Reflex Marine FROG XT10 User manual

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

Rev 0.2 1 | P a g e
Introduction
This manual contains information for operating, maintaining and storing the FROG-XT10
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-XT10 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.
Please retain this manual for future reference. Additional copies may be obtained by
contacting Reflex Marine 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.

Rev 0.2 2 | P a g e
Contents
Introduction...........................................................................................................................................1
1Product Specifications ..................................................................................................................4
2Operating Parameters ..................................................................................................................5
2.1 General...................................................................................................................................5
2.2 Recommended Operating Parameters...............................................................................7
3Using the FROG-XT10 ..................................................................................................................8
3.1 Safety Features .....................................................................................................................8
3.2 Passenger Instructions.........................................................................................................8
3.3 Entry and Exit........................................................................................................................9
3.4 Passenger Flow ...................................................................................................................10
3.5 Deck Crew Instructions......................................................................................................12
3.6 Safety Harness Procedure .................................................................................................13
3.7 Stretcher Mode....................................................................................................................14
3.8 Carrying Luggage................................................................................................................18
3.9 Lifting Assembly Connection .............................................................................................19
3.10 Control of Lifting Assembly ...............................................................................................20
4Inspection & Maintenance.........................................................................................................21
4.1 Introduction.........................................................................................................................21
4.2 Definitions............................................................................................................................21
4.3 Inspection Types.................................................................................................................22
4.4 Frequency ............................................................................................................................22
4.5 Supporting Documentation ...............................................................................................23
4.6 FROG-XT10 Inspection and Maintenance Schedules ....................................................24
4.7 Load Test Procedure ..........................................................................................................25
4.8 Load Testing Arrangements ..............................................................................................26
4.9 Pre Use Check .....................................................................................................................28
4.10 Visual Inspection Checklist Form......................................................................................29
4.11 Examination Checklist Form ..............................................................................................32
4.12 Post Load Test Inspection Checklist Form ......................................................................35
5 Handling & Storage ....................................................................................................................36
5.1 Stock Inspections................................................................................................................36
5.2 Forklift ..................................................................................................................................37

Rev 0.2 3 | P a g e
5.3 Crane ....................................................................................................................................37
5.4 Securing ...............................................................................................................................37
5.5 Inspection ............................................................................................................................37
5.6 Preparation for Road Transport........................................................................................37
5.7 Shipping ...............................................................................................................................37
5.8 Storage.................................................................................................................................38
5.9 Feet Deformation during Storage.....................................................................................38
5.10 Replacement Parts..............................................................................................................38
6Replacement Parts......................................................................................................................39
6.1 Introduction.........................................................................................................................39
6.2 Kits ........................................................................................................................................39
6.3 Parts identification ..............................................................................................................40
6.4 Accessories ..........................................................................................................................40
7Certificates...................................................................................................................................42
7.1 EC Attestation of Conformity ............................................................................................42
8Contact Details ............................................................................................................................43

Rev 0.2 4 | P a g e
1Product Specifications
Table 1 Product Specifications
Model No.
XT10
Dimensions
(Nominal)
Width 1
4090 mm
Width 2 (Across Buoyancy)
2660 mm
Height
2180 mm
Weight
Maximum Gross Mass
2120 kg
Tare Weight
970 kg
Payload - SWL
1150 kg
Materials
Frame
316l stainless steel, a4 stainless fixings
Central Column / Load Plate
316Ti stainless/ 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 balls
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 coated heavy duty coil spring
Dampers
4 x stainless steel 400mm recoil dampers
Seating
Seats
10 x full height seats
Harnesses
3 point, quick release buckle
Grab Handles
2 per buoyancy panel
Lifting Points
SWL
Main
1060 kg
Backup
1060 kg
Handling
1060 kg
Wire Rope
Lifting
Assembly
Safe Working Load
Two-leg lifting assembly: 2170 kg
Wire Rope
Galvanised steel wire rope
Number of
Passengers
Standard
10
Stretcher Mode 1 Stretcher
3 + 1 stretcher
Stretcher Mode 2 Stretchers
2 + 2 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 3.7 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 1-10 passengers
Submerged Self-Righting
Up to 180˚ inverted to the vertical position
Type Approval
Class
CE Marked by independent body
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

Rev 0.2 5 | P a g e
2Operating Parameters
2.1 General
The FROG-XT10 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-XT10 has a suspension and damping system which prevents passengers from
experiencing shock loads up to relative velocities of 3.7 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.

Rev 0.2 6 | P a g e
Table 2 Operating Parameters
1.4
2.7
3.5
4.1
1.2
2.2
2.8
3.3
012345678
Vessel to Vessel
F.P.S.O. to Vessel
Semi-sub to Vessel
Platform to Vessel
Significant Wave Height (m)
FROG-XT10 Operational Sea State Limits
Recommended Operating Limits XT10 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.
▪FROG-XT10 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.

Rev 0.2 7 | P a g e
2.2 Recommended Operating Parameters
Table 3 Recommended Operating Parameters
Parameter
Recommendation
Wind Speed
40 knot (equivalent to 20 m/s)
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
/ Installation
When considering the size of landing area required a risk
assessment of factors such as deck hazards, weather, sea
state, vessel size, station keeping should be carried out. The
landing should be large enough to allow the carrier to be
landed safely with sufficient space around the carrier for all
passenger to exit the carrier.
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.

Rev 0.2 8 | P a g e
3Using the FROG-XT10
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 individual
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 mounted on a suspension system which consists of coil springs and recoil
dampers
ii. Semi-upright seat position and soft, pommel seats
iii. Impact absorbing EVA foam feet
Lateral impact protection:
i. Stainless steel frame
ii. Buoyancy panels
iii. High backed 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-XT10 floats with both passengers and stretcher above
the water line. The FROG-XT10 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 the 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 semi squat position
especially during landing and take-off

Rev 0.2 9 | P a g e
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. Please refer to section 3.4 for
detailed loading instructions.
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 (note trip hazard) using the
exit to their left.
Passengers should move clear of the carrier as
directed by the deck crew, ensuring they remain
clear of the lifting assembly.

Rev 0.2 10 | P a g e
3.4 Passenger Flow
Passengers can be loaded into the FROG-XT10 using either the different coloured
harnesses or by using the seat numbering.
3.4.1 Seat Harness Colours
6 or Less Passengers
When loading passengers should be seated in the 6 end seats (3 at either end). This will
ensure faster loading times as each passenger will have their own dedicated entrance.
Passengers should enter from the right hand side of the buoyancy panel and take the seat
on their left hand side.
The end seats are easily identified as they have red seat harnesses.
More Than 6 Passengers
Load the first 6 passengers as directed above into the end seats, which are fitted with red
seat harnesses.
Once the first 6 passengers are loaded then load the remaining 4 passengers 2 at a time as
indicated below into the remaining seats fitted with yellow seat harnesses.
Entry
Exit

Rev 0.2 11 | P a g e
3.4.2 Seat Numbering
In order to perform loading efficiently and safely, the following procedures are
recommended:
Organise the passengers into groups of 10 (see note).
Confirm that passenger and luggage weight does not exceed the SWL of the carrier.
i. Split the passengers into three groups and assign each passenger a seat number
Group A: 1, 2, 3, 4, 5 and 6
Group B: 7 and 8
Group C: 9 and 10
ii. Firstly load Group A
iii. Next load Group B
iv. Lastly load Group C remaining seats.
Note: When the FROG-XT10 is used for less than 10 passengers, continue to follow the
loading procedure above for as many passengers as possible. In this way the unit will
always be balanced as far as possible.

Rev 0.2 12 | P a g e
3.5 Deck Crew Instructions
Briefings
Deliver passenger briefings prior to every transfer lift, it should contain the following
information:
i. Location specific instructions
ii. Loading and unloading procedures
iii. Emergency procedures
iv. Potential hazards
v. Seating position
Other Responsibilities
i. Highlight potential hazards to passengers e.g. trip hazards during entry/exit
ii. Remain alert from any hazards as they arise and take appropriate action
iii. Check that passengers’ harnesses are secure and correctly fitted
iv. When the carrier is in the static position on deck for passenger entry and exit, the
wire rope lifting assembly will be in a static position and may obstruct one or more of
the entry / exit points. Ensure passengers remain clear of the wire rope lifting
assembly. Deck crew may need to clear the lifting assembly from carrier entrances.
v. Ensure passengers keep hands clear of any pinch points, as illustrated below.
1. Keep hands
away from the
load plate
2. When folding
down the seat
beware of
pinch hazard
3. Keep hands
away from the
suspension
system
Figure 1 Pinch Points

Rev 0.2 13 | P a g e
3.6 Safety Harness Procedure
To make passenger entry more efficient, where possible, deck crew or passenger should loosen harness prior to entering the carrier. All
passengers should be familiar with the seating procedure and practice entry prior to operations.
Step 1
Enter the carrier
from the right
hand side of
your chosen
seating position
Step 2
Pull the harness
straps over your
shoulders and
pull the buckle
together
Step 3
Take the lap
fastener clip and
feed through eye.
Step 4
Fold over the
clip and the
safety belt is
secure
Step 5
Next pull the
LOWER straps
first
Step 6
Then the UPPER
straps to make a
tight fit
Reverse the
operation for
quick release
Step 7
Fold back
buckle
Step 8
Pull apart
harness straps
Step 9
Exit the carrier to
the left

Rev 0.2 14 | P a g e
3.7 Stretcher Mode
The following steps outline the procedure to convert the FROG-XT10 into stretcher mode.
The FROG-XT10 can accommodate two stretchers, either both at the same time or one on
its own.
3.7.1 Converting to Stretcher Mode
i. For one stretcher, fold down the three seat backs
behind buoyancy panels B and C (seats numbers1,
5 & 7).
ii. For two stretchers, fold down the three seat backs
behind buoyancy panels B and C (seats numbers 1,
5 & 7) and the three seat backs behind buoyancy
panels E and F (seats numbers 8, 6 & 2).
iii. Use one 13mm spanner/socket, to remove the two fittings on each seat as indicated
below and fold down each seat (Note: pinch hazards). There is one fitting on each
side of the seat to remove.
iv. These bolts are then replaced in the cross holes on both sides as indicated below.

Rev 0.2 15 | P a g e
3.7.2 Stretcher Positioning
The clamp channel has been designed to fit the Ferno Basket stretcher. However the clamp
channel can be adjusted in height to accommodate the use of alternative stretcher types.
Please note that not all stretcher types will fit.
The clamp should be checked and adjusted to fit the specific stretcher type in use prior to
operation.
i. Three people should handle the stretcher. Two at the head end and one at the foot
end.
ii. Line up the stretcher as indicated below.
iii. Guide the head of the stretcher onto the folded seats.
iv. As the stretcher is slide onto the seat the rim of the stretcher should be lined up with
the clamp channel.
v. When in position the head end of the stretcher should have a small (25mm) clearance
with the buoyancy panel.
CLAMP CHANNEL
STRAP ANCHOR
POINTS
Figure 2 Stretcher Fitment (Buoyancy panels have been removed for illustration
purposes only.)

Rev 0.2 16 | P a g e
3.7.3 Securing the Stretcher
1. Loosen the clamp thumbscrew,
then pass the clamp through the hand
hold in the stretcher
2. Turn clamp 90 degrees with folded
edge upwards
3. Tighten clamp with thumb screw –
this should be tight enough to prevent
the stretcher from sliding
longitudinally.
4. Now attach the two stretcher
securing straps as indicated using the
two attachment points.

Rev 0.2 17 | P a g e
3.7.4 Seating Arrangement
When using the FROG-XT10 in stretcher mode it is advised to keep the carrier evenly
balanced, however it is understood that it is not always possible.
The below images detail how to load the FROG-XT10 when in stretcher mode.
1 Stretcher
When transporting only one stretcher up to 3 additional passengers may travel in the FROG-
XT10.
2 Stretchers
When transporting two stretchers up to 2 additional passengers may travel in the FROG-
XT10.

Rev 0.2 18 | P a g e
3.8 Carrying Luggage
Luggage may be transferred with passengers, however Reflex Marine recommend where
practical, passenger luggage should be transferred separately in a cargo box or basket. This
will minimise the risks from carrying out additional procedures whilst transferring personnel.
Two types of luggage containers are available as accessories: an under-seat light luggage
box for small handheld items or under-seat floor containers for larger kit bags.
The following recommendations should be considered when transferring luggage:
i. The weight of the passengers plus the luggage should not exceed the SWL.
ii. All luggage items should be handled by deck-crew, not passengers, to minimise the
time passengers spend in the hazardous zone.
iii. Items should be secured prior to passenger boarding, and removed after passenger
exit.
iv. Heavy or large materials such as tools, boxes, or equipment should be transferred
separately in suitable cargo box or basket.
There are two options for carrying luggage and these are:
i. Small, individual, hand-carry items such as laptop bags may be secured directly
underneath a seat in one of the light luggage boxes. Items should not exceed 400
mm (w) x 300 mm (l) x 120 mm (h) (16”x 12”x 5”) and 5 kg (11 lbs) per item.
ii. Larger luggage may be secured in under seat floor containers. It is recommended
that no more than 20 kg of luggage per person is loaded. Luggage should fit
comfortably in the containers provided and remain secure. Items should not exceed
500(l) x 400(w) x 200(h) mm so that it will not impede the damping system.
Note: The under seat carrier and the floor container cannot be fitted at the
same time.
Figure 3 Luggage Maximum Height
Seat base compressed
Seat base at maximum height

Rev 0.2 19 | P a g e
3.9 Lifting Assembly Connection
Figure 4 Lifting Assembly
Lifting assembly is fitted to the FROG-XT
by initially lowering it through the letter
box openings at the top of the carrier.
As there are two pairs of legs, one pair
needs to go into each of the letterbox
openings at the top of the unit.
The main leg connects to the centre hole
on each load plate and the backup leg
connects to the outside hole. This leaves
the two inside holes spare. They can then
be used for handling purposes.
Note: The lifting assembly is fitted with two different terminations. The main leg is fitted with a bow
shackle and the back-up leg is fitted with a spelter socket.