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
0 1 2 3 4 5 6 7 8
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.

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3.4 Deck Crew Instructions
Briefings
Deliver passenger briefings prior to every transfer lift and 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.
3. Keep hands away from
the load plate
2. When folding down
the seat beware of
pinch hazard
1. Keep hands away from
the suspension system
Figure 1 Pinch Points

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3.5 Safety Harness Procedure
To make passenger entry more efficient, where possible, deck crew or passengers should loosen harness prior to entering the carrier. All
passengers should be familiar with seating procedure and practice entry prior to operations.
Step 1
Enter the carrier
from the
appropriate 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 on
appropriate side

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3.6 Stretcher Mode
The following steps outline the procedure to convert the FROG-XT6 into stretcher mode.
3.6.1 Converting to Stretcher Mode
i. Fold down the three seat backs behind buoyancy
panel A.
ii. Use one 13mm spanner/socket 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.
iii. These bolts are then replaced in the cross holes on both sides as indicated below.

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3.6.2 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/one at the foot end.
ii. Line up the stretcher as indicated below in figure 1.
iii. Guide the head of the stretcher onto the folded seats.
iv. As the stretcher is slid 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 doorframe.
CLAMP CHANNEL
STRAP ANCHOR
POINTS
Figure 2 Stretcher Fitting (Buoyancy panels have been removed for illustration purposes only.)

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3.6.3 Securing the Stretcher
1. Loosen the clamp thumbscrew,
then pass the clamp through hand
hold in the stretcher
2. Turn clamp 90 degrees with
folded edge upward
3. Tighten clamp with thumb screw –
this should be tight enough to
prevent the stretcher from sliding
longitudinally
4. Use the supplied stretcher straps
to secure the stretcher using the two
attachment points

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3.7 Carrying Luggage
Luggage may be transferred with passengers, however 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 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. Small, individual, hand-carry items such as laptop bags may be secured directly
underneath a seat in one of two 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.
v. Larger luggage may be secured in under seat floor containers. It is recommended
that no more than 15 kg of luggage per person is loaded. Luggage should fit
comfortably in the containers provided and remain secure. Height of luggage placed
underneath seat should be restricted to 200 mm (8”) so that it will not impede the
damping system.
Figure 3 Luggage Height
vi. Heavy or large materials such as tools, boxes, or equipment should be transferred
separately in suitable cargo box or basket.

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3.8 Lifting Assembly Connection
Figure 4 Lifting Assembly
Lifting assembly is fitted to the FROG-XT
by initially lowering it through the letter
box opening at the top of the carrier.
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.
The main leg connects to the centre hole
in the load plate and the backup leg
connects to the larger of the two
remaining holes
A handling line can then be fitted to the
free hole in the load plate

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3.9 Control of Lifting Assembly
The FROG-XT6 is designed to stay firmly on the deck of the vessel whilst passengers are
entering or leaving the capsule. The Crane Operator must maintain slack in the line upon
landing to allow for the vessel movement.
Table 4 Control of lifting assembly
Parameter
Recommendation
Ideal Sling Length
The recommended limits in this section are based on the use
of the standard FROG-XT wire rope lifting assembly length of
30 ft (9 m).
Shorter Slings
For the use of shorter lifting assemblies an additional risk
assessment combined with dry runs should be performed to
establish safe operational routines and weather conditions.
Using a shorter sling set also increases risks associated with
the hook block being in close proximity to the capsule
Table 5 Sling lengths
Sling Length
Recommended
Slack
Allowable Drift
Distance to the
Crane Hook
30 ft
10 ft
22.4 ft
20 ft
20 ft
10 ft
17.3 ft
10 ft
10 ft
8 ft
9.8 ft
2 ft
Figure 5 Lifting assembly slack

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3.10 Precautions
i. Passengers must remain seated, holding the grab handles and ensure that head,
hands and feet remain inside the carrier at all times during the transfer operation.
ii. Passengers should be aware of the potential trip hazard of the floor grating when
entering and exiting. This should be highlighted during the pre-transfer briefing. Deck
crews should reiterate awareness of trip hazards to passengers during entry and exit.
iii. Deck crew should always double check that all passenger harnesses are secure and
correctly fitted prior to any transfer.
iv. Deck crew should always check that passengers’ hands are on the grab handles.
v. 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. Passengers must take care to remain clear of the wire rope
lifting assembly and, if obstructed, should wait until it is held clear by the deck crew.

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4Inspection & Maintenance
4.1 Introduction
Following the recommended procedures set out in this section will help to ensure safe
operation of the FROG-XT6.
4.2 Definitions
Transfer Lift
A transfer is defined as one pickup and put down when passengers are on board, or when
the unit carries more than its tare weight.
Usage Category
This is defined by the number of transfer lifts per year. There are four different usage
categories from low to very high.
Critical Parts
These are the identified set of load bearing parts.
Competent Person
A competent person is a person who has appropriate practical and theoretical knowledge
and experience of the equipment. This will enable them to detect defects and weaknesses
and to assess their importance in relation to the safety and continued use of the equipment.
It is essential that the competent person is sufficiently independent and impartial to allow
objective decisions to be made.
Non Destructive Testing
Although not considered necessary, some operators choose to adopt a dye penetrant crack
inspection prior to any re-installation of a critical part.