Reflex Marine FROG-XT6 User manual

USER MANUAL
Rev 0.2
Issue date: 13/04/2015
Original Instructions

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Introduction
This manual contains information for operating, maintaining and storing the FROG-XT6
personnel carrier.
The key to safe operations is the familiarisation and participation in planning of all crew
involved. Please refer to the Crane Transfer Guidelines. This is a separate document that
contains comprehensive guidance and information on each element of operation. It is for
those researching, planning, managing or carrying out the safest possible crane transfers.
Safe and proper use of the FROG-XT6 is the responsibility of the user after having taken due
regard of the information provided in this document.
You should ensure that all safety measures as required by relevant legislation and by good
operational practice are in place.
Appropriate training should be provided for all personnel involved in the use of this device.
For the purposes of this manual RML will be deemed to mean Reflex Marine Limited.
Please retain this manual for future reference. Additional copies may be obtained by
contacting RML or by downloading the latest version from
www.reflexmarine.com/support.
All information disclosed in this document is the property of Reflex Marine Ltd except where otherwise stated.
Reflex Marine Ltd reserves all patent rights, design rights, manufacturing rights, copyright and sales use rights
thereto, and to any article disclosed within this document except where such rights are expressly granted to
others or where not applicable to vendor proprietary parts.
© 2014 Copyright Reflex Marine Ltd, All rights reserved.

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Contents
Introduction ................................................................................................................ 1
1 Product Specifications.......................................................................................... 4
2 Operating Parameters .......................................................................................... 5
2.1 General ............................................................................................................. 5
2.2 Recommended Operating Parameters ................................................................. 7
3 Using the FROG-XT ............................................................................................... 8
3.1 Safety Features ................................................................................................. 8
3.2 Passenger Instructions ....................................................................................... 8
3.3 Entry and Exit.................................................................................................... 9
3.4 Deck Crew Instructions .................................................................................... 10
3.5 Safety Harness Procedure ................................................................................ 11
3.6 Stretcher Mode ................................................................................................ 12
3.7 Carrying Luggage ............................................................................................ 15
3.8 Lifting Assembly Connection ............................................................................. 16
3.9 Control of Lifting Assembly ............................................................................... 17
3.10 Precautions ..................................................................................................... 18
4 Inspection & Maintenance ................................................................................. 19
4.1 Introduction .................................................................................................... 19
4.2 Definitions....................................................................................................... 19
4.3 Inspection Types ............................................................................................. 20
4.4 Frequency ....................................................................................................... 20
4.5 Supporting Documentation ............................................................................... 21
4.6 FROG-XT6 Inspection and Maintenance Schedules............................................. 22
4.7 Load Test Procedure ........................................................................................ 23
4.8 Pre Use Check ................................................................................................. 25
4.9 Visual Inspection Checklist Form ....................................................................... 26
4.10 Examination Checklist Form.............................................................................. 29
4.11 Post Load Test Inspection Checklist Form.......................................................... 33
5 Handling & Storage ............................................................................................ 34
5.1 Stock Inspections............................................................................................. 34
5.2 Forklift ............................................................................................................ 35
5.3 Crane.............................................................................................................. 35
5.4 Securing.......................................................................................................... 35

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5.5 Inspection ....................................................................................................... 35
5.6 Preparation for Road Transport......................................................................... 35
5.7 Shipping.......................................................................................................... 35
5.8 Storage ........................................................................................................... 35
5.9 Feet Deformation during Storage ...................................................................... 36
5.10 Replacement Parts ........................................................................................... 36
6 Replacement Parts ............................................................................................. 37
6.1 Introduction .................................................................................................... 37
6.2 Kits ................................................................................................................. 37
6.3 Parts identification ........................................................................................... 38
6.4 Accessories...................................................................................................... 38
7 Certificates.......................................................................................................... 40
7.1 EC Attestation of Conformity............................................................................. 40
8 Contact Details ................................................................................................... 41

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1Product Specifications
Table 1 Product Specifications
Model No.
XT6
Dimensions
(Nominal)
Width 1
2110 mm
Width 2 (Across Buoyancy)
2660 mm
Height
2180 mm
Weight
Maximum Gross Mass
1200 kg
Tare Weight
540 kg
Payload - SWL
660 kg
Materials
Frame
316 stainless steel, A4 stainless fixings
Central Column / Load Plate
316 duplex stainless
Other Steel Components
All stainless except for floor grating
Buoyancy
Polyethylene (PE) moulded shell with
polyurethane (PU) closed cell foam fill.
Seat Base/ Seat Back
Polyolefin shell filled with polystyrene
closed cell
Landing Feet
EVA closed cell foam
Operating
Temperatures
Standard Model
-20°C to +50°C
Arctic Model
-40°C to +50°C
Suspension
Springs
4 x stainless steel heavy duty coil spring
Dampers
2 x stainless steel 400mm recoil dampers
Seating
Seats
6 x full height seats
Harnesses
3 point, quick release buckle
Grab Handles
8
Lifting Points
SWL
Main
1200 kg (man-riding)
Backup
1200 kg (man-riding)
Handling
1200 kg
Wire Rope
Lifting
Assembly
Safe Working Load
1200 kg
Wire Rope
Anti-rotation wire rope
Number of
Passengers
Standard
6
Stretcher Mode
1 + stretcher
Luggage
Capacity
Light Luggage
Accessory available on request
Large Luggage Tray
Accessory available on request
Impact
Protection
Vertical impacts
Passengers are protected during heavy
landings at speeds of up to 4.5 m/s
Lateral impacts
Passengers are protected from lateral
impacts at speeds of up to 2 m/s
Stability
Horizontal
35°, for a load of 1-6 passengers
Submerged Self-Righting
Up to 180˚inverted to the vertical position
Type Approval
Class
EC Type examination certificate No.
MAC000005 i01
Quality
System
Manufactured to ISO 9001:2008
Standards
National Technical Standards
UK, BS EN 1993 series: ‘The Use of
Structural Steel in Building’
Industry European Standards
EC Machinery Directive
EN 14121-1, BS EN 12100-10
Load Test –ILO152 / LOLER
National Regulations
UK, PUWER / LOLER

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2Operating Parameters
2.1 General
The FROG-XT range has been designed to ensure passenger safety in the most demanding
conditions.
There are a large number of factors that affect the safe conduct of marine personnel
transfers. These include: crew skill and experience, met-ocean conditions, landing areas,
vessel station keeping capability and response to sea conditions, visibility and line of sight. A
combination of many factors will determine the risk involved.
2.1.1 Sea State
The FROG-XT6 has a suspension and damping system which prevents passengers from
experiencing shock loads up to relative velocities of 4.5 m/s. The maximum recommended
significant wave height is based on the maximum relative velocity between the load (or
hook) and the deck.
The calculated operational sea states detailed below are based on vertical impact speeds
and bio-mechanical considerations. They reflect the ability to withstand such impacts with
minimal risk of injury to the human body. However there are many additional factors that
may affect the safety of crane transfer operations. These include vessel station-keeping,
crew competence, wind and visibility. The operator should always refer to general guidelines
on crane transfers operations to assess overall risks.
Technical note:
The calculation for relative velocity used here is based on the European offshore crane standard,
BS EN 13852-1:2013. Whereby the maximum anticipated relative velocity between a load and a
vessel deck, is given by the following;
Relative velocity = (0.5*Hook velocity)1+ √ (Vessel deck velocity 2+ Boom tip velocity 2)
1Equal to 1.67 m/s (100 m/min) for lifts below 5 tonnes. Higher crane hook speeds may be available, and it
follows that the higher the available crane speed the higher the possibility of a heavy landing or take off.
However, with a qualified Crane Operator, it is considered unlikely that the FROG-XT will be landed at full
hook speed on a deck rising at full speed.
If there are concerns about heavy landings, operators may wish to consider the following methods to reduce
risks; dry runs without passengers, landing in centre of deck where there is less vessel movement,
transferring fewer passengers to increase damping, using a hook speed indicator.

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Table 2 FROG-XT6 Operating Parameters
2.0
4.0
5.6
7.1
1.3
2.5
3.3
4.0
012345678
Vessel to Vessel
F.P.S.O. to Vessel
Semi-sub to Vessel
Platform to Vessel
Significant Wave Height (M)
FROG-XT6 Sea State Limits
Recommended Operating Limits XT4 Performance Limit Outisde Operating Limits
Note:
▪Recommended Operating Limit - This is the envelope in which it would normally be considered safe subject to due consideration of other
risk factors.
▪XT6 Performance Limit - This envelope is defined by the performance limits of the capsule and the theoretical translation to significant
wave height by EN13852-1:2013. However it is assumed that in such elevated sea states other risk factors may become
substantial. Operations should not normally be performed in this range without conducting a thorough risk assessment. Contact Reflex
Marine if you need assistance.
▪Outside operating Limit - It is not recommended - sea states are above the safe design envelope of the capsule.
XT6 Performance Limit

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2.2 Recommended Operating Parameters
Table 3 Recommended Operating Parameters
Parameter
Recommendation
Wind Speed
40 knot / 20 m/s (The Frog-XT is very stable in high winds.
However crane limits must be observed)
Visibility
Crane Operator should have a clear view of the pickup and
set down areas.
Vessel Motion
Pitch 10⁰
Roll 10⁰
Vessel Station-Keeping
Able to maintain position within a 5 m (16 ft) radius.
If a high risk of the vessel losing position exists, disconnect
the carrier for passenger embarkation.
Landing Area
Must be clear of obstructions, protrusions, and trip and fall
hazards.
Landing Area –Ice /
Spills
Ice and spills must be cleaned from landing area prior to
transfer.
Landing Area on Vessel
6 m x 6 m (20 ft x 20 ft) landing area is recommended,
equivalent to 2m (6.5 ft) clearance all round. Smaller landing
areas may be used provided a risk assessment of factors such
as deck hazards, weather, sea state, vessel size, station-
keeping is carried out.
Landing Area on
Installation
4 m x 4 m (13 ft x 13 ft) clear landing area is recommended
based on additional 1m entry and exit path on all sides.
Crane Requirements
Crane must be suitable for lifting personnel and properly
maintained.
Communications
Radio communication must be established between the Crane
Operator and the Vessel Deck Crew and Master.

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3Using the FROG-XT
3.1 Safety Features
Protected Seating Position:
Seats are positioned behind the buoyancy panels and framework. This provides maximum
protection and minimises sense of exposure. The arrangement of the seats and entry / exit
points allow rapid access and egress, allowing faster and more efficient transfers.
Fall Protection:
3-point harness system and grab handles protect from the risk of falling during transfer.
Vertical impact protection:
i. Seats are mounted on a suspension system which consists of coil springs and recoil
dampers
ii. Semi-upright secure seat position, cushioned saddle seat
iii. Impact absorbing EVA foam feet
Lateral impact protection:
i. Stainless steel frame
ii. Buoyancy panels
iii. High backed protective headrest designed to reduce risk of whiplash
iv. Grab handles and saddle shaped seat cushion for secure seating position
Floatation:
Buoyancy panels ensure the FROG-XT6 floats with both passengers and stretcher above the
water line. The FROG-XT6 self-rights up to 180° inverted to the vertical position and is very
stable in a range of conditions.
3.2 Passenger Instructions
i. Enter carrier and take the appropriate seat
ii. Fasten seat harness
iii. Keep hands and feet inside the carrier
iv. Hold the grab handles or the chest straps of the seat harness to keep body stabilised
v. Place feet onto the floor in front of the buoyancy panel
vi. Bear weight slightly onto feet in order to adopt a comfortable secure position especially
during landing and take-off

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3.3 Entry and Exit
Passenger entry and exit should only be conducted with the
carrier in a stable position on deck as advised by the crane
operator to the deck crew member in charge of the transfer
operation.
Note: All exiting passengers must be clear of the carrier
before any new passengers attempt to board.
Each individual seat has a dedicated entry / exit point to
prevent confusion and ensure an efficient operation. All
passengers must enter and exit from the same direction.
Chevrons on the buoyancy panels are present to indicate the
direction of entry.
Entry
When advised to do so by the deck crew, passengers should
proceed as directed to one of the four entrances and be
aware of any tripping hazard. When instructed, all passengers
should enter the carrier as illustrated and take their assigned
seat.
Passengers should ensure they are securely seated and
ensure the seat harness is securely fastened. Grab handles
are provided on the tubular upright members either side of
the buoyancy panel and passengers should grip these firmly
or the harness straps whenever seated. Passengers should
never place their hands near the load plate.
Exit
Following landing and when advised to do so by the deck
crew, passengers should unfasten the safety harness, stand
and exit the FROG-XT6 (note trip hazard) by the appropriate
exit.
Passengers should move clear of the carrier as directed by
the deck crew, ensuring they remain clear of the lifting
assembly.