Instruction
Contents
1. 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 5 for wire rope specifications Ensure all fasteners are properly tightened Leave slack in the turnbuckle to allow for system tensioning IMPORTANT Lifeline assemblies longer than 60 feet require a Zorbit HLL energy absorber on each lifeline end Figure 10 Installation of Thimble and Clips Torque cable clips to 45 ft lbs 3 8 Diameter 7 Step 3 Install the lifeline assembly to structural Wire Rope anchorage attachment points See section 2 4 for anchorage specifications Tension the lifeline until taut The cable deflection at mid span must be 6 inches or less with no weight on the HLL See Figure 10 for installation of 3 8 inch thimble and cable clips supplied with Zorbit kit 7401033 3 3 HORIZONTAL LIFELINE INSTALLATION WHEN USING OTHERTHAN DBI SALA CONNECTING SUBSYSTEMS 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 8 and 9 do not apply The required clearance must be determined by using the lifeline deflection data given in Figure 11 and subsystem perfor2. inspected by a qualified person when left installed for an extended 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 defective 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 Z
3. or carabiner to disengage from the connecting point Small ring or other non compatibly shaped element 1 Force is applied to the 2 The gate presses against 3 The gate opens allowing the snap hook the connecting ring snap hook to slip off Connectors hooks carabiners and D rings must be capable of supporting at least 5 000 Ibs 22 2kKN Connectors must be compatible with the anchorage or other system components Do not use equipment that is not compatible Non compatible connectors may unintentionally disengage See Figure 5 Connectors must be compatible in size shape and strength Self locking snap hooks and carabiners are required by ANSI 2359 1 and OSHA 2 3 MAKING CONNECTIONS Only use self locking snap hooks and carabiners with this equipment Only use connectors that are suitable to each application Ensure all connections are compatible in size shape and strength Do not use equipment that is not compatible Ensure all connectors are fully closed and locked DBI SALA connectors snap hooks and carabiners are designed to be used only as specified in each product s user s instructions See Figure 6 for inappropriate connections DBI SALA snap hooks and carabiners should not be connected A Toa D ring to which another connector is attached B Inamanner that would result in a load on the gate NOTE Large throat opening snap hooks should not be connected to standard size D rings or similar objects which will resu
4. CIFICATIONS 7 1 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 Ibs minimum tensile strength Cable Clips Galvanized steel A WARNING THIS HORIZONTAL LIFELINE ENERGY ABSORBER EAHLL MUST ONLY BE USED AS PART OF A DBI SALA HORIZONTAL LIFELINE SUBSYSTEM HLLSS OR AS PART OF A COMPLETE PERSONAL FALL ARREST SYSTEM INCORPORATING A HLLSS WHICH MAINTAINS 7 2 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 U S Patent No 6 279 680 FOR HORIZONTAL LIFELINE SYSTEMS ENERGY ABSORBER 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 DBI RED WING MN 55066 800 328 6146 CANADA 260 EXPORT BLVD MISSISSAUGA ONTARIO CANADA L5S 1Y9 800 387 7484 8 0 LABELING 8 1 This label must be present and fully legible 10 9 0 INSPECTION AND MAINTENANCE LOG DATE PURCHASED DATE OF FIRST USE INSPECTION DATE INSPECTION ITEMS CORRECTIVE ACTION MAINTENANCE NOTED PERFORMED Approved By Ap
5. Instructions for the following series products Zorbit Energy Absorber Kits See back page for specific model numbers 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 Shackle i se Se Zorbit HLL N be Energy Absorber NV Y 5 8 Lock Nut A SET 1 2 Lock Nut Zorbit Kit 7401031 5 8 Bolt a Zorbit HLL Shackle Se Energy Absorber 5 8 Lock Nut 3 8 ume PE 3 8 Wire Rope Cable Clip 1 2 Bolt Turnbuckle 1 2 Lock Nut Zorbit Kit 7401033 IMPORTANT If you have questions on the use care or suitability of this equipment for your application contact DBI SALA 1 0 APPLICATION 1 1 PURPOSE Zorbit H
6. bit Kits Zorbit HLL Energy Absorber Lifeline supplied by customer Anchorage Anchorage Connector ce wy 2 1 60 ft Max one Zorbit HLL Energy Absorber required ee Anchorage Lifeline supplied by customer Anchorage Connector Zorbit HLL Energy Absorber pO 100 ft Max two Zorbit HLL Energy Absorbers required a Figure 4 Swing Fall Hazard AN caution Do not rigidly mount Zorbit to structure or stanchion May cause failure due to bending Mount so Zorbit can pivot and move freely as shown in Figure 3 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 required 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 equipment in areas with physical or environmental hazards may require additional precautions to reduce the possibility of injury to the user or damage to the equipment 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 t
7. d aircraft cable The system performance information contained in this manual is based on using this wire rope type Larger cable sizes with greater or equal 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 Figure 7 Anchorage Strength Requirements yj FEER 5 000 Ibs Minimum 5 000 Ibs Minimum qmm Q ml fu eee JS ee ee Cd SD 3 600 Ibs Minimum in all potential directions of fall arrest applied loading 2 6 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 there 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 equipment according to steps liste
8. d in section 5 2 Do not use this equipment 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 Figure 8 Clearance Evaluation using DBI SALA Energy Absorbing Lanyards Span Length aol LOJ f 7 Energy Absorbing Lanyard Length X NI N S 1 Find your system span length row in the clearance table Veg Z 2 Find your lanyard length column in the clearance table 3 The required clearance is where the span length intersects with the lanyard length Energy Absorbing Lanyard Required Clearance from nearest lower level or obstruction to HLL system height Use this distance to determine if adequate clearance exists in the event of a fall If there is inadequate clearance do not use the system or reduce your span or lanyard length and reevaluate your required clearance Example Span is 42 feet lanyard length is 5 feet your required clearance is 21 6 Lower Level or Obstruction Clearance Table DBI SALA Energy Absorbing Lanyards Clearances given in feet and inches iia e a re 7 77 3 4 5 6 T 15 20 19 2 20 6 2t 10 22 1 23 1 1 DE 2 23 10 6 65 22 1 23 1 24 1 25 1 27 8 ERE rr 7 a 29 0 gt Greater than lt Less than or equal to Figu
9. ingle Zorbit HLL energy absorber or 100 feet when a Zorbit HLL energy 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 C CONNECTING SUBSYSTEM Each person s connecting subsystem see Figure 2 must limit fall arrest forces to 900 Ibs or less See section 2 6 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 requirements See section 3 0 and subsystem manufacturer s instructions for more information 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 swing fall if injury could occur See Figure 4 Swing falls will significantly increase the clearance required 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 Figure 3 Typical Horizontal Lifeline Installation with Zor
10. lt in a load on the gate if the hook or D ring twists or rotates Large throat snap hooks are designed for use on fixed structural elements such as rebar or cross members that are not shaped in a way that can capture the gate of the hook C Inafalse engagement where features that protrude from the snap hook or carabiner catch on the anchor and without visual confirmation seems to be fully engaged to the anchor point D Toeach other E Directly to webbing or rope lanyard or tie back unless the manufacturer s instructions for both the lanyard and connector specifically allow such a connection 4 F To any object which is shaped or Figure 6 Inappropriate Connections dimensioned such that the snap hook or carabiner will not close and lock or that roll out could occur 2 4 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 7 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 5 LIFELINE WIRE ROPE REQUIREMENTS DBI SALA requires as a minimum 3 8 inch diameter 7x19 galvanize
11. mance provided by the manufacturer Figures 12 and 13 show clearance factors to consider 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 1 minimum Mm Z Position next to thimble Figure 11 Lifeline Deflection Table Vertical Deflection of HLL Under Static Load Span Length in feet of 900 Ibs Per User in feet and inches One User Two Users gt 0 but lt 10 0 11 1 10 10 20 20 30 30 40 40 50 50 60 60 70 70 80 80 90 90 100 gt Greater than lt Less than or equal to 1 a a tae N Cc aja en ee oe ee i olalla lalol ejna Figure 12 Clearance Evaluation Factors Energy Absorbing Lanyards Initial Energy Absorbing Lanyard Length i Energy Absorber Extension E A Required clearance RC above nearest lower level or obstruction when using an energy absorbing lanyard RC D LL EA H FOS Required Clearance above nearest lower level or obstruction RC Distance from dorsal D ring to tips of feet during a fall Factor of Safety F O s Nearest lower level or obstruction Figure 13 Clearance Evaluation Factors Self Retracting Lifelines UE S
12. nsure changes have not been made to the system installation i e length or occurred at the job site that could affect the required fall clearance C Donotuse 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 6 feet When using a self retracting lifeline SRL 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 5 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 4 Determine the span length and evaluate the required clearance using Figure 8 or 9 Figures 8 and 9
13. orbit HLL energy absorber for extension or deformities There should be no tearing of the metal between holes in the Zorbit coiled section Increase inspection frequency if the Zorbit is exposed to prolonged vibration 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 IMPORTANT If this equipment is subjected to the forces of a fall arrest it must be removed from service and destroyed or returned to DBI SALA for inspection or repair 5 3 If inspection reveals an unsafe or defective condition remove unit from service and destroy or contact DBI SALA for possible repair 5 4 USER EQUIPMENT Inspect harnesses and energy absorbing lanyards or SRL s used with the HLL system according to manufacturer s instructions 6 0 MAINTENANCE SERVICE STORAGE 6 1 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 6 2 USER EQUIPMENT Maintain service and store user equipment according to manufacturer s instructions 7 0 SPE
14. orizontal Lifeline HLL 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 Zorbit kit numbers and parts identification See Figure 2 for a description of a personal fall arrest system incorporating a horizontal lifeline subsystem Copyright 2005 DB Industries Inc 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 Figure 2 Personal Fall Arrest System PFAS Incorporating a Horizontal Lifeline System 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 s
15. pan Length a ae eee Deflection Distance a Dp _ Required clearance RC above nearest lower level or obstruction to working surface when using a self retracting lifeline SRL must 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 a Nearest lower level or obstruction Factor of Safety FOS B CONNECTING TOTHE 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 SRLs may require a rolling connection pulley to the lifeline 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 inadequate clearance do not climb above the HLL To avoid swing fall hazards do not work too far from either side of the HLL 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
16. potential for the second person falling increases as the HLL span length increases The use of independent HLL systems for each person or shorter span length is recommended to minimize the potential of the second person falling 8 E FREE FALL The personal fall arrest system must be rigged to limit free falls to 6 feet or less when using an energy absorbing lanyard or such that the SRL is overhead and without slack according to OSHA requirements 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 components G INTHE EVENT OF A FALL The responsible party must have a rescue plan and the ability to implement a rescue Tolerable suspension time in a full body harness is limited so a quick rescue is critical IMPORTANT Use care when handling an expended Zorbit energy absorber The tearing of the energy absorber material produces extremely sharp edges 3 5 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 req
17. proved By Approved By Approved By Approved By Approved By Approved By Approved By Approved By Approved By Approved By Approved By Approved By Approved By Approved By Approved By Approved By Approved By This instruction applies to the following models 7401013 7401019 7401033 7401016 7401031 7401035 7401018 7401032 7401037 Additional model numbers may appear on the next printing of these instructions USA Canada 3833 SALA Way 260 Export Boulevard Red Wing MN 55066 1837 Mississauga Ontario L5S 1Y9 Toll Free 800 328 6146 Toll Free 800 387 7484 Phone 651 388 8282 Phone 905 795 9333 Fax 651 388 5065 Fax 905 795 8777 www capitalsafety com www capitalsafety com This manual is available for download at www capitalsafety com OR 9001 x Form 5911863 Certificate No FM 39709 Rev E 12
18. rained in the correct application and use of this equipment See section 4 0 1 3 APPLICABLE STANDARDS Refer to national standards including ANSI Z359 1 and local state and federal OSHA 1910 66 and 1926 502 requirements for more information on personal fall arrest systems and associated components 2 0 SYSTEM REQUIREMENTS 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 3 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 are considered to be compatible with connecting elements when they have been designed to work together in such a way that their sizes and shapes do not cause their gate mechanisms to inadvertently open regardless of how they become oriented Contact DBI SALA if you have any questions about compatibility Figure 5 Unintentional Disengagement Roll out If the connecting element that a snap hook shown or carabiner attaches to is undersized or irregular in shape a situation could occur where the connecting element applies a force to the gate of the snap hook or carabiner This force may cause the gate of either a self locking or a non locking snap hook to open allowing the snap hook
19. re 9 Clearance Evaluation using DBI SALA Self Retracting Lifelines Span Length Self Retracting Required Clearance from nearest lower Lifeline SRL level or obstruction to working level 1 Find your system span length row in the clearance table 2 Read the required clearance distance from the distance column to determine if adequate clearance exists in the event of a fall If there is inadequate clearance do not use the system or reduce your span length and reevaluate your required clearance Example Span is 65 feet required clearance is 13 6 Lower Level or Obstruction WARNING This information only applies when the HLL and SRL are located overhead and above the level of the harness attachment point and the user is standing Clearance Table DBI SALA Self Retracting Lifelines Clearances given in feet and inches Span Length in feet Required Distance gt 0 but lt 10 10 20 9 ie 20 30 90 100 gt Greater than lt Less than or equal to 16 10 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 requirements have been adhered to Review applicable information regarding system clearance criteria and e
20. uired the HLL system should be removed from the job site To 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 equipment These individuals must be aware of the consequences of improper installation or use of this equipment 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
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