lever on the electro magnetic service brake Warning Never use the emergency manual descent when normal powered movement is possible 4 Top limit switch The Top limit switch cuts the up movement when it is activated by the striker plate which is clamped onto the sa...

Page 34: ...e connected in series If one overheating protector is triggered then the up movement of both hoists is halted 8 Overspeed Safety device Mandatory for any BAP 360 platform The overspeed safety device locks onto the suspension rope when the suspension rope passes through the hoist descent speed at more than 15 m min The overspeed safety device can also be triggered manually by pressing the manual re...

Page 35: ... rope should be brazed to form a bullet end with a maximum length of 10mm without loose or broken wires Use protective gloves to manipulate the Steel Wire Ropes If Steel Wire Ropes are too long carefully wind any extra cable into a loop or onto the wire holders and tie up leaving the coil suspended just clear of the ground WARNING Steel Wires Ropes must be replaced in any of the following conditio...

Page 36: ...low the TSP is open to the public preventive measures have to be taken to safeguard the people below e g barriers roof protected walkways etc f All hazards related to the platform encountering obstructions are not completely covered by the TSP s safety devices The operator shall check for obstructions along the travel of the platform g Overload detection device may not protect TSP platforms in all...

Page 37: ...gency stop button and check that the platform cannot go up or down turn button in direction of arrow to reset 6 Push down on the Top Limit Switch and check that it cuts the up and down direction for both hoists Repeat procedure for other stirrup Drive the platform 1 2 meters off the ground to continue the tests 7 a ON ONE HOIST ONLY Pull on the No Power emergency descent lever and check that the h...