(EN 1176-1, 1998)
Important!
Maintenance inspections should be conducted on a frequent basis. We recommend that maintenance is carried out at least twice a year, or more often if the structure experiences a high play frequency.
Please give these instructions to the assigned service personnel, including the tools provided.
Technical Hotline: 030 - 414724 - 25 / - 30 As of: Februar 2008
Berliner Seilfabrik
GmbH & Co.
Lengeder Straße 4
D - 13407 Berlin
Phone: 030 - 414724 - 0
Fax: 030 - 414724 - 33

1.
Visual inspection of all parts
2.
Operational inspection and maintenance
2.1.
Frameworx ® space framework
Framework nodes (hollow aluminum balls)
2.2.
Condition of ropes and nets
2.3.
Peripherals
2.4.
Determining the net tension
2.5.
Adjusting the net tension
2.6.
Technical inspection of the attachment parts
3.
Annual main inspection
3.1.
Inspection of Frameworx ® foundation parts
4
6
7
7
3
3
3
2
2
2
3
When documenting damage or for determining necessary spare parts it is recommended to take photos and/or to make sketches that help to identify the exact position of the damaged elements in the play structure or that clearly show the dimensions.
According to standard EN 1176-7 the condition of the play structure must be determined through regular inspection. At the same time the soft fall material must be inspected and replenished if necessary. The amount of soft fall material required will depend on the structure. For Spaceballs, the soft fall material should reach the centre of the ground ball, i.e. the centre of the ball is the play level (ground level). However in other structures the upper edge of the ground ball is at the play level. Therefore please refer to the foundation plan in all cases. The frequency of the visual inspection will depend on the play activity and the season. We recommend weekly inspections.
:
Frameworx® space framework
Check the stability of the framework. Try to vigorously shake the frame. If the framework is unstable or if single pipes are loose, retighten the pipe connections to the nodes (hollow aluminium balls).
Usually the tubes of the framework are not susceptible to corrosion.
Nevertheless the tubes should be checked for corrosion. If parts of the tube have rusted, grind the relevant regions eliminate the corrosion and paint with zinc dust paint.
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Nodes (hollow aluminum balls):
Inspect the system nodes for external damage. Check the small hole at the underside of each ball (condensation water run-off) for permeability.
Moreover ensure that the rubber cap in the assembly opening of each node is in place and plugged in properly. Check all screws and drill holes for corrosion (if required remove rust and touch up with zinc dust paint; rusted screws should be replaced).
Inspect all ropes for abrasion of the polyamide coating and for wire fractures.
Replace any broken wires. Isolated abrasion of the Polyamide cover does not affect the safety of the part and does not impair the play function.
Ensure that a suitable soft fall material is at the correct level and replenish if necessary. The amount of soft fall material required will depend on the structure. For Spaceballs, the soft fall material should reach the centre of the ground ball, i.e. the centre of the ball is the play level (ground level). However in other structures the upper edge of the ground ball is at the play level.
Therefore please refer to the foundation plan in all cases.
Impurities and dangerous sharp-edged objects must be removed from the soft fall area.
First make sure that each cloverleaf ring is in the correct position. The rings must be placed into the visible deflection points of the rope.
Moreover it is important to make sure that no rope ends intersect before the balls.
Two people are required to determine the tension of the net, irrespective of the type of model. The only tool required is a normal folding ruler.
The reference points for the determination of the net tension are the bold net mesh in the drawings.
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•
Let one person stand on the reference net mesh (see drawing).
•
Measure the yielding of the rope
Clearance
The second person measures the clearance between the center of the loaded rope and the center of the (fictitious) horizontal rope in the unloaded condition. center of loaded rope
Irrespective of the type of model the clearance should be between 25mm
(1’’) and 40mm (1-9/16’’).
Should the clearance be beyond the range of tolerance (especially when overstepped), an adjustment of the net tension is necessary.
All bolted connections to the framework nodes are situated inside the hollow alluminium balls. To adjust the net tension it is necessary to firstly unplug the rubber caps covering the assembly openings. Use two big screwdrivers (for slotted screws) to remove the rubber caps.
Once all caps have been removed start tensioning each level beginning from the top of the structure and tension in a diagonal order. The connections to the four foundation balls are fixed points. They are not tensioning points.
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Pull tight at the hexagon tensioning screw (M20x200) inside the ball with socket wrench SW30 (SW = Wrench size) and a ratchet at the hexagon screw inside the ball. (When replacing a net, always use new self-locking nuts).
The aim of the tensioning process is to make sure that the tension is sufficient and the same in each rope.
Important: Tighten the screws equally so that each tensioner has the same length after tensioning.
After tensioning please re-check that the tension is sufficient and consistent in each rope.
Replace the rubber caps with a hammer.
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Depending on the type of Cosmo, different additional parts are included. The following maintenance procedures apply:
1. Sliding Pole, Banister:
Inspection of tubes and balls as described in chapter 2.1. Inspection of foundation parts as described in chapter 3.1.
2. Climbing Wall, Climbing ramp:
Inspection of tubes and balls as described in chapter 2.1. Inspection of foundation parts as described in chapter 3.1.
Inspect plastic panels and plate clamps for damage and position, if necessary tighten the screws and/or replace missing/damaged parts.
Inspection of semi-hollow balls for damage and position, if necessary tighten the screws and/or replace missing/damaged parts. If parts of the balls exhibit rust, the relevant regions are to be removed with adequate grinding to eliminate the corrosion and then painted with zinc to prevent further corrosion from occurring.
3. Access net:
Inspection of the ball as described in chapter
2.1. Inspection of foundation parts as described in chapter 3.1.
Inspection of the access net as described in chapter 2.2.
Inspection of the rope clamps for damage and position, if necessary tighten the screws and/or replace missing/damaged parts.
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Within the scope of the main annual inspection are all the steps of the operational inspection and maintenance (see point 2) plus a check of all
Frameworx ® foundation parts.
For corrosion to occur, three elements are required: an anode, a cathode and an electrolyte. The combination of these three elements results in the generation of an electrochemical potential, which causes corrosion to occur.
In theory, there should be no problem when using steel in concrete, as the concrete is an insulator and acts as a protective, passive layer due to the alkaline environment it provides. However, concrete is a porous material which is subject to carbonation and can readily absorb solutions containing various aggressive species (i.e. chloride ions). Thus, if steel is located close to the surface of the concrete, passivation of the steel is reduced. Therefore a minimum thickness of concrete cover is required to reduce the likelihood of corrosion occurring. The thickness required will depend on a number of factors, including the grade of concrete used.
Corrosion of the steel will occur when concrete is in contact with the soil. The soil contains solutions of various salts and gases which act as an electrolyte to facilitate corrosion. The electrolyte is absorbed into the concrete and diffuses through to the steel surface, which results in corrosion of the steel. Indications include cracking of concrete and/or a red-brown stain apparent on the surface of the concrete, due to the formation of rust.
However, our steel posts are safeguarded against corrosion as they are coated with a zinc/epoxy/polyester powder finish. The coating acts as a barrier which prevents aggressive ions from coming into contact and reacting with the steel surface. Therefore, corrosion of the post will not occur providing the coating is not damaged.
In order to prevent pitting and localized corrosion, the transition area must be inspected annually.
Attention: During inspection, to avoid damage to the posts please use a piece of wood or a brush to free the foundation post. With a sharp tool you may damage the protective surface layer and initiate corrosion!
Please note: All replacement parts and tools necessary maintenance can be obtained by calling the Technical Hotline (refer to the first page for contact details). Please have the product identification number at hand. This number can be found written on the product label on a framework ball in the first level.
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