KARAM Vertex PN 7000 User manual

PRODUCT INFORMATION
with Check Card
This Leaflet Contains
Information on Fixed Line
Systems Consisting of
Vertical Life Line Systems
Vertex PN 7000
Vertex PN 8000
Vertex PN 9000
Horizontal Life Line Systems
Horizon PN 4000
Horizon PN 5000
FIXED LINE SYSTEMS
www.karam.in
For further details on all our products contact below:-
C-35A, Phase-III, ESIP, Sitarganj,
Distt. Udham Singh Nagar, Uttarakhand-262405, India.
Customer Care No. : 1800 103 7085 (Toll Free)
e-mail: [email protected]

Ifthereareanyquestionsorqueriesaboutinstallation,usage,inspectionormaintenanceourteamwouldbeHappy
toHelp.Youmaypleasecontactuson[email protected]
EachinstallationcanbeviewedbyscanningtheQRCodeontherespectivepage.
Disclaimer : Illustrations may be changed without notice. All dimensions and specifications are approximate and
drawingsnottoscale.Ifindoubtclickonthefollowingviewthelatestupdatedmanual.
Thankyou,TogetherletusmakeourworkforceSAFE.
KARAMistheonlycompanyintheworldwhichhasaverticallyintegratedmanufacturingsetup.Startingwithyarnandprocessing
it tomake premiumquality ofWebbingand Rope,converting hotrolled coils,flats andextrusionsof SteelandAluminiumAlloys
intoWorldclassFallArrestComponents.
OvertheyearsKARAMhaswidenedthescopeoffallprotectiontosuitworkersofmostindustriesincludingTelecommunications,
Oil&Gasindustry,Engineeringindustry,PowerTransmissionplantsandConstructionIndustry.
ConstantinnovationandprimefocusonresearchanddesignhasenabledKARAMtoprovideFallprotectionsolutionstoaworker
workinginsomeofthe mosthazardousindustrialconditions.
OperationsatKARAMareunderconstantvigilancetoprovidethefinestinQualityofproductandservice.
FALL PROTECTION EQUIPMENT
MANUFACTURING-
01
CongratulationsonyourPurchase!
You are now a proud owner of KARAM FIXED LINE SYSTEM and CONGRATULATIONS again that you have
steppedintothebusinessofsavingpreciouslives.
To ensure the fixed line systems lives up to all expectations, it is important to read and comply with this instruction
manual.Pleaseensure thatthismanualiseasilyaccessible toallworkersworkingon thelifelineasitisan important
forallpersonnelinstalling,usingandmaintainingthesystem.
The instructionmanual isdesigned andwrittento beused forguidance forinstallation aswell astips onusageand
maintenanceofthesystem.
Vertex PN 7000
Vertex PN 4000
Vertex PN 8000
Vertex PN 9000
Horizon PN 5000
VerticalAnchorage Lifeline
System on Rigid Cable Line
HorizontalAnchorage Life
Line System
VerticalAnchorage Lifeline
System onAluminum Rail System
Mounting Bracket & Rungs
HorizontalAlu-Rail System
Proof loading
Pre-Use Checks
Precautions
Annual Inspection
Tools
Torque Chart
Check Card
INDEX
2-9
10-22
23-35
26-27
28-31
32
33
34
35
36
37
40-41
PRODUCT CODE PAGE No.
www.karam.in

System Ref. Vertex PN 7000
ShockAbsorber
Ref. PN 7000 (02)
Wire Rope (with one end having a
swaged loops)
Ref. PN 9XXXSL (where XXX is the
length of the wire rope meters
Wire Rope Cap
Ref. PN 7000 (12)
Tensioner
Ref. PN 7000 (05)
Extremity Plates for Two Ladder Rungs
Ref. PN 7000 (13)
Rope Grab
Ref. RG-02 112
Intermediate
Ref. PN 2001(04)
Set of U-bolts and Thimbles
Ref. PN 6000 (01)
Step 01 - Installation of The Mounting Bracket (Top & Bottom)
TheSystemPN7000isinstalledinthefollowingway:
Step 1A: Installation of the Mounting Bracket Ref. PN 7000 (01) on
theUpperLadderRung:
Themountingbracketscanbeinstalledondifferentsectionsoftheladder
rungwithorwithoutthehelpofthetwochannelgripsandfastenedonthe
same withthe helpof thegiven fasteners.The drawings belowillustrate
thepositionofthechannelgripsfordifferentsections.
COMPATIBLE
SUPPORT SECTION
PROCESS
Recommended Torque:
VERTICAL LIFE LINE SYSTEM
Ref. PN 7000 MOUNTING BRACKET Ref. PN 7000
03
02
Step 1A :
on the Upper Ladder Rung
Installation of the Mounting Bracket Ref. SA12 .
Step 1A
Step 1B
Step 1C
SomeStructureshavebracketsweldedforfallprotection.InSuchcases.
aneyeboltSA12maybeusedasthemountingbracket,SA12iscertified
toEN795.
Step 1B :
on the Upper Ladder Rung
Installation of the Mounting Bracket Ref. PN 7000 (13)
Step 1C: Installation of the Mounting Bracket Ref. PN 7000 (21)
on the Upper Ladder Rung
ThePN7000(13)bracketsisfixedontworungsoftheladder
The mounting bracket PN 7000(21) is used to hold the life line on a
monopoleuptill120mmdiameter.

Step 3A: Assembling the Cable Extremity: Ref. PN 7000 (03)
Ÿof the cable extremity.
ŸOpen the strands of the wire.
ŸInsert the core of the cable in the poke pin. The core is the straight
strand, all other strands are twisted.
ŸWith a hollow Center-punch hammer the poke pin deep inside the
housing of the cable extremity
ŸTighten the connector of the extremity to the housing of the cable
extremity.
ŸConnect the cable extremity to the mounting bracket (for the upper
ladder rung) by a locking pin.
ŸInsert the pin ring in to the locking pin to lock.
Open up the cable roll and then insert the cable in to the housing
Wire Crimping
Assembly PN7000(14)
(Step 3B)
Aluminum
Ferrules
Aluminum
Endcap
SS Thimble
Heat Shrink
Tube
CABLE TERMINATION
Ref. PN 7000
STEP 3B: Wire CrimpingAssembly PN 7000 (14):
ŸInsert2ferrulesinthewire.
ŸInsertthewireinheatshrinkingtube.
ŸLoopthewireacrosstheStainlessSteelThimble.
ŸInserttheendofthewirebackintotheFerrule.
ŸCrimp the Ferrule using a 20 Ton Hydraulic Crimping head and
2
300mm crimpingdies.
ŸEnsurethatthefirstferruleisascloseaspossibleto thethimble, the
nextferruleshouldbe50mmapartfromthefirstone.
ŸInsertthealuminumcapinthefreeendofwireandcrimpit.
ŸCovertheentireassemblyuptothebottomedgeof theferrulewitha
heatShrinkabletube.
ŸShrinkthetubewithahotairgun.
Cable\ Extrimit Poke\ Pi
STEP 1
STEP 2
STEP 3
STEP 4
0504
STEP 3C: Cable Swaging
ŸInsertthecableintotheswagetube
ŸTheswagetubehasmarkingstoidentifyexactpositionsofcrimping
ŸPlace the swage tube on the hex loc die of a hydraulic crimping
tool(130kNcapacity).
ŸEnsurethatthemarkontheswagetubeisinthe centerofthedie.
ŸOperate the machine to start the swaging operation until the green
lightison.
ŸRepeattheprocessforallmarkings(5timesminimum).
STEP 3D: U bolt & Thimble
ŸLooptheCableacrossthethimbleandensureatleast300mmofthe
cableisoverlapping.
ŸNext, fasten the stainless steel U bolts (Part of Ref PN 6000 (01))
approximately50mmapart.
ŸIfthecableisinexcessmakealoopandtietheloopwithcableties.
ŸIf itisnecessary tocutthe cable,sealthe looseendof thecableby
adhesivetapeaftercuttingit.
50mm
Ubolt & Thimbles
PN 6000 (01)
(Step 3D)
SHOCKABSORBER &
Ref. PN 7000 CABLE TERMINATION
ŸConnect the shock absorber to top mounting bracket by inserting
the fastener and the nylon spacer so as to pass through mounting
bracket and eye of energy absorber.
ŸThe spacer ensure the correct position of energy absorber.
ŸEnsure that the energy absorber is fitted with red arrow on label
pointing down wards
ŸConnect the end extremity to energy absorber by inserting
fastener through eye of energy absorber.
Step 02 - Installation of Shock Absorber
A suitable cable termination may be selected according to the site
condition u-bolts and thimbles are only Allowed at bottom termination
accordingtoEN353.1:2014
Step 03- Cable Termination

INTERMEDIATE & TENSIONER
Ref. PN 7000
0706
EXTENSIONARM
Ref. PN 7000
If the System has been provided with the Extension Arm, this shall be
installedinplaceofUpperMountingBracketasinstep:
1. The Extension Arm is provided pre-installed with the Mounting
BracketfortheUpperendofthesystem.
Followthesimplestepsforeasyinstallation-TopRung
* Hold the extension arm against the upper last three rungs of the
ladder.
* Holdthefisherplateinfrontoftheextensionarm.
* Insert the given U- bolts through the rung in to the fisher plate.
Tighten the nuts of the U-bolts Repeat the exercise for the Second
Rungfromthe topOnthethirdrungoftheladder,fromthetopInsert
the given U-bolt through the ladder rung in to the slot so as to pass
throughtheextensionarmtightenthenutsoftheU-Bolt.
Step 06- Installation of the Extension Arm: Ref. PN7000 (06)
Step 4: Installation of the Intermediate: Ref. PN 2001 (04)
Placethe fisherplate oftheIntermediate onthebackof theladder rung.
Fasten the Intermediate Plate with the fisher plate with the help of the
given fasteners.Ensurethat thecableis inbetweenthe twoarms ofthe
intermediate. Itis recommended toinstall anIntermediate at aninterval
ofevery10mlengthoftheCable.
The intermediates reduces large deflections in the cable due to wind
pressure.
ŸTheTensionerisinstalledatthelowerendofthesystem.
ŸOpen the threads of the extension rod of the tensioner from both
ends.Ensurethat75%ofthethreadisopen.
ŸInsert the eye of the tensioner to the mounting bracket at the lower
ladderrung.
ŸInsertthestainlesssteellockingpinsoastopassthroughtheeyeof
thetensionerandthemountinbrackets.
ŸInsertthepinringinthelockingpintolockit.
Fixthetensionertothewirerope.
ŸFixthethimble(part ofRefPN6000(01))to theeyeofthetensioner
bythegivenfastener
ŸLooptheCableacrossthethimbleandensureatleast300mmofthe
cableisoverlapping.
ŸNext, fasten the stainless steel U bolts (part of Ref PN 6000 (01))
approximately50mmapart.
ŸIfthecableisinexcessmakealoopandtietheloopwithcableties.
ŸIf itis necessaryto cutthe cable,seal theloose end ofthe cableby
adhesivetapeaftercuttingit.
Providingtensiontothewirerope:
ŸOpenboththechucknutsandholdthetensionereye.
ŸInsert a steel rod in the housing of the tensioner and rotate the
tensionerinanticlockwisedirection.
ŸRotateituntilreasonabletensionisachievedinthecable.
ŸTightenboththechucknuts.
Step 5: Installation of the Tensioner: Ref PN 7000 (05)
50mm TheLabelisfixedtothelowermostrungoftheladderusingcableties
Step 07- Label
ADDRESS
Helpline: 09323123468
KARAM INDUSTRIES C-35A, PHASE-III, ESIP, SITARGUNJ,
DISTT. UDHAM SINGH NAGAR, UTTARAKHAND
PRODUCT
CODE
INSTALLATIONDATE
LENGTH
INSPECTION REPORT
/ /
MTRS.
Date : / /
BATCH NO. YEAR OF MANUFACTURE :
REVALIDATION DUE ON

FALLARRESTER
Ref. PN 7000
Step 08 -Installation of the Rope Grab: Ref. RG (02)
Connect Rope Grab to the Cable following the given simple steps:
* Hold the Rope Grab as shown in the figure.
* Push the Rope Grab through the cable and rotate it counter
clockwise.
* Ensure the arrow on Rope Grab points up wards.
* Insert the karabiner of the shock absorbing lanyard (Ref PN 2001
(02)) in the eye of the Rope Grab.
* Connect the other end of the shock absorbing lanyard to the
harness of the user by the other Karabiner.
A/2
A/2
Step 9:Connect the Harness to the Rope Grab
* Checktheharnessthatallthestrapsareconnectedandbucklesare
securedandtheharnesshasbeenadjustedtogiveitasnugfit.
* ConnecttheRopeGrabtothefrontattachmentpointofthefullbody
harness with the help of the Karabiner of the connecting lanyard
(RefPN7000(07)).
* Ensurethatthegateofthe karabinerisclosedandlockedproperly.
0908
RECOMMENDED PPE
Ref. PN 7000
Once the system is installed the user can use a work positioning
harnessalongwithashockabsorbingtwinlanyardtoclimbup.Hecan
use the double lanyard when he needs to exit the fall arrest system
while working on towers. When the user needs to exit from the fall
arrest system in a horizontal plane towards the edge of the tower he
mayneedtotravelrestraintlanyardmodel2003.Whileworkingonthe
tower a work positioning lanyard helps in attaining a comfortable
position.

HORIZONTAL LIFELINE
Ref. PN 4000 (O.H.)
10
HORIZONTAL LIFE LINE
Ref. PN 4000 (O.R.)
Ref. HORIZON PN 4000
(Over the Roof)
Tensioner
Ref.PN4000(03)
WireRope
Ref. PN 9XXXS (Where XXX is the
lengthofthewireropeinmeters)
CarriageBody
Ref.PN4000(08)
CornerPice
Ref.PN4000(06)
Intermediate
Ref.PN4000(10)
CableExtremity
Ref.PN7000(03)
7 STRANDS OF
19 WIRES
Roof Top Anchor Port
Extremity
Ref.PN07(A)
Roof Top Anchor Port
Intermediate
Ref.PN07(B)
11
Ref. HORIZON PN 4000
(Over the Head)
Wire Rope
Ref. PN 9XXXS
Intermediate
Ref. PN 4000 (10)
Carriage Body
Ref. PN 4000 (08)
Spring Type
ShockAbsorber
Ref. PN 4000MU(02)
Cable Extremity
with swaged end
PN 4000 (15)
Inspection Plate
Ref. PN 4000 (20)
Wheel Type Carriage Body
Ref. PN 4000 (17)
OPTIONAL
Spring Type
ShockAbsorber
Ref. PN 4000MU(02)

POSTS
Ref. PN 4000
TYPE SIZE(mm) QTY
8
FASTENERS/CONNECTOR
Blind Rivet
Hex Bolt
Nylock Nut 12X20
12
16
4
4
TRAPEZOIDAL ROOF SHEETS
The post can be fitted using water proof blind rivets. The posts are adjustable
to hold difference rib profiles.
The life line is now ready with shock absorber and tensioner at one end and cable extremity at the other end intermediates are
insertedaccordingtothespanlength.
Wenowneedtoselectsuitablepostsfordifferentkindofrecievingstructure
Thissectiondetailsextremityposts,intermediatePostsandcornerPostfordifferentstructuresavailable.
12
èInsertthecablethroughtheCorner.
èConnecttheCornertotheintermediatepostwiththefastener.
Step D : Corner; Ref. PN 4000(17)
èSticktheends ofthe baseplatesofthepostto theroof withdouble
adhesiveEPDMsheet.
èDrill32holesfortheblindrivets.
èRivetwitharivetinggun.
èCovertherivetswithaweatherproofingflashtape.
èMount the top and the bottom brackets on the base plates using
nutsandbolts.
èConnecttheeyeonthejunctionoftopandbottombrackets
Step A: Roof TopAnchor Post Extremity; Ref. SA07A
Step B : Roof TopAnchor Post Intermediate; Ref. SA 07B
èStick the post to the bottom plate of the roof with double adhesive
EPDMsheet.
èDrill16holesfortheblindrivets.
èRivetwitharivetinggun.
èCovertherivetswithaweatherproofingflashtape.
èMount the top and the bottom brackets on the base plates using
nutsandbolts.
Step C : Intermediate Bracket; Ref. PN 4000(10)
èInsertthecablethroughtheintermediate.
èConnect the intermediate to the receiving structure with the
fastener.
èThe angle of the Intermediate may be changed by inserting the
intermediatefastenertodifferentholesprovided.
Standing Seam Roof Sheets Upto 430 Mm Seam Distance
Thesepostsarefittedontheseamsusingaluminumseamclips.ThePostsareadjustableandcanbefittedonstandingseamroof
upto430mmseamdistance.
13
Step A: Roof TopAnchor Post Extremity; Ref. SA07C
èWithgrubscrewsfixthestandingseamclipstotheseam.
èMount the roof post base plates on the seam clips and with
fasteners.
èMount the top and the bottom brackets on the base plates using
nutsandbolts.
èConnecttheeyeonthejunctionoftopandbottombrackets.
Step B : Roof TopAnchor Post Intermediate; Ref. SA 07D
èWithgrubscrewsfixthestandingseamclipstotheseam.
èMount the roof post base plates on the seam clips and with
fasteners.
èMount the top and the bottom brackets on the base plates using
nuts.
èInsertthecablethroughtheintermediate.
èConnect the intermediate to the receiving structure with the
fastener.
èThe angle of the Intermediate may be changed by inserting the
intermediatefastenertodifferentholesprovided.
Step C : Intermediate Bracket; Ref. PN 4000(10)
Step D : Corner Piece
èInstallthepostasdescribedinStep2.
èInsertthecablethroughtheCornerTube.
èConnecttheCornerpieceassemblytothepostwiththefastener.
POSTS
Ref. PN 4000
Step 1 : Installation of Posts on Receiving Structure

Standing Seam Roof Sheets Upto 600 Mm Seam Distance
These posts are used for larger seam distance up to 600mm.
14
Step D : Corner Piece; PN 4000(16)A
èInstallthepostasdescribedinStep2.
èInsertthecablethroughtheCornerTube.
èConnecttheCornerpieceassemblytothepostwiththefastener.
Step C : Intermediate Bracket; Ref. PN 4000(10)
èInsertthecablethroughtheintermediate.
èConnect the intermediate to the receiving structure with the
fastener.
èThe angle of the Intermediate may be changed by inserting the
intermediatefastenertodifferentholesprovided.
Step B : Roof TopAnchor Post Intermediate; Ref. SA 07F
èWithgrubscrewsfixthestandingseamclipstotheseam.
èMount the roof post base plates on the seam clips and with
fasteners.
èMount the top and the bottom brackets on the base plates using
nutsandbolts.
Step A: Roof TopAnchor Post Extremity; Ref. SA07E
èWithgrubscrewsfixthestandingseamclipstotheseam.
èMount the roof post base plates on the seam clips and with
fasteners.
èMount the top and the bottom brackets on the base plates using
nutsandbolts.
èConnecttheeyeonthejunctionoftopandbottombrackets.
POSTS
Ref. PN 4000
Trapezoidal Roof Sheets
These Posts are suitable for a variety of trapezoidal roof sheet designs.
It has multiple holes to suit different peak distances.
15
Step A: Roof TopAnchor Post Extremity; Ref. SA07G
èStick the base plates of the post to the roof with double adhesive
EPDMsheet.
èDrill16holesfortheblindrivets,fourateachcorner,rotatethebase
0
plateby90 iftheholesdoesnotmatchtheseamposition.
èRivetwitharivetinggun.
èCovertherivetswithaweatherproofingflashtape.
èMount the top and the bottom brackets on the base plates using
nutsandbolts.
èConnecttheeyeonthejunctionoftopandbottombrackets.
Step B : Roof TopAnchor Post Intermediate; Ref. SA 07H
èStick the bottom plate of the roof with double adhesive EPDM
sheet.
èDrill8holesfortheblindrivets.
èRivetwitharivetinggun.
èCovertherivetswithaweatherproofingflashtape.
èMount the top and the bottom brackets on the base plates using
nutsandbolts.
Step C : Intermediate Bracket; Ref. PN 4000(10)
èInsertthecablethroughtheintermediate
èConnect the intermediate to the receiving structure with the
fastener.
èThe angle of the Intermediate may be changed by inserting the
intermediatefastenertodifferentholesprovided.
Step D : Corner Piece; PN 4000(26)
èInstallthepostasdescribedinStep2.
èInsertthecablethroughtheCornerTube.
èConnecttheCornerpieceassemblytothepostwiththefastener.
POSTS
Ref. PN 4000

Standing Seam Roof Sheets
These Posts are suitable for a variety of trapezoidal roof sheet designs.
It has multiple holes to suit different peak distances.
16
Step A: Roof TopAnchor Post Extremity; Ref. SA07I
èWithgrubscrewsfixthestandingseamclipstotheseam.
èMount the roof post base plates on the seam clips and with
fasteners.
èMount the top and the bottom brackets on the base plates using
nutsandbolts.
èConnecttheeyeonthejunctionoftopandbottombrackets.
Step C : Intermediate Bracket; Ref. PN 4000(10)
èInsertthecablethroughtheintermediate.
èConnect the intermediate to the receiving structure with the
fastener.
èThe angle of the Intermediate may be changed by inserting the
intermediatefastenertodifferentholesprovided.
Step D : Corner Piece; PN 4000(27)
èInstallthepostasdescribedinStep2.
èInsertthecablethroughtheCornerTube.
èConnecttheCornerpieceassemblytothepostwiththefastener.
Step B : Roof TopAnchor Post Intermediate; Ref. SA 07J
èWithgrubscrewsfixthestandingseamclipstotheseam.
èMount the roof post base plates on the seam clips and with
fasteners.
èMount the top and the bottom brackets on the base plates using
nutsandbolts.
POSTS
Ref. PN 4000
Trapezoidal Roof Sheets (Blank Posts)
These are blank posts on which holes may be punched to match the roof Profile on trapezoidal roof.
17
Step A: Roof TopAnchor Post Extremity; Ref. SA07K
èUsingthetemplateidentifythelocationoftheholes tobe punched
intheblankbaseplate.
èMountthetemplateandtheblankbaseplateonthebaseofthedrill
machine.
èDrillholesontheblankBaseplatethroughthetemplate.
èMount the top and the bottom brackets on the base plates using
nutsandbolts.
èConnecttheeyeonthejunctionoftopandbottombrackets.
Step B : Roof TopAnchor Post Intermediate; Ref. SA 07L
èUsingthetemplateidentifythelocationoftheholestobepunchedin
theblankbaseplate.
èMountthetemplate andtheblankbase plateonthebaseof thedrill
machine.
èDrillholesontheblankBaseplatethroughthetemplate.
èMount the top and the bottom brackets on the base plates using
nutsandbolts.
Step C : Intermediate Bracket; Ref. PN 4000(10)
èInsertthecablethroughtheintermediate.
èConnect the intermediate to the receiving structure with the
fastener.
èThe angle of the Intermediate may be changed by inserting the
intermediatefastenertodifferentholesprovided.
Step D : Corner Piece; PN 4000(28)
èInstallthepostasdescribedinStep2.
èInsertthecablethroughtheCornerTube.
èConnecttheCornerpieceassemblytothepostwiththefastener.
POSTS
Ref. PN 4000