Manual - Hydrospex Strand Jacks - ENG REV-B PDF

User Manual
‘Strand Jacks’
Hydrospex Cylap BV
Hydrospex Cylap BV
User Manual
Strand Jacks
User Manual
‘Strand Jacks’
Hydrospex Cylap BV
Opaalstraat 44
7554 TS Hengelo
P.O. Box 421
7550 AK Hengelo
The Netherlands
Tel. +31 - 74 - 242 20 45
Email: info@hydrospex.nl Page 1

Hydrospex Cylap BV
User Manual
Strand Jacks
Contents
1. GENERAL INFORMATION.........................................................................................................4
2. TRANSPORT AND POSITIONING .............................................................................................5
3. THE STRAND JACK .....................................................................................................................7
3.1. COMPONENTS ............................................................................................................................7
3.2. LIFTING CYCLE ..........................................................................................................................9
4. CONNECTING THE SYSTEM...................................................................................................10
4.1. HYDRAULIC CONNECTIONS .....................................................................................................10
4.2. ELECTRICAL CONNECTIONS ....................................................................................................12
4.3. MANUAL OPERATION ..............................................................................................................15
5. PREPARATION AND INSPECTION BEFORE LIFTING .....................................................17
5.1. THE WEDGES ...........................................................................................................................17
5.2. STRANDS .................................................................................................................................17
5.3. ATTACHING THE LIFTING ANCHOR TO THE LOAD ...................................................................20
5.4. HYDRAULISCHE STRAND TENSIONER (OPTIE) .........................................................................21
5.5. OIL ..........................................................................................................................................23
5.6. PLUNGER SURFACE..................................................................................................................23
5.7. PRESSURE TEST .......................................................................................................................23
5.8. TEST CYCLE .............................................................................................................................24
6. LIFTING ........................................................................................................................................25
6.1. INTRODUCING SCC .................................................................................................................25
6.2. THEORETICAL LIFT ..................................................................................................................26
6.3. THE SCC NETWORK VERSION .................................................................................................40
6.4. TIPS AND TRICKS .....................................................................................................................41
7. POST-LIFTING CHECKS...........................................................................................................42
7.1. THE WEDGES ...........................................................................................................................42
7.2. ROD SURFACE..........................................................................................................................42
7.3. PAINT ......................................................................................................................................42
7.4. CABLES ...................................................................................................................................42
7.5. COUPLINGS ..............................................................................................................................42
8. MAINTAINING THE STRAND JACK ......................................................................................43
8.1. MAIN JACK ..............................................................................................................................43
8.2. MINI JACK ...............................................................................................................................47
8.3. THE WEDGES ...........................................................................................................................51
8.4. THE ANCHOR BLOCK ...............................................................................................................54
8.5. HYDRAULIC STRAND TENSIONER ......................... FOUT! BLADWIJZER NIET GEDEFINIEERD.

Hydrospex Cylap BV
User Manual
Strand Jacks
Disclaimer
This manual is regularly improved and adapted to new situations. We are always
interested in reactions and tips from clients in order to improve the Strand Jack.
Despite the fact that this manual has been composed with the utmost care we
cannot guarantee that it does not contain any errors. Using the information in this
document and using the Strand Jack takes place at the responsibility of the client.
Hydrospex Cylap B.V. does not accept any responsibility for damage resulting
from possible errors and/or imperfections in this manual.
All rights reserved. Nothing in this document can be duplicated, stored in an

automated data bank or published, in any manner of form, either electronically,
mechanically, by way of photocopies, pictures or any other way, without the prior
written approval of Hydrospex Cylap B.V.

Hydrospex Cylap BV
User Manual
Strand Jacks
1. General information
In this manual all aspects of working with a Strand Jack will be explained.
The instructions in the manual only apply to a Hydrospex Strand Jack in the
condition in which it has been supplied by the manufacturer. Furthermore, the
Strand Jack should only be used in combination with a hydraulic power pack and
control supplied by Hydrospex.
Ensure that you and other persons in the surrounding area wear a safety helmet
during the operation of the Strand Jack and that the applicable safety regulations
are adhered to. When necessary safety gloves, safety glasses, etc. should be
worn.
Only use original Hydrospex components to repair mechanical failures.
Maintain your concentration during work. Don't get careless, carelessness could
cause serious injuries and even death.
Operate the Strand Jack only when you have been certified by Hydrospex as an
authorised operator.

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Strand Jacks
2. Transport and positioning
The Strand Jack can be transported in various ways. Transport in a container is a

good solution as in this way the Strand Jack is well protected against dirt. Place it
flat on the ground and tie down tightly in order to avoid it sliding around.
The Strand Jack should be hoisted by at least two of the hoisting points welded
onto the Strand Jack in various positions. The hoisting points are designed for the
weight of the Strand Jack. Never hoist a Strand Jack together with its load by its
hoisting points.
Base plate
Hoisting points
to hoist the
Strand Jack Distance between supporting beams
Decide when the Strand Jack should be hoisted into position; before feeding the
strands in or after. The strands are best fed in while the Strand Jack is still lying
on the ground. It is after all not easy to feed the heavy strands in at working
height.
In Chapter 5.2. it is explained how the strands should be cut to size before they
are fed into the Strand Jack.
When the Strand Jack is placed into the right

position with a crane, it will turn from a horizontal
position into a vertical position. Ensure that the
strands (when they have been fed in beforehand)
do not bend when the Strand Jack turns. Damaged
or bent strands should not be used for lifting.
Bending the strands can be prevented by guiding

the base plate with a forklift truck when hoisting
the Strand Jack.

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When the Strand Jack has been placed in the correct position on a lifting frame it
should be secured with four bolts. The base plate contains holes for these bolts.
The distance between the supporting beams under the Strand Jack should be large
enough to pass a bundle of strands through the opening. When the distance
between the beams is much larger than the diameter of the bundle the base plate
will fail due to bending. Check whether the frame on which the Strand Jack will be
placed is able to endure the actual load. The beams or construction on which the
Strand Jack will be placed should absorb the force.
The Strand Jack can be used in all different positions; horizontally, vertically as
well as upside down.

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Strand Jacks
3. The Strand Jack

The Hydrospex HSL Strand Jack is a fully automated linear winch making use of a
unique system in order to lift. It uses a bundle of steel strands, which together
carry the load. One strand consists of seven steel wires, which are first twisted
together and then pressed together to form one strand.
The Strand Jack is able to carry a load by way of wedges gripping all strands
simultaneously.
Lifting and lowering a load is achieved

by hydraulically controlling the main
jack and both mini jacks alternately.
With the aid of SCC software the
control is carried out via a computer.
Strand Wedge
3.1. Components
The Strand Jack consists of a number of
components of which the main jack and both mini
jacks are very important. Top
anchor
3.1.1. Main jack Mini jack

The main jack is responsible for raising and
lowering the load. In reality it is a hollow cylinder
through which the strands are guided. The main
jack is mounted on the bottom anchor. The
bottom anchor contains one of the two mini
jacks. On the inner pipe of the main jack the top
anchor has been mounted. The top anchor also
contains a mini jack and a system to guide the
exit of the strands.
Main jack
The force of the Strand Jack is determined by the
operating pressure of the main jack. One should
never use a higher pressure than indicated in the
drawing.
Strand guidance
Bottom
Mini jack
anchor

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3.1.2. Mini jack

The mini jack contains the system for
Push pipes clamping and releasing the strand. This
not drawn
takes place by way of moving the push
pipes up or down. This results in the
wedges being pushed into or out of the
anchor block.
When the push pipes are in the lower

position the wedges are pushed into the
anchor block by the springs. The holes in
the anchor block are shaped like
wedges. Due to the wedge shape the
Wedge wedges become smaller when they are
free pushed into the anchor block and will
clamp the strand.
Wedge
When the push pipes are in the higher
fixed Anchor block position they push the wedge out of the
anchor block and the strand will no
longer be clamped by the wedge.
Wedges clamping the strand Wedges releasing the strand
The operating pressure of the mini jack is 60 bar.

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3.1.3. Strand guidance
The strand guidance consists of a set of tubes through which the strands are
guided. Each strand is lead through a separate tube. The telescopic part in the
main jack prevents the occurrence of a ‘bird cage’. We us the term bird cage when
a bundle of strands in the main jack has twisted together. This could happen in a
Strand Jack without strand guidance when one of the mini jacks is not releasing
the strands properly or when the Strand Jack is controlled without the aid of a
computer. By way of using strand guidance this situation can be prevented.
3.2. Lifting cycle

In order to understand the principle of the Strand Jack the following picture shows
the lifting cycle:
Both anchors The main jack is The load is The top anchor The main
are closed extended with a taken by the is open and jack is
closed bottom bottom anchor bottom anchor retracted
anchor is closed
In order to lower the load a similar cycle is used:
The load is The top The main Both The top The main
taken by anchor is jack is anchors are anchor is jack is
the bottom open extended closed. the closed and almost fully
anchor load is bottom retracted
taken by anchor is
the top open
anchor

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4. Connecting the system

In this chapter it is described how the hydraulic and electric components should be
connected.
4.1. Hydraulic connections

Try to place the power pack as close as possible to the Strand Jack on the same
platform. Ensure that the power pack has been secured properly. When the power
packs and Strand Jacks are in the correct position connection of the hydraulic
system can commence.
Check the couplings for dirt and damage before connecting these and clean if
necessary. Dirt can affect and damage the hydraulic system.
The hoses can be under pressure due to exposure to sunlight. In that case it will
be difficult to connect the couplings. In order to reduce the pressure in the hose
the coupling can be twisted of the hose a little until oil is coming out of the hose.
Now turn the coupling tight again and connecting them should be easier.
Unscrew the coupling to reduce
the pressure
Mini jack connections
Main jack
connections
Mini jack connections
The connections of the Strand Jack and power are carried out with rapid couplings.
Ensure that both hoses of both mini jacks are connected to the right valve.

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Connection
on bar side
Relief valve
Pressure sensor Connection on

bottom side
The relief valve is a safety device to prevent the Strand Jack being blown apart
when the connections are not correctly positioned.
A big disadvantage of this valve is that it sprays oil when the pressure is too high.
The relief valve sprays oil when the Strand Jack has not been
connected properly. Contact Hydrospex when the Strand Jack is
to be operated in surroundings where the relief valve should not
be used.
Male screw
coupling
Female screw
coupling
Pressure point for opening

the pipe
The screw coupling should be screwed completely together as during the

tightening of the couplings the oil passage is opened up. When the couplings have
not been tightened up sufficiently this could lead to a pressure build up in the
Strand Jack which could result in serious damage.
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4.2. Electrical connections

When the hydraulic system has been connected the cables for the electrical
system can be connected. The power supply for the power packs should be
present on the Strand Jack platform and can now be connected.
Take the following steps to connect the components to the computer:
Connect the RAM cable: Power pack to Strand

1
Jack

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Dongle /
Connect the RS485 data cables + 2 dongles to end plug
2
the power pack and the computer.
Dongle / end plug Dongle / end plug
3 Connect the power supply cable to the power

pack
4 Turn the main switch to ‘1’

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Turn the control switch to 'REM' (remote).

5
('LOC'= local)
6 Check that the 'Power on' light is on.
Check the emergency stop. Turn the switch

7
clockwise to ensure that it is not engaged.
8 Repeat steps 1 to 7 for all other power packs.

9 Connect the power supply of the computer.
When the power supply has been connected the
computer can be turned on with the switch on the
10
front of the computer. The monitor will
automatically start up.
Check the emergency stop. It should not be
11
engaged.
When the system has been connected correctly
the emergency stop can be reset. The blue light
will extinguish. If this does not happen all steps
should be checked again.
The communication with the valves should be
correct. This means that the data cables should
be connected properly and the valves should be
12 live. When the communication from the valves to
the computer is not correct the LED situated to
the utmost right on the SCC print, output 8, will
light up. When the communication between the
SCC print and the computer is correct a red LED
will light up to indicate that the print is sending
information to the computer.
-If the password is unchanged the programme

13 SCC60 will start automatically.
-When the computer has been assigned a
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password the following message will appear after
starting up: 'Press CTRL-ALT-DELETE to logon'.
Press the abovementioned buttons simultaneously
and enter the password. The lifting programme
will now start. First an introduction screen will
appear after which the Main Menu will become
visible.
4.3. Manual operation
Using manual operation should be avoided as much as possible as this can lead to
dangerous situations. Manual operation should only be engaged during installation
or maintenance work. The user should know exactly how the Strand Jack system
works. When the Strand Jack is not loaded it is possible to open the bottom and
top anchor simultaneously manually. This means that the strands are no longer
clamped by an anchor and can fall out of the Strand Jack in an uncontrolled
manner.
When the computer is used with the SCC programme this dangerous situation can
not occur as the control will not allow both anchors to open simultaneously.
Check whether using manual operation is the only option.

1 Do not use manual operation when it is possible to use the
computer.
Check whether the blue light indicating that the emergency

2
switch is off is lit up.

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3 Turn the control switch on the power pack to 'LOC' (local).
When the power supply cables have been connected to the

power pack, the indicator light for the emergency switch is
4
off and the RAM cable for the remote control is connected,
manual operation can start.
The red light on the remote control means that the head is
open: DANGER!
The green light on the remote control means that the head
is closed: SAFE!

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5. Preparation and inspection before lifting
In this chapter it is explained which components of the Strand Jack require extra
attention before lifting should start. Storage and transport can have a negative
influence on the condition of the Strand Jack. Especially when it has been stored in
a damp room for a long period vital components could be damaged or no longer
function properly.
5.1. The wedges
The operation of the wedges is based on local plastic deformation of the strands.
The wedges have a toothed interior surface which clamp onto the strands under
load. As the load increases the wedges will grip deeper into the strands. The
exterior of the wedge has a conic shape.
The lifespan of the wedges is dependent on various factors: the number of strokes
of the Strand Jack, the quality of the strands, weather conditions, etc. In general a
wedge is able to lift approximately 100 meters with a stroke of 450 mm. This is
however only an indication. Regularly checking of the wedges is required.
The teeth of the wedges should be sharp. There should be no dirt or rust between
the teeth. When this is the case the wedges will not be able to get a grip on the
strands which could have disastrous results. When in doubt about the condition of
the wedges it is advised that these should be replaced.
5.2. Strands
Only use 15.7 or 18 mm (dependent on the type of Strand Jack) 'dy-formed'

strands supplied by Hydrospex. The strands should fulfil the requirements of the
standard BS 5896.
There are a number of strand suppliers who possibly have cheaper strands but not
of the required quality. An incorrect type of strand can lead to damage to the
Strand Jack and a bad grip of the wedges on the strand with possibly disastrous
consequences.
Check whether the strand is in good condition and there is no visible damage.
5.2.1. Length of the strands

The length of the strands can be calculated as follows: measure the distance from
the top of the Strand Jack to the ground and add 200 cm. When the load is
suspended at a certain height above the ground, this distance can be deducted
from the length of the strand.

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An example of calculating the height:
The top of the Strand Jack is 50 meters above the ground and the load is
suspended 10 meters above the ground. The length of the strands should be 50 +
2 – 10 = 42 meters.
a = Distance from the top of the

Strand Jack to the ground
b = Ensure that the strand projects
2 meters.
a d c = Distance from the ground to the
fastening point of the load
d = In this example the length of
the strands is:
50 + 2 – 10 = 42 meters
When a strand guide is used the length of the curve and the
distance between the Strand Jack and the strand guide
should be added to the calculated length.
Strand guide
5.2.2. Cutting the strands
In order to cut the strands to size a surface is needed of a
number of meters wide and the length of the strand. Ensure
that the surface to lay the strands onto is hard and clean,
possibly a tarpaulin or something similar.
Cut a tapered end to both ends of the strand. This angle is

necessary to guide a strand properly through the Strand
Jack.
Tapered ends

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5.2.3. Feeding the strands in
Feed the strands from the bottom anchor in and ensure that the projecting section
of strand is at least as long as a stroke of the Strand Jack.
Close the top anchor during the feeding in of the strands. This can be done by
manual operation.
In Chapter 6. it is explained how the strands can be fed in with the help of the
SCC software.
When both heads are opened the wedges will not clasp the strand and it could
slide out of the Strand Jack. It is therefore important that at least one of the
heads is always closed.
Ensure that there are no obstacles around the Strand Jack which could cause the
strands to bend or kink. The strands should be thoroughly cleaned before they are
fed in.
When a load is to be lowered a bundle of strands will project from the end of the
Strand Jack. When the length of the projecting section is not longer than 10
meters a strand guide should be used. When this is not used there is a chance
that the sideways load on the inner pipe of the Strand Jack becomes too great,
which will result in damage.
When the strands have been fed into the Strand Jack the anchor block can be
attached to the ends of the strands. Push the strands one by one through the
anchor block and the wedge until they reach the stop plate or just project through
the stop plate.
Ensure that the strands do not twist or cross
each other.
Crossing the strands is easily prevented by
way of using a auxiliary plate with the hole
pattern of the Strand Jack. This plate can
guide the strands from the Strand Jack to
the anchor.
It is not yet a problem that the strands are
not all of the same length. In chapter 5.4. it
is explained how the strands should be
tensioned with a hydraulic strand

tensioner. In Chapter 6.2.6 it is
explained how the strands should
be pretensioned when the special
hydraulic tensioner is not available.
Auxiliary plate
with hole
pattern
Strands should not
cross each other

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5.3. Attaching the lifting anchor to the load
When the strands have been fed into the anchor block the lifting plates can be
attached. The anchor block is held by both anchor plates.
Step 1: attach both lifting plates. Step 2: attach the load to the lifting anchor by
way of pushing the pin through the load and securing this with the end plate.
Stud frame
2
2
Pin
End plate
Load
In the above picture a stud frame can be seen. These are applied for the larger
types of Strand Jack. Not all Strand Jacks are equipped with a stud frame.

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5.4. Hydraulic strand tensioner (optional)
The hydraulic strand tensioner can be bought in combination with a strand jack.
This tensioner is designed to give the strands all the same length after they are
inserted in the Strand Jack. Tensioning leads to equal loads in each strand while
lifting.
On the picture is a strand

bundle shown which is just
inserted and not tensioned.
The strands hang limply
down.
They have to be tensioned
for making a straight
bundle.
The strand tensioner will be attached on the top of the strand jack. The strands
will be tensioned when the main jack is extending. The strands which already are
tight will slide trough the tensioner.
The tensioner consists of

three piled plates with
holes for the strands. The
middle plate can slide
between the others with
the tension cylinder.
This plate contains
bushings of friction
material for clamping the
strands.
Middle plate with

bushings

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When the strands must be tensioned, the tension cylinder will be extended to
clamp the strands and the main jack will be extended.
The strands get all the same length and the bundle hangs straight.
All of the strands will get an equal load when a load is attached to the liftanchor.
Tensioned
strands
5.4.1. Connecting the tensioner to the powerpack

In the powerpack a function is added for connecting the tensioner.
Manometer for pressure

in tension cylinder
Accu for keeping pressure

on the tension cylinder
Connections for the

tension cylinder

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5.5. Oil
In order to guarantee the reliability of the system the following should be adhered
to with regard to the hydraulics.
1. After maintenance work let the pump run a few minutes without any
pressure and without operating the valves. This removes all the air from the
system and pumps the oil through the reservoir and filter a number of
times.
2. For normal use when the outside temperature is not lower than -15°C and
not higher than 50°C SHELL TELLUS 32 is used. Contact Hydrospex when
the Strand Jack is used outside this temperature range.
In 90% of the cases a defect of the hydraulic component is caused by dirty oil.
Examples of contamination are:

• Welding spats
• Rust
• Steel splinters of machined components
• Sand
As the Strand Jack system contains components which are sensitive to

contaminated oil it is important to achieve good filtration. Check the oil and the
filter before and after operation in order to avoid the chance of a defect due to
contaminated oil during operation.
All power packs are equipped with a dirt indicator in order that contaminated oil
and the filter can be changed in due time. Filters are always kept in stock at
Hydrospex.
5.6. Plunger surface
The exterior surface of the plungers of the main jack and mini jacks should be free
of scratches and rust.
Clean the plunger surface with a
degreaser. Small rust spots and
scratches can be removed with fine
sand paper. Contact Hydrospex
when the rust spots and scratches
are too large to be removed.
Plunger
5.7. Pressure test

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In order to ensure that there are no leaking seals in the Strand Jack it is
necessary to carry out a pressure test. Extend the main jack until it reaches the
end of the stroke. Pressure will now build up in the cylinder. Ensure that the
pressure does not exceed the working pressure. Maintain the pressure on the
main jack for a few minutes and then check the pressure again. The pressure
should not have decreased.
Give the main jack a visual check to see if there is any oil coming from the
cylinder.
Now retract the main jack fully. Let the pressure build up again until the
calculated pressure and maintain this for a few minutes. Check the main jack
again for any oil coming out.
When the cylinder is extended while the connection for retracting the cylinder is
pressurised, it means that the plunger seal is leaking or that the pipe is damaged.
Disassemble the main jack as described in Chapter Fout! Verwijzingsbron niet
gevonden.
The pressure test should also be carried for both mini jacks.
5.8. Test cycle
After the visual test of the Strand Jack a number of cycles should be carried out
with the computer.
Let the Strand Jack carry out a lift of, for example, 50 meters. Do this without the
strands and before the Strand Jack is in its final position. In this way any possible
electronic or hydraulic defects can be observed in due time and is it possible to
carry out a repair quickly.
After this test has been carried out the lowering of a load should also be
simulated. Carry out a lowering cycle of, for example, 20 meters with the Strand
Jack.
Contact Hydrospex when a defect has been observed or the computer displays an
error message which cannot be resolved.

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6. Lifting
The Strand Jack system is equipped with the latest version of the Smart Cylinder
Control (SCC) system.
This part of the manual describes how the programme works and how a lift should
be carried out with the Strand Jack.
6.1. Introducing SCC
The SCC system was developed at the beginning of the nineties. The reason for
this development was that manually operating the Stand Jack presented one
difficulty; it was difficult to read the load. This can lead to problems when more
than one Strand Jacks lift a load together. In such a case it would be impossible to
check that they are running synchronised and are subjected to the same load
without the aid of a computer.
The key feature of the SCC system is that each cylinder has its own electronic
control and that all these units are connected in series with each other and the
computer. The computer is able to control each Strand Jack separately and to
receive information.
As the Strand Jacks are all connected in series all information can be sent through
one data cable while the computer is able to control and visualise all Strand Jacks
separately.
The SCC prints are built into the power pack and have their own power supply
which also supplies the valves and sensors.
When the SCC programme has been installed it is possible to use all components
of the programme separately. We strongly recommend that the operator
familiarises himself with the system and that a number of test lifts are made
before the Strand Jack is used to carry out an actual lift.
Before lifting should commence a number of data are of importance:

• The number of Strand Jacks
• The expected load of each separate Strand Jack
• The type of Strand Jack used
• The address number of the power pack and its location with regard to the
control room.
Important terminology:
Lift Moving the load
Stroke The stroke of the main jack
Load The weight on the hoisting eye
Expected Load The expected weight of the load
Preload stroke The stroke made by the main jack from zero to the
position on which all wedges clamp the strand
Absolute max. position The extreme position of the extended main jack
Absolute min. position The extreme position of the retracted main jack
Offset The weight of the components not part of the load,
such as lifting anchors, strands, etc.
Hysteresis The allowed a-synchronicity of the Strand Jacks

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Lift counter start % The percentage of the expected load at which the lift
counter starts running
6.2. Theoretical lift
In order to get to know the SCC programme this part of the manual will simulate a
theoretical lift. It is assumed that all Strand Jacks are in the correct position and
that no strands have been fed in yet.
We will use eight Strand Jacks of the type HSL2000 in order to lift a load of 1100
ton. The addresses of the Strand Jacks are numbered 1 to 8. Strand Jacks number
2 to 7 will all lift 150 ton each. The numbers 1 and 8 will lift 100 ton each.
The anchors are lying on the ground and should first be lifted three meters high
before they can be attached to the load.
The Strand Jacks should run synchronised within 8 mm.
6.2.1. Main menu

The main menu of the SCC programme contains nine submenus and the possibility
to close the programme.
When the mouse is moved across a function on the screen a text box will appear
with a description of the function concerned.
The screen with the main menu not only displays the lift functions but also the
user name, license number and revision number.
Please make a note of these data as they can be important when the computer
crashes.

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Description of the available menus:
Lifting The lifting menu.
Lowering The lowering menu.
Manual To manually control all movements of the Strand Jacks.

No protection against bird cages.
Engines To control the speed of the engines.
Installation Uncontrolled operation. Use this menu only to feed in the

strands.
General To enter the general settings of the lift.
Preset To enter the features of the individual Strand Jacks.
Ram To adjust the features of the cylinder (factory settings).
6.2.2. Preset menu:
Go to [preset]:
In this menu it is possible to enter for each individual Strand Jack of the system
the address, type, expected load, etc.
Only the Strand Jacks with a tick in the bock 'enabled' will be displayed on the
screen when lifting the load.

Hydrospex Cylap BV
User Manual
Strand Jacks
Under 'RAM type' the Strand Jack to be used can be selected. By clicking on the
arrow a menu will open in which various Strand Jacks can be selected. When using
the demo version of the programme 'Demo' should be selected.
Subsequently the expected load should be entered. This is possibly one of the
most important parameters of the system. The expected load should be
determined as accurately as possible as a number of matters such as the overload
alarm and lift counter start refer to this value.
In this case select the HSL2000 in the library. The expected load of the Strand
Jacks 1 and 8 is 1000kN and for the numbers 2 to 7 it is 1500kN.
The value of the offset box can be entered manually but can also be set
automatically to zero by way of the [Zero-balance] button. The offset function is
used for example when a lifting frame is used between the Strand Jacks and the
load. The mass of the frame can be ignored by the offset function in order that
only the load is displayed when lifting.
There is also an option present to reset the entered values with the [Reset total
lift] button.
When a power failure or communication failure occurs a pop-up screen will appear
on which the error message will be displayed. The computer will store all data
related to the error message. By clicking on [Reset unstable] the computer will
continue at the last stored point.
In the stroke box the desired stroke length during the lift will be entered. When
several Strand Jacks with different strokes are used the box should contain a
value smaller than the smallest stroke.

Hydrospex Cylap BV
User Manual
Strand Jacks
6.2.3. General:
Go to [General]:

Hydrospex Cylap BV
User Manual
Strand Jacks
In the [Hysteresis] box the allowed stroke deviation between the Strand Jacks
should be entered. When the different Strand Jacks need to run very closely
matched the value in this box will be small. The fastest running Strand Jack will,
when exceeding the hysteresis value, wait for the slower Strand Jacks. When the
hysteresis value is only a few millimetres the lift will not only take very long but
the load will also start to swing.
The [Lift counter start] indicates at what percentage of the expected load the
system should start measuring the distance travelled by the load. The first part of
the stroke cannot be seen as a movement of the load as the wedges do not
immediately completely clamp the strands. The Strand Jack should first make a
small stroke before the load can be detected by the wedges.
[Overload] indicates to what percentage the expected load can be exceeded

before the system will interrupt the lift. When the system becomes overloaded it
can be reset manually. In the manual mode the overload can also be increased. It
is not allowed to set the overload to more than 150% of the expected load in
connection with the design safety of the Strand Jacks and the strands.
The [Anchor open load] displays the percentage of the expected load hanging in
the lifting anchor before the anchor without load should open.
[Delay time anchor] When the sensors give the signal that the anchor is open or
closed the system will continue to control the anchor for the set time in order to
ensure that the anchor is at the end of the stroke.
When all specifications of the lift have been entered the strands can be fed in.

Hydrospex Cylap BV
User Manual
Strand Jacks
6.2.4. Engines:
This part is not part of every SCC system. When this part is missing the power
packs can be started and the next chapter can be started.
In this menu the speed of the various power packs can be controlled.
Fuel engines:
[Global control] ensures that all selected engines run at the same speed.
The engine can be started by ticking the [Contact] box and press start. Keep the
start button pressed until the engine runs.
Electric engines:
Electric engines can be started by ticking the [Motors on] box.

Hydrospex Cylap BV
User Manual
Strand Jacks
6.2.5. Installation menu
Deselect the Strand Jacks which are not used by clicking on them with the mouse.
When the Strand Jack has a dark colour it will not respond to any commands.
Positions of the anchor head:

Arrows pointing inwards indicate that the wedges are clamped around
the strands. The anchor is closed and safe. The colour of the arrow is
therefore green or blue.
Arrows pointing outwards indicate that the wedges are not clamped
around the strands. The anchor is open. The colour of the arrows is
red.
The colour if the arrows turns to yellow or white when the anchor
changes position. None of the sensors is able to detect the anchor.
When the colour stays yellow or white it is possible that one of the
sensors is not functioning correctly.
Remember that in this mode both anchors can be opened

simultaneously. This can lead to dangerous situations.
Please close the anchors immediately after all strands have been
fed in.
Exit the [Installation] menu when the strands have been fed in.
6.2.6. Manual:
In the manual
operation menu all
movements can be
carried out.
Pretensioning the
strands is necessary to
divide the load evenly
across the strands. The
strands should be
pretensioned before
every lift. First deselect
the Strand Jacks which
are not going to be
used. Open the top
anchor (bottom anchor remains closed) and grab the strand which is not under
tension with a clamp. Use, for example, a pair of grip pliers. Now extend the main
jack by way of the [Extend] button until the strand to be tensioned is just as tight
as the others.
Repeat this for all strands for each lift.
As an alternative special pretensioning buttons can be used. These can tension all
strands simultaneously. The pretensioning buttons can be ordered separately.

Hydrospex Cylap BV
User Manual
Strand Jacks
Further options in this menu:
The speed of the engines can be entered by clicking on the button with the
revolution counter (F8). With this button the difference in speed between the lift
stroke and the unloaded stroke can be entered.
The yellow dot under the slides indicates which one is being operated.
By clicking on the tortoise the automatic speed control can be switched on or off.
When the automatic speed control is switched on the Strand Jack will operate at
the maximum speed for unloaded movements.
6.2.7. Lifting:
Go to the [Lifting]
menu.
Now that the

settings for the
lift have been
entered lifting can
start.
The Strand Jacks
do not yet detect
a load. For this to
take place a few
strokes should be
made. By
pressing the start
button the Strand
Jacks will start to
lift. As it is more than likely that they will not detect the pre-load value during the
first few strokes an error message will appear during these strokes.
Press the [Unloaded] button to prevent this problem. The button will light up until
the load has been detected. The system will now request that you switch off the
Unloaded function.
When the [Start] button has been pressed it will change into a [Stop] button.
When during a cycle the [Stop] button is pressed it will change into a [Resume]
button. Press the [Resume] button to resume the movement.

Hydrospex Cylap BV
User Manual
Strand Jacks
With this button the automatic speed control can be switched off.
In this case the tortoise with the text 'off' will be visible.
When the programme recognises the possibility to work at a

higher speed the button with the hare will become visible and the
speed of the engines will increase. This can take place during a
return stroke.
By way of this button it is possible to switch directly to the

engine menu where the basic settings can be changed.
During operation information is available for each Strand Jack.

The picture will show how far the jack has been extended and
whether the anchors are open or closed.
Below the picture the maximum stroke, the load for the specific
Strand Jack and the lift stroke made in the current cycle are
visible. This stroke will always be smaller than the maximum
stroke as the pre-load stroke is not counted.
Finally the total length lifted is displayed. This value is calculated
by adding the lift strokes.
The small graph next to the figures shows the load hanging in the
Strand Jack. From blue to green is the area until the 'lift counter
start'. When this percentage changes the blue area moves along.
The green area runs from 'lift counter starts' until the 'expected
load'. Above this the graph is red. The figure 150 indicates 150%
of the maximum load.
6.2.8. Lowering:
Go to the [Lowering] menu.
The basic instructions are the same for lowering as for lifting.
It is possible that the Strand Jack after lifting is not in the correct position to start
lowering the load. For this reason the anchors will close and movement will stop
when the start button has been pressed. When the start button is pressed again
the Strand Jack will make a lift stroke until the [Anchor open load %] has been
achieved. Subsequently the lower anchors will open and lowering the load can be
started.

Hydrospex Cylap BV
User Manual
Strand Jacks
6.2.9. Ram:
In this menu the characteristics of a Strand Jack can be adjusted and a new
Strand Jack can be created.
To create a new Strand Jack:

Click on [New] and enter the name and specifications of the Strand Jack:
Anchor open time out: When an anchor is being opened it should reach the end
switch within a certain time. Large Strand Jacks need more time to open an
anchor than small ones. Measure the time needed for opening and add a few
seconds. When the anchor needs more time it could be that the end switch is not
functioning or that there is a fault in the hydraulic system.
Anchor close time out: When the anchor is being closed the same applies as for
opening the anchor. This value is also set at 15 seconds as standard.
Absolute minimum position: The plunger is not allowed to touch the bottom of
the cylinder when lifting. This is why the minimum position of the plunger is
indicated. In this case the plunger will stop at a distance of 10 mm from the
bottom.
Absolute maximum position: The top of the plunger is also not allowed to touch
the head when lifting. This is why the maximum position of the plunger is also
indicated. In this case the plunger will stop at a distance of 470 mm from the top.
Pre load stroke: When a lifting stroke has been completed the lower anchor
closes and takes over the load. To enable this the Main jack will descend 20 mm
with a closed top head. This stroke is made every time the load is taken over by
another anchor.
Anchor stroke: The stroke of the Mini Jack.
Max. design load: The maximum capacity of the Strand Jack.
Hydrospex Cylap BV
User Manual
Strand Jacks
AD max.: This value can be found by extending the main jack manually until the
plunger touches the head. Now go the main menu and press the following buttons
simultaneously: Ctrl, Alt and T. The following screen will appear:
In the AD max. box enter the value appearing under Analog 1. The values of the
different Strand Jacks will vary a little but that is not a problem. As the plunger
will never touch the bottom or the top when lifting (set under Abs. min. pos. and
Abs. max. pos.) there is room for a little variation.

Hydrospex Cylap BV
User Manual
Strand Jacks
AD min.: This value can be found by retracting the main jack manually until the
plunger touches the bottom. Now go the main menu and press the following
buttons simultaneously: Ctrl, Alt and T. The following screen will appear:
In the AD min. box enter the value appearing under Analog 1. Use the value of the
Strand Jack which had also been used for the AD max. value.
The AD min. and the AD max. values cannot be less than 800- and not more than
4096. This scale is equal to the 4-20 mA scale of the stroke counter.
AD max. alarm: Here a value can be entered at which the computer will provide
an error message when this value is exceeded. The value should be higher than
the AD max. value.
AD min. alarm: Here a value can be entered at which the computer will provide
an error message when the value drops below the set value. The value should be
less than the AD min. value.
Scale: In this box the total stroke of the main jack should be entered. The scale
of the AD values will be adapted automatically.
RPM: The boxes under RPM are only applicable when power packs with variable
speeds are used. The scale of the RPM is the maximum speed of the engine of the
power pack.
6.2.10. Exit
Click on 'EXIT' in order to close to programme in the correct manner. After a few
moments the following message will appear on the screen: "It is now save to turn
off your computer". So the computer can be turned off.
When the programme is closed off in the correct manner all data will be stored on
the hard disc of the computer. All set values will be stored in this manner.

Hydrospex Cylap BV
User Manual
Strand Jacks
6.2.11. Hydraulic Strand Tensioner (optional)
When a hydraulic strand tensioner is included in the delivery, the main menu of
the SCC program looks as follows:
Push the AUX-button to enter the tension menu.

Hydrospex Cylap BV
User Manual
Strand Jacks
In the tension menu every single tensioner can be controlled.
With this button the tension

cylinder will extend.
With this button the tension

cylinder will retract.
With this button all of the tension

cylinders will extend
With this button all of the tension

cylinders will retract
Select with this which valves you

are using for the tensioning.
Tensioning procedure:
1. Extend the cylinder of the right Strand Jack to clamp the strand bundle.
2. Go to [menu] and then to [Manual]
3. Close the bottom anchor of the Strand Jack and open the top anchor.
4. Extend the Main Jack. The strands will be tensioned at this time.
5. Repeat this method for every Strand Jack.

Hydrospex Cylap BV
User Manual
Strand Jacks
6. Go to the tension menu when all strands are tensioned and retract the
tension cylinder.
6.3. The SCC network version
With one computer twenty Strand Jacks can be operated simultaneously. In a

situation in which more than twenty Strand Jacks are needed a network version of
the SCC programme is available. Please contact Hydrospex for this network
version.

Hydrospex Cylap BV
User Manual
Strand Jacks
6.4. Tips and tricks
6.4.1. Calibrating the stroke counters:
The SCC programme offers the possibility to calibrate stroke counters.
1. Go to 'Installation' and fully extend the main jack. Go back to the Main
Menu and press simultaneously on the buttons Ctrl, Alt and T. Make a note
of the value appearing under Analog 1.
2. Fully retract the main jack and repeat the above procedure.
3. Go to the Ram menu.
4. Enter the AD min. and AD max. values.
5. Enter the stroke of the main jack at 'Scale'. The stroke counter has now
been calibrated.

Hydrospex Cylap BV
User Manual
Strand Jacks
7. Post-lifting checks
A Strand Jack is often operated under harsh conditions. This means that the
Strand Jack can get damaged. In order to ensure that possible damage does not
unnecessarily increases the Strand Jack should be completely inspected after use.
Clean the Strand Jack first of all with water after use. This means that possible
damage is easier to see. Then continue the inspection as follows.
7.1. The wedges

Clean the wedges when lifting has been completed. The rusty strands will have left
a mark on the wedges. Check whether the wedges can be reused. When
necessary, replace them. See Chapter 8.3. for assessing the quality of the wedges
and to replace them.
7.2. Rod surface

When rust has formed on the rod surface this should be removed with fine sand
paper. Then clean the surface with a degreaser. When the damage to the rod is
substantial it is possible that a new protective coating needs to be applied. In this
case please contact Hydrospex.
7.3. Paint
When the paint has been damaged the steel will start to rust. Bolted connections
can also start to rust which could lead to a less strong connection. For this reason
touch up the paintwork of the Strand Jack after cleaning.
7.4. Cables
Check the power supply and data cables for damage. Replace any cable of which
the insulation has been damaged. As a final check the Strand Jack should be
connected to the computer. When a cable is cut or not connected properly the
computer shows an alarm. In this way it is easy to check the cables.
7.5. Couplings
Due to the use of quick couplings it is always possible for dirt to enter the system.
Despite the fact that the power packs have been equipped with oil filters it is
always possible that dirt is left behind in the system. Dirt can lead to damage to
the components.
Clean the couplings thoroughly before they are connected. Use degreaser and
clean the inside and outside of the couplings. Dry the couplings with paper and
visually check them for dirt. Do not use any brake cleaner or other detergents
which could affect the couplings.

Hydrospex Cylap BV
User Manual
Strand Jacks
8. Maintaining the Strand Jack
In this chapter it is described how the Strand Jack should be disassembled, what
is important and how to reassemble the Strand Jack.
8.1. Main jack
When a seal in the main jack is leaking the jack should be disassembled. For this
the top anchor should be removed first. Remove all hoses and cables connected to
the top anchor. Also unscrew the sensors of the mini jacks. Warning!! When
reassembling the sensors it can be that they need to be reset.
Now remove the stroke counter by unscrewing the bolts of the bracket:
Main jack
Stroke counter
Subsequently remove the bolts with which the top anchor has been attached to
the main jack:
Top anchor
Remove the bolts

Hydrospex Cylap BV
User Manual
Strand Jacks
Pull the top anchor from the main jack:
Pull Clean
Ensure that the top of the main jack is thoroughly cleaned to prevent dirt falling
into the cylinder.
It is now possible to remove the cylinder head of the main jack. In some Strand
Jacks the head is bolted while in others the head is screwed, depending on the
type:
Wire holes
Bolted version
Use the two wire holes to pull the head of the main jack.

Hydrospex Cylap BV
User Manual
Strand Jacks
Place the cylinder head on a clean surface. When a seal of the head is leaking it
should be replaced. Ensure the head is clean and free of grease.
Wiper Rod seal
Support ring
Guide ring
O-ring
Never use sharp tools to remove seals. The smallest bit of

damage can lead to leaking.
When a plunger seal is leaking the rod will also have to be removed from the pipe.
First remove the ring keeping the wiper seal in position by loosening the bolts:
Ring Inner wiper
Remove the bolts

Hydrospex Cylap BV
User Manual
Strand Jacks
Now carefully remove the inner wiper seal. Use the two wire holes to pull the rod
from the pipe:
Pull
Place the rod on a clean surface. Ensure all surfaces are clean and free of grease.
Replace the damaged seals.
Guide band
Plunger seal
Guide band Plunger seal
Degrease all components before the main jack is reassembled. Check for sharp
edges in the main jack which could damage the seals when assembling.
Repeat all steps for disassembling the main jack in reverse order. Use special
assembly grease to grease on the seals and to ensure that all seals slide easily
across the surface.

Hydrospex Cylap BV
User Manual
Strand Jacks
8.2. Mini jack
The mini jacks can also have leaking seals. In order to replace these the mini
jacks need to be disassembled.
Top anchor Bottom anchor
Mini jack
The top anchor is easy to remove (see previous chapter). Disassembly of the
bottom anchor is a little more difficult.
Place the Strand Jack in a horizontal position on the ground in such a way that the
Strand Jack rests on the main jack in order that the bottom plate is off the
ground. If necessary wood can be placed under the main jack to lift it a little of
the ground.
Now remove the bolts with which the base plate is attached to the feet. Ensure
that the base plate does not fall over as the mini Jack is still attached.
Base plate
Remove the bolts

Hydrospex Cylap BV
User Manual
Strand Jacks
Place the base plate with the mini Jack attached on the ground.
Subsequently loosen the bolts with which the mini Jack is attached to the base
plate:
Remove the bolts
Both mini jacks can now be disassembled and placed upside down or on its side in
order that the bottom can be accessed.
Top anchor
Remove the bolts
Pressure plate
Loosen the bolts attaching the flange and the bolts attaching the pressure plate.

Hydrospex Cylap BV
User Manual
Strand Jacks
The mini jack will look as follows:
Loosen the bolts connecting the head of the mini jack to the pipe:
Head
Pipe
Remove the bolts
Pretensioning
plate
In order to simplify removing the head completely the pretensioning plate should
also be removed. This plate is for some types of Strand Jack attached to the top
anchor.

Hydrospex Cylap BV
User Manual
Strand Jacks
Hold the casing of the mini jack and pull the head and pipe carefully of the casing.
The result will look as follows:
Rod seal Plunger seal
Guide band Wiper seal
Rod seal
O-ring Guide band
Wiper seal Support ring
Use degreaser to thoroughly clean the inside of the mini jack before replacing any
seals. Now the leaking seal can be replaced. Ensure that the new seal is clean and
check that it is undamaged. Note the position of the support ring when replacing
the o-ring. It should be place behind the o-ring on the side where the oil cannot
reach.
Never use sharp tools to remove seals. The smallest bit of

damage can lead to leaking.

Hydrospex Cylap BV
User Manual
Strand Jacks
8.3. The wedges
The wedges form essential components of a Strand Jack.
The Hydrospex Strand Jack is designed in such a way that the wedges can be
removed even with a load present.
Although the load should of course not be hanging on the anchor from which the
wedges are to be removed. Carry out the following steps to replace the wedges.
Remove the
Remove the bolts
pretensioning plate
Remove
the pins
Remove the bolts
The pins (when attached to the top anchor) have flat ends, in order that they can
be held easily with a spanner.
Loosen the pins and bolts carefully as the plate with the pipes is under tension due
to the springs below. Each wedge is pushed into the anchor block by a spring. For
a larger Strand Jack a larger number of wedges is used, which also increases the
total spring force on the plate.

Hydrospex Cylap BV
User Manual
Strand Jacks
Spring
Be careful when removing the plate. The springs under the plate
are under tension!
Remove the springs and spring caps to expose the wedges:
Spring
Spring cap
Wedge

Hydrospex Cylap BV
User Manual
Strand Jacks
The wedges can now be removed from the anchor block. Each wedge consists of
three identical components held together with a rubber ring. Remove the rubber
ring and thoroughly clean the wedge. This is simply done by laying all wedges in a
container with degreaser. Remove any rust and ingrained dirt with a steel brush.
It is necessary that clean wedges are used for lifting. The teeth in the wedge
should also be reasonably sharp. Wedges filled with rust and dirt cannot get a
good grip on the strands. This can have disastrous results.
Wedge
Tooth
Rubber ring
Conical
surface
Do not use the steel brush on the outside of the wedges. The surface should
remain smooth in order that the wedge slides easily into the anchor block. When
the conical surface is too damaged, by for instance wear and tear, the wedge
should be replaced.
Lubricate the outside of the wedges thoroughly before placing them back into the
anchor block. Use stick lubricant or another type of pressure resistant grease. Do
not use oil!
Ensure that there is no grease on the inside of the wedge.

This will reduce the grip of the wedge on the strand.

Hydrospex Cylap BV
User Manual
Strand Jacks
8.4. The anchor block
Now that all wedges are removed from the anchor block, this can also be
inspected. First remove the spring ring from the groove:
Spring ring
Spacer
Some types of Strand Jack only contain a spring ring and no spacer. Use a
spanner to remove the spring ring.
Anchor block

Hydrospex Cylap BV
User Manual
Strand Jacks
Use the wire ends to pull the anchor block from the mini jack:
Pull
Conical hole
Use degreaser to thoroughly clean the anchor block. The conical hole should have
a smooth and scratch-free surface. When necessary, use some fine sand paper to
achieve this. Contact Hydrospex when the damage is too great.
Thoroughly clean the anchor block after the repair work. Lubricate the conical
holes with grease when the anchor block has dried out.
Reassemble the mini jack in reverse order. Please note the position of the hole
pattern, it will only fit in one direction.

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User Manual

Email: info@hydrospex.nl Page 1

Email: info@hydrospex.nl Page 2

All rights reserved. Nothing in this document can be duplicated, stored in an

Email: info@hydrospex.nl Page 3

Only use original Hydrospex components to repair mechanical failures.

Email: info@hydrospex.nl Page 4

2. Transport and positioning

The Strand Jack can be transported in various ways. Transport in a container is a

When the Strand Jack is placed into the right

Bending the strands can be prevented by guiding

Email: info@hydrospex.nl Page 5

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3. The Strand Jack

Lifting and lowering a load is achieved

3.1.1. Main jack Mini jack

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3.1.2. Mini jack

When the push pipes are in the lower

Wedges clamping the strand Wedges releasing the strand

The operating pressure of the mini jack is 60 bar.

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3.2. Lifting cycle

In order to lower the load a similar cycle is used:

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4. Connecting the system

4.1. Hydraulic connections

Mini jack connections

Mini jack connections

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Pressure sensor Connection on

Pressure point for opening

The screw coupling should be screwed completely together as during the

4.2. Electrical connections

Take the following steps to connect the components to the computer:

Connect the RAM cable: Power pack to Strand

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Dongle / end plug Dongle / end plug

3 Connect the power supply cable to the power

4 Turn the main switch to ‘1’

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Turn the control switch to 'REM' (remote).

6 Check that the 'Power on' light is on.

Check the emergency stop. Turn the switch

8 Repeat steps 1 to 7 for all other power packs.

-If the password is unchanged the programme

4.3. Manual operation

Check whether using manual operation is the only option.

Check whether the blue light indicating that the emergency

Email: info@hydrospex.nl Page 15

3 Turn the control switch on the power pack to 'LOC' (local).

When the power supply cables have been connected to the

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5. Preparation and inspection before lifting

5.1. The wedges

Only use 15.7 or 18 mm (dependent on the type of Strand Jack) 'dy-formed'

5.2.1. Length of the strands