LINDSTRAND HiFlyer Installation guide

LTL TATM LTL Vol 1 Issue 1.0 i
LINDSTRAND TECHNOLOGIES LTD
HiFlyer
TRAINING MANUAL VOLUME 1
BASIC OPERATION AND MOORING PROCEDURES
FOR LTL WINCH
Lindstr nd Technologies Ltd
M esbury Ro d
Oswestry
Shropshire
SY10 8HA
UK
Tel: [phone]
F x: [phone]
www.lindstr ndtech.com
All rights reserved. No part of this manual may be reproduced or transmitted in any form or by any means, electronic, or
mechanical, including photocopy, recording, or any information storage and retrieval system, without permission in writing
from Lindstrand Technologies Ltd, Maesbury Road, Oswestry, Shropshire, SY10 8HA, England.

LTL TATM LTL - Vol 1 Issue 1.0 ii
Record of Amendments
No. Date Affected Pages Incorporated By
Amendments:-
This manual is kept up to date by amendments consisting of loose-leaf pages, required to add new
information or amend existing information. The pages affected by an amendment and the effective
dates are shown above. The pages themselves are identified by a change of the issue number at
the bottom of each page. The number after the point in the issue number represents the
amendment level of that page, e.g. a page marked Issue 1.4 is at Issue 1, modified by Amendment
4. The checklist of pages indicates the issue level of all pages included in this Training Manual.
Amendments are issued to all relevant operators of the Lindstrand Balloon Ltd Hi Flyer System on a
free of charge basis provided that the Inclusion Check Sheet is signed and returned to Lindstrand
Balloons Ltd for each issued amendment.
Change of Ownership
If the ownership of this balloon changes, it is important for the new owners to contact Lindstrand
Balloons Ltd to ensure that they receive Amendments and Supplements, as appropriate. This can
be simply achieved by photocopying Page ii of this manual and writing your name and full
correspondence address on the reverse side and sending to Lindstrand Balloons Ltd.

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Manual Supplements
Supplement No. Title Tick if Applicable

LTL TATM LTL - Vol 1 Issue 1.0 1
Contents
1. OUTLINE 2
2. DESCRIPTION OF THE HIFLYER 2
3. MOORING AND UN-MOORING 2
3.1 Outer Mooring 4
3.2 Mooring winches 8
3.3 Lower Apex Mooring 10
3.4 High Mooring from flying 10
3.5 Low Mooring 12
3.6 High Mooring from Low Mooring Position 16
3.7 Flying from High Mooring Position 17
4. CONTROLS 19
4.1 Control panel 19
4.2 Winch Controls 20
5. NORMAL PROCEDURES 21
5.1 Pre-flight 21
6. SAFETY 25
6.1 Rope Safety 25
6.2 High Pressure Gases 25
6.3 Fire 27
6.4 Site Safety 27
7. EMERGENCY PROCEDURES 28

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1. Outline
The purpose of this training manual is to provide guidance to level 1 operators.
A level 1 operator should be proficient in:
•High mooring technique
•Low mooring technique
•Winch operation
•Basic Safety Procedures
This manual is to be used as an aid to training in conjunction with the HiFlyer Operations Manual.
All operators should aim to become familiar with the operations manual, as it is a comprehensive
document covering all aspects of the HiFlyer system.
2. Description of the HiFlyer
The Lindstrand HiFlyer consists of three major sub-systems:
•A balloon and net, which provides the necessary lift to support all the equipment and passenger
weights.
•A gondola, which provides a safe carrying structure for the occupants.
•A winch system which secures the balloon and controls the ascent and descent.
3. Mooring and Un-mooring
The mooring and un-mooring of the HiFlyer are two of the most important tasks to be undertaken by
the operator.
The envelope is over 22 metres in diameter, which means that a large surface area is exposed to the
wind. This surface area combined with the large amount of lift generated by the Helium means that
injury, damage and possibly envelope failure could occur if the HiFlyer is incorrectly moored.
The HiFlyer can be moored in two separate ways depending on wind speeds (the operations manual
states the limits for different windspeeds).
•High moor for lighter winds
•Low moor for stronger winds and overnight.

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There are three separate sets of mooring points:
Mooring point: Description: Attached to:
Equator Rope The equator of the net has 16 winch
mooring lines. These are fastened to the 16
mooring winches which are set around the
main winch at a diameter of 23 metres.
USED FOR BOTH HIGH and LOW MOOR
MOORING
WINCH DRUM
Polar Rope The upper section of the net has 16 tether
lines. These are fastened to concrete hard
points which are set around the main winch
at a diameter of 50 metres
USED FOR BOTH HIGH and LOW MOOR
2.5 TONNE
RATCHET
STRAP
Outer mooring winch
option
Used for both High and Low Moor MOORING
WINCH DRUM
Lower apex mooring The lower apex of the envelope has 8 load
patches fixed to it. Straps are fastened to
these load patches and anchored to hard
points set into the concrete base supporting
alternate mooring winches.
LOW MOOR ONLY
2.5 TONNE
RATCHET
STRAP
The HiFlyer is able to rotate on a swivel connection, which is situated between the main winch cable
and load ring assembly. This means that the mooring lines on the net and envelope cannot always be
attached to the same mooring point.
Sections 3.4, 3.5 and 3.6 describe how to moor and un-moor the HiFlyer from the high and low
positions

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3.1 Outer Mooring
(a) Open the ratchet handle out fully and pull the ratchet release lever up. Feed out the strap until
there is only 300mm of the free end of the strap through the handle. Operate the ratchet
mechanism a few times to secure the strap, then close the handle to lock the ratchet.
(b) Using a karabiner, connect the looped end of the strap up to the highest loop of the mooring line
that can be reached.

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(c) The karabiner should be connected as
shown.
(d) Open the ratchet handle out again and pull the loose end of the strap through to take up the slack.
It is important to take up all of the slack, if too much slack is left when the ratchet is tightened the
volume of strap wrapped around the spool will jam the mechanism.

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(e) Keep the strap under tension with one hand and operate the ratchet mechanism with the other
until the strap and mooring line are fully tensioned. Make sure that the strap is not twisted or out
of alignment, otherwise this will cause premature wear.
(f) There should be no sag in the mooring line when correctly tensioned. Close the ratchet handle to
finally lock the mechanism.

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(g) Route the free end of the strap back through the handle of the ratchet. Coil up the loose mooring
line and tie it off to the strap to prevent it dragging on the ground.

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3.2 Mooring winches
Remove the equatorial mooring line from its storage bag on the gondola. Make sure that it is not
tangled or knotted. Set the mooring winch control pendant to LOWER and MOOR ONE.
(a) Pass the sewn-in loop back through itself to form a ‘slipping loop’.
(b) Place the slipping loop around the mooring winch drum and pull it tight. Make sure that the
sewn-in loop is positioned so that the free rope locks back around, to secure the rope onto the
drum.

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(c) Operate the winch from the local control panel and guide the mooring rope onto the drum.
SAFETY: Make sure that fingers, loose clothing, jewellery etc. cannot be snagged or trapped around
moving parts of the winch
(d) Take up an equal amount of slack on each winch. If the rope is too tight the motor may back
drive. It is best to one-person judge the tension for all 16 ropes before continuing.

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LOW MOORING
Firstly ensure that all outer mooring ropes are attached to the ratchet straps, or if fitted with outer
mooring winch system, with equal tension to all ropes. When all 32 mooring ropes have an equal
amount of tension, change the mooring winch control pendant over to MOOR ALL and LOWER, and
winch the envelope down to its low mooring position.
3.3 Lower Apex Mooring
This procedure is similar to section 3.1 Outer Mooring.
8 x 2.5 tonne ratchet straps are attached with karabiners directly to 8 extension straps on the load
patches located on the bottom of the envelope. The technique for securing and tensioning the straps
is the same as for outer mooring. The ratchet mechanism is secured to a hard point on the concrete
mooring winch support block.
As there are only 8 lower apex mooring points, the ratchet mechanisms should be fixed to each
alternate winch hard point situated on the winch motor.
NOTE: The strap and extension should be routed over the top of the gondola mooring ring - This is to
ensure that the load applied to the patches on the envelope is aligned in tension, and will not cause a
peel load
3.4 High Mooring from flying
OPERATIONS MANUAL REFERENCE: SECTION 3.4.7 High Mooring System
Procedure
With little or no wind
When the gondola is on the platform, take the outer mooring ropes from their gondola mounted
storage bags (or release them from the karabiners) pull them out towards the outer mooring hard
points or winches (if fitted) and attach securely.
With moderate to strong winds
The movement of the balloon will cause the ropes to swing and possibly snag on the inner mooring
winches. This could damage the balloon or cause injury to personnel. With this in mind it is best to

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remove the outer mooring ropes individually and secure them to the ratchet straps or winches one at
a time.
The up wind ropes will be subjected to a lot more load than the remaining ropes.
The first ropes to secure during mooring are those perpendicular to the wind direction (Fig 3). These
will steady any sideways motion which should make it easier to connect the remaining ropes.
Place the karabiner through the first loop at the end of the outer mooring ropes.
When all outer mooring lines are secured at the end loop, starting with the perpendicular, move the
karabiners progressively up to the highest loop possible on each rope and tighten (Refer to Section
3.1).
The balloon should now be stable and movement should be minimal.

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Ensuring that the mooring winch control pendant is set to LOWER and moor one, remove the inner
mooring lines from their gondola mounted storage bags (or release them from the karabiners) and
secure to the mooring winches (Refer to Section 3.2).
Ensure that all inner and outer mooring lines have equal tension. Where there is an outer mooring
winch system, ensure the balloon has been secured in the high moored position first, then the outer
mooring ropes may be attached to their respective winches and tensioned by use of the pendant
control.
The balloon is now in the High Moored Position.
3.5 Low Mooring
OPERATIONS MANUAL REFERENCE: SECTION 3.4.8 Low Mooring System
In order to Low Moor, the balloon must be in the High Moored Position. At least two crew, preferably
three are required for low mooring. One person is to be designated ‘operator in charge’.
With the mooring winch control pendant, set to MOOR ALL and LOWER.
The operator in charge of Low Mooring should stand where the control panel in the gondola is visible.
The HELIUM VALVE switch on the control panel should be set to MANUAL to prevent pressure from
opening the valve.
Other personnel should stand clear of the mooring winches, but in a position where as many of them
are visible as possible.
Before depressing the button to commence Low Mooring, the operator should indicate to other
personnel that the winches are about to work by shouting “WINCHES”. Other personnel should return
this call to indicate that they are aware that the winches are about to be used. Once the operator is
satisfied that all personnel are clear, the mooring button should be depressed.
Maintain equal tension on outer mooring winch ropes. It may be necessary to stop the inner winches
whilst the outer winches ‘catch-up’, or vice-versa.
The operator should watch the load assembly as the balloon descends, making sure that there are no
snags and that the load ring falls into the cradle horizontally.
The remaining ground crew should watch the winches for any sign of malfunction or problems.

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If anyone is not satisfied with the function of any of the mooring winches, they are to shout “STOP”. If
the word “STOP” is heard, Low Mooring is to cease immediately and the reason made clear to all
personnel.
As the mooring winches lower the envelope the outer mooring lines not attached to winches will
slacken. If there is a moderate wind, the envelope will move around as the balloon is lowered. If
movement becomes excessive, immediately cease the Low Mooring and re tension all of the outer
mooring lines to equal tension.
Bring the envelope down to within 500mm of the gondola-mooring ring.
The operator should be aiming to land the envelope onto the mooring ring as centrally as possible.
The envelope may move around in the wind. Once the envelope is 500mm from the mooring ring re-
fasten the outer mooring lines to take up the tension again on the outer mooring ropes.
In moderate to strong winds, it may be prudent to attach the lower apex mooring lines whilst the
balloon is in this position. This will prevent the envelope from straying towards the mooring ring and
damaging the fan assembly at the bottom of the balloon.
The operator can now lower the envelope on to the mooring ring. It is important to monitor the helium
and ballonet pressures during this process. The balloon should be lowered until the mooring ring
causes the lower apex of the balloon to indent by approximately 500mm.
As the balloon is being lowered, the helium and ballonet pressure will rise rapidly. The operator is to
ensure that the helium pressure does not exceed 38mm and the ballonet pressure does not exceed
14mm.
Once in position, the outer mooring ropes should be re-tensioned and the 8 lower apex-mooring
straps (if not already in place) should be attached and tensioned.

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The gondola should now be secured to the decking using the ratchet straps (2.5T).
The balloon is now in the Low Moored Position.

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3.5.1 Ground Fan
The ground fan should be used during high winds and in case of ballonet fan failure. It can also be
used to save battery power when the balloon is low moored overnight or if it is not operational for a
long period.
It is essential to maintain pressure when the balloon is moored during windy conditions to prevent the
envelope from indenting, and reduce wind drag and balloon movement.
To speed up pressure recovery in gusty conditions when ballonet air is blown out of the pressure relief
valve, the ground fan has a higher performance than the ballonet mounted fan.
If the ground fan was operated continuously there is a danger that the balloon could be over-
pressurised and helium vented. To prevent this the fan is linked into the pressure sensing system
displayed in the instrument box which switches the fan in and out to limit pressure.
The ground fan is powered by mains or generator A C supply either 240 V or 110 V this means there
is a continuous supply and no drain on the on board batteries, which can be charged.
The ground fan must be disconnected before the balloon is flown or raised to the high
mooring position.
3.5.1.1 Ground Fan Installation
Locate fan on the platform outside the gondola.
Lead the duct over the top of the gondola and under the mooring ring.
Couple the duct up to the connection under the ballonet fan using the four ‘over centre’ catches.
Mains lead - plug in to mains (or generator) supply socket.
The connection of the ground fan controller lead to the control panel is the responsibility of the
supervisor. He must also connect the battery charger to ensure overnight charging.
3.5.1.2 Emergency Operation
If there is a failure in the automatic system or in severe storm conditions the fan may be plugged
directly into the mains supply and operated continuously.
In this case an operator should monitor the ballonet and helium pressure closely. If the ballonet
pressure exceeds 14 mm WG, or He pressure exceeds 38 mm WG, the fan should be switched off
until the pressure drops around 3 mm WG before switching on again.
If there is a mains power failure the ground fan can be connected and operated from the internal
lighting generator.
3.5.1.3 Ballonet Fan Reconnection
Before the balloon is flown or raised from the low mooring position the ground fan must be
disconnected.

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3.6 High Mooring from Low Mooring Position
OPERATIONS MANUAL REFERENCE: SECTION 3.4.8.2 Un-mooring Procedure
The un-mooring procedure is largely the reverse of the low mooring procedure.
Remove the outer mooring lines from the ratchet straps and reconnect to the last loop. If outer
mooring winch system is fitted, leave the ropes attached to the winch drums as these will
automatically wind out.
Take two turns through the buckle, ready for re-mooring if necessary.
Remove the Lower Apex Mooring straps and the gondola securing straps.
Switch the Mooring Winch Control Pendant to MOOR ALL and RAISE. The operator should stand in
a position where the control panel in the gondola is visible.
The HELIUM VALVE switch on the control panel should be set to AUTOMATIC. Other personnel
should stand clear of the Mooring Winches, but in a position where as many of them are visible as
possible.
Before depressing the button to commence High Mooring, the operator should indicate to other
personnel that the winches are about to work by shouting “WINCHES”. Other personnel should return
this call to indicate that they are aware that the winches are about to be used. Once the operator is
satisfied that all personnel are clear, the mooring button should be depressed.
The operator should watch the load assembly as the balloon ascends, making sure that there are no
snags and that the load ring leaves the cradle. The operator should also keep an eye on the cable to
ensure it is located into the fleeting sheave correctly.
The remaining ground crew should watch the winches for any sign of malfunction or problems.
If anyone is not satisfied with the function of any of the mooring winches, they are to shout “STOP”. If
the word “STOP” is heard, High Mooring is to cease immediately and the reason made clear to all
personnel.
As the weight of the balloon comes onto the bridles and load assembly, the Free Lift will start to rise.
As the free lift increases, stop raising the balloon.
The outer mooring ropes should be re-tensioned.