User Instruction Manual Zorbit™ Energy Absorber Kits
Contents
1. User Instruction Manual Zorbit Energy Absorber Kits for Horizontal Lifeline Systems This manual is provided as the Maunfacturer s Instructions and should be used as part of an employee training program as required by OSHA WARNING This product is part of a fall protection system The users must read and follow the manufacturer s instructions for each component of the system These instructions must be provided to the users of this equipment The users must read and understand these instructions before using this equipment Manufacturer s instructions must be followed for proper use and maintenance of this product Alterations or misuse of this product or failure to follow instructions may result in serious injury or death Figure 1 Parts Identification 5 8 Bolt Zorbit HLL Energy Absorber Shackle 5 8 Bolt 5 8 Lock Nut 1 2 Bolt Zorbit HLL Energy Absorber Shackle 5 8 Lock Nut 1 2 Lock Nut Zorbit Kit 7401031 5 8 Bolt Zorbit HLL shackle Energy Absorber 5 8 Lock Nut 3 8 Thimble Z 3 8 Wire Rope Cable Clip 112 Bolt b P 1 2 Lock Nut 2 Turnbuckle Zorbit Kit 7401033 i Copyright 2002 DB Industries Inc 1 0 APPLICATION 1 1 PURPOSE Zorbit HLL horizontal lifeline energy absorber kits are intended to be used as elements within a horizontal lifeline subsystem HLLSS forming part of a complete personal fall arrest system PFAS See Figure 1 for Z2. and associated components 20 SYSTEM REOUIREMENTS 2 1 COMPATIBILITY OF COMPONENTS AND SUBSYSTEMS Zorbit HLL energy absorbers and Zorbit kit components must only be used with fall arrest system components subsystems or elements that have been designated by the manufacturer as suitable for such use and comply with these instructions Non compatible components and subsystems could affect the safety and reliability of the complete system 2 2 COMPATIBILITY OF CONNECTORS Connectors used to attach to the HLL hooks carabiners D rings must support at least 5 000 lbs Connectors and attachment elements must be compatible in size shape and strength Non compatible connectors may unintentionally disengage roll out Only self locking snap hooks and carabiners may be used to connect directly to the horizontal lifeline Do not use non locking connectors with this system Connectors used to attach the horizontal lifeline to end anchors must be compatible with the connection point The connection must be positive and with connecting elements capable of sustaining a 5 000 Ibs load without failure 2 3 STRUCTURE LOAD REQUIREMENTS Structural anchorage points must be rigid and capable of supporting at least 5 000 Ibs along the axis of the horizontal lifeline Anchorages must also support at least 3 600 Ibs applied in all potential directions of fall arrest that are perpendicular to the axis of the horizontal lifeline See Figure 5 Figure 5 Ancho
3. S Deflection Distance Initial Energy Absorbing Required clearance RC above sa ol al nearest lower level or obstruction wnen using an energy absorbing lanyard RC D LL EA H FOS Energy Absorber Extension E A Required Clearance above nearest lower level or obstruction RC Distance from dorsal D ring to tips of feet during a fall H Factor of Safety E Os Y Nearest lower level or obstruction Figure 11 Clearance Evaluation Factors Self Retracting Lifelines Span Length Required clearance RC above nearest haapa Y lower level or obstruction to working surface Deflection Distance when using a self retracting lifeline SRL must a pe be located overhead and the user is standing RC A D H FOS Working Level SRL Arrest Distance A Distance D ring moves above dorsal location during a fall H Required Clearance above nearest lower level or obstruction RC l bstructi Factor of Safety or obstruction FOS Nearest lower level T 3 9 4 0 4 1 5 0 5 1 5 2 H RESCUE With the number of potential scenarios for a worker requiring rescue an on site rescue team is beneficial The rescue team is given the tools both in equipment and techniques so it can perform a successful rescue Training should be provided on a periodic basis to ensure rescuers proficiency SYSTEM REMOVAL When no longer required the HLL system should be removed from the job site To
4. feet required clearance is 13 6 Level 20 3 et p 40 50 Man 15 8 16 10 gt Greater than lt Less than or equal to Lower Level or Obstruction 3 4 OPERATION A PERSONAL FALL ARREST SYSTEM COMPONENTS Inspect and don the full body harness according to manufacturer s instructions Attach the connecting subsystem energy absorbing lanyard or SRL to the dorsal connection on the harness B CONNECTING TO THE HLL SYSTEM Approach the work area using the appropriate access equipment Secure the personal fall arrest system by attaching the energy absorbing lanyard or SRL to the HLL Connectors must meet all compatibility and strength requirements NOTE Due to their weight SRUs may require a rolling connection pulley to the lifeline C HAZARDOUS SITUATIONS Do not take unnecessary risks such as jumping or reaching too far from the edge of the working surface Do not allow the connecting subsystem to pass under arms or between feet To avoid inadeguate clearance do not climb above the HLL To avoid swing fall hazards do not work too far from either side of the HLL D TWO PERSONS CONNECTED TO THE HLL When a person falls while connected to the HLL the system will deflect If two persons are connected to the same HLL and one person falls the second person may be pulled off the working surface due to deflection The potential for the second person falling increases as the HLL span length increases The use of independe
5. slacken the HLL loosen the turnbuckle until tension is removed from the wire rope Disconnect the HLL system from the anchorages Ensure there are no knots or kinks in the wire rope before storage TRAINING It is the responsibility of all users of this equipment to understand these instructions and are trained in the correct installation use and maintenance of this eguipment These individuals must be aware of the conseguences of improper installation or use of this eguipment This user manual is not a substitute for a comprehensive training program Training must be provided on a periodic basis to ensure proficiency of the users INSPECTION FREQUENCY BEFORE EACH INSTALLATION Inspect the Zorbit HLL energy absorber kit components and other system components according to these or other manufacturer s instructions System components must be formally inspected by a qualified person other than the user Formal inspections should concentrate on visible signs of deterioration or damage to the system components Items found to be defective must be replaced Do not use components if inspection reveals an unsafe or defective condition Record results of each inspection in the inspection and maintenance log in section 9 0 of this manual INSTALLED SYSTEMS An inspection of the HLL system by a qualified person must be completed after the system is installed The system must be periodically inspected by a qualified person when left installed for an ex
6. system height 1 Find your system span length row 35 A 2 1 in the clearance table cg a 2 Find your lanyard length column N Find y yard leng nthe dearance ahi 45 60 a chy rapes ain 20 10 21 10 22 10 23 10 eninge Use this distance to determine if adequate clearance 97 8 23 8 24 8 25 8 exists in the event of a fall If there is inadequate 70 75 clearance do not use the system or reduce your span i or lanyard length and reevaluate your required clearance 75 80 80 85 242 8 25 8 260 8 27 8 Example Span is 42 feet lanyard length is 5 feet BE OD your required clearance is 21 6 a 90 95 26 0 ee 35 100 or Obstruction gt Greater than lt Less than or equal to Figure 8 Clearance Evaluation using DBI SALA Self Retracting Lifelines Span Length WARNING This information only applies when Self Retracting the HLL and SRL are located overhead and Required Clearance from nearestlower Lifeline SRL above the level of the harness attachment point level or obstruction to working level and the user is standing 1 Find your system span length row in the clearance table y Clearance Table DBI SALA 2 Read the reguired clearance distance Self Retracting Lifelines from the distance column to determine Clearances given in feet and inches if adequate clearance exists in the event i and reevaluate your reguired Working 40 20 BO Example Span is 65
7. e assemblies longer than 60 feet require a Zorbit HLL energy absorber on each lifeline end Step 3 Install the lifeline assembly to structural Figure 6 Installation of Thimble and Clips anchorage attachment points See section 2 3 for anchorage specifications Torgue cable clips to 45 Lu Tension the lifeline until taut The cable 3 8 Diameter y deflection at mid span must be six Wire Rope inches or less with no weight on the HLL See Figure 6 for installation of 3 8 inch thimble and cable clips supplied with Zorbit kit 7401033 2 1 minimum 3 3 HORIZONTAL LIFELINE INSTALLATION WHEN USING OTHER THAN DBI SALA CONNECTING Position next SUBSYSTEMS to thimble The lifeline may be installed as described in section 3 2 above however because DBI SALA cannot predict the performance of non DBI SALA subsystem components Figures 7 and 8 do not apply The required clearance must be determined by using the lifeline deflection data given in Figure 9 and subsystem performance provided by the manufacturer Figures 10 and 11 show clearance factors to consider Figure 7 Clearance Evaluation using DBI SALA Energy Absorbing Lanyards Span Length Clearance Table DBI SALA Energy Absorbing Lanyards Clearances given in feet and inches Length of Energy Absorbing Lanyard in feet and inches N gp emp te To fa fs 6 4 i gt 0 but lt 10 E o 10 15 Lanyard X 15 20 Required Clearance from nearest lower level NW or obstruction to HLL
8. here is reason to doubt your fitness to absorb the impact from a fall arrest Age and fitness can affect your ability to withstand fall arrest forces Pregnant women and minors must not use this system 3 1 BEFORE EACH USE inspect this eguipment according to steps listed in section 5 2 Do not use this eguipment if inspection reveals an unsafe or defective condition Plan your use of the fall protection system prior to exposing workers to dangerous situations Consider all factors affecting your safety before using this system A Read and understand all manufacturer s instructions for each component of the personal fall arrest system All DBI SALA harnesses and connecting subsystems are supplied with separate user instructions Keep all instructions for future reference B Review sections 1 0 and 2 0 to ensure system limitations and other reguirements have been adhered to Review applicable information regarding system clearance criteria and ensure changes have not been made to the system installation i e length or occurred at the job site that could affect the reguired fall clearance C Do not use the system if changes are required 3 2 HORIZONTAL LIFELINE INSTALLATION WHEN USING DBI SALA CONNECTING SUBSYSTEMS Figure 3 shows typical horizontal lifeline system installations When using an energy absorbing lanyard to connect to the system the end anchorages must be located at a height which will limit the free fall to six feet When us
9. ing an SRL self retracting lifeline to connect to the system the end anchorages must be located above the worker The SRL when fully retracted must be above the harness attachment level The HLL system should be positioned at a level that will minimize free fall but allow ease of use The lifeline should be positioned near the work location to minimize swing fall hazards see Figure 4 The connecting subsystem length should be kept as short as possible to reduce the potential free fall and required clearance distance Both anchorages must be installed at approximately the same elevation so that the HLL system is not sloped more than five degrees IMPORTANT Lifeline installation must be supervised by a qualified person See section 1 2 Step 1 Determine the locations of the end anchorages and evaluate their strengths in accordance with section 2 3 Determine the span length and evaluate the required clearance using Figure 7 or 8 Figures 7 and 8 apply to one or two users connected to the system Step 2 If possible assemble the HLL system on the ground before attaching to the anchorages using hardware provided or with customer supplied connecting components Connectors must meet the requirements specified in section 2 2 Typical lifeline assemblies are shown in Figure 3 See section 2 4 for wire rope specifications Ensure all fasteners are properly tightened Leave slack in the turnbuckle to allow for system tensioning IMPORTANT Lifelin
10. ing fall if injury could occur See Figure 4 Swing falls will significantly increase the clearance reguired when a self retracting lifeline or other variable length connecting subsystem is used If a swing fall situation exists in your application contact DBI SALA before proceeding F FALL CLEARANCE There must be sufficient clearance below the worker to arrest a fall before striking the lower level or obstruction See section 3 0 for reguired clearance information G BODY SUPPORT Zorbit HLL energy absorbers must only be used with personal fall arrest systems incorporating a full body harness See Figure 2 H PHYSICAL AND ENVIRONMENTAL HAZARDS Use of this eguipment in areas with physical or environmental hazards may require additional precautions to reduce the possibility of injury to the user or damage to the eguipment Hazards may include but are not limited to heat chemicals corrosive environments high voltage power lines gases moving machinery and sharp edges Contact DBI SALA if you have questions about using this equipment where physical or environmental hazards exist I TRAINING This equipment must be installed and used by persons trained in the correct application and use of this eguipment See section 4 0 1 3 APPLICABLE STANDARDS Refer to national standards including ANSI Z359 1 ANSI A10 14 and local state and federal OSHA 1910 66 and 1926 502 requirements for more information on personal fall arrest systems
11. l Free 800 387 7484 Phone 651 388 8282 Phone 905 795 9333 Fax 651 388 5065 Fax 905 795 8777 www salagroup com ISO Bal ANSI RAB F 900 1 V y Form 5911863 R A Certificate No FM 39709 ev B 12
12. nt HLL systems for each person or shorter span length is recommended to minimize the potential of the second person falling E FREE FALL The personal fall arrest system must be rigged to limit free falls to six feet or less when using an energy absorbing lanyard or such that the SRL is overhead and without slack according to OSHA reguirements F SHARP EDGES Avoid working where the connecting subsystem or other system components will be in contact with or abrade against unprotected sharp edges If working around sharp edges is unavoidable a protective cover must be used to prevent cutting of the PFAS componenis Figure 9 Vertical Deflection ae m ee E ae aad Te we oL ae m Lifeline Deflection Table Vertical Deflection of HLL Under Static Load of 900 Ibs Per User in feet and inches G IN THE EVENT OF A FALL The responsible party must have a rescue plan and the ability to implement a Span Length in feet rescue Tolerable suspension time in a full body harness is limited so a quick rescue is critical 0 30 gt a 2 ae E 50 0 60 7 IMPORTANT Use care when handling an expended Zorbit energy absorber The tearing 70 80 80 90 of the energy absorber material produces extremely sharp edges 90 100 er o gt Greater than lt Less than or egual to Figure 10 Clearance Evaluation Factors Energy Absorbing Lanyards Span Length hd Es m
13. orbit Kit numbers and parts identification See Figure 2 for a description of a personal fall arrest system incorporating a horizontal lifeline subsystem Figure 2 Personal Fall Arrest System PFAS Incorporating a Horizontal Lifeline System 1 Lanyard with Energy Absorber 2 Self Retracting Lifeline cg AS aN Fall Arrest Attachment Element dorsal D ring 2 K 1 Fuli Body Harness 2 Others not allowed 1 2 LIMITATIONS The following limits apply to the installation and use of Zorbit HLL energy absorber kits Other limitations may apply IMPORTANT OSHA regulations state that horizontal lifelines shall be designed installed and used under the supervision of a qualified person see below for definition as part of a complete personal fall arrest system that maintains a safety factor of at least two Qualified Person An individual with a recognized degree or professional certificate and an extensive knowledge and experience in the subject field who is capable of design analysis evaluation and specification in the subject work project or product Refer to OSHA 1910 66 1926 32 and 1926 502 A HORIZONTAL LIFELINE SPAN Zorbit HLL energy absorbers must only be used for single span horizontal lifeline applications Multiple span systems using intermediate supports are not allowed The maximum horizontal lifeline span length is 60 feet when using a single Zorbit HLL energy absorber or 100 feet when a Zorbit HLL energ
14. ould be no tearing of the metal between holes in the Zorbit coiled section Extended Zorbit HLL energy absorbers must be removed from service and destroyed or marked for training only Inspect securing hardware for strength and function Step 4 Inspect Zorbit label The label must be present and fully legible See section 8 0 Replace label if missing or illegible 6 0 6 1 6 2 7 0 7 1 7 2 8 0 8 1 If inspection reveals an unsafe or defective condition remove unit from service and destroy or contact DBI SALA for possible repair USER EQUIPMENT Inspect harnesses and energy absorbing lanyards or SRLs used with the HLL system according to manufacturer s instructions MAINTENANCE SERVICE STORAGE The Zorbit kit components require no scheduled maintenance other than repair or replacement of items found defective during inspection See section 5 0 If components become heavily soiled with grease paint or other substances clean with appropriate cleaning solutions Do not use caustic chemicals that could damage system components USER EQUIPMENT Maintain service and store user equipment according to manufacturer s instructions SPECIFICATIONS MATERIALS Zorbit Energy Absorber Stainless steel Bolts Grade 5 or Grade 8 zinc plated steel Nuts Zinc plated steel Shackles Galvanized steel 5 000 lbs minimum tensile strength Thimbles Galvanized steel Turnbuckle Galvanized steel 5 000 lbs minimum tensile s
15. rage Strength Reguirements jj EM 5 000 Ibs Minimum 5 000 Ibs Minimum qmm TT mm 3 600 Ibs Minimum in all potential directions of fall arrest applied loading WARNING Anchorages must be rigid Large deformations of the anchorage will affect system performance and may increase the required fall clearance below the system which could result in serious injury or death 2 4 LIFELINE WIRE ROPE REQUIREMENTS DBI SALA requires as a minimum 3 8 inch diameter 7x19 galvanized aircraft cable The system performance information contained in this manual is based on using this wire rope type Larger cable sizes with equal or greater strength and stiffness properties may also be used Do not use synthetic lifelines NOTE Wire rope cable clips provided with Zorbit kit 7401033 are for use with 3 8 inch diameter wire rope only 2 5 CONNECTING SUBSYSTEM REQUIREMENTS The connecting subsystem is the portion of the personal fall arrest system that is used to connect between the horizontal lifeline subsystem and harness fall arrest attachment element see Figure 2 For systems incorporating Zorbit HLL energy absorbers each connecting subsystem must limit forces applied to the horizontal lifeline to 900 Ibs or less 3 0 OPERATION AND USE WARNING Do not alter or intentionally misuse this equipment Use caution when using this equipment around moving machinery electrical and chemical hazards and sharp edges WARNING Consult your doctor if t
16. tended period Periodic formal inspections should be performed at least monthly or more frequently when site conditions and use warrant Inspections of installed systems should include the inspection steps listed in section 5 2 ANNUALLY A Qualified Person shall inspect the entire system including the anchorage points Inspect for deterioration or damage Items found to be defective must be replaced Do not use components if inspection reveals an unsafe or defective condition Record the results of each inspection in the Inspection and Maintenance Log section 9 0 of this manual BEFORE EACH USE Before each use the user shall inspect the Zorbit HLL energy absorber kit components and other system components Inspect according to section 5 2 Items found to be defetive must be replaced before using system INSPECTION STEPS Step 1 Inspect the turnbuckle for damage Ensure sufficient threads are engaged into the turnbuckle body Look for any cracks or deformities in the metal Inspect metal components for rust or corrosion that may affect their strength or operation Step 2 Inspect the wire rope for rust corrosion broken wires or other obvious faults Inspect the HLL for proper tension See sections 3 2 and 3 3 Inspect all hardware fasteners shackles wire rope cable clips etc securing the HLL assembly to ensure they are present and properly installed Step 3 Inspect the Zorbit HLL energy absorber for extension or deformities There sh
17. trength Cable Clips Galvanized steel ENERGY ABSORBER PERFORMANCE Peak Dynamic Pullout Load 2 500 Ibs Average Dynamic Pullout Load 2 000 Ibs Maximum Pullout 48 5 inches Minimum Tensile Strength 5 000 Ibs Patents Pending LABELING A WARNING This label fully egib Buy SAE HR feu DRI j j LY BE USED AS PA A DBI SALA H NTAL LIFEL is label must be present and fu y egib G SUBSYSTEM HLLSS OR AS PART OF A COMPLETE PERSONAL FALL ARREST SYSTEM INCORPORATING A HLLSS WHICH MAENTAINS A SAFETY FACTOR OF AT LEAST TWO DESIGNATED INSTALLED AND USED UNDER THE SUPERVISION OF A QUALIFIED PERSON REFERENCE OSHA REGULATIONS DO NOT USE AS A PERSONAL FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR DEATH ENERGY ABSORBER FOR HORIZONTAL LIFELINE SYSTEMS SPECIFICATIONS MATERIAL STAINLESS STEEL PEAK DYNAMIC PULLOUT LOAD 2500 LBS AVERAGE DYNAMIC PULLOUT LOAD 2000 LBS MAXIMUM PULLOUT 48 5 INCHES ULTIMATE STRENGTH 5000 LBS MODEL 7401013 PATENT PENDING USA 3965 PEPIN AVE RED WING MN 55066 800 328 6146 CANADA 260 EXPORT BLVD MISSISSAUGA ONTARIO CANADA L3S 1Y9 800 387 7484 10 9 0 INSPECTION AND MAINTENANCE LOG DATE OF MANUFACTURE MODEL NUMBER DATE PURCHASED INSPECTION DATE INSPECTION ITEMS CORRECTIVE ACTION MAINTENANCE NOTED PERFORMED h USA Canada 3965 Pepin Avenue 260 Export Boulevard Red Wing MN 55066 1837 Mississauga Ontario L5S 1Y9 Toll Free 800 328 6146 Tol
18. y absorber is installed on each end of the system See Figure 3 The span length must be reduced when clearance is limited See section 3 0 for clearance information B SYSTEM CAPACITY The maximum capacity of horizontal lifeline subsystems see Figure 2 with Zorbit HLL energy absorbers is two persons The maximum weight of each person including tools and clothing is 310 Ibs Figure 3 Typical Horizontal Lifeline Installation with Zorbit Kits Zorbit HLL Energy Absorber Anchorage Lifeline supplied by customer Anchorage Connector pe 60 ft Max one Zorbit HLL Energy Absorber required MH Anchorage Lifeline supplied by customer Anchorage Connector Zorbit HLL Energy Absorber ME 100 ft Max two Zorbit HLL Energy Absorbers reguired NI C CONNECTING SUBSYSTEM Each person s connecting subsystem see Figure 2 must limit fall arrest forces to 900 Ibs or less See section 2 5 D FREE FALL Rig and use the personal fall arrest system such that the maximum potential free fall does not exceed government regulatory and subsystem manufacturer s reguirements See section 3 0 and subsystem manufacturer s instructions for more information Figure 4 Swing Fall Hazard E SWING FALLS Swing falls occur when the anchorage point is not directly overhead The force of striking an object in a swing fall may cause serious injury or death Minimize swing falls by working as directly below the anchorage point as possible Do not permit a sw
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