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

Standing Seam Roof Sheets (Blank Posts)
There are blank posts on which holes may be punched to match the roof profile on standing seam roof.
18
Step A: Roof TopAnchor Post Extremity; Ref. SA07M
èUsing thetemplateidentify thelocationof theholesto bepunched
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 07N
èUsing thetemplate identifythe locationofthe holesto bepunched
intheblankbaseplate.
èMountthetemplateandtheblankbaseplateonthebaseof thedrill
machine.
èDrillholesontheblankBaseplatethroughthetemplate.
èMount the top and the bottom brackets on the base plates using
nutsandbolts.
Step C: Intermediate bracket: Ref. PN4000(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
èConnecttheCornerpieceassemblyto thepost withthefastener.
POSTS
Ref. PN 4000
Step A: Extremity Roof TopAnchor Post SA25
èPlace the top flange of the post on the metal rafter of the roof or
gratingofthewalkway.
èHoldthe bottomplate onthebottomside ofthe structureoron the
topflageincaseofanIBeam.
èInsertthestuds.
èTightenthenutsonthetopandbottomoftheposts.
èPlacetheuniversalextremityplateonthetopflange.
èTightenthenutsandboltstosecuretheuniversalextremityplateto
thepost.
Step B :Intermediate Roof TopAnchor Post SA25
èPlace the top flange of the post on the metal rafter of the roof or
gratingofthewalkway.
èHoldthebottomplateonthebottomsideofthestructure.
èInsertthestuds.
èTightenthenutsonthetopandbottomoftheposts.
èInsertthecableintheIntermediate.
èPlacetheIntermediatePN4000(10)onthetopflange.
èTighten the nut and bolt to secure the universal extremity plate to
thepost.
Step D : Corner Roof TopAnchor Post SA24; PN 4000(21)
èPlace the top flange of the post on the metal rafter of the roof or
gratingofthewalkway.
èHoldthebottomplateonthebottomsideofthestructure
èinsertthestuds
èTightenthenutsonthetopandbottomoftheposts.
èInsertthecableinthecornertube.
èPlacethebottomflangeofthecornerpieceonthetopflangeofthe
post.
èTightenthenutandbolttosecurethecorner tothepost.
for frasite roof on roof with wooden rafters, the top layer of the roof cut open and roof posts are installed on the rafter using
fischer plate. The post are available in sizes of 300mm, 500mm, and 750mm and can be selected depending on the
position of the rafter.
Forroofshavingfragilesheetsormetalgratings,SteelAnchorpostsareused.Theroofsheetiscuttoexposetherafterbelowa
suitable postis installed. SA25is usedfro rectangularhollow sections,where the sectionis holdusing topand bottom flange
platesusing4studs.IncaseofanIbeamthepostSA56isusedwhichholdsthetopflangeusingtwobottomflangeplate.Incase
ofgratingthepostisfixedonthesectionbelowwhichholdsthegrating.
19
SA56 SA25
SA56 SA25
SA56 SA25
POSTS
Ref. PN 4000

CABLE TERMINATION & SHOCKABSORBER
Ref. PN 4000
Cable\ Extrimit Poke\ Pi
STEP 1
STEP 2
STEP 3
STEP 4
èInsertthecableintotheswagetube
èTheswagetubehasmarkingstoidentifyexactpositionsofcrimping
èPlace the swage tube on the hex loc die of a hydraulic crimping
tool(130kNcapacity).
èEnsurethatthemarkontheswagetubeisinthe centerofthedie.
èOperatethe machineto starttheswaging operationuntil thegreen
lightison.
èRepeattheprocessforallmarkings
1320
Step 2A : Cable Extremity
èInsertthecableintothehousingofthecableextremity.
èOpenthestrandsofthewire.
èInsert the core of the cable in the poke pin. The strand which is
Straightisthecore,theotherstrandsaretwisted.
èWith a hollow Centre punch hammer the poke pin deep inside the
housingofthecableextremity.
èTighten the connector of the extremity to the housing of the cable
extremity
èConnect the cable extremity to the universal end extremity Plate
PN4000(09)byalockingpin.
èInsertthepinringintothelockingpintolock.
Step 2B : Cable Swaging
èInserttheconnectortothe universalextremityplate,PN4000(09)
èConnecttheotherconnectortothetensionerPN4000(03)
èApplytensiontothecableuntiltheLtensionindicatorplatetouches
thespring
èTake the shock absorber out of service when the spring is
elongatedduetoanimpactfromafalloftheuser.
Step 3: Shock Absorber: Ref. PN 4000MU(02)
TENSIONER & INTERMEDIATE
Ref. PN 4000
èOpen the threads of the tensioner from both ends. Ensure 75% of
thethreadisopen.
èInsert the locking pin so as to pass a the eye of the tensioner and
theShockAbsorber,PN4000(07).
èInsertapinringinthelockingpintolockit.
21
èInsertthecablethroughtheintermediate
èConnect the intermediate to the receiving structure with the
fastener.
èThe angle of the Intermediate may be changed by inserting the
plasticintermediatefastenertodifferentholesprovided.
Step 6 : Intermediate; Ref. PN 4000(10)
Step 4 : Mounting the tensioner on the system
èHoldthetensionereye
èInsert thetensioning toolin thehousingof thetensioner androtate
the tensioner in clock wise direction. Rotate it until reasonable
tensionisachievedinthecableandthegreenindicatorrodisvisible
inhe shockabsorber.Stopapplyingtension whentheredindicator
beginstoappearinshockabsorber
èTightenboththechucknuts
Step 5 : Applying Tension To the line
UPWARD PULL FOR
TENSION

CARRIAGE BODY
Ref. PN 4000
22
Oncethesystemisinstalledtheusercanuseawork positioningharness alongwith ashock absorbingtwinlanyardtoclimbup.
Hecanusethedoublelanyardwhenheneedstoexitthe fallarrestsystemwhileworkingontowers. Whentheuserneedstoexit
fromthefallarrestsysteminahorizontalplanetowardstheedgeofthetowerhemayneedtotravelrestraintlanyardmodel2003.
Whileworkingonthetoweraworkpositioninglanyardhelpsinattainingacomfortableposition.
Toconnectthelinetotheuser,thereisafreelymovingCarriageBodyPN4000(08),whichmovesalongthelengthofthelinewith
theuser,whoisconnectedto itby usinga karabinerfollowed byaConnectingelementconnectedtothefullbodyharnessofthe
user.
Thecarriagemaybeattachedordetachedfromthelineatanygivenpointbytwoconsecutivedeliberateaction.Inapplicationson
roofs,thecarriermaybeusedoneithersideoftheroof.
RECOMMENDED PPE
Step 7 : Carriage Body
VERTICALANCHORAGE LIFE LINE SYSTEM
Ref. PN 8000 & PN 9000
Aluminium Rail Extremity
PN 5000 (02)
Alu.Rail Intermediate
PN 5000 (01)
Rung Clamp
PN 8000 (03) Junction
PN 5000 (08)
Rung Clamp
PN 8000 (03) Ceiling Mounting Bracket
PN 5000 (06)
Ladder Rung
PN 9000 (01)
Ladder Rung
PN-9000(01.1)L
Ladder Rung
PN-9000(01.1)R
Alu. Extension
PN 8000 (02)
Karabiner
PN 111
Vertical Trolley
PN 8000 (01)
VERTICALANCHORAGE LINE SYSTEM
Ref. PN 8000 & PN 9000
23

JUNCTION & ALU RAIL EXTREMITY
Ref. PN 8000 & PN 9000
Step 02 : Junction: Ref. PN 5000 (08)
Join two lengths of Alurail intermediate. Match the sections of both the
Alu. Rail. Place the junction plate on either side of theAlu. Rail with the
holesofjunctionplatematchingwiththoseofAlu.Railintermediate.
Fixboththeplatesby4setsoffasteners.
Ensurethatthegapbetweenthetworailsisnotgreaterthan1.5mm.
24
Step 01 : Installation of Alu Rail Extremity PN 5000 (02)
ALU RAIL EXTENSION & TROLLEY
Ref. PN 8000 & PN 9000
Step 4: Vertical Trolley: Ref. PN 8000(01)
* Insert thetrolley intheAlu. Rail extremity. Pressthe terminationof
theextremityandpassthe trolleyoverthetermination.
* AfterthetrolleyslidesontheAlu.Railtheterminationconesbackto
its original position ensuring that the trolley does not slide off the
Alu.Rail.
SAFETY LOCKING PIN
L - CLAMP
LOCKING JIB
L - CLAMP
LOCKING JIB
25
Step 3: Installation of Alu Rail Extension PN (8000 (03))
* Repeat step 3 to join the Alu rail Extension with the Alu Rail
Intermediate.
* Select the correctAlu Rail Extension Support depending upon the
typeofroof
* Connect the Alu rail Extension support to the end of the Alurail
Extensionusingamountingnut.
* For trapezoidal roof sheets use blind rivits to install the Alurail
Extensionsupport tothe roof,forstandingseam fastenthe bracket
usingnutbolts

RUNGS, HALFAND FULL
Ref. PN 8000 & PN 9000
TheAlurailhastwoholesatregularintervals toholdtherungs,insertthe
boltalongwithwasherintotherungandtightenit
Step 03 : Installation of Ladder Rung PN9000(01)
27
RECOMMENDED PPE
Forked Lanyard with Energy absorber
Ref: PN 351
Work Positioning Lanyard with GripAdjuster
Ref: PN 242
Rhino Full Body Harness
Ref: PN 56
Guided Type Fall Arrester System on Flexible
Anchorage Line
Ref: PN 2003
Step 4: Installation of Alu Rail Extension PN (8000 (03))
* Repeat step 3 to join the Alu rail Extension with the Alu Rail
Intermediate.
* Select the correctAlu Rail Extension Support depending upon the
typeofroof
* Connect the Alu rail Extension support to the end of the Alurail
Extensionusingamountingnut.
* For trapezoidal roof sheets use blind rivits to install the Alurail
Extensionsupport tothe roof,forstandingseam fastenthe bracket
usingnutbolts
27
MOUNTING BRACKET
Ref. PN 8000 & PN 9000
Step 1: Installation of Mounting Nut PN5000(03)
Insert the mounting nut into the alu rail extremity. The first mounting nut
must be at 300mm from the bottom edge and second needs to be
1500mmfromthefirstmountingnutandsoon.
The Mounting Brackets can be installed on metal as well as concrete
structure by special fasteners. Chemical fasteners are used to fix the
brackets to the concrete wall and SS fasteners for metal structure. The
shorter end of the bracket is mounted on alu rail by mounting nut and
longerendtothereceivingstructurebyusingfasteners
Step 02 : Installation of Alu Rail Extremity PN5000(02) &
Mounting Bracket PN5000(06)
26

HORIZONTAL ALU- RAIL SYSTEM
Ref. PN 5000
HORIZONTAL ALU- RAIL SYSTEM
Ref. PN 5000
28
MOUNTING NUT & MOUNTING BRACKET
Ref. PN 5000
Step 2A: Wall Mounting Bracket Flush Type: Ref. PN 5000 (04)
èConnectthebrackettothemountingnutasshowninthedrawing.
èTo install the mounting bracket in concrete use 12 mm Chemical
fasteners.
OptionalAccessory:ChemicalFastenerSA12(04)
Concrete:25mPA
Step 2B: Wall Mounting Bracket with Recess: Ref. PN 5000 (05)
èConnectthebrackettothemountingnutasshowninthedrawing.
èTo install the mounting bracket in concrete use 12 mm Chemical
fasteners.
OptionalAccessory:ChemicalFastenerSA12(04)
Concrete:25mPA
Step 2C: Ceiling Mounting Bracket: Ref. PN 5000 (06)
èConnectthebrackettothemountingnutasshowninthedrawing.
èTo install the mounting bracket in concrete use 12 mm Chemical
fasteners.
èOptionalAccessory:ChemicalFastenerSA12(04)
èConcrete:25mPA
29
Insert the mounting nut in the channel as shown in the drawing. The
mountingbracketsmaythenbeconnectedtotheAluRailbyafastener.
Step 01: Mounting Nut

BEND
Ref. PN 5000
Step 3A: Curved Alu. Rail (Outer Wall Mounted):
Ref. PN 5000 (09A)
èJoin the curved Alu. Rail with the Alurail intermediate. Match the
sectionsofboththeAlu.Rail.
èPlacethejunctionplate oneithersideoftheAlu.Rail withtheholes
ofjunction platematchingwiththoseofAlu. Railintermediateand
curvedalurailfixboththeplatesby4setsoffasteners.
èEnsure that the gap between the two rails is not greater than
1.5mm.
Step 3B: Curved Alu. Rail (Inner Wall Mounted):
Ref. PN 5000 (09B)
èJoin the curved alurail with the Alurail intermediate. Match the
sectionsofboththeAlu.rail.
èPlacethejunctionplate oneithersideoftheAlu.Rail withtheholes
of junction plate matching with those ofAlu. Rail intermediate and
curvedalurailfixboththeplatesby4setsoffasteners.
èEnsure that the gap between the two rails is not greater than 1.5
mm.
Step 3C: Curved Alu. Rail (Floor/ceiling):
Ref. PN 5000 (10)
èJoin the curved alurail with the Alurail intermediate. Match the
sectionsofboththeAlu.rail.
èPlacethejuncti-onplateoneithersideoftheAlu.Railwiththeholes
of junction plate matching with those ofAlu. Rail intermediate and
curvedalurailfixboththeplatesby4setsoffasteners.
èEnsure that the gap between the two rails is not greater than 1.5
mm.
30
TROLLEY & RECOMMENDED PPE
Ref. PN 5000
Step 4A: Trolley For Wall Ref. PN 5000 (13)
èInsert thetrolleyin theAlu. Railextremity. Pressthe terminationof
theextremityandpassthetrolleyoverthetermination.
èAfterthetrolleyslidesontheAlu.Railtheterminationconesbackto
its original position ensuring that the trolley does not slide off the
Alu.Rail.
Step 4B: Trolley For Ceiling/Floor: Ref. PN 5000 (12)
èInsertthe trolleyin theAlu.Rail extremity. Presstheterminationof
theextremityandpassthetrolleyoverthetermination.
èAfter thetrolleyslides ontheAlu. Railthetermination comesback
toitsoriginalpositionensuringthatthetrolleydoesnot slideoffthe
Alu.Rail.
31
Once the system is installed the user can use a work positioning harness along with a shock
absorbing twin lanyard to climb up. He can use the double lanyard when he needs to exit the fall
arrest systemwhile workingon towers.When the userneeds toexit fromthe fallarrest systemin a
horizontal planetowardsthe edgeof thetowerhe mayneed totravelrestraint lanyardmodel 2003.
Whileworkingonthetoweraworkpositioninglanyardhelpsinattainingacomfortableposition.
RECOMMENDED PPE

PROOF LOADING
PROCESS OF PROOF LOADING OF HORIZONTALAND VERTICAL LIFE LINES
Thecableterminationmaybeproofloadedupto6KNusinghydrajawstestingequipment.
Thehydrajawsequipmentpullsthewireoutofthetermination,usingahydrauliccylinder.
Thepullforceisincreasedto6kN,&thepressuregauge,mountedonthecylinderdisplaystheexact
tensionachieved.Once6KNisachievedthetensionisreleased.
Nowweknowthatthecableterminationissuccessful
PRE USE-CHECKS
Checks and Precautions
èOnceinstalled,itisimportanttoinspectthecompletelinebymovingtheentirelengthoflifeline.
èOnsitetestingofthereceivingstructuremaybeprovidedatanextracost.
It is mandatory for the Site Inspector/ Supervisor and the actual users of the system to perform a
thorough check of the same before carrying out work. KARAM conducts a brief training of all
concernedpersonnelon thesubject ofPre-UseInspectionof theSystem asperadefinedguideline
afterthesystemhasbeeninstalledbyKARAMpersonnel.
Post Installation Inspection
Pre Use-Checks
Donotusethesystemreceivingstructureisfoundweak.
Checking the receiving structure
Checking the System
èCleanthesystemfromdust/dirt.Checkforanymechanicaldefects.
èCheckforwearandtearinallcomponentsorunusualbendingordeformation.
èCheckforanymodificationsdonebytheuser.
èCheckforanymissingcomponent.
èCheckforanydamagesthatmayhavebeencausedduetoweldingwhilemaintenanceofother
equipment.
èCheck the Identification Plate. The system needs to be put out of service if the label is not
legibleormissing.
Checking the Cable
èSee thatthere issufficienttension onthe cableby checkingthe tensionindicator inthe shock
absorber.
èChecktheconditionofthecable.Wearhandglovesandcheckthewirefromallsides.Checkfor
brokenstrandsoranydeformityinthecable.Reportifstrandsarefoundbroken.
32 33
Hydra Jaws Lifeline Testing

PRECAUTIONS WHILE USING
Precautions While Using the System
The following points of precautions needs to be considered
For safe use of the Fixed Line Systems
èThe life line is for the purpose of fall protection while working at height.Aback up fall arrest
systemisrequiredwhentransitioningonandoffthelifelinesystem.
èNeverdisengagethefallarrestinglanyardfromthelifelinewhileworkingatheight.
èAvoid using grease to lubricate the system. If any fall is reported put the system out of use.
Contactthemanufacturerforrepairsandre-validation.
èOnly certified KARAM full body harness with proper attachment anchorage points should be
wornwhileusingKARAMFixedLineSystems.
èDo not alter or misuse this equipment. Always take an advice from KARAM personnel while
using this equipment in combination with components or subsystems other than those
described in this manual. Usage of certain component/sub system may interfere with the
proper functioning of this equipment and the system may not deliver the working as per its
intendeduse.InsuchcaseKARAMmaynotbeheldresponsibleforanymalfunction.
èThelifelinesmustbekeptfreefromdust,greaseetc.,byperiodiccleaning.Thesystemcanbe
cleanedbyasoftdrycloth.
Hazards
Hazardsexistinginimmediateenvironmentmayrequireadditionalprecautionstolimitthepossibility
ofinjurytotheuserordamagetotheequipment.Hazardsmayincludebutarenotlimitedto,extreme
temperatures, caustic chemicals, corrosive environments, high voltage power lines, explosive or
toxicgases,movingmachinery,sharpedges,highvelocitywindsEtc.Donotexposetheequipment
toanyhazardwhichitisnotdesignedtowithstand.Consultthemanufacturerifindoubt.
Rescue Plan
Itismandatorytoensurethat theuser shallhave arescue planand meanstoexecuteitwhileusing
thisequipment.Therescueplanneedstobeprojectspecific.Theemployeesmustbetrainedinself-
rescueoralternativemeansshallbeprovidedforpromptrescueinaneventofafall.
Alwaysworkinapairtoensurethatinaneventofafallyourpartnermayhelpinrescue.
34
ANNUAL INSPECTION KARE
Fall Protection Equipment is a life saving product. As per the EN 365 of PPE
Directives89/686/EEC, It is mandatory to have a ‘Competent Authority’ to inspect the Fall
Protection Equipment at least once annually.
KARAM Kare Inspection software takes care of the equipment for at least 20 years.
èCloud Based Online as well as off line software.
èCaptures Geo Coordinates where the system is installed.
èRFID / Bar code compliant.
èGenerates Report in real time.
èReminds user of items due for inspection.
èCaptures images of components.
èuser customizable.
èCan be integrated to client software.
èReports can be shared with multiple recipients in real time.
Inspection and Revalidation
Kare
35

TOOLS
TOOLS
MACHINES
ANCHORS
Crimping Plier
Double End Spanner Socket Set
Tensioner Tightening Tool
Hydra Jaws Lifeline Testing Hydraulic Crimping Head Power Bird
Riveting Machine
Swaging Tool
Cordless Impact Wrinch
Hammer Drill Machine
Cordless Drill Machine
Bolt Cutter Allen Key
36 37
Ring Spanner
Hex Bolt
Wrench Size
Socket Size
6 8 10 12 16
10 13 16 19 24
10 13 16 19 24
Allen Bolt Size
Allen Key Size
Allen Grub Screw Key Size
6 8 10 12
4 6 8 10
3 4 5 6
WRENCH SIZE
ALLEN KEY SIZE
TORQUE CHART
Bolt size
Recommended Torque:
6 mm 8 mm 10 mm 12 mm 14 mm 16 mm
9 Nm 22Nm 29 Nm 50 Nm 80 Nm 125Nm
Measuring Tools
Detect Digital Torque Wrench Distance Meter Laser Tool
Tape
Vernier
Consumables, Miscellanous Tools
Blower ChemicalApplicator
Dust Pump Hole Saw Cutter
Hot Air Gun Setting Tool
Paint Brush Drill Bit Impact Drill