Harken R27LS User manual

Rail R27 LongSpan
R27LS
Instruction Manual
Read the manual carefully before using the system.
Translation of the
original instructions
UR27LS-B 26-01-2022

26/01/22 ENGLISH 3
Index
ABOUT THIS MANUAL 5
SAFETY INFO 6
THE RAIL 7
R27LS Rail 7
Components 7
Rail 7
Coloured rail 7
Bent rail with a minimum radius of curvature of 15m (valid for all trolleys) 7
Bent rail with radius between 2.75m and 15m (valid for all trolleys) 8
Bent rails at 90° (valid for trolleys INCAR1-CURVE, INCAR1-CURVE (BLACK), INCAR2-CURVE,
INCAR2-CURVE (BLACK), INCAR-360) 8
Compatibility Curved Trolleys-Tracks 8
Brackets 9
Stair brackets 9
Brackets for metal roof 9
Connectors 10
Turntables 10
Terminals 11
Trolleys 11
Rail components R27LS 12
Prerequisites and limitations 15
DESIGN 17
Load angle limitation 17
Design specifications 17
Preliminary info 17
Placing the rail 19
Type of use and distance between the brackets 20
USE OF accessorIES 22
Turntables 22
Connectors INMID-ENTRY 23
End fittings IN1642.CLEAR, INSTOP-OPEN.LS 24
Thermal expansion 25
INSTALLATION 26
ISTRUZIONI di Installazione 26
Bracket assembly instructions 27
BRACKETS FOR METAL ROOF assembly instructions 29
CONNECTORS assembly instructions 29
END STOP assembly instructions 32
Recommended end fitting 32
Terminali opzionali 33
CHECKS 34
Preliminary and periodical checks 34
Annual Check 34

4 ENGLISH 26/01/22
MAINTENANCE - CERTIFICATIONS - WARRANTY 35
PACKAGING, STORAGE, TRANSPORTATION 35
Maintenance 35
CertificaTionS 35
LABELING 36
Signs 36
Sign for vertical and oblique rigid rail 16° -90°: 37
Warranty 37
CERTIFICATION OF CONFORMITY 38
CORRECT INSTALLATION FORM 39
ACCEPTANCE REPORT 40
MAINTENANCE-inspection REGISTER 41
MAINTENANCE-inspection REGISTER 42
MAINTENANCE-inspection REGISTER 43
DATASHEET 45
ANNEXES 68
Installation layout – brackets for stairs INBRKT.STEP L1
Installation layout – aluminum brackets and connectors - FALL ARREST SYSTEM L2
Installation layout – aluminum brackets and connectors - HUMAN SUSPENSION SYSTEM L3
Installation layout – stainless steel brackets and connectors - FALL ARREST SYSTEM L4
Installation layout – stainless steel brackets and connectors - HUMAN SUSPENSION SYSTEM L5
Installation layout – brackets for metal roofs - FALL ARREST SYSTEM L6
Installation layout – brackets for metal roofs - HUMAN SUSPENSION SYSTEM L7
Installation layout – connection without connectors L8
Installation layout – bent rail 1 L9
Installation layout – bent rail 2 L10
Installation layout – bent rail 3 L11
Installation layout – rail INR27-CURVE FLAT.LS L12
Installation layout – rail INR27-CURVE CONVEX.LS L13
Installation layout – rail INR27-CURVE CONCAVE.LS L14
Installation layout – rails INR27-CURVE FLAT.LS, INR27-CURVE CONVEX.LS,
INR27-CURVE CONCAVE.LS for angles different from 90° L15
Installation layout – turntable INTURN1.LS L16
Installation layout – turntable INTURN2.LS L17
Installation layout – Connector INMID-ENTRY1.LS L18
Installation layout – Connector INMID-ENTRY3.LS L19

26/01/22 ENGLISH 5
Before installing or using the Harken R27LS rail, read the instructions contained in this Manual thoroughly.
This instruction manual is an integral part of the product, and it supplies all the necessary information for its
correct installation, safe use and maintenance.
If you don’t understand some of the instructions, please contact Harken’s authorized dealer/installer. Harken
shall not be liable for damages, injuries or death caused by a non-compliance to the safety and other
instructions contained in this manual.
This manual is intended for qualified installers. The installer is responsible for integrating the supplied
information according to current legislations.
This manual, including the information supplied by the installer, must be stored by the client and made
available to the user. It must be stored in a suitable place, near the fail arrest system entrance, and it must be
made available to the user.
This manual may be modified without notice.
See http://www.harkenindustrial.com for updated versions.
WARNING!
It is essential for the safety of the user that if the product is re-sold outside the original country of
destination the reseller shall provide instructions for use, for maintenance, for periodic examination
and for repair in the language of the country in which the product is to be used.
ABOUT THIS MANUAL

6 ENGLISH 26/01/22
•Harken R27LS rail must be installed by personnel authorized by Harken or Harken dealer or by qualified
personnel trained on the installation of the Harken R27LS rail, and who are familiar with the safety
regulations in force on site and trained on PPE (Personal Protective Equipment)
•The rail installer must make sure that the structure where the rail will be installed is suitable to fasten the
device and to support the loads for which the rail has been certified.
• The type of structure anchor/fixing must be defined by a qualified professional.
•The procedure to fasten the rail to the base must be documented in suitable reports, made available for
future consultation.
•Each rail has maximum load limits, which mostly depend on the structure where it is installed and on the
distance between the anchor/fixing; those limits must not be exceeded.
•The R27LS rail must be used solely with Harken trolleys (IN9606, IN9608, IN9565, IN158, IN9606.CLEAR,
IN9608.CLEAR, IN9565.CLEAR, IN158.CLEAR, INCAR1-CURVE, INCAR1-CURVE (BLACK), INCAR2-CURVE,
INCAR2-CURVE (BLACK) and INCAR-360), wearing suitable PPE (Personal Protective Equipment) compliant
with the laws in force on workplace safety.
•Before using the rail, check its path and the falling hazards, evaluating the minimum fall clearance and
choosing the PPE with shock absorber deployment most suitable to the type of hazard.
•Before each use, check the system for any trace of wear, corrosion, deformation, loose connection, etc... In
case of doubts, if a rail seems unsafe, it must be checked by Harken or Harken dealer’s authorized personnel
or by qualified personnel.
•All operators using the rail must observe the instructions for uses, and especially the maximum number of
operators it can support at the same time.
•In case of extreme weather events, do not use the rail
•In case of fire or if the rail has been struck by lightning, stop using it, report the issue to Harken Approved
Installer &/or Harken to arrange a detailed inspection by Approved & Qualified Personnel.
•Do not change the rail in any way, unless previously authorized in writing by Harken Or Harken dealer’s
authorized personnel or by qualified personnel.
•Harken shall not be liable for injuries or damages resulting from an improper use of the rail.
•The system must be used only by physically and psychically healthy personell. Cardiac and circulatory
problems, taking medications, alchool and drugs could compromise the safety of the user when working at
height.
•Before installing and using the Harken Access Rail system it is mandatory to organize a rescue plan to deal with
any emergencies that may occur during work. In rescue situations, the section of track involved in the possible
fall of the operator must not be used by rescuers, but a separate personal protection system must be used.
SAFETY INFO

26/01/22 ENGLISH 7
R27LS RAIL
The anodized aluminium R27LS rail (INR27.LS) must be fastened to a supporting structure using suitable
brackets. A low friction trolley, is to be installed to the rail, providing a mobile anchorage point. This assembly
includes a rigid fall arrest system. By installing and using this system correctly, the risk of the operators falling
whilst working at height can be eliminated or significantly reduced.
Furthermore, the R27LS rail in horizontal installation (0°±5°) can be used as a Rope Access Anchorage
System, to provide a safe anchorage for twin rope working (rope access & work positioning), with good
anchor mobility under load.
COMPONENTS
The R27LS rail must be used with the following components:
Rail
THE RAIL
Extruded anodized aluminium rail of 3m of length.
The rail can be supplied also bent. For more details,
refer to the Bent Rail chapter.
INR 27.L S
Coloured rail
The standard rail is supplied in (CLEAR) anodized aluminium colour. Aluminium rail, brackets and connectors can
be supplied on request, powder coating or anodized coloured.
Stainless steel brackets and connectors can be supplied powder coating coloured.
For more information, contact Harken.
Bent rail with a minimum radius of curvature of 15m (valid for all trolleys)
The straight rail can be installed on bent surfaces, which have a minimum bending radius of 15m.
The bending rail can be done manually in the 3 directions during the installation procedure and to do this, it is
necessary to install the rail using a minimum of four brackets with a maximum distance of 1m between a bracket
and another. See paragraph Installation Layout – bent rail 1, 2 and 3.
1
2
3

8 ENGLISH 26/01/22
Bent rail with radius between 2.75m and 15m (valid for all trolleys)
For bending radius included between 2,75m and 15m in all the three direction, it's possible to require the bending
rail to Harken. The bent rail has 250mm of straight rail at the extremity due to the production process.
For more information contact Harken. See paragraph Installation Layout – bent rail 1, 2 and 3.
Bent rails at 90° (valid for trolleys INCAR1-CURVE, INCAR1-CURVE (BLACK), INCAR2-CURVE, INCAR2-
CURVE (BLACK), INCAR-360)
The rails INR27-CURVE FLAT.LS, INR27-CURVE CONVEX.LS and INR27-CURVE CONCAVE.LS have a bend radius
of 90° and can only be used with the trolleys INCAR1-CURVE, INCAR1-CURVE (BLACK), INCAR2-CURVE,
INCAR2-CURVE (BLACK) and INCAR-360. These rails also have a straight section of 250mm at the ends.
For angles other than 90 °, the rail can be cut and the brackets INBRKT.2, INBRKT.3 or INBRKT.4 can be installed
at a distance of 100±10mm on both ends. For installation with INBRKT.1, contact assistance Harken.
COMPATIBILITY CURVED TROLLEYS-TRACKS
Bent rails
Trolley 15m 2.75 ÷ 15m INR27-CURVE
FLAT.LS
INR27-CURVE
CONVEX.LS
INR27-CURVE
CONCAVE.LS
IN9606
IN9606.CLEAR
IN9608
IN9608.CLEAR
IN9565
IN9565.CLEAR
IN158
IN158.CLEAR
INCAR1-CURVE
INCAR1-CURVE (BLACK)
INCAR2-CURVE
INCAR2-CURVE (BLACK)
INCAR-360

26/01/22 ENGLISH 9
Brackets
Extruded aluminium bracket, including the necessary
bracket/rail coupling accessories
(bracket/structure anchor/fixing are not included; they
must be selected and specified by the Approved
Installer at the design stage).
INBRKT.AL
Four types of stainless steel brackets, including all necessary bracket/rail coupling accessories(bracket/structure
anchor/fixing are not included; they must be selected and specified by the approved Installer at the design stage).
INBRKT.1 INBRKT.2 INBRKT.3 INBRKT.4
Stair brackets
Bracket designed to be used with various types of stairs
installed with inclination angles between 75° and 90° with
respect to the horizontal plane.
INBRKT.STEP
Brackets for metal roof
Brackets for metal roof. For more information, refer to the specific manual.
INBRKT.X5 INBRKT.X6

10 ENGLISH 26/01/22
Turntables
Connectors
Stainless steel “unsupported” connector, to
connect a rail to the adjacent one.
Alignment pin (two
alignment pins are
required to connect the
rail).
Extruded aluminium connector, to be used with
extruded brackets if it is possible to fasten it to
the structure (otherwise, the stainless steel
“unsupported” connector must be used).
L (90°) Turntable. It permits to realize a continuous line
with direction changes of right angle (90°).
T (90° - 180°) Turntable. It permits a three ways
intersection (0° - 90° - 180°).
INLINK.LS INLINK.AL
INTURN1.LS INTURN2.LS
INPIN.LS INMID-ENTRY1.LS INMID-ENTRY3.LS
Connector to be used with
aluminium extruded brackets.
Allows the insertion of the trolley
along the line.
Connector to be used with
stainless steel brackets. Allows
the insertion of the trolley along
the line.

26/01/22 ENGLISH 11
Terminals
Fixed stainless steel end
fitting.
Pair of fixed aluminium
end fittings.
Removable aluminium end
fitting.
INSTOP.LS IN9561.CLEARIN1642.CLEAR
Trolleys
Trolleys R27:
For the rail, bracket and connector technical characteristics and installation instructions, refer to the technical
sheets in chapter “Technical Sheets” and in chapter “Installation”.
Four types of trolleys (single trolley for fall arrest system and double trolley for human suspension) for
installation of rail 0°±5° with respect to the horizontal plane.
The .CLEAR versions have natural coloration (showed above), the others are black anodized.
IN9606
IN9606.CLEAR
IN9608
IN9608.CLEAR
IN9565
IN9565.CLEAR
INSTOP-OPEN.LS
Opening aluminium endstop.
The two INCAR trolleys has been designed as an adjustable anchorage point for fall arrest, for installing the rail at
0°±5° with respect to the horizontal. Moreover the INCAR1-CURVE trolley has been designed to be used also for
the rope access (human suspension) in this case two trolleys must be used (single trolley to be used for fall
arrest, double trolley for human suspension).The (BLACK) versions are black anodized, the others have natural
coloration (showed above).
IN158
IN158.CLEAR
Trolleys R27 INCAR:
Trolley designed to be used exclusively with the R27LS track and related
accessories as a mobile anchor point for fall arrest for installation of the
track from 0° to 90°.
The INCAR-360 trolley cannot be used for human suspension.
Trolley INCAR-360:
INCAR-360
INCAR1-CURVE
INCAR1-CURVE (BLACK)
INCAR2-CURVE
INCAR2-CURVE (BLACK)

12 ENGLISH 26/01/22
Rail components R27LS
Components 0-5° 6-15° 16-74° 75-90°
INR 27.L S
INR27-CURVE FLAT.LS
INR27-CURVE CONCAVE.LS
INR27-CURVE CONVEX.LS
INBRKT.1
INBRKT.2
INBRKT.3
INBRKT.4
INBRKT.AL
INBRKT.STEP
Angles to the horizontal plane

26/01/22 ENGLISH 13
Components 0-5° 6-15° 16-74° 75-90°
INBRKT.X5
INBRKT.X6
INLINK.LS
INLINK.AL
INPIN.LS
INMID-ENTRY1.LS
INMID-ENTRY3.LS
INTURN1.LS
INTURN2.LS
INSTOP.LS
Angles to the horizontal plane

14 ENGLISH 26/01/22
Components 0-5° 6-15° 16-74° 75-90°
IN1642.CLEAR
IN9561.CLEAR
INSTOP-OPEN.LS
IN9606
IN9606.CLEAR
IN9608
IN9608.CLEAR
IN9565
IN9565.CLEAR
IN158
IN158.CLEAR
INCAR1-CURVE
INCAR1-CURVE (BLACK)
INCAR2-CURVE
INCAR2-CURVE (BLACK)
INCAR-360
Angles to the horizontal plane

26/01/22 ENGLISH 15
PREREQUISITES AND LIMITATIONS
The R27LS rail has been designed to support any accidental operator fall. In order to guarantee its correct
operation, and maintain the mechanical integrity in case of fall, each user must wear the Personal Protective
Equipment (PPE) recommended by workplace safety regulations.
All PPE must be certified and marked according to the relevant national regulations. By using the personal
protective equipment, in case of a fall, the force transmitted to the operator (and consequently to the trolley
sliding on the rail) will be maximum 6 kN.
Personal Fall-arrest systems used with this equipment must meet controlling regulations for the country of use.
Fall clearance - There must be sufficient clearance below the user to arrest a fall before the user strikes the
ground or other obstruction and it consists of the stopping distance plus the free space of 1m under the feet of
the user. See appropriate documentation published by regulatory authority.
WARNING!
The use of non-compliant PPE can result in severe injuries, including death.
Fall clearance
Stopping distance
1 m
WRONGCORRECT
WARNING!
It is essential for safety to verify the fall clearance required beneath the user at the workplace before
each occasion of use, so that in the case of a fall there will be no collision with the ground or other
obstacle in the fall path.
WARNING!
To avoid personal injury, the Harken trolleys must be used with a full body safety harness (EN361
certified) equipped with a front attachment point for fall arrest and the full body harness is the only
acceptable body holding device that can be used in a fall arrest system. For applications from 0°
to 74° an energy absorber (EN355 certified) and possibly a lanyard (EN354 certified) must also
be used, and the absorber-lanyard system must have a maximum length of 2 meters. The energy
absorber and lanyard must also meet the fall protection standards as required by the local regulato-
ry authority of the country of use. Connectors (hooks, carabiners and D-rings EN362 certified) must
be capable of supporting at least 22kN (5000 lb). For applications from 75° to 90° with respect to
the horizontal, connect the INCAR-360 trolley directly to the front attachment point of the operator's
fall arrest harness using only the connector on the trolley.

16 ENGLISH 26/01/22
Before using the Access Rail system make sure that all the people and objects are clear of the system’s moving
components.
The R27LS rail is subject to the following limitations:
•for installation at 0°±5° the maximum number of operators per 3m span is equal to 4, when used as Fall
Arrest System and 2 operators per 1,5m span when used as Human Suspension System. This number may
vary based on the structure to which the system is installed and on the distance between the structure
fastening brackets;
•for installation from 6° to 15° the maximum number of operators allowed at the same time on 3m span is 1
when used as Fall Arrest System. Human suspension is not allowed.
•for installation from 16° to 74° the maximum number of operators allowed at the same time on 3m span is 1
when used as Fall Arrest System. Human suspension is not allowed.
•for installation from 75° to 90° the maximum number of operators allowed at the same time on 1.5m span is
1 when used as Fall Arrest System. Human suspension is not allowed.
•do not exceed the maximum recommended number of simultaneous operators.
•it must be used only by qualified operators trained in working at height and adequately trained on the correct
use of the system in safe conditions of use.
•it cannot be used for purposed different than the intended purpose.
•it cannot be used as load lifting system.
•it cannot be modified, tampered with or repaired.
•When using this equipment, the employer must have a rescue plan and the means at hand to implement it. The
plan must be communicated to authorized persons and rescuers. The system and trolley integrity MUST be
assessed prior to any rescue for the safest and quickest recovery.
WARNING!
Consult Harken when using this equipment in combination with components or subsystems other
than those described in this manual. Altering or intentionally misusing this equipment may cause
the system to fail which can cause a fall, which could result in severe injury or death.
WARNING!
The body harness must be properly adjusted to fit perfectly and should not be used if it is loose.
WARNING!
If the harness becomes loose it must be properly adjusted again from a safe position.

26/01/22 ENGLISH 17
Load angle limitation
Rails can be mounted at various angles on the vertical mounting structure. Harken IN9606, IN9606.CLEAR,
IN9608, IN9608.CLEAR, IN9565, IN9565.CLEAR, IN158, IN158.CLEAR, INCAR1-CURVE, INCAR1-CURVE
(BLACK), INCAR2-CURVE, INCAR2-CURVE (BLACK) trolleys have the ability to handle loading at an angle up to
15° beyond vertical. Loads beyond 15° from vertical will overload trolley. See images below.
DESIGN SPECIFICATIONS
Preliminary info
The fall arrest system must be suitably designed by a qualified professional, since the correct installation and
subsequent safety of the users depend on its correct design.
The following are of the utmost importance:
•analysis of the installation location, in order to define the position where the rail will be installed;
•definition of anchor points (where the anchor brackets will be placed);
•distance between fastening brackets;
•how to fasten the brackets to the supporting structure (the Approved Designer/Installer and/or Structural
Engineer will decide whether to use mechanical or chemical dowels, bolts, screws... depending on the
anchorage structure’s characteristics).
Consider all factors that will affect safety during use of this equipment. Rail must be laid out and positioned
strictly in accordance with drawings and specifications supplied by the project authorized architect or other
suitably qualified person. System must meet controlling work at height regulations for country of use. Installer
shall ensure suitability of base materials and structural materials to which rail is fixed, follows controlling work at
height regulations for country of use, and ensures base and structural materials are capable of sustaining a proof
test force.
The weakest structural materials have been simulated in laboratory to evaluate the anchor device and its
fastening. Anyway, the test results don't supply any information on the structure capability to bear the loads,
which can occur during the use. The capability to bear the loads connected to a fall arrest is subjected to different
assessments, which are excluded from the application of the Regulations for which the product is certified.
NOTE!
The fastening system must always be designed by a qualified professional.
DESIGN

18 ENGLISH 26/01/22
NOTE!
The fall arrest system must be designed, if applicable,
for TOTALLY PREVENTED or CONTAINED falls, so
as to prevent the significant mechanical stress due
to the risk of falling.
WARNING!
The structure where the R27LS rail will be installed from 0° to 15° must have structural charac-
teristics so as to support at least the maximum loads of 15 KN in the parallel and perpendicular
direction, that could be transmitted in service from the anchor device to the structure. This value has
been recorded on the anchor device during the dynamic strength and integrity test and must be take
into account in order to evaluate the base material, the structural anchorages or the anchor/fixing
correctly. Thus, the system designer must carry out the necessary checks to verify that the system
can be solidly fastened to the structure and that it can withstand the loads in case of fall.
For installations from 16° to 74° with respect to the horizontal plane, the maximum load that could
be transmitted in service from the rigid anchor line to the structure is 15 kN.
For installations from 75° to 90° the maximum load that could be transmitted in service from the
rigid anchor line to the structure is 15 kN.
WARNING!
It is essential for safety that the anchor device or anchor point should always be positioned, and the
work carried out in such a way, as to minimise both the potential for falls and potential fall distance.
WARNING!
In the fall arrest system it is necessary to verify the absence of sharp edges, which could trailing or
looping lanyards or lifelines. The design of the fall arrest system must avoid pendulum falls, which
could cause post-fall oscillation of the body with possible impact against obstacles.
WARNING!
For installations from 75° to 90° with respect to the horizontal plane, all points of the rigid anchor
line where the guided type device could detach from the rigid anchor line must be equipped with a
stop, like a IN1642.CLEAR or INSTOP-OPEN.LS terminal.
In order to prevent bi-metallic corrosion events, we recommend that a suitable insulating material be fitted
between dissimilar metals that could cause corrosion.
The R27LS rail must be connected to the lightning protection, in compliance with current regulations.
The rigid anchor line must not be installed in an aggressive atmosphere.

26/01/22 ENGLISH 19
Placing the rail
The R27LS rail can be installed with installation angles and limitations as indicated in the respective
Regulations for which compliance has been verified. Below is the graph of the regulatory fields of application
based on the angle of installation of the line (Pic.A).
90°
0°
75°
15°
EN 353-1:2014+A1:2017
PPE-R/11.116(v2)
EN 795:2012
90°
15°
15° 15°
90°
15°
15°
15°
90°
Pic.A
The R27LS rail installed from 0° to 5° with respect to the horizontal plane can be mounted in any position: floor,
wall, ceiling and intermediate angles.
The installation of the rail for the INCAR-360 trolley is only allowed on the floor, wall or staircase respecting the
angles indicated in the table.
Positioning of the rail according to the trolleys used:
Floor Wall Ceiling Stairs
All trolley (0-5°)*
except INCAR-360
INCAR-360 (0-5°)*
INCAR-360 (6-74°)*
INCAR-360 (75-90°)*
* Angles referred to the horizontal plane
Ceiling
Wall
Floor
WARNING!
The rail used with the INCAR-360 trolley cannot be
ceiling mounted.

20 ENGLISH 26/01/22
NOTE!
To optimize the sliding of the R27 and INCAR1-CURVE, INCAR1-CURVE
(BLACK) trolleys on the track, it is recommended to position the track so that the
load has the direction perpendicular to the sliding plane of the trolley on the rail. Sliding plane
NO
In order to better install the rail in the recommended position (with the suspension force perpendicular to the
sliding plane), you can choose between different types of brackets, compliant with the different fastening
situations. The following brackets CANNOT be installed in the load application directions indicated:
Type of use and distance between the brackets
The brackets and the connectors don't change considering the different type of use (FALL ARREST or HUMAN
SUSPENSION), instead the maximum distance between the anchor/fixing can vary considerably. Thus, it is
important, in the design phase of the system, to define the method of use.
For use as a fall arrester:
0-5° 6-15° 16-74° 75-90°
Fall arrest
Span 3m 3m 3m 1.5m
Operators N° 4 1 1 1
For use in human suspension, to increase the rigidity of the system and therefore the comfort of the user, we
recommend:
0-5° 6-15° 16-74° 75-90°
Human suspension
Span 1.5m
Operators N° 2