Harken R32 User manual

R32 ACCESS RAIL SYSTEM
Certified
User Manual – Intended for specialized personnel or expert users
4393 09-18
WARNING! This product is part of a personal fall-arrest system. Manufacturer's instructions
must be provided for each component of the system. The user must read and understand
these instructions before using this equipment. They provide proper use, inspection and
maintenance information. Alterations or misuse of this equipment, or failure to follow these
instructions, may result in a fall or failure to arrest a fall leading to serious injury or death.
Please read these instructions carefully before installing, servicing, or operating the equipment.
This manual may be modified without notice. See: http://www.harkenindustrial.com for updated versions.
PLEASE SAVE THESE INSTRUCTIONS

Access Rail System – R32
TABLE OF CONTENTS
Access Rail System – R32
Page
Introduction and safety precautions........................... 3
1Parts ........................................................................... 4
1Applications ........................................................5-6
a Purpose
b Standards
c Limitations
d Load angle limitations
e Training
2System requirements 7
a Dual trolley assembly description
b Other system requirements
3 Requirements for planning installation .............. 8
aDrawings by architect
b Base materials
c Resources
d Avoiding sharp edges
4Proof testing - unknown structure ......................8-9
aTest objective
b Approving authority
c New build representative testing
d Retrofit full testing
eTesting rail high-risk locations
f Testing procedure
gAfter testing, ball bearing replacement
5Rail installation guidelines ............................ 10-12
a General comments and responsibility
b Rail and fastener specifications
c Fastener material
d Fastener spacing
eJoining rail segments
f Horizontal rail mounting defined
gThermal expansion
hRail length and loading trolley assembly
i Ceiling, floor, or wall mount
jAngled wall mount
6Rail Installation requirements ....................... 13-14
a Fastener distance to end of rail
b Rail alignment
c Drilling holes
d Threadlocking fasteners
e Preventing corrosion between fasteners and rail
fInstalling endstops
g Using removable endstops
hLoading trolley assembly on rail
Page
7Installation testing...............................................15
a Objective
b Rail test locations
c Test description
d Test intervals
eTest scheduling and records
8Training and access to manual ...........................16
9Using system................................................... 16-17
a Inspection before use
b Connections to Access Rail system
c Connection requirements
d Operating pinstop
eUsing removable endstop
10 Rescue plan .......................................................18
11 After a ball, replacing equipment .....................18
12 Inspection before each use .......................... 18-19
a Inspect shackle
b Inspect pinstop
c Inspect all rail screws
d Inspect endstop screws
eInspect ball bearings
13 Annual formal inspection ............................. 20-21
a Inspect trolleys for damage
b Inspect ball bearings
c Inspect ball bearing quantity
d Replace missing or damaged ball bearings
e Inspect pinstop
f Inspect rail attaching fasteners
g Failed Inspection
14 Maintenance ........................................................22
a Keep ball bearings and races clean
b Use ball conditioner
15 Labeling ...............................................................23
16 Records ................................................................23
17 Customer declaration ..........................................24
18 Statement of vision..............................................25
19 Periodic and extraordinary maintenance............26
20 Worldwide limited warranty................................27
Appendix A .............................................................. 28-29
Reference documents, standards
Appendix B ................................................................... 30
EC Declaration of conformity
Service and recertification centers .............................32

Access Rail System – R32
INTRODUCTION AND SAFETY PRECAUTIONS
WARNING! Strictly follow all instructions to avoid an accident, personal injury, or death.
See www.harken.com/manuals for additional safety information.
WARNING! Using the Access Rail system demands a few important precautions:
• Do not use the Harken®Access Rail System if you are not sufficiently trained and experienced in abseiling generally
and in the use of Access Rail system equipment in particular.
• Before using the Access Rail system make sure that all people and objects are clear of the systems's moving
components.
WARNING! This product is part of a personal fall-arrest system. Manufacturer's instructions must be
provided for each component of the system. The user must read and understand these instructions
before using this equipment. They provide proper use, inspection and maintenance information.
Alterations or misuse of this equipment, or failure to follow these instructions, may result in a
fall or failure to arrest a fall leading to serious injury or death.
INTRODUCTION
This user manual contains important information for the correct use of the Access Rail system. Read it carefully
before using the system. If you do not understand an instruction, contact Harken. Do not use the Access Rail
system unless you have a sufficient level of training and experience in abseiling. Harken accepts no responsibility
for damage or harm caused by not observing the safety requirements and instructions in this manual. See general
warnings and instructions at http://www.harkenindustrial.com/technical-information/industry-updates/.

Access Rail System – R32
IN150.CLEAR
IN151.CLEAR
R32 COMPONENTS
IN3212.CLEAR
IN10448.CLEAR
IN185.CLEAR
IN3198
HARKEN INDUSTRIAL EXCEPTION: The Access Rail system may be used for human suspension.
WARNINGS AND INSTRUCTIONS. You must carefully read, understand, and follow all of the warnings and instructions in the
manual provided by Harken Industrial in order to avoid an accident. Never, under any circumstances, exceed the maximum rated load.
IN10459.CLR
R32 Trolleys
Part
No. Description
Length Width Fits
railin mm in mm
IN150.CLEAR* Single trolley with pinstop 7 3/8 192 3 11/32 85 32 mm
IN151.CLEAR* Single trolley 7 3/8 192 3 11/32 85 32 mm
IN10448.CLEAR* 2-trolley assembly/coupler 15 3/16 385 3 11/32 85 32 mm
*To order black hardcoat-anodized, remove .CLEAR from end of part number.
R32 Rail & Accessories
Part
No. Description
Length
Mounting
hole spacing Fasteners
Endstop Splice linkft/in m in mm in mm
IN10459.CLR* Pinstop rail for countersunk fasteners 9' 10 1/16" 3 3 15/16 100 3/8 FH 10 FH IN3212, IN185 IN3198
Use only endstops listed above. *To order black hardcoat-anodized, remove .CLEAR or .CLR from end of part number.
IN3198 Splice link 3" 76 mm Purchase one splice link for each rail joint.
IN3212.CLEAR Removable endstop 2 9/16" 65 mm Purchase one endstop for each end of system rail.
IN185.CLEAR* 32 mm rail endstop 2 9/16" 65 mm Purchase one endstop for each end of system rail.
Splice link
For longer spans join track
sections with splice link
IN3198
Endstop
IN185.CLEAR
Pinstop rail
IN10459.CLEAR
Pinstop
Working
trolley
Forged stainless
steel shackle
IN10448.CLEAR
One IN10448 assembly required
per person for CE certification
Fall-arrest
trolley
IN10448
Forged stainless
steel shackle
Pinstop
disengaged
Pinstop
engaged
IN150.CLEAR
Removable endstop
IN3212.CLEAR
IN151.CLEAR

Access Rail System – R32
1a Purpose
Human suspension (rope access) - The rail and dual trolley system is designed for human suspension (rope
access) as an adjustable anchorage point for external access to facilitate external maintenance. The system using
rail and double trolley assembly is designed for rope access (human suspension). The double trolley assembly is
designed for single person use. It consists of a fall-arrest trolley (1) joined to the working trolley (2), using a
permanent coupler.
12
1. Fall arrest trolley
Used with full-body safety
harness
2. Working Trolley
Used for suspension with
working harness or chair
Pinstop Permanent
coupler Stainless steel
shackle
Rail
Fall restraint - Rail plus a single trolley is designed for use as a
mobile anchor point for fall restraint.
Fall arrest - Rail plus a single trolley is also used for fall arrest.
Fall arrest requires a shock-absorbing lanyard so falling force is
reduced.
1 - APPLICATIONS

Access Rail System – R32
1b Standards - Access Rail systems are CE certified and independently tested under EN795.2012 Type B/D, meet
ANSI Z359 and are OSHA compliant. See full list of standards in the appendix.
1c Limitations
Capacity - In normal use, no more than one person may be connected to a two-trolley assembly at one time.
Typically, the combined load (including clothing, tools, etc) must not exceed 140 kg (310 lb). The Access Rail
system has been tested and certified to CEN/TS 16415:2013 and proven capable of supporting up to four users
per three (3) meter rail segment with fasteners at 300 mm (11.8") centers.
Test reports - Test reports available from Harken upon request.
Free fall - Personal fall-arrest systems used with this equipment must be rigged to limit the free fall to no more
than 1.8 m (6').
Suspension - Personal suspension system must be rigged so that no vertical free fall is possible.
Maximum
2 m (6.5')
INCORRECT
CORRECT
Fall arrest clearance - There must be sufficient
clearance below the user to arrest a fall before the user
strikes the ground or other obstruction. Height of user,
plus extended safety lanyard length, must not be more
than the height from rail to ground minus 2 m (6.5').
15°
1e Training - The user must have appropriate training in order to use this product. It is the responsibility of the
purchaser, installer, and user of this equipment to assure that they are familiar with these instructions, trained in
the correct care and use of the equipment, and are aware of the operating characteristics, application limits, and
the consequences of improper use of the equipment. Rope access operators using this equipment must be trained
to a least Irata level 1 or SPRAT level 1 equivalent.
1d Load angle limitations - Rail must be installed between 0° and 5°
of horizontal. See below. Rail can be mounted at various angles on
the horizontal mounting structure. Harken IN10448, IN150, and IN151
trolleys have the ability to handle loading at an angle up to 15° beyond
vertical. Loads beyond 15° from vertical will overload trolley. See
image at right.
1 - APPLICATIONS (Continued)
5°
Maximum to horizontal

Access Rail System – R32
WARNING! Avoid personal injury. The Access Rail System must be
used with a full body safety harness and/or working harness or chair
that meets , ANSI, and OSHA support standards. 12
1. Full-body safety harness secured to fall arrest trolley
Use a full-body safety harness attached to Access trolley with pinstop.
Full-body safety harness must meet /ANSI and OSHA support standards.
2. Working harness secured to working trolley
Use a working harness or chair attached to access trolley. Working harness
or chair must meet /ANSI and OSHA support standards.
2b Other system requirements - Connectors (hooks, carabiners and D-rings) must be capable of supporting at least
22 kN (5000 lb), in accordance with EN362.
Personal fall-arrest systems used with this equipment must meet controlling regulations for the country of use.
Personal fall-arrest systems include, but are not limited to: a shock-absorbing mechanism, lanyard and a full
body harness to limit the maximum arresting force to 4 kN (900 lbf).
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.
2a Dual trolley assembly description
2 - SYSTEM REQUIREMENTS

Access Rail System – R32
3a Drawings by architect - 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.
3b Base materials - Installer shall ensure suitability of base materials and structural materials into which rail is
fixed follows controlling work at height regulations for country of use, and that it is capable of sustaining a proof
test force as detailed in section 4 below.
3c Resources - See list of standards in Appendix A. Consult with work at height regulations for country of use.
3d Avoiding sharp edges - Avoid attaching system components where suspension and/or fall arrest rope may
come in contact with, or abrade against, unprotected sharp edges.
The following is the good faith interpretation by Harken of the standards that we understand are the current
methods that will meet the many test procedures to assure a safely installed Harken Access Rail system.
Harken is not responsible for any future changes, alternate interpretations, or other requirements imposed by
inspection officials. Harken does not accept any responsibility for the consequences of failed installations,
including but not limited to personal injuries, costs or any related damages, or from failed alternative installation
methods.
The Harken Access Rail system is fully tested and certified as a fall arrest anchor device. However, we have
had a number of requests to approve alternative methods of fastening due to different construction and building
techniques.
Regrettably, it is simply not possible for us to approve all these alternatives without detailed engineering, testing,
and surveying of every individual case.
Therefore, the purpose of this guidance is to illustrate how alternative methods of attachment can be considered
by the installer as suitable.
To be 100% explicit, this guidance pertains to the installation of the product and has nothing to do with the
product itself.
Any safety equipment or lifting device must have its installation inspected and surveyed as per standard
industry practice. Likewise, periodic inspection is necessary to ensure nothing has deteriorated due to age, wear
or corrosion. There are well established systems and protocols in place to ensure this is done. This is nothing
special or unique to the Harken Access Rail system.
The installer carries the full responsibility for a proper and safe installation that is tested to meet all relevant
standards. Normally this would be verified by an independent safety engineer/surveyor.
3- REQUIREMENTS FOR PLANNING INSTALLATION
4 - PROOF TESTING - UNKNOWN STRUCTURE

Access Rail System – R32
4a Test objective - The test objective is for the installer to prove their individual installation methodology for each
type of base material/fastener type, or where working with unknown factors.
4b Approving authority - The engineer/surveyor will have to approve the individual test regime and be satisfied it
was done correctly. In practice this normally means overseeing the test.
4c New build representative testing - For new builds or for identical constructions, the proof test can be done on
representative sample pieces. These should be long enough to hold a pair of trolleys and end stops in normal
configuration.
4d Retrofit full testing - In the case of retrofits where the construction is not necessarily known (due to
modifications, corrosion or aging), the proof testing is done in situ.
4e Testing rail high-risk locations - If done in place, then we recommend testing the highest risk locations such
as where personnel gain access to the system, or at the ends of the rails.
4f Testing procedure - Subject to engineer/surveyor approval, the proof test procedure is:
- Insert the trolley in the rail and achieve a load of 1200 kg (2654 lb)
- Hold for three (3) minutes without deformation, paying attention to system stability
- Remove the load and repeat the same in two (2) other locations (or sample pieces)
- The system should remain functional
Note: This is a static test. There is no drop load. The trolley is not expected to move under these conditions.
4g After testing, removing from service - Purchase a separate trolley and rail for proof testing. After testing
carefully remove rail without causing damage to the structure and anchors. If structure is damaged or test has
failed, consult with engineer/surveyor or Harken to determine how to remedy the situation.
The following Code of Practice details the maintenance and testing regime of anchor devices for fall protection. It
recommends an initial sample proof test of 12kN (1200 kgf) for three (3) minutes if the installation is into a base
material that the installer has no information on or has never installed into before. After proof testing at this load,
destroy trolley and rail. Do not use for service or clearly label as "not fit for use". If the samples tested pass, the
rest of the anchor points shall be tested to 6kN (600 kgf), for 15 seconds.
If the anchor device is only used for fall protection, the device should be thoroughly examined and tested annually
to 6kN (600 kgf) for 15 seconds and torque tested per the post installation inspection procedure to follow.
Refer to local codes or regulations for standards that offer guidance on testing of any new or retrofit rail
installation. Our interpretation in practical application is explained in 4a to 4f below.
4 - PROOF TESTING - UNKNOWN STRUCTURE (Continued)
WARNING! Do not use trolley for human suspension after testing to 1200 kg (2654 lb). Do not use
for service. Destroy trolley or clearly label as test only, not fit for use.

Access Rail System – R32
5b Rail and fastener specifications - IN10459 rail uses M10 (3/8") countersunk fasteners.
5c Fastener material - All rail listed in this manual is designed to use stainless steel fasteners with Grade A4 70
(316) or Grade A2 70 (304) specification or greater. Harken does not recommend using aluminum fasteners for
installation. The installer is responsible for the use of non-stainless steel fasteners and could be held liable. Fasteners
must be designed to meet the requirements of controlling work at height regulations for country of use.
IMPORTANT! Use an anti corrosion paste on the fastener head to prevent galvanic corrosion between fastener and
rail. Do not use for nuts on fastener.
5d Fastener spacing - Rail is supplied with mounting holes every 100 mm (3.94"). The Access Rail system has
been tested and certified to EN795-2012 and CEN/TS 16415:2013 and proven capable of supporting up to four (4)
users per three (3) meter rail segment with fasteners at 300 mm (11.8")centers.
5a General comments and responsibility - Installers are responsible for planning, installing and testing
installation. Following are guidelines related to the assembly of Harken parts.
The fastening of the rail must be made by the installer in the manner defined by the designer (engineer enabled)
who is responsible for the design of the system and the related certification. It is not possible to define a standard
number and type of fasteners, as this is dependent on the material into which the rail is installed, the intended
purpose, and the subsequent maximum load requirement of that purpose.
5f Horizontal rail mounting - The rail must be mounted
horizontally, with a maximum angle of 5° to the horizon.
5e Joining rail segments - Fasten each rail segment in
the last fastener hole near the splice link IN3198. The
splice link is not structural and is used only to maintain
alignment and linearity of the individual rail segments.
Splice link
Fastener Fastener
5°
5 - RAIL INSTALLATION GUIDELINES