KStrong FXline AFF6000 User manual

THESE INSTRUCTIONS APPLY TO THE FOLLOWING MODEL:
FXLINE SYSTEMS
INSTALLATION GUIDE
FXline AFF6000
Horizontal Life Line Systems
FXline AFF5000FXline AFF8000
Vertical Life Line Systems
FXline AFF9000
FXline AFF4000 Floor & OverheadFXline AFF7000
FXline AFF4000 Roof Mounted

Disclaimer: Illustrations may be changed without notice. All dimensions and specifications are approximate and drawings not to scale.
If there are any questions or queries about installation, usage, inspection or maintenance our team would be Happy to Help.
Please forward your inquiry to: [email protected]
Warning: The products enumerated in this instruction manual are a part of personal protective, work support, or rescue system. The user must read
and follows the manufacturer's instructions for each component of the system. This manual contains information that is important to the user's safety
and should be kept in a safe place for future reference as needed. Please contact KStrong for any questions regarding the use of this equipment. Fall
arrest systems and equipment are lifesaving products and are designed to reduce the potential of serious injury in the event of a fall. However, in the
event of a fall, the user may experience a force on their body. In case there is a doubt about the user's ability to utilize this product, the user must
consult a physician. Pregnant women and minors are not considered fit for the use of this equipment..
Please read and understand the manufacturer's instructions for each component or part of the complete system. Manufacturer's instructions
must be followed for proper use, care, and maintenance of this product. These instructions must be retained and be kept available for the
user's reference at all times. Alterations or misuse of this product, or failure to follow instructions, may result in serious injury or death.
Note: The user is advised to keep this user instructions document for the life of the product.
01
Vertical Anchorage Lifeline System on Aluminium Rail System and
Vertical Anchorage Lifeline System on Aluminium Rails with Rungs
Product Code Page No.
Vertical Anchorage Lifeline System on Rigid Cable Line FXline AFF6000 2
FXline AFF7000 3-9
AFF4000
(Floor/Ceiling Mounted)
AFF4000
(Roof MOUNTED)
Horizontal Anchorage Life Line System
Horizontal Anchorage Life Line System
INDEX
Vertical Anchorage Lifeline System on Rigid Cable Line
10
11-21
AFF8000 & AFF9000
AFF5000
Horizontal Aluminum System
22-26
27-30
Proof loading
Pre-Use Checks
Precautions
Kstrong Compass App
Tools
Torque Chart
Equipment Record
31
31
32
32
33
34

1. VERTICAL ANCHORAGE LINE SYSTEM ON RIGID CABLE LINE
Ref: FXline AFF6000
02
ŸMaterial: Stainless Steel 316
ŸConstruction: 7x19
ŸDiameter: 8mm
ŸD Shackle: Stainless Steel
Wire Rope (Cable Wire) with D Shackle
Conforms to: EN353-1:2014 + A1:2017
Ref. AFF518XXX(DS) (where XXX is the
length of the wire rope in meters)
Wire Rope Cap
Ref. AFF513100
ŸMaterial : Aluminium Alloy
Set of 2 U-Bolts and 1 Thimble
Ref. AFF513000
ŸU- Bolts : Qty- 2 nos.
Material : Stainless Steel 316
ŸThimble : Qty- 1 no.
Material : Stainless Steel 316
Mounting Bracket
Ref. AFF511000
ŸMaterial of Rope Grab:
Stainless Steel Grade 316
ŸMaterial of Karabiner: Alloy
Steel
ŸAnti inversion mechanism
Rope Grab
Ref. AFG805203
Intermediate
Ref. AFF511500
ŸMaterial: Stainless Steel Grade 316
ŸRecommended Installation - Every 10 m
Tensioner
Ref. AFF514000
ŸQuantity: 1 nos
ŸRegulates tensioning of the cable
Equipped with a Tension Indicator
ŸMaterial: Stainless Steel Grade
316
Shock Absorber
Inspection Plate
Ref. AFF115100
Extension Arm (Finish-ED Coating Black) - Ref.: AFF516600
Optional
ŸMaterial: Stainless Steel 316
ŸCompatible with rung
diameter: Ø25.0mm -
Ø96.0mm
ŸComplies with EN 795 Type A
ŸBreaking Strength > 23 kN
Optional
ŸMaterial: Stainless Steel.
ŸMinimum Breaking Strength:
23 kN
Mounting Bracket
Ref. AFF511001
ŸCompatible with rung
diameter- Ø22.0mm-
Ø114.0mm

Intermediate
ŸRecommended Installation- Every 10 m
ŸMaterial: Stainless Steel 316
Ref. AFF511500
Shock Absorber
Ref. AFF512000
ŸLimits the impact of force in the
event of fall to less than 6 kN
ŸMaterial: Stainless Steel 316
ŸConstruction: 7x19
ŸDiameter: 8mm
ŸMaterial: Stainless Steel 316
ALSO AVAILABLE
Wire rope without loop Ref. AFF518XXX(S)
Wire Rope (Cable Wire)
Ref. AFF518XXX (Where XXX is the Length of
the wire rope in meters)
Wire Rope Cap
ŸMaterial: Aluminium Alloy
Ref. AFF513100
Inspection Plate
Ref. AFF115100
Mounting Bracket*
Ref. AFF511000
ŸBreaking Strength > 23 kN
ŸComplies with EN 795 Type A
ŸMaterial: Stainless Steel 316
Wire Crimping Assembly
ŸMaterial of Rope Grab: Stainless Steel
316
ŸAnti inversion mechanism
ŸMaterial of Karabiner: Alloy Steel
Rope Grab
Ref. AFG805101
ŸU - Bolts: Qty - 2 nos. Material:
Stainless Steel 316
ŸThimble: Qty - 1 no. Material:
Stainless Steel 316
Set of 2 U-Bolts & 1 Thimble
Ref. AFF513000
Tensioner
Ref. AFF514000
ŸQuantity: 1 nos.
ŸMaterial: Stainless
Steel 316.
ŸRegulates tensioning
of the cable.
Equipped with a
Tension Indicator
2. VERTICAL LIFE LINE SYSTEM
Ref: FXline AFF7000
03
Conforms to: EN353-1:2014 + A1:2017

CABLE TERMINATION
Ref. AFF6000 & AFF7000
Ÿ A suitable cable termination may be selected according to the
site condition, u-bolts and thimbles are only allowed at bottom
termination according to EN353.1:2014
STEP 1: CABLE TERMINATION
Wire Crimping
Assembly
(Step 2)
Aluminum
Ferrules
Aluminum
Endcap
SS Thimble
Heat Shrink
Tube
Ÿ Ensure that the first ferrule is as close as possible to the thimble,
the next ferrule should be 50mm apart from the first one.
Ÿ Crimp the Ferrule using a 20 Ton Hydraulic Crimping head and
300mm2 crimping dies.
Ÿ Insert the wire in heat shrinking tube.
Ÿ Loop the wire across the Stainless Steel Thimble.
Ÿ Shrink the tube with a hot air gun.
Ÿ Insert the aluminum cap in the free end of wire and crimp it.
STEP 2: WIRE CRIMPING ASSEMBLY
Ÿ Insert 2 ferrules in the wire.
Ÿ Insert the end of the wire back into the Ferrule.
Ÿ Cover the entire assembly up to the bottom edge of the ferrule
with a heat Shrinkable tube.
04

CABLE TERMINATION
Ref. AFF6000 & AFF7000
Ÿ The swage tube has markings to identify exact positions of
swaging.
STEP 3: CABLE SWAGING
Ÿ Insert the cable into the swage tube.
Ÿ Operate the machine to start the swaging operation until the
green light is on.
Ÿ Repeat the process for all markings(5 times minimum).
Ÿ Ensure that the mark on the swage tube is in the center of the
die.
Ÿ Place the swage tube on the hex loc die of a hydraulic swaging
tool (130kN capacity).
50mm
U bolt & Thimbles
AFF513000
Ÿ Loop the Cable across the thimble and ensure at least 300mm of
the cable is overlapping.
Ÿ If it is necessary to cut the cable, insert aluminium cap in the free
end of wire rope and crimp it
STEP 4: U BOLT & THIMBLE
Ÿ Next, fasten the stainless steel U bolts (Part of Ref AFF513000)
approximately 50 mm apart.
Ÿ If the cable is in excess make a loop and tie the loop with cable ties.
05

INTERMEDIATE & TENSIONER
Ref. AFF6000 & AFF7000
The intermediates reduces large deflections in the cable due to wind pressure.
Ÿ Place fisher plate of the Intermediate on the back of ladder rung.
Fasten the Intermediate Plate with the fisher plate with help of
given fasteners. Ensure that the cable is in between the two arms
of intermediate. It is recommended to install an Intermediate at an
interval of every 10 m length of the Cable.
STEP 5: INSTALLATION OF THE INTERMEDIATE: Ref. AFF511500
06
Ÿ Next, fasten the stainless steel U bolts (part of Ref AFF513000)
approximately 50 mm apart.
Ÿ Rotate it until reasonable tension is achieved in the cable and the
tension indicator disc is free to rotate.
Ÿ Tighten both the chuck nuts.
Ÿ The Tensioner is installed at the lower end of the system.
Ÿ Open both the chuck nuts and hold the tensioner eye.
Ÿ Insert a steel rod in the housing of the tensioner and rotate the
tensioner in anti clock wise direction.
Ÿ Insert the eye of tensioner to the mounting bracket at the lower
ladder rung.
Ÿ Open the threads of extension rod of the tensioner from both ends.
Ensure that 75% of the thread is open.
Ÿ Insert the pin ring in the locking pin to lock it.
FIX THE TENSIONER TO THE WIRE ROPE:
Ÿ Insert the stainless steel locking pin so as to pass through the eye
of the tensioner and the mountin brackets.
Ÿ If it is necessary to cut the cable, insert aluminum cap in the free
end of wire rope and crimp it.
Ÿ Loop the Cable across the thimble and ensure at least 300mm of
the cable is overlapping.
PROVIDING TENSION TO THE WIRE ROPE:
Ÿ If the cable is in excess make a loop and tie the loop with cable ties.
Ÿ Fix the thimble (part of Ref AFF513000) to the eye of the tensioner
by the given fastener.
STEP 6: INSTALLATION OF THE TENSIONER: REF AFF514000

SHOCK ABSORBER & CABLE TERMINATION
Ref. AFF7000
Ÿ A suitable cable termination may be selected according to the
site condition, u-bolts and thimbles are only allowed at bottom
termination according to EN 353.1:2014
STEP 8: CABLE TERMINATION
ŸEnsure that the energy absorber is fitted with red arrow on label pointing
down wards.
ŸThe spacer ensure the correct position of energy absorber.
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.
ŸConnect the end extremity to energy absorber by inserting fastener
through eye of energy absorber.
STEP 7: INSTALLATION OF SHOCK ABSORBER
07

EXTENSION ARM
Ref. AFF6000 & AFF7000
ADDRESS
PRODUCT
CODE
INSTALLATION DATE
LENGTH
INSPECTION REPORT
/ /
MTRS.
Date : / /
BATCH NO. YEAR OF MANUFACTURE :
REVALIDATION DUE ON
STEP 9: INSTALLATION OF THE EXTENSION ARM: Ref. AFF516600
Ÿ The Extension Arm is provided pre-installed with the Mounting
Bracket for the Upper end of the system.
Follow The Simple Steps For Easy Installation-top Rung
If the System has been provided with the Extension Arm, this shall be
installed in place of Upper Mounting Bracket as in step:
Ÿ On the third rung of the ladder, from the top Insert the given U-bolt
through the ladder rung in to the slot so as to pass through the
extension arm tighten the nuts of the U-Bolt.
Ÿ Repeat the exercise for the Second Rung from the top.
Ÿ Hold the extension arm against the upper last three rungs of the
ladder.
Ÿ Hold the fisher plate in front of the extension arm.
Ÿ Insert the given U- bolts through the rung in to the fisher plate.
Tighten the nuts of the U-bolts
STEP 10: LABEL AFF115100
Ÿ The Label is fixed to the lower most rung of the ladder using
cable ties.
08

FALL ARRESTER
Ref. AFF6000 & AFF7000
A/2
A/2
Ÿ Check the harness that all the straps are connected and buckles
are secured and the harness has been adjusted to give it a snug
fit.
STEP 12: CONNECT THE HARNESS TO THE ROPE GRAB
Ÿ Connect the Rope Grab to the front attachment point of the full
body harness with the help of the Karabiner of the connecting
lanyard.
Ÿ Ensure that the gate of the karabiner is closed and locked
properly.
STEP 11: INSTALLATION OF THE ROPE GRAB:
Ref. AFG805203
Ÿ Hold the Rope Grab as shown in the figure.
Ÿ Push the Rope Grab through the cable and rotate it counter
clockwise.
Connect Rope Grab to the Cable following the given simple
steps:
Ÿ Ensure the arrow on Rope Grab points up wards.
Ÿ Connect the other end of the shock absorbing lanyard to the
harness of the user by the other Karabiner.
Ÿ Insert the karabiner of the shock absorbing lanyard AFG8052031
12 in the eye of the Rope Grab.
09
RECOMMENDED PPE

5. HORIZONTAL LIFELINE
Ref. AFF4000 (FLOOR/CEILING MOUNTED)
(FLOOR / CEILING MOUNTED)
Universal Extremity Plate
Ref. AFF113710
ŸMaterial: StainlessSteel 316
ŸMaterial: Stainless Steel 316
ŸConstruction: 7x19
ŸDiameter: 8mm
Wire Rope (Cable Wire)
Ref. AFF518XXX(S) (Where XXX is the
Length of the wire rope in meters)
Swaged Tensioner
Ref. AFF114100
ŸRegulates tensioning of the cable.
ŸMaterial: Stainless Steel 316.
ŸFeature: Swaged termination.
Shock Absorber
Ref. AFF112100
ŸMaterial: Stainless Steel 304
Swaged Cable Extremity
Ref. AFF113210
Carriage body
Ref. AFF119000
ŸMaterial: Stainless Steel 316
ŸFeature: Friction Free movement
Intermediate
Ref. AFF111510
ŸMaterial: Stainless Steel 316
ŸRecommended Installation-
every 15 mtrs.
Inspection Plate
Ref. AFF115100
ŸMaterial: Stainless Steel 316.
ŸAllows crimping of the cable wire at the
desired length, and eliminates danger of
any loose wire.
ŸFeature: Swage termination
OPTIONAL
Wheel Type
Carriage Body
Ref. AFF119100
Double Tandem Pulley Small
with SS Sheaves
Ref. AFX206009
Conforms to
EN 795:2012 Type C, TS 16415:2013
10

7. HORIZONTAL LIFELINE
Ref. AFF4000 (ROOF MOUNTED)
Tensioner
Ref. AFF114100 Wire Rope
Ref. AFF518XXX(S) (Where XXX is the
length of the wire rope in meters)
Carriage Body
Ref. AFF119000
Intermediate
Ref. AFF111510
7 Strands of
19 Wires
Roof Top Anchor Port Extremity
Ref. AFA935100
Shock Absorber
Ref. AFF112100
Swaged Cable Extremity
Ref. AFF113210
Corner Post
Ref. AFA935201
Conforms to
EN 795:2012 Type C, TS 16415:2013
11

These Posts are suitable for a variety of trapezoidal roof sheets with a minimum thickness of 0.40mm. The posts have multiple holes to suit
different peak distances ranging from 217mm to 465mm.
TRAPEZOIDAL ROOF SHEETS
Ref. AFF4000
STEP B: ROOF TOP ANCHOR POST INTERMEDIATE; Ref. AFA935151
Ÿ Mount the top and bottom brackets on base plates using
nuts and bolts.
Ÿ Stick the base plates of post on the roof sheet with double
adhesive tape.
Ÿ Drill 16 holes for the blind rivets. 4 drills each at 4 corners
of base plates.
Ÿ Rivet with a riveting gun
Ÿ Insert the cable through intermediate.
Ÿ Connect the intermediate on the junction of top and
bottom brackets of roof post AFA935151 with fastener.
STEP C: INTERMEDIATE BRACKET; Ref. AFF111510
Ÿ The angle of Intermediate may be changed by changing
the position of intermediate fastener (pair) in to different
holes provided.
Ÿ Drill 16 holes for blind rivets. 4 drills each at 4 corners of
base plates.
Ÿ Stick the base plates of post on the roof sheet with
double adhesive tape.
Ÿ Rivet with a riveting gun.
STEP D: CORNER PIECE; AFA935201
Ÿ Insert cable through the Corner Tube.
Ÿ Mount the top and bottom brackets on base plates using
nuts and bolts.
Ÿ Stick the base plates of post on the roof sheet with double
adhesive tape.
Ÿ Rivet with a riveting gun.
STEP A: ROOF TOP ANCHOR POST EXTREMITY; Ref. AFA935101
Ÿ Connect eye on the junction of top and bottom brackets
Ÿ Drill 16 holes for the blind rivets. 4 drills each at 4 corners of
base plates.
12

These Posts are suitable for a variety of trapezoidal roof sheets with a minimum thickness of 0.40mm. The posts have multiple
holes to suit different peak distances ranging from 217mm to 465mm.
TRAPEZOIDAL ROOF SHEETS
Ref. AFF4000
ROOF ENERGY ABSORBER POST; Ref. AFA935310
Ÿ Stick the ends of the base plates of the post to the roof with
double adhesive EPDM sheet.
Ÿ Drill 16 holes for the blind rivets.4 at each corner of the
base plate.
Ÿ Rivet with a riveting gun.
Ÿ Cover the rivets with a weather proofing flash tape.
ROOF CONSTANT ENERGY ABSORBER POST; Ref. AFA935320
Ÿ Stick the ends of the base plates of the post to the roof with
double adhesive EPDM sheet.
Ÿ Cover the rivets with a weather proofing flash tape.
Ÿ Rivet with a riveting gun.
Ÿ Drill 16 holes for the blind rivets.4 at each corner of the
base plate.
13

These Posts are suitable for a variety of Standing Seam roof profiles. The posts have multiple holes to suit different peak distances.
STANDING SEAM ROOF SHEETS
Ref: AFF4000
Ÿ Mount the top and the bottom brackets on the base plates using nuts
and bolts.
Ÿ Mount the roof post base plates on the seam clips with fasteners.
STEP A: ROOF TOP ANCHOR POST EXTREMITY; Ref. AFA935102 / AFA935103
Ÿ Connect the eye on the junction of top and bottom brackets.
Ÿ Fix standing seam clips to the roof seam with grub screws.
STEP B: ROOF TOP ANCHOR POST INTERMEDIATE; Ref. AFA935152 /
AFA935102
Ÿ Mount the roof post base plates on the seam clips with fasteners.
Ÿ Mount the top and the bottom brackets on the base plates using
nuts and bolts.
Ÿ Fix standing seam clips to the roof seam with grub screws.
Ÿ The angle of Intermediate may be changed by changing the
position of intermediate fastener (pair) in to different holes
provided.
STEP C: INTERMEDIATE BRACKET; Ref. AFF111510
Ÿ Insert the cable through intermediate.
Ÿ Connect the intermediate on the junction of top and bottom
brackets of roof post AFA935152 with fastener.
Ÿ Insert cable through the Corner Tube.
STEP D: CORNER PIECE; AFA935202 / AFA935203
Ÿ Mount the seam clips on the base plates of roof post with
fasteners.
Ÿ Fix standing seam clips to the roof seam with grub screws.
14

These Posts are suitable for a variety of Standing Seam roof profiles. The posts have multiple holes to suit different peak distances.
STANDING SEAM ROOF SHEETS
Ref: AFF4000
Ÿ Connect the eye at the top of the post. Lock the thread of the eye
with the grub screw.
Ÿ With grub screws and Allen bolts fix the standing seam clips to the
seam.
CONSTANT FORCE ENERGY ABSORBER POST ; Ref. AFA935340
Ÿ Mount the roof post base plates on the seam clips and with
fasteners.
15

For fragile roof sheets, the sheet is to be cut open allowing the posts to be installed on the rafter or truss using Fischer plates. The posts are available
in sizes of 300mm, 500mm, and 750mm and can be selected depending on the position of the rafter.
AFA935831
AFA935821
STEP C: CORNER ROOF TOP ANCHOR POST
Ÿ Place the top flange of the post on the metal rafter of
the roof.
Ÿ Place the bottom flange of the corner piece on the top
flange of the post.
Ÿ Tighten the nut and bolt to secure the corner to the
post.
Ÿ Insert the studs.
Ÿ Hold the bottom plate on the bottom side of the
structure or on the top flange in case of I beam.
Ÿ Tighten the nuts on the top and bottom of the posts.
Ÿ Insert the cable in the corner tube.
AFA935831
AFA935821
AFA935851
Ÿ Insert the studs.
Ÿ Insert the cable in the Intermediate.
Ÿ Hold the bottom plate on the bottom side of the
structure or on the top flange in case of an I Beam.
Ÿ Tighten the nuts and bolt to secure the intermediate to
the post.
Ÿ Place the top flange of the post on the metal rafter of
the roof.
Ÿ Tighten the nuts on the top and bottom of the posts.
STEP B: INTERMEDIATE ROOF TOP ANCHOR POST
Ÿ Place the Intermediate on the top flange.
AFA935831
AFA935821
Ÿ Place the top flange of the post on the metal rafter of
the roof.
Ÿ Insert the studs.
Ÿ Place the universal extremity plate on the top flange.
STEP A: EXTREMITY ROOF TOP ANCHOR POST
Ÿ Hold the bottom plate on the bottom side of the
structure or on the top flange in case of an I Beam.
Ÿ Tighten the nuts on the top and bottom of the posts.
Ÿ Tighten the nuts and bolts to secure the universal
extremity plate to the post. AFA935811
AFA935801
Ref: AFF4000
16

This post can only be installed on the purlins
TOGGLE ANCHOR
Ref: AFA935301
Ÿ Insert the rubber washer followed by steel washer in
the threaded rod.
Ÿ Insert the pipe with a plastic pad at either end in the
threaded rod.
Ÿ Tighten the anchorage Eye on the end of the threaded
rod.
Ÿ Adjust the flanges up or down the threaded stud (by
rotating), so that when the pipe is inserted in the
threaded stud, at least 15mm of thread is available at
the top to tighten the eye.
Ÿ Lock the threads of the eye by tightening the grub
screw present in the eye with an Allen key.
Ÿ Insert the base plate in the threaded rod. Ensure that
the base plate sits firmly on two ribs of the roof sheet.
Ÿ Insert a nut in the threaded rod and tighten it. Now the
purlin and roof sheets are sandwiched between the
flanges (at the bottom of the purlin) and the steel
washer at the top of the roof sheet. The rubber washer
helps in water proofing.
Ÿ Using a 36mm hole saw, drill a hole directly through
the roof sheet and purlin.
Ÿ Insert the threaded stud with flanges closed to
maximum, allowing the stud to pass through the hole.
Once the flanges open, anchor will take its place.
17

This post is used as an intermediate post.
TOGGLE ANCHOR
Ÿ Insert a nut in the threaded rod and tighten it. Now the
purlin and roof sheets are sandwiched between the
flanges (at the bottom of the purlin) and the steel
washer at the top of the roof sheet. The rubber washer
helps in water proofing.
Ÿ Insert the rubber washer followed by steel washer in
the threaded rod.
Ÿ Insert the base plate in the threaded rod. Ensure that
the base plate sits firmly on two ribs of the roof sheet.
Ÿ Adjust the flanges up or down the threaded stud (by
rotating), so that when the pipe is inserted in the
threaded stud, at least 15mm of thread is available at
the top to tighten the eye.
Ref: AFA935301WE
Ÿ Insert the pipe with a plastic pad at either end in the
threaded rod.
Ÿ Using a 36mm hole saw, drill a hole directly through
the roof sheet and purlin.
Ÿ Insert the threaded stud with flanges closed to
maximum, allowing the stud to pass through the hole.
Once the flanges open, anchor will take its place.
Ÿ Now insert the intermediate AFF111510, and tighten
the nut.
18

CABLE TERMINATION & SHOCK ABSORBER
Ref. AFF4000 Roof Mounted, Wall & Ceiling Mounted
STEP 1: UNIVERSAL EXTREMITY ANCHOR PLATE: Ref. AFF113710
STEP 2: SHOCK ABSORBER: Ref. PN AFF112100
Ÿ Insert the connector to the universal extremity plate.
Ÿ Apply tension to the cable until the L tension indicator plate
touches the coil of shock absorber.
Ÿ Connect the other connector to the tensioner.
The Universal Extremity Anchor plate can be installed on metal as well as
concrete structure by using M16 fasteners. Chemical fasteners are used to fix
the brackets to the concrete wall and Stainless Steel fasteners for metal
structure. Refer to Hilti HVU installation guide for Chemical fasteners.
19