FIXED LADDERS ALO 60 & ALO 72

Transcription

1 HIGH LEVEL ACCESS SOLUTIONS FIXED LADDERS ALO 60 & ALO 72 FOR WIND TURBINES AND ACCESS TO MACHINERY DIN EN ISO : 2016 Original instructions for installation and use English Part no

2 Revision and Changes 03/2018 V01R05 EN Hailo Wind Systems GmbH & Co. KG Kalteiche-Ring 18 D Haiger, Germany Phone: +49 (0) Fax: +49 (0) 2773/ Internet: Hailo Wind Systems - No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval medium, or translated into another language or computer language without the prior written permission of Hailo Wind Systems. Infringements of copyright laws may also affect the product support provided by Hailo Wind Systems for this equipment. Hailo Wind Systems reserves the right to make changes to this manual and to the product described therein without prior notice. The content of this manual contains no contractual or other obligation on the part of Hailo Wind Systems and is also not legally binding. This publication has been prepared with great care. However, if you find any errors or wish to suggest improvements, please write to Hailo Wind Systems. This original version of this manual is available in the German language. If desired, you can request a copy in writing.

3 Table of Contents Table of Contents 1. About this document 4 2. Standards and regulations 5 3. Safety 6 4. Markings and instructions Transport and storage - technical data System overview Installation General installation instructions Technical specifications Ladder bracket Ladder connection Rung repair kit Floor fastening Resting platforms Potential equalisation Use Safety instructions Inspection and maintenance Installation report Protocol for examination 54 3

4 1. About this document These instructions for installation and use describe the installation, use, maintenance and inspection of the aluminium ladder system. Please read this manual completely and observe all safety instructions before starting the installation work and using the ladder. Hailo Wind Systems assumes no liability for damage caused by non-compliance with this manual and the safety instructions. These instructions for installation and use are only valid for Hailo Wind Systems ladder systems. NOTE! Product changes Hailo Wind Systems reserves the right to make technical changes and improvements which do not affect the tested design model with regard to the criteria relevant to safety. Hailo Wind Systems reserves the right to make changes to the content of the technical documentation. i Language of the manual If the ladder system is to be sold to another country, for the safety of the user it is necessary for this manual to be available in the language of the respective country. Translations are available at documentation@hailo-windsystems.com. 4

5 2. Standards and regulations The ladder system meets the requirements of the following standards: OSHA OSHA ANSI 14.3 (Parts) AS 1657 (only ALO-72) EN ISO : 2016 Safety of machinery - Permanent means of access to machinery - Fixed ladders BGV / GUV-V A1 Principles of prevention BGI / GUV-I 5189 Selection and use of ladders DGUV Selection, training and evidence of formal qualification of specialists for personal protective equipment to prevent falls DIN EN Wind turbines - Protective measures for design, operation and maintenance Fall arrest requirements According to DIN EN ISO : 2016, a fall arrest system is required from a fall height 3 m. According to DIN EN ISO : 2016, for heights over 10 m and a single ladder design, only a fall arrest system in accordance with DIN EN 353-1: 2014 is permitted. Fall arrest requirements The fall arrest system must comply with DIN EN 353-1: The ladder must be equipped with a fall arrest system with a fixed guide. Observe national regulations. Arrangement for entering and exiting ladders with fall arrest system The fall arrest system and its environment must be designed in such a way that the user enters or exits this from a secured position, e.g. by providing an anchor point according to DIN EN 795 or a floor flap which leads to a fully protected platform with self-locking barrier according to DIN EN ISO : 2016,

6 3. Safety Intended use The fixed ladder is specially designed for use in wind turbines and access to machinery. It serves the safe ascent and descent of service personnel to and from high-level workplaces. Here, the user armed with his personal protective equipment (PPE) against falls from a height is attached to the available fall arrest system, which runs along the entire length of the ladder system. The ladder system must not be used unless the user is secured, for example by means of the fall arrest system. The owner or operator of a plant must provide a plan which takes account of all possible emergencies that may occur during the use of the ladder system and explains the necessary rescue measures. The fixed ladder may only be used in perfect condition. These instructions for installation and use must be observed by all persons who install and use the ladder. The fixed ladder may only be installed by trained persons. The prerequisite for the safe handling and fault-free installation and use of the ladder is compliance with the safety instructions and safety regulations. Structural changes are only possible after approval by Hailo Wind Systems. A copy of the approval must be added to the technical documentation (manual). The fixed ladder may only be used by persons who have been instructed in the use of the ladder and fall arrest system and who are familiar with the safety concept in the wind turbine generator or mechanical installation. This includes any necessary rescue measures as well as their initiation and implementation. The accident prevention regulations applicable to the respective place of use and the safety regulations specified here must be observed. The operator of the wind turbine generator must secure the ladder system against access by unauthorised persons. 6

7 The ladder system may only be used for the intended purpose. non-observance of the safety instructions. Use other than for the intended purpose is prohibited and can lead to the failure of individual components and thus to the failure of the entire system. The ladder system must not be used in the event of: improper installation; safety defects or incorrectly performed repairs; arbitrary, unauthorised structural changes to the ladder system; the use of other than original spare parts; use by insufficiently qualified personnel; ignorance of or non-compliance with the instructions for installation and use; inadequate maintenance and care or neglect of the timely inspection of the ladder system. No liability is assumed for personal injury or property damage resulting from violations of the provisions set out here or from 7

8 3. Safety Safety instructions Classification of the safety instructions The safety instructions in the manual serve to provide information which must be heeded and precautionary measures which must be taken, in order to avoid a dangerous situation. In this manual, there are four classes of safety instructions and useful or important information is highlighted (tip / info). DANGER! DANGER indicates an imminent dangerous situation which, if not avoided, will result in serious injury or death. WARNING! WARNING indicates a potentially dangerous situation which, if not avoided, can result in serious injury or death. A distinction is made between: CAUTION! WARNING indicates a potential dangerous situation which, if not avoided, can result in minor injuries. NOTE! WARNING indicates a potentially dangerous situation which, if not avoided, can result in material damage. i Tip / Info This symbol alerts you to important or helpful information. 8

9 Before installing and using the ladder system NOTE! Failure to observe the manual may cause material damage Therefore, please note: Before installing and using the ladder system, carefully read and take note of the instructions. Only persons who have been instructed and authorised by the manufacturer may install and use the ladder system and fall arrest system. The operator must ensure that these instructions for installation and use are kept on site for each ladder system and are available to the personnel. ATTENTION! Put on personal protective equipment (PPE) to prevent falling Protection against falling from more than a low height. Carry communication device(s) (mobile phone / radio) Constant voice contact between the persons must be ensured during the stay in and on the wind turbine. Ensure contact between the persons by means of a mobile phone or radio. Wear a protective helmet Protection of the head against falling objects and impacts due to falls or in cramped conditions. Wear safety shoes Protection of the feet against heavy falling parts, slipping, or stepping on sharpedged parts left lying around. Wear safety gloves Protection of the hands against friction, abrasions, puncture wounds and cuts. 9

10 3. Safety Warning information DANGER! Danger of falling! Failure to observe the safety instructions can lead to a fall, resulting in serious injury or death. Therefore, please note: Before using the ladder system, using the personal protective equipment (PPE) against falls from a height, secure yourself on the fall arrest system provided. The PPE against falls from a height must be properly selected, applied and tested. In the event of icing, the use of the ladder system is not permitted. In lattice towers, the use of the ladder system is also not permitted under extreme temperature and weather conditions (e.g. hail, strong wind, snow and ice). Do not use the ladder system if you feel unwell or are in poor physical condition. Care must be taken to ensure that there are no items of equipment or objects underneath the ladder system that represent an additional hazard in the event of a fall. There must be no oil, grease or other lubricants on the rungs and climbing surfaces. Do not exceed the maximum permissible load capacity of 150 kg in one ladder section between two ladder brackets. The system or components of the system must be immediately withdrawn from use in case of doubt regarding their safe condition. 10

11 DANGER! Danger of injury from electric shock! Improper use can result in life-threatening injuries or death. Therefore, please note: The ladder must be earthed over the entire length (potential equalisation)! The ladder must not come into contact with electrical wiring or electrical components which are damaged or have no suitable insulation. WARNING! Danger of injury from improper use! Improper use can result in serious personal injury or property damage. Therefore, please note: The ladder system may only be used by trained personnel. Damaged components may only be replaced by specialist personnel (authorised by the manufacturer) and by original parts. No modification or extension of the ladder system may be made without the manufacturer's express prior written consent. A copy of the approval must be added to the technical documentation (manual). Any necessary repairs must be carried out in accordance with the procedures specified by the manufacturer. Never override the safety equipment. Pay attention to tidiness and cleanliness! Loosely stacked or scattered objects such as tools, cables and components are sources of accidents. 11

12 3. Safety Failure to observe safety instructions may cause material damage. Observe the safety regulations for the wind turbine generator and the instructions of the system manufacturer. NOTE! Inspection and maintenance periods The prescribed time periods for recurring inspections / maintenance must be observed! The ladder system must be inspected for proper condition by a competent and qualified person at least once a year. The control sheet for the inspection can be found in the appendix of this manual. NOTE! Language of the manual If the ladder system is to be sold to another country, for the safety of the user it is necessary for this manual to be available in the language of the respective country. Translations are available at documentation@hailo-windsystems.com. 12

13 4. Markings and instructions Ladder nameplate NOTE! Markings on the fixed ladder Please pay particular attention to all markings or stickers containing safety instructions. Manufacturer, year of manufacture, type designation Materials and dimensions Notes on the load of the ladder Ladder identification plate Notes on the fall arrest system Inspection labels for the annual inspection by an expert Notes on the load of the ladder 13

14 5. Transport and storage - technical data Transport and storage All system components must be secured in such a way that their function is not impaired and all components are in a perfectly safe condition. Move and load the components of the ladder system with caution. To avoid damage, do not turn the ladder components on their edges during transport and storage. Do not burden the system components with additional loads during transport and storage. During transport and storage, protect the components of the ladder system from moisture, exhaust gases, chemicals or other harmful substances. Before installing the ladder system, check all parts for perfect condition. There must be no transport damage to system components. Damaged parts must be replaced before installation. Technical data The permissible temperature range for the use of the ladder is between 40 C and +60 C. The permissible storage temperature lies in the range between 40 C and +60 C. 14

15 6. System overview Ladder with fall arrest rail (DIN EN 353-1: 2014) and resting platform i Scope of supply All illustrations are examples and, depending on the version, may deviate from the representation shown. Ladder types Aluminium ladder Rail profile 72 x 25 mm Aluminium ladder Rail profile 60 x 25 mm Ladder mounting Mounting of the ladder by means of ladder clamps Mounting of the ladder by means of ladder brackets with rung adapters 15

16 6. System overview Ladder connector Internal rail connector Plastic 72 x 25 mm Internal rail connector Aluminium 60 x 25 mm External rail connector Section rail connector 16

17 Floor fastening Resting platform Floor fastening with ladder clamp Resting platform with separated standing area Floor fastening on ladder rung Rung repair kit Rung repair kit 17

18 7. Installation 7.1 General installation instructions Proof of load-bearing capacity Before commencing the installation, ensure that the load-bearing structure is capable of absorbing the generated loads. If no corresponding information and documents are available for this purpose, static proof must be provided, which takes account of the required load bearing capacity. Hailo Wind Systems assumes no liability for damage if the necessary proof of safe force absorption on the load-bearing structure is not provided. Installation personnel The personnel responsible for installing the ladder system must be qualified and competent and have appropriate training. For more information on service training, visit www. hailo-windsystems.com/sara. Protection of the installation personnel DANGER! Danger of falling! For installation work performed at height, there is a danger of injury from falling! Therefore, please note: Use your full PPE against falling from height! Use an approved fall arrest system during the installation operation. Use an approved anchor point in accordance with DIN EN 795 or CEN / TS The installation personnel must not be secured on the system to be installed. 18

19 General installation instructions Installation and repair Use only clean and undamaged system parts. Damaged parts must be replaced by new, original parts. This may only be done by specialist personnel (authorised by the manufacturer). Any necessary repairs must be carried out in accordance with the procedures specified by the manufacturer. No modification or extension of the ladder system may be made without the manufacturer's express prior written consent. A copy of the approval by Hailo Wind Systems must be added to the technical documentation (manual). Installation report The installation of the ladder system must be fully documented by the responsible manager of the installation company. For this purpose, please complete the installation report in the final chapter of this manual in full. Installation specifications The design and construction of the ladder system must comply with the standard DIN EN ISO : Presentation of tightening torques Exemplary presentation of tightening torques: Thread dimension Tightening torque ST: Steel VA: Stainless steel 19

20 7. Installation 7.2 Technical specifications Interval of anchor points for ladder brackets Occurring loads must be reliably dissipated into the bearing structure by means of at least 4 anchor points per conduction path, or at least 2 per side rail. The anchor points must be arranged in pairs in one plane. When setting the anchor points, Hailo Wind Systems recommends that you do not exceed a vertical distance of 2000 mm. A distance of 1960 mm is sufficient for a rung grid of 280 mm. Larger distances must be agreed with Hailo Wind Systems in advance. NOTE! Specifications for the use of a fall arrest system When using a fall arrest system according to DIN EN 353-1: 2014, the static loads of 15 kn must be taken into account. When using a fall arrest system, the country-specific specifications must also be observed. Loads to be absorbed The anchor points and their connections (brackets and fastening elements) must be able to absorb the corresponding loads. Loads of 15 kn per ladder bracket interval (7.5 kn per side rail) must be taken into account here. This corresponds to a load of up to 3.75 kn for each anchor point. The following must be considered here: weight of the ladder system, maximum number of persons on the ladder system, and the load in the event of a fall. 20

21 Installation specifications First ladder bracket The seat of the first pair of ladder brackets depends on the type of conduction fixture. The specifications can be waived if the ladder is screwed to the floor with a floor fastening. Ladder fastening by side rail clamps The first ladder bracket is attached under the first rung, between the first and second or second and third rungs. Ladder fastening by rung adaptors The first ladder bracket is attached to the first or second rung. 21

22 7. Installation Last ladder bracket The seat of the last pair of ladder brackets depends on the fall arrest system used and the type of ladder fastening. Larger distances between the last pair of ladder brackets and the end of the ladder must be agreed with Hailo Wind Systems. Ladder fastening by side rail clamps Fall arrest system with rail: The last ladder bracket is placed above the first rung, between the first and second or second and third rungs from above. Rope-based fall arrest system: The last ladder bracket must be no more than 280 mm below the end of the side rail. 22

23 Ladder fastening by rung adaptors Fall arrest system with rail: The last ladder bracket is placed on the first or second rung from above. Rope-based fall arrest system: The last ladder bracket is placed on the first rung from above. 23

24 7. Installation Ladder entry dimension The distance between the entry surface (e.g. floor) and the upper edge of the lowest rung must be greater than 100 mm and less than 400 mm (according to DIN EN ISO : 2016). If a service lift from Hailo Wind Systems is operated on the ladder, the distance between the rail end of the ladder and the floor must not be more than 100 mm. 24

25 Installation specifications Ladder exit dimension The top edge of the uppermost rung must be level with the stepping surface of the exit surface. Wall distance - ladder exit NOTE! Specifications for the wall distance at the ladder exit According to DIN EN ISO : 2016: The distance between the rung and the stepping surface at the ladder exit must not exceed 75 mm. It may be necessary to provide an exit extension. This is bolted on by means of a rail bracket under the last rung. Other versions / sizes are possible. Clearance ladder bracket Number of rungs on the exit extension mm mm mm mm 5 25

26 7. Installation Entry and exit elements Entry and exit elements can be used as protection against over climbing at the top end of the climbing path. In the case of ladder exit protection, an additional anchor point must be provided. If other components such as entry and exit elements, railings, barriers, floor flaps or platforms are used, they must comply with the standards (DIN EN ISO : 2016 and DIN EN ISO : 2016). Exit rail clamp, long; material: stainless steel or galvanised steel Exit rail clamp, short; material: stainless steel or galvanised steel 26

27 Installation specifications Minimum tread depth and wall distances c d b a NOTE! Observe minimum tread depth! According to DIN EN ISO : 2016: a. The distance from the front edge of the rungs to the fastening surface must be at least 200 mm. b. In the case of obstacles (1, e.g. tower flange) behind the ladder, the distance from the front edge of the rungs to the fastening surface must be at least 150 mm. c. The distance from the front edge of the rungs to the surface in front of the ladder (e.g. tower wall) must be at least 650 mm. d. In the case of obstacles (1) in front of the ladder, the distance from the front edge of the rungs must be at least 600 mm. 27

28 7. Installation Potential equalisation Ensure that the ladder is earthed over its entire length (potential equalisation). Specifications for fastening to the structure The substructure of the anchor points on the bearing structure must be able to absorb the above loads. Only dowels approved by the building authority may be used. This applies to concrete structures as well as masonry works. For undefined substructures, the fastening system must be designed in agreement with the structural engineer. Suitable fastening types Threaded bushings M12 / M16 in steel constructions Anchor dowel fastenings on concrete structures with a concrete quality of at least C 20/25. This must be agreed with the structural engineer. Pay attention to the installation instructions of the dowel manufacturer! 28

29 Installation specifications General screw tightening torques (unless otherwise specified) Steel screws strength class 8.8 Scew sizes M8 M10 M12 M16 M20 Tightening torque 17.9 Nm 36.0 Nm 61.0 Nm Nm Nm Steel screws strength class 10.9 Scew sizes M8 M10 M12 M16 M20 Tightening torque 26.2 Nm 53.0 Nm 90.0 Nm Nm Nm Max. tightening torques MA (Nm) with a total friction coefficient μ = 0.08 (μ = 0.08 corresponds to a galvanised, unoiled, dry surface). Stainless steel screws A2 and A4 Strength class 70 Scew sizes M8 M10 M12 M16 M20 Tightening torque 14.5 Nm 30.0 Nm 50.0 Nm Nm Nm Max. tightening torques MA (Nm) with a total friction coefficient µ = 0.10 (μ = 0.10 corresponds to a galvanised, unoiled, dry surface). Strength class 70 corresponds to cold press production up to nominal lengths of 8 d and yield strength utilisation of Rp 0.2 = 90%. 29

30 7. Installation 7.3 Ladder brackets i Sequence of installation steps The sequence of installation steps can change depending on the specifications of the wind turbine manufacturer. Ladder bracket with rail clamp 1. Screw ladder bracket to load-bearing structure. In doing so, make sure that the rail clamps for the ladder support are directed inwards. 2. After all ladder brackets have been installed, place the ladder between the ladder brackets. 3. Clasp the rail clamps around the ladder and screw to the ladder bracket. Pay attention to the correct tightening torques! 30

31 Ladder bracket Ladder bracket with rung adaptor 1. Screw ladder bracket to load-bearing structure. In doing so, make sure that the lugs of the ladder bracket are directed outwards. 2. After all ladder brackets have been installed, place the ladder between the ladder brackets. 3. Place the rung adaptor around the ladder rung and fasten to the ladder bracket with the U-bolt. In doing so, pay attention to the correct tightening torque! 31

32 7. Installation 7.4 Ladder connection Internal rail connector - aluminium Suitable for use in rail profile mm. The installation depth of the connector is limited by the ladder rung. The rails are precision guided over the surfaces of the internal rail connector. 1. Insert the internal rail connector up to the rung at the end of the ladder. 2. Push the ladder section to be installed up to the stop on the internal rail connector. Internal rail connector - plastic Suitable for use in rail profile mm The ladder rails are precision guided over the surfaces of the internal rail connector. 1. Insert the internal rail connector up to the stop at the end of the ladder. 2. Push the ladder section to be installed onto the internal rail connector. 32

33 Ladder connection NOTE! Specifications for internal rail connectors An internal rail connector is provided exclusively for the purpose of guiding the ladder rail. After installation, it may be visible on a length of 30 mm, provided the specified rung spacing is maintained. A deviation of the rung spacings by ±15 mm is permitted only in wind turbine generators (EN 50308). Hailo Wind Systems recommends a maximum deviation of the rung spacing of ±2 mm. The internal connectors must not be cut off! Additional screw joint when installing in lattice tower systems NOTE! Installation in lattice tower systems When installing in lattice tower systems, the internal rail connectors must be screwed to the ladder in order to provide additional security. Required screw components (not included in the scope of supply!): 4 pcs. countersunk screw M8 40 DIN pcs. washer M8 ISO pcs. self-locking nut M8 ISO Mark the drilling position and drill completely through the ladder rail (Ø 9 mm). 2. Screw both ladder parts to the ladder end. After tightening the self-locking nut, the inner surface of the countersunk head screw should lie flat against the ladder rail. 33

34 7. Installation External rail connector Threaded bolt material: Stainless steel or steel (galvanised): C-connector material: Aluminium Available for rail profile mm and mm. 1. Insert threaded bolts into the ladder rung and centre with centring sleeves at both ends. 2. Mount the C-profiles on both rails and screw together. In doing so, pay attention to the correct tightening torque! NOTE! Distance between ladder rails Provided the specified rung spacing is maintained, there may be a distance of 30 mm between the ladder pieces to be joined. A deviation of the rung spacing of ±15 mm is permitted only in wind turbine generators (EN 50308). Hailo Wind Systems recommends a maximum deviation of the rung spacing of ±2 mm. CAUTION! Danger of cutting due to sharp edges! The ends of the ladder may have sharp edges. Therefore, always wear protective gloves! The cutting edges (e.g. on rail ends) must be properly deburred. 34

35 Ladder connection Section rail connector Material: Stainless steel. Suitable for use in rail profile mm and mm. The section rail connector enables the subsequent installation or replacement of an intermediate ladder piece, for example on a ladder with ladder-guided service lift. 1. Place the ladder ends flush against the rail surfaces. 2. Position the plate with screw sleeves vertically and horizontally in the centre of the ladder rails and fix with 2 screw clamps. 3. Through the drill sleeves, drill 4 holes (Ø 10 mm) in the ladder rail. Then loosen the screw clamps and remove the plate. 4. Drill the holes on the outside of the ladder rail to Ø 16.5 mm. 5. Install the section rail connector. Insert the plate with screw sleeves into the holes on the ladder rail from the outside. Place the second plate on the inside of the ladder rail and tighten the rail connector. NOTE! Material damage is possible! Observe the dimensional specifications for the installation of an intermediate ladder piece! 35

36 7. Installation Mounting aid i Mounting aid Material: Steel (galvanised). Available for rail profile mm and mm. Hailo Wind Systems recommends the use of the mounting aid for the installation of the ladder. It facilitates the precise cutting and drilling of the respective components. The mounting aid can be ordered by writing to service@hailo-windsystems.com. 1. Place the mounting aid for cutting the ladder on the rail and fix into position (use a screw clamp if necessary). 2. Using the saw guide, saw through the ladder rail with a straight cut (90 ). Repeat for the other three cuts. 3. Remove the cut-out ladder piece and insert a new, customised ladder piece. Place the mounting aid on the rail and fix into position (use a screw clamp if necessary). 36

37 Ladder connection 4. Insert the plate with screw sleeves into the mounting aid and use as a drilling guide. 5. Through the drill sleeves, drill 4 holes (Ø 10 mm) in the ladder rail. Then remove the mounting aid. 6. Drill the holes on the outside of the ladder rail to Ø 16.5 mm. 7. Attach the ladder connector. 37

38 7. Installation Installing an intermediate ladder piece i The intermediate ladder piece is used to join ladder sections in case of the repair of the ladder or in the flange transition area of a wind turbine generator. Installation situation: Intermediate ladder piece in flange transition area Preparation of the intermediate ladder piece for mounting on an existing ladder in the flange transition area of a wind turbine generator. NOTE! Specifications for the flange transition area 1. Determine the distance dimension of the ladder. 2. Cut the supplied intermediate ladder piece to size with a gap of max. 2 mm on the top and bottom end if necessary. Saw at an angle of 90 to the ladder rail and then properly deburr the cut surfaces. 3. Mount the intermediate ladder piece on the ladder with the aid of the section rail connector or the external rail connector. If possible, internal rail connectors can also be used to connect the ladder elements. When installing an intermediate ladder piece in the flange transition area of a generator, a deviation of the rung spacings of ±15 mm is permitted. 38

39 Ladder connection Installation situation: Repair of a climbing path section Preparation of the intermediate ladder piece for repairing a ladder in the area of the climbing path. A damaged section of the ladder is replaced by an intermediate ladder piece. 1. Measure the damaged ladder section and if possible saw out midway between the rungs. Saw at an angle of 90 to the ladder rail and then deburr the cut surfaces. 2. Mount the intermediate ladder piece on the ladder with the aid of the section rail connector or the external rail connector. If possible, internal rail connectors can also be used to connect the ladder elements. NOTE! Specifications for the intermediate ladder piece When installing an intermediate ladder piece in a wind turbine generator, a deviation of the rung spacings of ±15 mm is permitted. Hailo Wind Systems recommends a maximum deviation of the rung spacing of ±2 mm. The length of the intermediate ladder piece is variable, but covers at least two rung lengths. Please observe the maximum deviation between the rails. This differs for the installation of internal rail connectors and external rail connectors. A maximum deviation of 2 mm between the rails ends must be adhered if a service lift is operated on the ladder. 39

40 7. Installation 7.5 Rung repair kit Rung repair kit Insertion tube material: aluminium; screw: steel (galvanised). Installation in case of repair. 1. Insert the insertion tube into the rung of the ladder. 2. Place the washer on both ladder rails and screw together. Mounting aid for rung repair kit Material: Installation in case of the repair of deformed rungs. 1. Screw the mounting aid onto the insertion tube. Close off the insertion tube on the opposite side with a screw. 2. Push the insertion tube through the damaged rung with the mounting aid. 3. Unscrew the mounting aid. 40

41 Floor fastening 7.6 Floor fastening Floor fastening with rail clamp Material: Stainless steel or steel (galvanised). Suitable for use in rail profile mm and mm. 1. Place the rail clamp around the ladder rail and screw into the screw lug. Do this for both ladder rails. 2. Position the lug with the long hole on the floor and screw onto the rail clamp. 3. Screw the lug with the long hole to the substructure. Floor fastening on ladder rung Material: Stainless steel or steel (galvanised). For use with ladder-guided service lifts. 1. Clasp the rung adaptor around the ladder rung and screw onto the lug with the long hole. 2. Screw the lug with the long hole to the substructure. 41

42 7. Installation 7.7 Resting platforms NOTE! Specifications for resting platforms In wind turbine generators, in accordance with DIN EN a resting platform must be installed every 9 m over the entire length of the ladder. In accordance with DIN EN ISO : 2016, a resting platform must be installed every 6 m over the entire length of the ladder. Resting platform on ladders without fall arrest rail Resting platform on ladders with perforated fall arrest rail a 1 a. Mount support rail in the centre of the rungs with 2 U-bolts. 1 b. Mount support rail in the centre of the rungs with 2 U-bolts. In doing so, tighten the spacer sleeves between the fall arrest rail and the support rail. The U-bolt clasps around the rung. b 2. Screw the stepping surface to the resting platform support rail. Tighten the hexagonal nut M12 only so much as to allow the resting platform to pivot easily. 42

43 Resting platforms Resting platform on ladder with unperforated fall arrest rail 1. Place the support rail over both rungs and fasten with 3 screws. 2. Screw the stepping surface to the resting platform support rail. Tighten the hexagonal nut M12 only so much as to allow the resting platform to pivot easily. 1. Insert the mounting block with thread into the groove of the fall arrest rail. Screw the screws through the spacer sleeves into the mounting block. 2. Screw the stepping surface to the support rail of the resting platform. Tighten the hexagonal nut M12 only so much as to allow the resting platform to pivot easily. i This resting platform variant can be used for various types of fall arrest rails. For more information write to info@hailo-windsystems.com. 43

44 7. Installation 7.8 Potential equalisation Potential equalisation via special conductive rung adaptor 1. Fasten the ladder bracket to the screw lug. In doing so, make sure that the lugs of the ladder bracket are directed outwards. 2. Place the rung adaptor around the ladder rung and fasten to the ladder bracket with the U-bolt. In doing so, pay attention to the correct tightening torque! 44

45 Potential equalisation Potential equalisation via equipotential busbar (connector) NOTE! Avoid deformation of the ladder due to compression Only insert connecting lugs together with internal rail connectors, otherwise the ladder can be compressed. Equipotential busbar (connector) material: Aluminium; Screw material: steel (galvanised). 1. Drill 2 holes (Ø 6.5 mm) in the ladder rails to be connected. In doing so, maintain a distance of 30 mm to the ladder ends. 2. Make sure that the ladder rails are connected to each other by means of internal rail connectors. 3. Fasten the equipotential busbar (connector) with the screws provided. 4. The ladder must be connected to the equipotential busbar (connector) over the entire length. 5. Finally, the ladder must be earthed on the bearing structure at both ends. 45

46 8. Use 8.1 Safety instructions DANGER! Danger of injury due to non-compliance with the safety instructions Before using the ladder system, carefully read and take note of the instructions. Particular attention must be paid to the safety instructions in the chapter Safety. The operator must ensure that these instructions for installation and use are kept on site for each ladder system and are available to the user. Fall arrest The user is personally responsible for his own safety. The personal protective equipment (PPE) against falling from a height must be checked for perfect and safe condition on a daily basis. Before and during use, take note of any damage to the fall arrest system. Permissible number of persons on the ladder The number of persons who are allowed to climb on the ladder at the same time may not exceed 5 persons. A minimum distance of 6 m should be maintained between the persons climbing the ladder system. In addition, the instructions provided by the manufacturer of the fall arrest system must be observed, since the permissible number of persons could be lower. Use of foldable resting platforms For climbing the ladder system that runs a service lift, ensure that the resting platforms are folded back after use. Otherwise there is danger of collision! Ensure that resting platforms can be folded easily. 46

47 Safety information User safety DANGER! Danger of falling! Failure to observe the safety instructions can lead to a fall, resulting in serious injury or death. Therefore, please note: Use your full PPE against falling from height! Connection to or release from the fall arrest system may only be carried out from a secure standing position. When transferring, always make a secure connection to suitable anchor points (see specifications of the wind turbine manufacturer). Securing to the rungs of the ladder is prohibited! Exiting the fall arrest system may only take place when the user is secured to a suitable anchor point. During the ascent or descent, the user must be able to hold onto the ladder with both hands. This means that he must not carry heavy loads in his hands. During the ascent or descent, the user should neither touch nor operate the accompanying safety harness. This could impair or even impede the brake function. Secure against unauthorised access The ladder system must be secured against access by unauthorised persons. 47

48 9. Inspection and maintenance Inspection each working day DANGER! Danger of falling! Damage to the system or lack of maintenance can lead to a fall, resulting in serious injury or death. Therefore, please note: Regular inspection of the ladder system is imperative. Before and during use, take note of any damage. The system or components of the system must be immediately withdrawn from use in case of doubt regarding their safe condition. This must be done by the manufacturer or by another competent person. In the event of a fall, the system must be checked immediately by a competent and qualified person. Annual inspection The ladder system must be inspected for proper condition and functionality at least once a year. This must be done by a competent and qualified person. The control sheet for the annual inspection of the ladder system can be found in the appendix of this manual. The applicable national operating and testing regulations must be observed. 48

49 NOTE! Compliance with inspection and maintenance periods The plant operator is responsible for timely compliance with the inspection and maintenance schedules. Proof of regular inspection is necessary for possible warranty claims. Service and maintenance All fixed components are maintenance-free. Resting platforms must be lubricated if necessary and checked for ease of movement. Damaged surfaces must be sealed with suitable anti-corrosive agents. Dirt must be removed with a gentle cleaning agent. Acids or alkalis must not be used. 49

50 10. Installation report Installation report for fixed ladders DIN EN ISO / DIN EN General data Installation date Location Wind turbine no. Material Aluminium Plastic Steel (galvanised) Stainless steel Type of ladder Ladder with fall arrest system according to DIN EN 353-1: 2014 Ladder without fall arrest system according to DIN EN 353-1: 2014 Ladder with safety cage Length in metres Entry to ladder OK Not OK Comment Correct entry dimension DIN EN ISO : mm Wall bracket OK Not OK Comment Fastening to tower wall (dimension) Firm seat of screw connections (torque) Screwlocking used 50 at least M12 YES Nm NO Distance to wall Distance to tower flange See instructions or design drawing of the wind turbine manufacturer DIN EN ISO min. 200 m distance rung front edge/wall behind ladder DIN EN ISO min. 150 m distance rung front edge / wall

51 Ladder bracket OK Not OK Comment Vertical distance Correct installation according to specification 2 m > 2 m Manufacturer authorisation present YES NO Ladder mounting OK Not OK Comment Correct installation Tight fit of screw connections (torque) Nm Rungs OK Not OK Comment Rung distances 280 ±2mm; ±15mm (flange) Ladder connectors OK Not OK Comment Section rail connector YES NO Rail misalignment max. 1 mm Tight fit of screw connection Air gap rail ends (max. 2 mm) External rail connector YES NO Tight fit of screw connection Air gap rail ends (max. 30 mm) Internal rail connector Screw connection (only required for lattice tower) Air gap rail ends (max. 30 mm) YES NO According to manufacturer's specification (see installation manual or design drawing of the wind turbine manufacturer) According to manufacturer's specification (see installation manual or design drawing of the wind turbine manufacturer) For ladder ends / replacement parts 51

52 10. Installation report Rest platforms OK Not OK Comment Correct installation according to specification Tight fit of screw connections (torque) Distance between platforms Ladder identification plate OK Not OK Comment Identification plate attached Inspection sticker attached / Installation date filled in Nm m According to manufacturer's specification (see installation manual or design drawing of the wind turbine manufacturer) According to manufacturer's specification (see installation manual or design drawing of the wind turbine manufacturer) According to manufacturer's specification (see installation manual or design drawing of the wind turbine manufacturer) Condition of climbing path YES NO Comment Initial installation Repair Fitness for use Next inspection Month Year Company carrying out the work Name of technician (in block capitals) Certificate number Signature 52

53 Comments 53

54 11. Protocol for inspection Recurring inspection of fixed ladders DIN EN ISO / DIN EN General data Date of inspection Location Wind turbine no. Material Aluminium Plastic Steel (galvanised) Stainless steel Type of ladder Ladder with fall arrest system according to DIN EN 353-1: 2014 Ladder without fall arrest system according to DIN EN 353-1: 2014 Ladder with safety cage Length in metres Marking OK Not OK Comment Available and legible Ladder bracket OK Not OK Comment Firm seat of screw connections Deformation / damage Corrosion Ladder mounting OK Not OK Comment Correct installation According to manufacturer's specification Corrosion Firm seat of screw connections Condition of fastening 54

55 Rungs OK Not OK Comment Check rung seat (loose, shaking, twisted) Rung wear (outer side of rail) Deformation < 1.5 mm > 1.5 mm Anti-slip surface Corrosion Cracks / burrs Rung distances (280 ±15mm) Firm seat of screw connections (repair kit) Rails OK Not OK Comment Deformation < 1.5 mm > 1.5 mm Cracks Burrs Corrosion According to manufacturer's specification when using service lift on ladder For ladder ends / replacement parts if rail fastened with repair attachment Ladder end connections OK Not OK Comment Section rail connector Rail misalignment YES < 1 mm NO > 1 mm Firm seat screw connection Air gap rail ends (max. 2 mm) External rail connector YES NO Firm seat screw connection Air gap rail ends (max. 30 mm) 55

56 11. Protocol for inspection Ladder end connections OK Not OK Comment Internal rail connector Screw connection (required for lattice tower) Air gap rail ends (max. 30 mm) YES NO Resting platforms OK Not OK Comment Fastening Function Corrosion Damage Result of inspection OK Not OK Comment Condition of ladder Fitness for use Repair / replacement Blocked prior to release Further inspection required YES YES YES NO NO NO Next inspection Month Year Company carrying out the work Name of technician (in block capitals) Certificate number Signature 56

57 Comments 57