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Installation, Operation and Maintenance Manual Model

1. 27 7 4 1 Position of Secondary Anchor Point 27 7 5 REDUCTION AND SUPPORT LINES 0 28 7 6 FITTING ZIPS TOP BRAKE 29 7 7 FITTING THE BRAKE 1 31 7 8 FITTING 33 7 9 FITTING THE ll 34 T 10 FITTING REDUCTION ioter en ettet e ne cie tw ER esit 35 7 10 1 1 1 Reduction 444 35 7 1022 Reduction 37 8 OPERATION OF 2 40 8 1 SAFETY PRECAUTIONS 2 44 84 2 etre 40 8 2 OPERATION DURING EXTREME WEATHER 40 8 3 RESETTING SYSTEM 41 9 42 0 1 TROUBLESHOOTING 42 10 RECERTIFICATION AND 43 2 7 43 10 1 1 Service Sche
2. 14 6 3 RIDER ARRIVAL SPEED 14 6 4 RIDER VVEIGB E tian tens 14 6 5 REDUCTION LINE RATIO 14 6 5 1 XN orco 15 6 5 2 FIN IIo 16 6 5 3 Possible System Configurations Informative Only 17 6 6 ZAP CINE SWOPE uu 19 6 6 1 Positive Slope 19 6 6 2 misi E n cR K 19 6 6 3 Negative Slope Line 20 6 7 CALCULATING ZIPS TOP BRAKING DISTANCES 21 6 8 22 6 9 ZIPS TOP BRAKING DISTANCE CHARTS nnn nnns 24 6 10 CONFIGURATION 5 0 24 6 11 zIPSTOP CONFIGURATION WORKSHEET 25 7 ZIPSTOP BRAKE ASSEMBLY INSTALLATION 26 T 1 M D M M 26 7 2 SAFETY 5 41 0 000 0 0 1 6 26 Always use the manual supplied with 2 2 brake Kit when installing operating or maintaining Z PSTOP components www thezipshop com 7 3 PRIMARY 27 7 4 SECONDARY
3. Rider Weight kg 0 10 20 30 40 50 60 Arrival Speed kph Always use the manual supplied with zjoS7OP brake Kit when installing operating or maintaining Z PS7OP components www thezipshop com 11 4 The Braking Line must be fully retracted into the zipSTOP at the point of Brake initiation for data in following Braking Distanc Chart to apply Serious injury death or damage to equipment can occur if Brake initiation occurs without a fully retracted Braking Line 1 1 Ratio Imperial Braking Distance ft BRAKING DISTANCE 1 1 Reduction Line Ratio 1 33 8 66 t 99 6 132 165 A 198 231 264 6 297 330 BDmin Arrival Speed mph Always use the manual supplied with zjoS7OP brake Kit when installing operating or maintaining Z PS7OP components www thezipshop com Rider Weight Ibs 2105 1 The Braking Line must be fully retracted into the zipSTOP at the point of Brake initiation for data in following Braking Distanc Serious injury death or damage to equipment can occur if Brake initiation occurs without a fully retracted Braking Line 11 5 2 1 Ratio Imperial Braking Distance ft BRAKING DISTANCE 2 1 Reduction Line Ratio 1 33
4. 7 3 1 INTRODUCTION 7 3 2 ZIPS TOP BRAKE UNIT 7 3 9 ZIPSTOP BRAKE TROLLEY gud Ve vaa Cete rod opus 8 4 OPERATING PRINCIPLES eere erre 9 4 1 iz zr 9 42 ZIPS TOP OPERATION 9 5 ZIPSTOP BRAKE ASSEMBLY 10 5 1 ONE A sects secs Mu 10 5 2 LUNPACICINGS A A 10 5 2 1 TO unpack the ZIDO 10 5 3 dS Id ERES EE 11 5 4 11 5 5 ADDITIONAL PARTS 0 4 2 44 12 5 5 1 12 5 5 2 Redirection 12 5 0 0 Minimum Hardware Requirements 12 5 5 4 PREG eif RM 2 13 5 5 5 Reduction Line Specification 13 6 ZIPSTOP BRAKE ASSEMBLY CONFIGURATION 14 6 1 M 14 6 2 SETUP VARIABLES 2
5. Zi STOP Installation Operation and Maintenance Manual Model 25125 08 NOTE TO INSTALLERS Always Read Instructions Before Use LEAVE THIS MANUAL ATTACHED TO THE Z PSTOP BRAKE UNIT THE INSTALLATION OPERATION AND MAINTENANCE MANUAL CONTAINS INFORMATION RELATING TO THE SAFE USE OF THE ZIPSTOP AND INCLUDES ALL PRODUCT REGISTRATION AND WARRANTY INFORMATION THIS DOCUMENT MAY ONLY BE REMOVED BY THE END USER ENSURE USER MANUAL IS READILY AVAILABLE TO OPERATORS AT ALL TIMES P N 7002 001 02 Always use the manual supplied with 2 2 brake Kit when installing operating or maintaining Z PS7OP components www thezipshop com Contents 1 SAFETY 4 1 1 SYMBOLS USED IN THIS MANUAL ccccccecececececcecececececeneaeecucuceaeananes 4 1 2 SAFETY AND INFORMATION 5 2 1 5 1 2 1 Location of Safety Labels 2 5 2 WARRANTY 6 2 1 WARRANTY 5 11111 1116 6 2 1 1 Customers Responsibility 6 lt 5
6. 8 66 ti 99 132 9 165 198 231 9 264 6 297 330 BDmin 0 9 18 27 36 Arrival Speed mph Always use the manual supplied with zjoS7OP brake Kit when installing operating or maintaining Z PS7OP components www thezipshop com Rider Weight Ibs 2105
7. Always carry out unmanned testing to determine actual braking distance A The information contained in this manual is intended for guidance only Calculated braking distances for the zipS TOP Brake Assembly estimates only and may differ from actual braking distances achieved on individual zip lines As there are infinite possibilities regarding participant weights and arrival speeds line slopes and environmental conditions a safe and functional installation can only be achieved after careful consideration of all factors in advance of the 205 TOP installation 6 2 Setup Variables A number of variables will influence the final braking distance and level of rider comfort these include e Rider arrival speed e Rider weight e Reduction Line Ratio e Zip line slope in the landing area e System friction e Environmental conditions wind rain temperature 6 3 Rider Arrival Speed Rider arrival speed is unique to each zip line installation and is a factor of line slope zip line length rider weight rider descent position wind and friction It is necessary to know the acceptable minimum and maximum rider velocities prior to configuring the zipS TOP 6 4 Rider Weight Suitable rider weight ranges will need to be determined by individual zip line operators The zipSTOP Brake unit will accommodate riders between 15 and 150 kg 33 and 330 155 It is necessary to know the acceptable rider weight range before configuring the z
8. buffer zone does not LEX exceed maximum 2 5 Braking Line extension see Note 1 Line Extension LEX BDmax BZ RR LEX must be less than or equal to 12 11 From relevant chart determine braking distance for BD2 minimum anticipated rider weight RWmin 12 Add pivot height to give minimum braking distance BDmin BDmin BD2 PVH 13 Check stopping distance is not below the BDmin line Above BDmin Y Distances below this line will result in severe line deceleration for the rider rum 1e BR BDmax BDmin ewe I RP BDmax BZ Always use the manual supplied with zjoS7OP brake Kit when installing operating or maintaining Z PS7OP components www thezipshop com 25 7 ZIPSTOPBRAKE ASSEMBLY INSTALLATION 1 1 General The zipSTOP Brake Unit is installed at the end of the zip line usually on or adjacent to the terminal end A Secondary Anchor Point is normally required upstream of the landing area to provide support for the Reduction Line pulleys Alternately a full length secondary cable of sufficient capacity can be installed to provide support for the Reduction Line and associated pulleys 1 2 Safety Precautions Proper design and testing of the complete braking system is always required The Complete Brake System for zip Lines consists of all brakes employed including Primary Brake and Emergency Arrest Device EAD All braking installations that include
9. www thezipshop com 44 10 4 Unscheduled Service Procedures 1041 zjpS7TOP Brake Unit Side Cover replacement The zipSTOP Brake Unit side covers are removable and simply clip into place on the supporting casing Remove side covers by placing a flat bladed screwdriver under the edge of the cover and carefully levering it up Do not operate the zipSTOP Brake Unit with covers removed The zipSTOP contains moving parts and must be operated with covers removed Keep fingers clear at all times 10 42 zipSTOP Brake Unit Nozzle replacement The zipSTOP Brake Unit Nozzle is located on the zipSTOP Brake Unit casing and provides guidance for the Braking Line when extending and retracting The Nozzle is a wear part and will need to be inspected regularly Replacement is on a conditional basis 10 4 83 Removing Nozzle assembly To remove the Nozzle assembly 1 Replacement of the Nozzle assembly may be carried out with the zipS TOP in place if safe secure access is available 2 zipSTOP Brake Unit is to be removed from its mounting refer to Section 7 6 Fitting zipS TOP Brake Unit 3 If necessary secure the Brake Unit to prevent damage to side covers 4 Hold Braking Line secure to prevent it retracing into the Brake Unit when the Nozzle is removed 5 Extract the Nozzle Pin 6 Holding on to the Braking Line to prevent it retracting lift out the two half sections of the Nozzle Always use the manual sup
10. 5 Brake Unit via a Shackle Link to assist with ease of replacement The Braking Line must be fully extended in order to complete Daily Inspection To inspect the Braking Line 1 With zipSTOP Brake Unit securely mounted pull out the full extent of Braking Line 2 Inspect the Braking Line by passing it slowly through your hands under a good light Inspect the Braking Line for Damage to stitching cuts abrasion Cuts to Braking Line especially to edges Abrasion across the surface of the Braking Line wear and fraying especially to the edges and the Braking Line loops e UV degradation although difficult to detect visual indications are discoloration fading and chalking of the Braking Line surface Chemical attack this result in soft or weak fibers color change or flaking of the surface e Heat or friction damage indicated by hard fibers or glazing of the surface Contamination from dirt grit sand rust Twisting knotting or permanent deformation of Braking Line 3 Slowly retract the Braking Line into the casing checking the action is smooth and adequate spring resistance is felt 4 Once line is fully retracted pull out line a short distance using reasonable force and allow it to retract Repeat two to three times to ensure line is firmly wound onto the drum 5 Return 2 5 Brake Unit to service and check for correct operation Always use the manual supplied w
11. Landing Area LA Area below the zip line where riders are stopped or are travelling slow enough to be retrieved or safely dismount NOTE Landing Area will vary depending on rider arrival speed stopping distances and line slope Arrest Zone AZ Area in which riders are being decelerated at the end of the zip line descent Reset Position The reset position defines the start of the Arrest Zone and is the location on the zip line the Brake Trolley will return to once the rider is removed Buffer Zone BZ Distance from the end of the Arrest Zone AZ to any object that may impact the rider in the event the rider overshoots the landing area The buffer zone must include the maximum distance required for the Emergency Arrest Device EAD to activate and arrest a rider Pivot Height PH Straight line distance between Brake Trolley and the Type 1 Pulley Changing pivot height will influence the stopping distance Pivot Length PL Horizontal distance between zipS Brake unit and Type Pulley Line Extension LEX Distance that zipSTOP internal Braking Line extends from the zipSTOP Brake unit Min LEX 0 40 m 15 5 Max LEX 12 0 124 Rider Weight RW The weight of the rider Always use the manual supplied with zjoS7OP brake Kit when installing operating or maintaining Z PS7OP components www thezipshop com 23 6 9 zipS TOP Braking Distance Charts Charts for calculating braking distances are located at
12. 2 1 1 Customers Responsibility The following items are considered to be the responsibility of the Customer and therefore are non reimbursable under the terms of the warranty e Normal maintenance routine services Normal replacement of service items e Replacements required because of abuse misuse or incorrect operation of equipment by the installer or operator e Field replaceable wear parts such as the Nozzle Braking Line quick links Reduction Line and pulleys Brake Trolley sacrificial bump stops and sheaves supplied as 205 branded parts e Normal deterioration due to use and exposure Strict adherence to the Installation Operation and Service Manual supplied manufacturer s instructions and advice given by zipS TOP service technicians is also a condition of warranty Always use the manual supplied with zjoS7OP brake Kit when installing operating or maintaining Z PSTOP components www thezipshop com 3 SPECIFICATIONS 3 1 Introduction The zipSTOP Brake Assembly is a controlled braking force device designed specifically for use in the zip line industry as a Primary or Emergency Arrest Device EAD at the end of zip line runs The zipSTOP caters to a range of rider weights and approach speeds and offers a smooth consistent braking force for all riders The design of the zipSTOP allows for simple installation and incorporates both an advanced self regulating brake unit and an automatic line reset The paten
13. actual braking distances achieved on individual zip lines Exceeding maximum recommended line speed can cause injury to participants and damage equipment Before starting zipS TOP configuration you will need to determine the rider weight range rider arrival speed range and preferred Reduction Ratio for the zipS TOP installation Information required for calculating zipS TOP braking distances Rider weight range e Arrival speed range ZIpSTOP Reduction Line ratio A number of other variables will affect the final performance of the system and must be taken into consideration when designing the complete zip line braking system These include but are not limited to Line slope e Emergency Arrest Device EAD design e Friction e Weather Conditions e g wind rain humidity temperature e Environmental factors Always use the manual supplied with zjoS7OP brake Kit when installing operating or maintaining Z PSTOP components www thezipshop com 21 6 8 Definition of Terms The following terms are used when configuring and installing the zipS TOP Brake Assembly brake line extension E pd TU A pe P M or BRAKE TROLLEY d wv RIDER ARRIVAL SPEED maximum arrival peed ASmax minimum braking distance BD min Minimum arrival speed ASmin i maximum braking cketance BD max 5 roll forward 1 back 5 landing area 8 Reduction Line Ratio RR Ratio of Br
14. and redirection for the Reduction Line and connections to the Braking Line The Type II Pulley is only required on the 2 1 Reduction Ratio set ups Example of Type Redirection Pulley Example of Type 11 Redirection Pulley Redirection Pulleys 5 5 3 Minimum Hardware Requirements All hardware required is to be purchased separately The following are minimum requirements for all hardware used for zipSTOP installation Description Size Qty Notes zipSTOP Brake Unit mounting M12 3 Grade 4 6 M12 bolts washers and lock nuts or ASTM A307 Grade A or B 1 2 1 2 Length to suit installation Suitable for all season outdoor use Type Pulley mounting To suit To suit Suitable for all season outdoor use hardware Always use the manual supplied with zjoS7OP brake Kit when installing operating or maintaining Z PSTOP components www thezipshop com Carabiners Snaps Rings To suit Minimum load rating 15 Thimbles Clevises Suitable for all season outdoor use 5 54 Reduction Line The Reduction Line is required to connect the zipSTOP Brake Unit to the Brake Trolley and will transfer the braking force from the Brake Unit The Reduction Line passes through the redirection pulleys and must meet minimum specification 2 92 Reduction Line Specification Typical Reduction Line Always use the specified Reduction Line Failure to utilize a Reduction Line of specified strength and quality can compromise 2 05 brak
15. knot and an optional load rated link If a load rated link is utilized ensure the gate on the link is screwed tight and thread lock compound is applied to prevent it from loosening over time Ensure the Type pulley is correctly positioned and secure Pass the Reduction Line through the Type I pulley ensuring it enters the pulley from underneath and passes over and around the sheave in the direction of the 2 05 Brake Unit Ensure zipSTOP Brake Unit is in the fully retracted position Note Braking Line extends approximately 400 mm 16 from Nozzle in fully retracted position Always use the manual supplied with 2 2 brake Kit when installing operating or maintaining Z PS7OP components www thezipshop com Tension the Reduction Line connect directly to the end loop of the 2 5 Braking Line using a Double Figure Eight knot and suitable locking link Ensure the gate on the locking link is screwed tight and thread lock compound is applied to prevent it from loosening over time Following the installation of the Reduction Line e Remove temporary restraint from the Brake Trolley e Check the Reduction Line to ensure that the Brake Trolley is in the correct Reset Position when zioSTOP Braking Line is fully retracted e Ensure that the Reduction Line is routed cleanly and in line through the pulley system to prevent contact with any surface other than the pulley sheaves e Tie ba
16. supplied with 2 2 brake Kit when installing operating or maintaining Z PS7OP components www thezipshop com 24 6 11 zipSTOP Configuration Worksheet Use this worksheet in conjunction with the braking distance charts at the back of this manual Read the zipSTOP Brake Assembly configuration notes and definitions before completing the worksheet Distances calculated by this worksheet are based on a flat line with no outside influences such as wind friction etc Actual braking distances can vary from these values Always determine actual braking distances by completing unmanned test runs on final zip line installation prior to putting the installation into operation 1 Select Reduction Ratio and go to braking distance chart for selected Reduction Ratio If Reduction Ratio lt 1 1 enter 1 If Reduction Ratio 2 1 enter 2 Enter maximum expected rider arrival speed ASmax B Enter minimum expected rider arrival speed ASmin 7 Enter maximum anticipated rider weight m o Enter minimum anticipated rider weight 5 Determine pivot height PH Minimum pivot height 1 0 m 40 7 Go to braking distance chart for selected Reduction Ratio Metric and Imperial charts are provided From relevant chart determine the braking distance for BD1 maximum anticipated rider weight RWmax Add pivot height to give maximum braking distance BDmax BDmax BD1 PVH Check maximum braking distance
17. the Arrest Zone 7 Fasten reduction line T S directly to ZIpSTOP Z E N Brake Line JT LE a kiz gt Pass reduction 4 AI graund Type Pulley 4 Attach reduction P to connection polni Fi Brake Trolley Single Line with 1 1 Ratio Shown Installation Notes e Check that the Reduction Line diameter is compatible with the redirection pulley size e Check that the Reduction Line meets the specified strength diameter wear resistance and UV resistance requirements e Ensure that the Reduction Line is routed cleanly and in line through the pulley system to prevent contact with any surface other than the pulley sheaves Ensure that the zipSTOP Braking Line is fully retracted into A the zipSTOP device at Brake initiation If any Braking Line is extended braking force will be increased resulting in Always use the manual supplied with zjoS7OP brake Kit when installing operating or maintaining Z PSTOP components www thezipshop com 35 participant injury or damage to the zipSTOP Brake Unit Ensure that the specified Reduction Line meets the specifications described in Section 4 5 5 Use of poor quality Reduction Line may lead to zip line brake system failure Position the Brake Trolley at the start of the Arrest Zone Reset Position and temporarily secure it at that position Connect the Reduction Line directly to the Brake Trolley using a Double Figure of Eight
18. the back of this manual These charts are to be used in conjunction with zipS TOP configuration worksheet to optimize the zipSTOP installation Always carry out unmanned testing to determine actual braking distance The information contained in this manual is intended for guidance only Calculated braking distances for the zipS TOP Brake Assembly are estimates only and may differ from actual braking distances achieved on individual zip lines Exceeding maximum recommended line speed can cause injury to participants and damage equipment 6 10 Configuration Notes 1 BDmin Line BDmin line indicates the rate of deceleration that may be considered uncomfortable and result in severe rider swing up when stopping It is not recommended to operate the zipSTOP with combinations of rider weights and arrival speeds that fall below the BDmin line 2 Line Extension LEX Line extension is the distance the Braking Line extends out of the zipSTOP brake Unit If LEX is greater than 12 0m then reduce max permissible approach speed ASmax Permissible rider weight RWmax or increase Reduction Ratio RR 3 Buffer Zone BZ Buffer zone is the area after the Arrest Zone in which riders are safe from impacting the terminal end or any other object in the event they overshoot the landing zone The buffer zone must include the maximum distance required for the Emergency Arrest Device EAD to arrest a wayward rider Always use the manual
19. the owner operator using and maintaining the device in accordance with the zipS TOP instructions including the requirement to maintain annual recertification as described in the Installation Operation and Maintenance Manual THIS WARRANTY IS EXPRESSLY IN LIEU OF OTHER WARRANTIES EXPRESS OR IMPLIED AND ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE IS HEREBY EXPRESSLY EXCLUDED The sole remedy for breach of said warranty or for any claim in negligence or strict liability in tort is the repair or replacement of any defective parts at the discretion of the manufacturer Such parts claimed to be defective shall be returned to the ZIpSTOP licensed Service Center transportation prepaid for inspection by zipS TOP to determine to its satisfaction that said part s are defective This warranty is null and void if other than genuine parts are used or if any modifications are carried out to the zipSTOP Brake Assembly or zipS TOP components without the expressed written permission of the manufacturer No person Agent or Distributor is authorised to give any warranty other than the one herein expressed on behalf of the zipS TOP Company or to assume for it any liability pertaining to such products The company makes no warranties in respect to trade accessories or component parts which are not manufactured by the company same being subject only to such warranties if any as may be made by their respective manufacturers
20. times Proper installation requires careful design and planning using zipS TOP and non zipS TOP components Owners and Operators are encouraged to seek the advice of their zip line installer or a proper engineering professional regarding the instructions in this Manual These instructions must be made readily available to the operator at all times Prior to installation and use all owners installers and operators must have read and shown to have understood all instructions labels markings and safety information pertaining to the installation operation care and maintenance of the zipSTOP system its component parts and all associated hardware Failure to do so may result in equipment damage serious injury and death A Always use the manual supplied with zjoS7OP brake Kit when installing operating or maintaining Z PSTOP components www thezipshop com 1 SAFETY INFORMATION 1 1 Symbols Used in this Manual The following safety symbols are used throughout this manual to highlight potential danger to operators and equipment One or more precautions may be associated with practices and procedures described within this manual Failure to adhere to any precautions highlighted can result in equipment damage serious injury and or death Ensure that you read and understand all safety related procedures related to the working environment and the task you are undertaking DANGER Indicates a hazardous situation exists that if not avo
21. up zipSTOP Brake Unit with the bottom mounting hole and insert the corresponding retaining pin and lynch pin Always use the manual supplied with zjoS7OP brake Kit when installing operating or maintaining Z PS7OP components www thezipshop com 29 Swing the 2 05 Brake Unit up and apply small amount of pressure against the compression rubber until upper mounting holes align Fit the upper mounting pin and lynch pin Check both lynch pins are correctly located and secure In order to prevent tampering insert a padlock or bolt in place of the lynch pin Always use the manual supplied with zjoS7OP brake Kit when installing operating or maintaining Z PSTOP components www thezipshop com 30 7 7 Fitting the Brake Trolley The Brake Trolley is installed on the zip line and is used to transfer the energy of the rider to the zipSTOP Braking Unit line Ensure that the 2 5 Braking Line is fully retracted into the zipS TOP device at Brake initiation If any Braking Line is extended braking force will be increased resulting in participant injury or damage Always use the correct Brake Trolley size for the Zip line A Failure to use the correct size may prematurely wear the trolley or zip to 2 5 Brake Unit To fit the Brake Trolley Installation Notes e Check the correct size Brake Trolley for zip line is being used e Some disassembly is required to fit the Brake Trolley to zi
22. Anchor Point and provides both support and a means of redirection for the Reduction Line The Type Pulley is required for both 1 1 and 2 1 Reduction Ratio setups The Type Pulley may be fixed horizontally or vertically to a solid surface or be clamped to acable The Type Pulley incorporates dedicated line attachment points for dead end loops Fit the Type I Pulley as follows Installation Notes Always position Type I Pulley higher than the zip line A minimum of 1 0 meter 40 is recommended Ensure the position of the pulley will not allow contact or interference between the rider and any lines or equipment Ensure the change in angle of the Reduction Line as it passes through pulley is minimized this may require mounting the pulley assembly angle towards the Brake Trolley Ensure the Type pulley assembly is mounted on a load bearing surface capable of withstanding all applicable load bearing requirements Ensure that the Reduction Line is routed cleanly and in line through the pulley system to prevent contact with any surface other than the pulley sheaves Always use the manual supplied with 2 2 brake Kit when installing operating or maintaining Z PS7OP components www thezipshop com 33 7 9 Fitting the Type II Pulley The Type II Pulley is fitted between the 2 5 Brake Unit and the Type Pulley as required to provide support and redirection for the Reduction
23. Line and connections to the Braking Line The Type II Pulley is only required on the 2 1 Reduction Ratio set ups Fit the Type II Pulley so as to ensure the position of the pulley will not allow contact or interference between the rider and any lines or equipment It is recommended that an overhead support line and link be used with the Type 11 Pulley to reduce the risk of line entanglement Type 1 Pulley Type Pulley zipSTOP Brake Unit Brake Trolley Double Line 2 1 Reduction Ratio Example Always use the manual supplied with 2 2 brake Kit when installing operating or maintaining Z PS7OP components www thezipshop com 34 710 Fitting Reduction Line Only use a Double Figure of Eight knot or approved termination system for all rope connections through the pulley system Contact between Reduction Line and any surface other than the pulley sheaves must be prevented in order to eliminate abrasion and undue wear Ensure that the Reduction Line is routed cleanly and in line Attachment of the Reduction Line will differ depending on the Reduction Ratio utilized for each 2 5 installation The length of the Reduction Line must be sufficient to reach between terminations with a single continuous line 7101 1 1 Reduction Ratio Ensure the Type pulley is securely fitted to the Secondary Anchor Point and is located higher than the adjacent zip line and in line with the start of
24. Pulley The Braking Line must feed from the device linearly without twist and centered within the Nozzle Accelerated Braking Line wear may occur if the line bears onto the Nozzle edge Do not reuse self locking nuts Always use new nuts as reuse of self locking nuts may compromise connection integrity Fit the zjoS Brake Unit as follows Installation Notes Always orient the zipSTOP Brake Unit directly in line with Type Pulley e Always use through bolts with large washers and self locking nuts is recommended that double helix spring washers are located under mounting nuts to allow for movement in primary mount point Always mount the 2 5 Brake Unit a sufficient distance from the zip line so that Reduction Lines and pulleys do not interfere with rider Once the installation is complete ensure that the zipS TOP Braking Line is not twisted and feeds linearly through the Nozzle Attach the supplied mounting bracket to the primary support with three 3 M12 or hex mE a head through bolts Ub D c Check bolt head is correctly located in the d P i zipSTOP Brake Unit mount Secure with flat washers double helix spring oe A washers and self locking nuts Torque fasteners to maximum of 15 Nm 11 ft Ib Do not over torque fasteners Line
25. S7OP brake Kit when installing operating or maintaining Z PS7OP components www thezipshop com 1 How to read Braking Distance Charts The Braking Line must be fully retracted into zipSTOP at the point of Brake initiation for the data in the following Braking Distanc Serious injury death or damage to equipment can occur if Brake initiation occurs without a fully retracted Braking Line 112 1 1 Ratio Metric Braking Distance m BRAKING DISTANCE 1 1 Reduction Line Ratio 15 30 8 45 2 60 75 90 A 105 120 6 135 lt 150 BDmin 0 10 20 30 Arrival Speed kph Always use the manual supplied with zjoS7OP brake Kit when installing operating or maintaining Z PS7OP components www thezipshop com Rider Weight kg MIO 2105 The Braking Line must be fully retracted into the zipSTOP the point of Brake initiation for data in following Braking Distanc Chart to apply Serious injury death or damage to equipment can occur if Brake initiation occurs without a fully retracted Braking Line 11 3 2 1 Ratio Metric BRAKING DISTANCE 2 1 Reduction Line Ratio 1 15 BA 30 EBH 45 2 60 75 90 A 105 e 120 9 135 lt 150 BDmin Braking Distance m
26. ake Trolley travel to zipS TOP line extension LEX Rider Arrival Speed Speed at which rider enters the braking ASmax maximum rider arrival speed Determined by ASmin ASmin minimum rider Slope of zip line arrival speed Rider size and weight Wind speed and direction Rider trolley rolling resistance Braking Distance Distance required to decelerate a rider maximum braking BDmax Braking distance is determined by i T BDmin Arrival speed BDmin minimum braking Rider weiaht distance 9 Reduction Ratio Slope of zip line at landing area NOTE Configurations that result in Braking distances that fall below the BDmin line shown on the chart are not recommended These short braking distances may be uncomfortable for the rider and may result in severe swinging up of rider when decelerating Rider Braking Range BR Difference between maximum and minimum braking distances Always use the manual supplied with zjoS7OP brake Kit when installing operating or maintaining Z PSTOP components www thezipshop com 22 Roll Forward RF Distance riders may roll down the Zip line once rider arrest is complete The amount of roll forward is determined by Line slope positive Rider weight System friction Roll Back RB Distance riders may roll back up the zip line once rider arrest is complete The amount of roll forward is determined by Line slope negative Rider weight System friction
27. ating or maintaining Z PS7OP components www thezipshop com 5 ZIPSTOP BRAKE ASSEMBLY 51 The zipSTOP Brake Assembly will be supplied as a kit of parts to aid in easy installation Additional components are required to complete the braking system 0 2 Unpacking Save Packaging For Reuse Keep all zipS TOP packaging for reuse when returning the zipSTOP Brake Unit for annual recertification Damages caused by shipping in improper packaging are not covered under warranty and will result in additional repair charges to the owner 9 2 1 To unpack the 205 TOP 1 Upon receipt of the zipSTOP Brake Assembly Kit inspect all parts for signs of shipping damage or contamination If any components show signs of damage or mishandling contact your zipS TOP distributor 2 Check that all information and safety labels affixed to the zipSTOP are present and legible Refer to Section 1 2 for label location SERIAL U RECERTIFICATION DATE a Do not use the zipSTOP after date shown here 3 Check the Certification Label on the zipSTOP Brake Unit for the Next Recertification Required date If the date shown has passed or the label is missing or illegible then the zjoS TOP Brake Unit must not be put into service 4 Register online at www thezipshop com registration or fill out the Product Registration Card included with the zipS TOP Brake Assembly Kit and return it to your zipSTOP distributor 4 Prod
28. ck any loose ends and check that all lines are free and untangled e Push the Brake Trolley down the zip line and check that no binding or interference occurs between the Reduction Line and any other part of the zioS TOP installation e Check that the maximum travel that can be achieved by the Brake Trolley does not exceed the full Line Extension of 2 5 Braking Line 7 10 2 2 1 Reduction Ratio Attach Type Il Pulley directly to zipSTOP Braking Line Pass reduction line around Type II Pulley T w Pass reduction line back y around Type I Pulley 4 Attach reduction line to directly to Type Pulley reduction line 1 to connection point on Brake Trolley 2 1 with Double Line Shown Installation Notes e Check that the Reduction Line diameter is compatible with the redirection pulley size Always use the manual supplied with 2 2 brake Kit when installing operating or maintaining Z PSTOP components www thezipshop com 37 Check that the Reduction Line meets the specified strength diameter wear resistance and UV resistance standards e When using a 2 1 ratio it is recommended that a support cable be installed to provide support for the Type II Pulley e Ensure that the Reduction Line is routed cleanly and in line through the pulley system to prevent contact with any surface other than the pulley sheaves Ensure that the zipSTOP Bra
29. duction Line towards the 205 TOP Brake Unit pass the Reduction Line around the Type II Pulley ensuring it enters the pulley from underneath and passes over and around the sheave in the direction of the Secondary Anchor Point Tension the Reduction Line and connect to the dedicated mounting point on the Secondary Anchor Point using an approved line termination system or Figure of Eight knot Following installation of Reduction Line Remove temporary restraint from Brake Trolley e Check the Reduction Line to ensure that the Brake Trolley is the correct Reset Position when 2 05 TOP Braking Line is fully retracted Ensure that the Reduction Line is routed cleanly and in line through the pulley system to prevent contact with any surface other than the pulley sheaves e Tie back any loose ends and check that all lines are free and untangled e Push Brake Trolley down the zip line and check that no binding or interference occurs between the Reduction Line and any other part of the 205 TOP installation Check that the maximum travel that can be achieved by Brake Trolley does not exceed the full Line Extension of 2 5 Braking Line Always use the manual supplied with zjoS7OP brake Kit when installing operating or maintaining Z PSTOP components www thezipshop com 39 8 OPERATION OF Z PSTOP 8 1 Safety precautions Always correctly install maintain and opera
30. dule uuaccoeedutepcrabkorbitan Cueia ea ced aps 43 10 2 DAILY INSPECTIONS scusa edat oq 43 10 3 SPARE PARTS amp ACCESSORIES 0000 0 44 10 4 UNSCHEDULED SERVICE 5 45 10 4 1 zipSTOP Brake Unit Side Cover replacement 45 10 4 2 zipSTOP Brake Unit Nozzle replacement 45 10 4 3 Removing Nozzle 45 10 4 4 To refit the Nozzle 46 10 4 5 Braking Line Inspection 47 10 5 BRAKING LINE 1 1 renes 48 10 5 1 Safety Precautions 48 10 5 2 Braking Line Replacement Procedure 48 10 5 3 Brake Trolley Bump Stop Replacement 50 11 BRAKING DISTANCE CHARTS 51 HOW TO READ BRAKING DISTANCE 52 ju Ls wuerde Tm 93 RATIO SIE TRIG E 54 oett ie atate EUM Mes ne buche 55 2 1 RATIO IMPERIAL 71207 1 1 414 56 A
31. e Redirection Pulley For every unit of Brake Trolley travel the Braking Line extends an equal distance Characteristics of the 1 1 ratio are e Suitable for low speeds e Strongest braking force e Short braking distances e Higher rate of rider deceleration e Maximum rider approach speed of 36 kph 22 mph A 1 1 Reduction Ratio is used for zip line installations where low arrival speeds are common Although suitable for speeds up to 36 kph 22 mph typically a 1 1 ratio would be employed when approach speeds are less than 20 kph 12 mph Always use the manual supplied with zjoS7OP brake Kit when installing operating or maintaining Z PSTOP components www thezipshop com 6 5 2 2 1 Ratio Attach pulley to zipsSTOP braking line with quicklink Attach reduction line and redirection pulley to _ secondary mount ISHMA Brake Trolley Single Line 2 1 Reduction Ratio 2 1 Reduction Ratio connects the 2 05 TOP Brake Unit to the ZipS TOP Brake Trolley via both Type and Type II pulleys With a 2 1 ratio the Brake Trolley travels twice the distance that the zipSTOP Braking Line extends Characteristics of the 2 1 ratio are Suitable for medium to high speeds Best combination of stopping distance and braking force Optimum rider comfort Longer braking distances than a 1 1 setup Overhead support line recommended Maximum approach speed of 60 kph 36 mph A 2 1 Ratio is us
32. e operation resulting in equipment damage serious injury or death Reduction Line will be subject to wear and abrasion Any Reduction Line selected for use will wear and must be replaced from time to time Lines must be carefully inspected prior to use each day and failure to do so may result in serious injury or death When selecting a reduction line the following considerations apply The line must meet the specifications described above e Alighter smaller diameter line is preferred to minimize resistance and weight and maximize reliable reset waterproof line is required Water absorption can add significant weight allowing the line to sag which increases the likelihood of incomplete reset for Brake Unit and Brake Trolley Always use the manual supplied with 2 2 brake Kit when installing operating or maintaining Z PS7OP components www thezipshop com 6 ZIPSTOPBRAKE ASSEMBLY CONFIGURATION 6 1 General The zioS TOP Brake Assembly is designed to be utilized as part of a complete zip line braking system and can be used for a wide range of zip line installations The zioS TOP Brake Assembly is suitable for use in both existing and new zip line installations Setup information contained within this manual relates only to the zipS TOP Brake Assembly The design installation and set up of other components comprising the complete braking system is the responsibility of the installer and or operator
33. e range of temperature and weather conditions Extreme heat and cold weather will not alter the performance of the equipment nor will operations in wet conditions however the following should be observed A Keep lines dry When operating in freezing temperatures it is of critical importance that that all lines are kept dry If lines become wet and subsequently freeze normal retraction extension may become limited which may result in increased or dangerous rates of deceleration or an increased likelihood of reset failure If lines become wet during freezing temperatures or when normal extension retraction becomes limited cease all operation immediately Fully extend Braking Line to allow drying A When operating the zipSTOP in wet conditions the Braking Line must be fully extended and allowed to completely dry in order to get the longest life from the lines Always use the manual supplied with 2 2 brake Kit when installing operating or maintaining Z PS7OP components www thezipshop com 40 Inspect line frequently extreme weather conditions A When operating in extreme wind weather temperature humid conditions and UV light exposure increase line inspection frequency and replacement frequency Under such conditions line must be replaced if any signs of deterioration are evident 8 3 Resetting System Check Brake Trolley has correctly reset after every run Failure to reset the Brake Trolley wi
34. ed on zip line installations where medium to high approach speeds are common but a soft stop for the rider is desired Although suitable for approach speeds up to 60 kph 36 mph typically a 2 1 ratio is employed when approach speeds are less than 40 kph 24 mph Always use the manual supplied with 2 2 brake Kit when installing operating or maintaining Z PS7OP components www thezipshop com 6 5 3 Possible System Configurations Informative Only The zipSTOP Brake Assembly can be used with other zip line configurations and higher rider velocities Please contact your 205 distributor for more information Some examples of alternative system configurations are shown below Attach redirection pulley ge to overhead line 24 7 Attach reduction line to zipSTOP braking line with quicklink Attach reduction line and redirection pulley to tha overhead ie Attach reduction line to zipSTOP braking line with quicklink Brake Trolley Overhead Cable 2 1 Reduction Ratio Always use the manual supplied with zjoS7OP brake Kit when installing operating or maintaining Z PSTOP components www thezipshop com 17 Attach redirection pulley to primary mount or overhead line Attach redirection pulley to overhead line Attach redirection pulley to zipSTOPbraking line with quickli Note Ensure sufficient height above platform for 2 Brake Unit t
35. ided will result in serious injury or death WARNING Indicates a potentially hazardous situation that if not avoided could result in serious injury or death CAUTION Indicates a potentially hazardous situation that if not avoided may result in injury or equipment damage NOTE Indicates an action that must be taken to ensure personal safety and prevent damage to property or equipment Care for the Environment A eo Take care to minimize impact on the environment when carrying out this procedure Always use the manual supplied with 2 2 brake Kit when installing operating or maintaining Z PS7OP components www thezipshop com 1 2 Safety and Information Labels Safety and Information Labels located on the zipS TOP components are not to be removed Ensure labels are in place and remain legible at all times 1 2 1 Location of Safety Labels Location of Labels Brake Unit Location of Labels Brake Trolley Always use the manual supplied with 2 2 brake Kit when installing operating or maintaining ZIPS TOP components www thezipshop com 2 WARRANTY INFORMATION 2 1 Warranty Conditions Manufacturers sole warranty The zipSTOP Brake Assembly will be sold free from defects in materials and workmanship excluding field replaceable wear parts for a period of two 2 years from date of purchase This warranty only applies to the original purchaser and is contingent upon
36. ine and complete Shackle Link assembly from the Drum Lead 7 Fit new Shackle Link supplied with the Braking Line Ensure the loop part of the Link is fitted to the Drum Lead Always use the manual supplied with 2 2 brake Kit when installing operating or maintaining Z PS7OP components www thezipshop com 48 Failure to do so may result in equipment failure serious injury or death to participants Ensure the factory applied thread locking compound is present on the Shackle Link Pin threads 8 Fit the new Braking Line passing the threaded Shackle Pin through the loop as shown 2 NM ZS 1037 Internal Line Holding Pin Joining Shackle Braking Line Correct shackle fitment 6 Tighten the Shackle Pin to 2 Nm 18 Ib in ensuring the threads are fully engaged and the end of the pin is flush with the Shackle Link as shown 7 Remove the Holding Pin and allow the new line to slowly retract until Drum Lead and Shackle Link are inside casing Ensure that the Braking Line feeds squarely and without twists when retracting back into the brake unit Failure to do so may result in equipment failure serious injury or death to participants 8 Refit Nozzle assembly Refer Refit Nozzle Assembly 9 Slowly retract the Braking Line into the casing checking the action is smooth and adequate spring resistance is felt 10 Once line is fully retracted pull out line a short d
37. ipS TOP 6 5 Reduction Line Ratio The Reduction Ratio is the most influential factor in the braking characteristics of the zioSTOP The Reduction Ratio is the difference between the Brake Trolley travel and the zipSTOP Braking Line extension The Reduction Ratio is achieved by passing the Reduction Line around a series of pulleys This alters the ratio of Brake Trolley travel to Braking Line extension allowing the installer to tailor the braking distances and deceleration rates accommodating a wide range of arrival speeds and rider weights Always use the manual supplied with 2 2 brake Kit when installing operating or maintaining Z PS7OP components www thezipshop com Various Reduction Ratios are possible e 1 1 Ratio e 2 1 Ratio e 3 1 and higher ratios contact your zipSTOP Distributor Systems shown are based on a single line zip line Dual zip lines and side by side systems may also be accommodated Please contact your 2 5 Distributor for information on alternate set ups When higher Reduction Ratios are employed retraction force is reduced and a manual reset of the Brake Trolley may be necessary 6 5 1 1 1 Ratio Attach reduction line to zipSTOP braking line with quicklink Attach redirection pt to secondary mount zip line Brake Trolley Single Line 1 1 Reduction Ratio The 1 1 Reduction Ratio directly connects the zipSTOP Brake Unit to the zipS TOP Brake Trolley a single Typ
38. irection pulley reduction line hy quick link L quick link brake trolley X 1 4 RESET POSITION Typical zipSTOP installation he zipSTOP Brake Unit is located at the zip line terminal end normally adjacent to the landing area It is connected via a redirection pulley and Reduction Line system to the zipSTOP Brake Trolley The Brake Trolley is located on the zip line and when idle zipSTOP Braking Line fully retracted will be positioned at the start of the rider Arrest Zone Reset Position The approaching rider trolley contacts the Brake Trolley moving it down the zip line As the Brake Trolley moves into the Arrest Zone it extends the Braking Line out of the zipS TOP Brake Unit via the Reduction Line As the Braking Line extends out of the zipSTOP Brake Unit the eddy current brake in the unit is activated controlling the rate of deceleration and slowing the rider in a smooth manner e load is removed from the Brake Trolley the spring return mechanism in the zipSTOP Brake Unit retracts the Braking Line automatically returning the Brake Trolley to the start of the Arrest Zone Reset Position on the zip line ready for the next rider Note When higher Reduction Ratios are employed retraction force is reduced and a manual reset of the Brake Trolley may be necessary Always use the manual supplied with 2 5 brake Kit when installing oper
39. istance using reasonable force and allow it to retract Repeat two to three times to ensure line is firmly wound onto the drum 11 Return 2 5 Brake Unit to service and check for correct operation Always use the manual supplied with zjoS7OP brake Kit when installing operating or maintaining Z PSTOP components www thezipshop com 49 10 5 3 Brake Trolley Bump Stop Replacement The Bump Stops may wear over time and should be replaced if they show signs of wear cracking or splitting hardening or deformation The Brake Trolley Bump Stops may be replaced with the trolley in situ on the zip line To replace the bump stops Remove the two self locking nuts and washers securing the bump stop to the Brake Trolley Fit new bump stops and secure with washers and new self locking nuts Torque to 10 Nm 7 ft lb Always use the manual supplied with 2 2 brake Kit when installing operating or maintaining Z PS7OP components www thezipshop com 50 11 BRAKING DISTANCE CHARTS A CAUTION Always complete unmanned testing is to determine actual braking distances and points of dismount Calculated braking distances shown on charts are for guidance use only Actual braking distances will vary due to site conditions weather co and final configuration of zip line set up Braking distances shown on charts refer to installations where 2 5 Braking Line is fully retracted when Brake Trolley is po
40. ith zjoS7OP brake Kit when installing operating or maintaining Z PSTOP components www thezipshop com 47 105 Braking Line Replacement If Braking Line shows signs of wear damage or contamination then it will need to be replaced Replace Braking Line as follows 1051 Safety Precautions Ensure that the Braking Line feeds squarely and without twists when retracting back into the brake unit Do not allow Braking Line or drum lead to retract into housing With Nozzle removed take care not to permit uncontrolled retraction of Drum Lead or Braking Line into casing Uncontrolled retraction will result in internal damage and require repair by the manufacturer _ Use only genuine zipS TOP replacement parts 10 5 2 Braking Line Replacement Procedure To replace the Braking Line 1 Remove the zipSTOP Brake Unit from service and place securely on the work bench 2 Remove the Nozzle assembly Refer to Section 10 4 3 Remove Nozzle Assembly While holding zipSTOP Brake Unit securely pull out the Braking Line until the end of the Drum Lead and the Shackle Link are exposed 4 Locate the loop in the Drum Lead approx 150 mm 6 in past the Shackle Link Place a suitable Holding Pin through the loop in the Drum Lead to prevent it retracting back inside the casing Drum Lead Braking Line Holding Pin Shackle Link Braking Line Shackle Link Assembly parts 5 Unscrew the Shackle Pin 6 Remove Braking L
41. ition and operation Inspect Reduction Line Redirection Pulleys 10 2 Daily Inspections The zipSTOP Brake Unit and Braking Line Brake Trolley Reduction Line and associated pulleys must be inspected on a daily basis for condition and correct operation Carry out the following inspections on a daily basis 1 Visually inspect the zipS TOP Brake Unit for damage corrosion and loose fittings and fasteners 2 Inspect the zipSTOP Brake Unit mounting bracket and pins for damage and ensure that it remains secured correctly 3 Fully extend the Braking Line from the zipSTOP Brake Unit Check the line condition for damage or discoloration If worn or damaged replace with a new Braking Line assembly 4 Check that the Braking Line extension and retraction is smooth and maintains good resistance to extension throughout its range 5 Inspect the zipSTOP Brake Trolley for damage wear and loose fittings and fasteners 6 Check the Brake Trolley Bump Stops are secure and free from damage or wear 7 Check the Brake Trolley operates smoothly throughout its operating range and that it correctly resets to the start of the Arrest Zone Always use the manual supplied with 2 5 brake Kit when installing operating or maintaining Z PS7OP components www thezipshop com 43 8 Inspect the Reduction Line and pulleys for freedom of movement Inspect overall condition of line and ensure it is in a safe and se
42. king Line is fully retracted into the zipSTOP device at Brake initiation If any Braking Line is extended braking force will be increased resulting in participant injury or damage to the zipSTOP Brake Unit Ensure that the specified Reduction Line meets the specifications described in Section 4 5 5 Use of poor quality Reduction Line may lead to zip line brake system failure Position the Brake Trolley at the start of the Arrest Zone Reset Position and temporarily secure it at that position Connect the Reduction Line directly to the Brake Trolley using a Double Figure of Eight knot and an optional load rated link If a load rated link is utilized ensure the gate on the link is screwed tight and thread lock compound is applied to prevent it from loosening over time Ensure the Type I pulley is correctly positioned and secure Pass the Reduction Line through the Type I pulley ensuring it enters the pulley from underneath and passes over and around the sheave in the direction of the 2 05 Brake Unit Always use the manual supplied with 2 2 brake Kit when installing operating or maintaining Z PS7OP components www thezipshop com 38 Ensure 25 Brake Unit is the fully retracted position with the Type II pulley correctly positioned and secure on the zipSTOP Braking Line Note Braking Line extends approximately 400 mm 16 from Nozzle in fully retracted position Run the Re
43. ll result in an insufficient braking distance and may result in serious injury or death of rider The zipSTOP Brake Trolley should automatically return to the start of the Arrest Zone Reset Position once the rider trolley is removed With the Brake Trolley positioned in the Reset Position the zipS TOP Braking Line will be fully retracted refer Fig 16 An arrival platform attendant should always check for the correct reset position of the Brake Trolley and the zipS TOP Braking Line at the completion of each run prior to a subsequent run If the Brake Trolley fails to reset check that the zjoS TOP Brake Unit is operating correctly and the Reduction Line is not tangled snagging or binding zioS TOP Brake Unit fully retracted Always use the manual supplied with zjoS7OP brake Kit when installing operating or maintaining Z PSTOP components www thezipshop com 41 9 TROUBLESHOOTING If problems occur during operation check the troubleshooting guide If a problem cannot be resolved remove components from service and contact your zioS TOP Service Center 9 1 Troubleshooting Guide Rider does not fully stop before reaching end of Arrest Zone Possible Cause Rectification Action Brake Trolley not correctly set at start Check brake trolley reset manually position trolley at start of of Arrest Zone Arrest Zone zipSTOP braking initiates too late Inspect and test zipSTOP Brake Unit for correct operation Adjust Arre
44. lways use the manual supplied with 2 2 brake Kit when installing operating or maintaining Z PSTOP components www thezipshop com A IMPORTANT SAFETY NOTICE Zip Lining is a Dangerous Activity Failure by the installer or operator to heed any and all instructions warnings and cautions for the correct installation operation care and maintenance of the zjoS TOP may result in serious injury or death The zipSTOP Brake Assembly including 205 TOP Brake Unit Model ZB125 08B zioS TOP Brake Trolley Model ZT125 17 and all associated equipment are designed and specified for use in the recreational zip line industry as the primary brake or as an Emergency Arrest Device EAD in a complete zip line braking system Use of the zipS TOP components for any purposes other than that intended by the manufacturer is not permitted The zipSTOP is designed to be utilized as a primary brake or Emergency Arrest Device EAD When using the zipSTOP as a primary brake the installer must utilize an independent Emergency Arrest Device to protect against operator error and third party equipment failure Design and installation of the zip line including the complete braking system is the responsibility of the installer or operator Owners and Operators of zipSTOP devices are responsible for the safety and supervision of any person using zipS and are required to assure that proper installation and operation procedures are followed at all
45. n and Support Lines Only use a double Figure of Eight knot or approved termination system A for all rope connections All terminations must be either sewn or spliced Secure rope ends so they cannot untie All Reduction Lines and support lines are to be manufactured to specified strength and are to be suitable for all season outdoor use Refer to Section 5 5 5 for specifications When installing reduction and support lines use a cable tidy or route lines to ensure that All lines are installed in such a way as to prevent loose or sagging lines tangling snagging or binding with other zip line components e Lines are to be routed to eliminate abrasion and undue wear All lines are laid out so as not to present a tripping or injury hazard to zip line staff or riders If necessary use cable tidies All lines are to be thimbled and whipped or tied with a Double Figure of Eight knot Typical Figure of Eight Knot all terminations must be either sewn or spliced Always use the manual supplied with 2 2 brake Kit when installing operating or maintaining Z PS7OP components www thezipshop com 28 7 6 Fitting zipS 7 OP Brake Unit The zipSTOP Brake Unit may be mounted horizontally or vertically The mounting bracket is designed for use with a flat or curved surface Curved surfaces must have a minimum 150 mm 6 diameter Only install the zipSTOP Brake Unit oriented directly inline with the Type I
46. nced during zip line operation Loads specified are for zipSTOP Brake Assembly installation only and do not allow for any additional equipment or other loadings applied to the secondary mount Loads at Secondary Anchor Point Inline with Reduction Line 11 0 kN Right angles to Reduction 3 5 kN Line The loads specified are applied loads for the Reduction Line and Redirection Pulley only These loads DO NOT allow for additional loads applied by other equipment or structures Ensure sufficient factor of safety is applied in the structural design of all zip line installations 7 4 1 Position of Secondary Anchor Point The Secondary Anchor Point is located in line with the start of the Arrest Zone Brake Trolley Reset Point It provides the location for the attachment of the Type Pulley above the zip line and also attachment of any secondary or support lines that may be required Ensure the Secondary Anchor Point and any supporting structure is a sufficient distance from the zip line to prevent contact with the rider Always install pulleys so as to prevent any prevent tangling snagging or binding with other lines or objects Ensure that the Reduction Line is routed cleanly and in line through the pulley system to prevent contact with any surface other than the pulley sheaves Always use the manual supplied with zjoS7OP brake Kit when installing operating or maintaining Z PSTOP components www thezipshop com 27 7 5 Reductio
47. nts will decelerate within the Arrest Zone at the completion of braking but typically don t roll forward or backward It is recommended that the platform is positioned to allow all riders to safely dismount Always use the manual supplied with zjoS7OP brake Kit when installing operating or maintaining Z PS7OP components www thezipshop com PRIMAR Y ee WI Tr Ed 9 HOLT LANDING AREA minimum braking distance maximum braking distance ARREST ZONE Reset FPositian Flat Line 6 6 3 Negative Slope Line On negative line installations riders will decelerate within the rider Arrest Zone and may roll backwards at the completion of braking MOWAT PRAY MOLT je TOLLEY fj Reset Position Negative Line Slope Always use the manual supplied with zjoS7OP brake Kit when installing operating or maintaining Z PSTOP components www thezipshop com 20 6 7 Calculating 2 05 TOP Braking Distances To calculate braking distances for the 205 TOP Brake Assembly follow the steps in the Configuration Worksheet using the information contained the Braking Distance Charts Refer to Section 11 Always carry out unmanned testing to determine actual braking distance The information contained in this manual is intended for guidance only Calculated braking distances for the zipS TOP Brake Assembly estimates only and may differ from
48. o fully extend Deck Mounted Brake Unit 2 1 Reduction Ratio Type Pulley Beam Mounted Type Il Pulley A Brake Trolley Beam Mounted Pulley 2 1 Reduction Ratio Always use the manual supplied with 2 2 brake Kit when installing operating or maintaining ZIPS TOP components www thezipshop com 6 6 Zip Line Slope Three zip line configurations at the end of the line are possible flat line positive line slope and a negative line slope The slope of the line will influence the braking distances as well as allowing the rider to roll slowly up or down the line once decelerated 6 6 1 Positive Slope Line This is the ideal configuration when designing a zip line The positive line slope configuration equalizes the braking distance between heavy and light riders therefore minimizing the length needed for the arrival platform 4 2 t zpesTOP JS KE TROLLEY E mmm Pf y 2 tance 2 minimum braking distance distance lt lt mum braking ard oe 8 roll forware es icy a a Positive Line Slope On positive line installations riders will decelerate within the Arrest Zone but may continue to slowly roll forward on completion of braking It is recommended that the platform is positioned to allow all riders to roll forward on to the platform for a safe dismount 6 6 2 Flat Line On a flat line participa
49. operating or maintaining Z PSTOP components www thezipshop com 3 3 zipS TOP Brake Trolley Reduction Line Mounting Bump Rubbers Point Top Roller Lower Rollers Models ZT 125 17 1 2 For use with 72 12 7 mm zip lines ZT 125 17 3 4 For use with 19 mm zip lines Classification Zip line Brake Trolley Dimensions 235 x 100 x 115 mm 15 x 12 6 x 5 5 in Net Weight 1 3 kg 2 8 105 Materials Casing Aluminium Alloy Wheels Steel Bump Stop EPDM Maximum Speed 72 kph 45 mph Minimum Rider Weight 15 kg 33 Ibs Maximum Rider Weight 150 kg 330 Ibs Always use the manual supplied with 2 2 brake Kit when installing operating or maintaining Z PS7OP components www thezipshop com 4 OPERATING PRINCIPLES 4 1 The 205 Brake Assembly is a controlled braking force device designed specifically for use as a Primary or Emergency Arrest Device EAD at the end of zip line runs The zipSTOP caters to a range of rider weights and approach speeds and offers a smooth consistent braking force for all riders zioS TOP brake performance relies on operators using the correct equipment and operating the system in accordance with the instructions contained within this manual 4 2 zipS Operation The zipSTOP Brake Assembly system consists of a 2 05 Brake Unit zipSTOP Brake Trolley redirection pulleys and associated Reduction Lines secondary mount primary mount red
50. p line e The Brake Trolley is installed with the Bump Stop toward the direction of rider arrival e Ensure the two lower pulley wheels are located below the line and the single upper wheel is above the line Check Brake Trolley is the correct size for the zip line Trolley size is located on the label Model zT 12547 3 4 LABEL PART NO 0418 005 Remove Reduction Line mount gt gt gt gt upper pulley gt gt Always use the manual supplied with zjoS7OP brake Kit when installing operating or maintaining Z PSTOP components www thezipshop com 31 gt gt and top half of the Bump Stop from Brake Trolley Place the Brake Trolley on the zip line with the Bump Stop facing in the direction of the approaching rider Refit the upper half of the Bump Stop rubber Torque to 10Nm 7 lb ft Refit the Reduction Line mounting bush Torque to 20 Nm 15 lb ft Refit the upper wheel to the Brake Trolley ensuring that all spacers are correctly positioned Secure the upper wheel with bolt washer and self locking nut Torque to 20 Nm 15 lb ft Check all fasteners are tight Do not over tighten Always use the manual supplied with zjoS7OP brake Kit when installing operating or maintaining Z PSTOP components www thezipshop com Check Brake Trolley rolls smoothly zip line 7 8 Fitting Type I Pulley The Type Pulley is fitted to the Secondary
51. plied with zjoS7OP brake Kit when installing operating or maintaining Z PS7OP components www thezipshop com 45 Lift out top half Lift out bottom half 7 Inspect the Nozzle assembly for Splitting cracking and deformation around slot mounting flanges Correct fitment in housing 10 44 To refit the Nozzle Assembly Ensure that the Braking Line feeds squarely and without twists when retracting back into the brake unit Failure to do so may result in equipment failure serious injury or death to participants 8 Refit the lower half of the Nozzle assembly into the recess on the casing 9 Fit the upper half of the Nozzle assembly Always use the manual supplied with zjoS7OP brake Kit when installing operating or maintaining Z PSTOP components www thezipshop com 46 10 Remove Braking Line and allow Braking Line to slowly rewind into the casing until fully retracted ensuring the Braking Line is not twisted and lays flat 11 Check zipSTOP for correct operation 12 Return zipSTOP Brake Unit to service 10 4 5 Braking Line Inspection Braking Line must be replaced immediately if it is worn or damaged or at 12 month intervals whichever comes sooner Failure to do so may result in equipment failure serious injury or death to participants The Braking Line is the 12 5 m 41 ft line that extends during the zipSTOP activation The inside end of the Braking Line attaches to the 2
52. r Inspection procedures 5 4 Parts Supplied The following parts will be included in each Brake Assembly Kit 1 zipSTOP Brake Unit 1 x zipSTOP Mounting Bracket 1 x zipSTOP Brake Trolley zioS TOP Installation Operation and Service Manual Brake Unit Brake Unit Mounting Bracket pm n D BUG M Brake Trolley Installation Operation and Service Manual zioS TOP Brake Assembly Kit Always use the manual supplied with zjoS7OP brake Kit when installing operating or maintaining Z PSTOP components www thezipshop com 5 5 Additional Parts Required 5 5 1 General Additional lines and equipment will be required to successfully install a zipSTOP Brake Assembly within individual zip line installations All hardware fasteners and accessories used in the installation of zipS TOP must meet or exceed the required loads and specifications and must be made of materials compatible with all season outdoor use Redirection Pulleys The following parts are not supplied as part of the zipSTOP kit and may be purchased separately from your 2 5 TOP distributor The Type Pulley is fitted to the Secondary Anchor Point and provides both support and a means of redirection for the Reduction Line The Type Pulley is required for both 1 1 and 2 1 Reduction Ratio setups A Type Pulley is fitted between the 2 05 TOP Brake Unit and the Type Pulley as required to provide support
53. res supports and anchors should be referred to your zip line s engineer The act of decelerating a rider at the termination of a zip line can generate extreme loads Always use the manual supplied with 2 2 brake Kit when installing operating or maintaining Z PS7OP components www thezipshop com 26 7 3 Primary Anchor Point The Primary Anchor Point provides support for the zipSTOP Brake Unit The anchor point and associated fittings must be of sufficient strength to provide a secure mount and to support all applied loads sustained during zip line operation Loads specified are for the zipSTOP Brake Assembly installation only and do not allow for any additional equipment or other loadings applied to the primary mount The zipSTOP Brake Unit is attached to the Primary Anchor Point using three M12 or gt fixing bolts Loads at Primary Anchor Point In line with Braking Line 6 0 kN Right angles to Braking Line Negligible The loads specified are applied loads for the zipSTOP Brake Unit only These loads DO NOT allow for additional loads applied by other equipment or structures Ensure sufficient factor of safety is applied in the structural design of all zip line installations 1 4 Secondary Anchor Point The Secondary Anchor Point provides support for redirection pulleys and hardware used in the Reduction Line system The design of the Secondary Anchor Point must be sufficient to withstand all applied loads experie
54. rviceable condition Replace if necessary 9 Check that all Reduction Line knots and terminations are secure Check that all Quick Links and Carabiner Gates are locked and secure 10 Inspect all Redirection pulleys are secure and ensure they are free from damage Check that pulley wheels operate smoothly and without excessive play 11 Check that the Reduction Line operation is smooth and line is free from wear damage tangles and snagging from foreign objects 10 3 Spare Parts amp Accessories The zipSTOP Brake Assembly is fitted with a number of user replaceable parts that may be refitted without returning the device to an authorized zioS TOP service center Always follow the manufacturer s instructions as detailed in the Operation Manual and any Part Replacement Guide supplied when undertaking replacement of a part Note For optimal performance of your zipSTOP Brake Assembly only use genuine zipS TOP spare parts and accessories When ordering replacement parts please specify the part number and description of the part To order replacement parts or accessories contact your authorized zipS TOP distributor or go online to www thezipshop com ZipSTOP Spare Parts Description Part Qty 2 Brake Trolley gt 12 7 mm 27125 17 112 Brake Tie o mm 2 Always use the manual supplied with 2 2 brake Kit when installing operating or maintaining Z PS7OP components
55. sitioned at the the Arrest Zone Reset Position If 2 5 Braking Line is not fully retracted or if static line extension is present when Brake Trolley is rese actual braking distance will be different to that that shown on the chart Braking distances that fall below the BDmin line will result in high level of braking force being felt by the rider and may cause severe swinging the rider s body during braking The Braking Line must be fully retracted into the zipSTOP at the point of Brake initiation for the data in the following Braking Distanc Charts to apply Serious injury death or damage to equipment can occur if Brake initiation occurs without a fully retracted Braking Line Always use the manual supplied with zjoS7OP brake Kit when installing operating or maintaining Z PS7OP components www thezipshop com The Braking Line must be fully retracted into zipSTOP at the point of Brake initiation for the data in the following Braking Distanc Charts to apply Serious injury death or damage to equipment can occur if Brake initiation occurs without a fully retracted Braking Line How to read braking distance charts BRAKING DISTANCE 1 1 Line Ratio Eraking Distanc e m Rider Welgit kg mn Mial Speed xph BDmin Line braking distances select minimum 1 select maximum below this line will result in arrival speed arrival speed severe force on rider Always use the manual supplied with zjo
56. st Zone start point Brake Trolley Reset Point to be farther from the dismount area Riders of all sizes brake too abruptly Possible Cause Rectification Action Incorrect Reduction Ratio Change Reduction Ratio to increase braking distance Reduction Line is binding tangled or Inspect Reduction Line remove any obstacles and check for snagged smooth operation Excessive friction in redirection pulleys Inspect all Reduction Line pulleys for damage and smooth operation Excessive friction in Brake Trolley Inspect Brake Trolley for damage and smooth operation Debris or foreign objects in brake Inspect Brake Trolley and pulleys Remove any foreign objects trolley or pulleys Light weight riders brake too abruptly Possible Cause Rectification Action Incorrect Reduction Ratio Change Reduction Ratio to increase braking distance Increase the weight capacity of light weight riders Brake Trolley does not reset correctly Possible Cause Rectification Action Reduction Line is binding tangled or Inspect Reduction Line remove any obstacles and check for snagged smooth operation Excessive friction in redirection pulleys Inspect all Reduction Line pulleys for damage and smooth operation Excessive friction in Brake Trolley Inspect Brake Trolley for damage and smooth operation Debris or foreign objects in Brake Inspect Brake Trolley and pulleys Remove any foreign objects Trolley or pulleys Insufficient re
57. te the zipSTOP Brake Assembly Failure to do so may result in serious injury or death to participants Always operate a zipSTOP Brake Assembly with Emergency Arrest Device EAD system active Failure to do so may result in serious injury or death to participants Always use the correct zipSTOP Brake Trolley Failure to use the correct trolley may compromise system operation and result in serious injury to rider Avoid contact between rider and rider trolley and or Brake Trolley Serious injury may result if rider is in contact with trolley when it impacts the Brake Trolley Always design the zipSTOP installation so rider cannot be in contact with or have any part of their body caught between the rider trolley and Brake Trolley Ensure all cables attachment lines and pulleys are correctly attached and maintained Ensure that the Reduction Line is routed cleanly and in line through the pulley system to prevent contact with any surface other than the pulley sheaves Any tangling snagging binding and abrasion may compromise system operation and result in serious injury to rider Ensure Brake Trolley always resets to the start of the Arrest Zone gt gt Failure to reset the Brake Trolley will result a reduction of braking force and distance and may result in serious injury and equipment damage 8 2 Operation during extreme weather conditions zioS TOP equipment has been designed for use in a wid
58. ted braking mechanism delivers smooth deceleration and is designed to minimize variations in the deceleration rate and stopping distance of both children and adults There are no friction parts in the brake mechanism ensuring reliability remains high while maintenance and operating costs are kept to a minimum Installation inspection operation and maintenance must be carried out in accordance with the instructions in this manual to protect the longevity of the zipS TOP components 3 2 zipS TOP Brake Unit zipSTOP mount y _ top mounting pin nozzle assembly braking line side cover pulley Model ZS 125 08B Classification Zip line Braking Device Dimensions 80 x 350 x 140 mm 15 x 12 6 x 5 5 in Net Weight 23 5 kg 52 5 Materials Casing Aluminium alloy Internal parts Zinc plated steel Nozzle Modified Acetal plastic Line 20 mm Nylon Spectra Braking Line Maximum Line Extension 12 5 m 41 ft Rider Weight Range 15 to 150 kg 33 330 Ibs Maximum Speeds 1 1 Reduction Ratio 36 kph 22 mph 2 1 Reduction Ratio 60 kph 36 mph Custom ratio 60 kph 36 mph Higher speeds may be utilized with the custom Reduction Ratios however braking distances will increase When planning a custom ratio note that the automatic line reset may become compromised requiring the necessity for either manual reset or supplementary reset system Always use the manual supplied with zjoS7OP brake Kit when installing
59. the zipS TOP as a component of the Braking System must be designed tested and operated according to this Installation Operation and Maintenance Manual and proper industry and engineering practices Failure to do so may result in serious injury or death to participants Exceeding maximum recommended line speed can cause injury to participants and damage equipment Failure to correctly install or maintain a zipSTOP Brake Assembly may result in serious injury or death to participants Always install an Emergency Arrest Device EAD An independent arrest device is required to safely stop riders in the event of operator error or third party equipment failure Avoid contact between rider and rider trolley and or Brake Trolley Serious injury may result if rider contacts the rider trolley or Brake Trolley during the braking phase Always design zipSTOP Brake Assembly installation to ensure rider cannot make contact with or have any part of their body caught between the rider trolley and Brake Trolley Ensure all cables attachment lines and pulleys are correctly attached and maintained to prevent tangling snagging binding and abrasion Ensure that the Reduction Line is routed cleanly and in line through the pulley system to prevent contact with any surface other than the pulley sheaves All structures supports and anchors must be evaluated and designed according to proper industry and engineering practices Questions about structu
60. turn force 2 05 Pull out zipSTOP Braking Line and check line operates Brake Unit smoothly and has good return force Check for unusual noises Reset by hand or change Reduction Ratio Braking Line or Reduction Line frozen Install a clean dry zipSTOP Braking Line assembly to Brake Unit and or Reduction Line If all above checked and line still does not reset correctly disconnect line and test retraction force If the line will not retract properly return the Brake Unit to a licensed Service Center for maintenance Always use the manual supplied with 2 2 brake Kit when installing operating or maintaining Z PSTOP components www thezipshop com 42 10 RECERTIFICATION AND MAINTENANCE 101 General Complete inspection and servicing of the zipSTOP unit Brake Trolley and associated pulleys and lines in accordance with the Service Schedule Service actions are detailed in their relevant sections 10 1 1 Service Schedule zipSTOP Brake Unit Scheduled Service Actions Daily Weekly 6 12 Month Month Inspect zipSTOP Brake Unit overall condition E Check 205 Brake Unit operation E Inspection of Nozzle and Braking Line Inspection of zipSTOP Brake Unit casing E Inspection of Internal Drum Lead and the Shackle Annual Recertification H Brake Trolley and Reduction Line Scheduled Service Actions Daily Weekly 6 12 Month Month Inspect Brake Trolley Cond
61. uct Registration must be completed The Product Registration must be completed either by registering online or by filling out and returning the Product Registration Card This is critical for receiving product notifications and up to date information for the safe use of the zipSTOP Brake Assembly 5 Read this entire Installation Operation and Maintenance Manual supplied with the zipS TOP and familiarize yourself with all aspects of installation operation care and maintenance Always use the manual supplied with 2 5 brake Kit when installing operating or maintaining Z PS7OP components www thezipshop com 5 3 Long Term Storage If the zipSTOP Brake Unit is to be placed into storage or left unused for longer than two weeks ensure the unit is clean and dry and protected from the environment Ensure the Braking Line is fully retracted into the unit Do not store Brake Unit in a wet condition After exposure to water or damp conditions thoroughly clean and dry the zioSTOP prior to storage Ensure that the 2 5 TOP Brake Unit is not left with a wet Braking Line retracted inside the casing as this will result in corrosion of the unit and deterioration of the Braking Line Always store clean and dry environment When returning the zipS TOP Brake Assembly to operation after an extended period of inactivity always carry out a full inspection and operational check of all components in the assembly Refer to Section 10 fo

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