Trublue XL Series User manual

NOTE TO INSTALLERS
Always Read Instructions Before Use
Leave this Operator Manual attached to the auto belay. The
Operator Manual contains information relating to the safe
use of the TRUBLUE Auto Belay and includes all product
registration and warranty information. This document may
only be removed by the end user. Ensure that this Operator
Manual is readily available to operators at all times
Head Rush Technologies TRUBLUE Operator Manual
P/N 10055-06
Head Rush Technologies products are covered by a number of patents, including
U.S. Patents 8,490,751; 8,851,235; 9,016,435; 8,851,235 and D654,412
& corresponding patents/applications in the USA and in other countries worldwide.
TRUBLUE /
TRUBLUE XL
AUTO BE L AY
Operator Manual
Models: TB150-12C / TBXL150-20A

3
www.headrushtech.com |[phone]
TABLE OF CONTENTS
1.0 SAFETY INFORMATION 6
1.1 Symbols Used in this Manual 6
2.0 WARRANTY CONDITIONS 7
2.1 Customer Responsibility 7
3.0 CERTIFICATION 9
3.1 Standards 9
4.0 DESCRIPTION 10
5.0 SPECIFICATIONS 11
6.0 AUTO BELAY PARTS 12
6.1 Label 12
6.2 Location of Safety Labels 13
6.3 Icon Descriptions 14
7.0 UNPACKING 16
7.1 Precautions 16
7.2 Receipt of the Auto Belay 16
7.3 Unpacking the Auto Belay 16
7.4 Storage 17
8.0 INSTALLATION 18
8.1 Precautions 18
8.2 Standards 18
8.2.1 Anchor Points 19
8.2.2 Harness 19
8.2.3 Secondary Connectors 19
8.2.4 Selecting a Location 20
8.2.5 Outdoor Installations 20
8.2.6 Mounting Points 20
8.2.7 Orientation 22
9.0 OPERATION 23
9.1 Operator Training 24
9.2 User Instruction 24
9.3 Climbing Harness 25
9.4 Carabiner Use 25
9.4.1 Operation 25
9.4.2 Secondary Connections 26

10.0 INSPECTION & MAINTENANCE 27
10.1 Annual Recertification 27
10.2 Maintenance 27
10.2.1 Safety Precautions 28
10.3 Daily Inspection 28
10.4 Weekly Inspection 28
10.4.1 Inspection Procedure 28
10.4.2 Webbing Wear 30
10.5 Six Month Inspection 33
10.5.1 Inspection Procedure 33
10.5.2 Webbing Inspection 33
10.6 Nozzle Replacement 35
10.7 Webbing Line Replacement 36
10.7.1 Safety Precautions 36
10.7.2 Webbing Line Replacement Procedure 37
10.8 Replacement Parts 39
10.9 Troubleshooting 39
10.10 Transportation 39
11.0 MANUFACTURER’S DETAILS 40
4www.headrushtech.com |[phone]

IMPORTANT SAFETY NOTICE
Climbing/Descent from Height
Is a Dangerous Activity
Read Before Installation & Operation
Failure by the operator to heed any and all instructions, warnings and cau-
tions for the correct installation, operation, care and maintenance of the
TRUBLUE Auto Belay may result in death and/or serious injury.
TRUBLUE Auto Belay Model TB150-12C, TRUBLUE XL Auto Belay Model
TBXL150-20A and their associated equipment are designed and specified for
use in the recreational climbing/aerial adventure industry as a controlled de-
scent device. Use of the TRUBLUE Auto Belay for any purposes other than that
intended by the manufacturer is not permitted.
Owners and operators of the TRUBLUE Auto Belay are responsible for the
safety and supervision of any person using the TRUBLUE Auto Belay and are
required to undergo training in the correct installation and operation of the
device prior to any use.
These instructions must be made readily available to the operator at all times.
Prior to installation and use, all owners and operators must have read and
shown to have understood all instructions, labels, markings, and safety infor-
mation pertaining to the installation, operation, care, and maintenance of the
TRUBLUE Auto Belay system, its component parts, and all associated hardware.
Failure to do so can result in death, serious injury and equipment damage.
Health and Safety
Owners and operators must abide by all Standards, International, Federal, State
and Provincial laws, and any specific health and safety regulations pertaining to
the installation and use of this product.
Site Rescue Plan
Owners and operators must have devised an emergency rescue plan for any
climber in distress at all sites operating TRUBLUE Auto Belay devices. Oper-
ators must inform Users of the Auto Belay of the procedure for rescuing a
climber in distress prior to climbing.
5
www.headrushtech.com |[phone]

1.0 SAFETY INFORMATION
1.1 Symbols Used in this Manual
The following safety symbols are used throughout this manual to highlight po-
tential dangers. One or more precautions may be associated with practices and
procedures described within this manual. Failure to adhere to any precautions
highlighted can result in death, serious injury, or equipment damage.
Ensure that you read and understand all safety procedures related to the work-
ing environment and the task you are performing.
DANGER
Indicates a hazardous situation exists that, if not avoided, will
result in serious injury or death.
WARNING
Indicates a potentially hazardous situation that, if not avoided,
could result in serious injury or death.
CAUTION
Indicates a potentially hazardous situation that, if not avoided,
may result in injury or equipment damage.
NOTE
Indicates an action that must be taken to ensure personal safe-
ty and prevent damage to property or equipment.
CARE FOR THE ENVIRONMENT
Take care to minimize impact on the environment when carry-
ing out this procedure.
6www.headrushtech.com |[phone]

2.0 WARRANTY CONDITIONS
The TRUBLUE and TRUBLUE XL Auto Belay Devices are warranted against
factory defects in materials and workmanship (excluding specific Field Re-
placeable Wear Parts - see “Replacement Parts” section below) for a period of
two (2) years from date of purchase. This warranty applies only to the original
purchaser, and is contingent upon the owner/operator maintaining and using
the device in accordance with TRUBLUE Auto Belay instructions, including the
requirement to continue to maintain annual re-certification as described in
this Operator Manual. This Warranty is in lieu of all other warranties, express or
implied.
The sole remedy for breach of this warranty, or for any claim in negligence
or strict liability in tort, is the repair or replacement of any defective parts by
Head Rush Technologies (Manufacturer). Upon notice in writing, Head Rush
Technologies will promptly repair or replace all defective items. Head Rush
Technologies reserves the right to have any defective equipment returned to
its facility, transportation pre-paid, for inspection before making a repair or
replacement.
This Warranty is null and void if parts other than genuine parts are used, or if
any modifications or services have been performed on the device by anyone
other than an authorized Head Rush Technologies servicing agent. This war-
ranty does not cover any damages resulting from abuse to the device, damage
in transit, or any other damage beyond the control of Manufacturer. Head
Rush Technologies makes no warranties in respect to trade accessories or
component parts which are not made by Head Rush Technologies. Head Rush
Technologies expressly excludes from this Warranty the replacement of specif-
ic Field Replaceable Wear Parts (see “Replacement Parts” below) which include
the nozzle, the webbing (line) kit, carabiners and/or any anchors supplied with
the product.
No person, agent or Distributor is authorized to give any warranty, other than
the one herein expressed, on behalf of Head Rush Technologies, or to as-
sume for it any liability pertaining to such products. Head Rush Technologies
expressly disclaims any implied guarantee of merchantability, or claim as to
whether the device is suited for a particular purpose. Purchaser agrees that
Head Rush Technologies shall not be held liable to Purchaser/Operator for
damages of any kind, including but not limited to, lost or projected profits,
equipment down time, or any losses considered to be caused by non-opera-
tion or servicing/re-certification down time of the equipment.
2.1 Customer Responsibility
The following items are considered to be the responsibility of the Customer
and are therefore non-reimbursable under the terms of the warranty.
Product installation.
Normal maintenance, including daily, weekly and bi-annual inspections.
7
www.headrushtech.com |[phone]

Normal replacement of service items.
Replacements required because of abuse, misuse or improper opera-
tional habits of the operator.
Field replaceable wear parts.
Normal deterioration due to use and exposure.
The installer and operator must fully understand these instructions. Any
questions must be submitted in writing to Head Rush Technologies.
Adherence to the this Operator Manual, manufacturer’s instructions, and ad-
vice given by authorized Head Rush service technicians is the responsibility of
the buyer, installer, and operator.
8www.headrushtech.com |[phone]

3.0 CERTIFICATION
3.1 Standards
NOTE
If the TRUBLUE Auto Belay is resold outside of the country of destination,
the reseller must provide instructions for use, service, maintenance and
repair in the language of the country of use.
The TRUBLUE and the TRUBLUE XL Auto Belay can be used as a climbing/de-
scent system device only in combination with other components. It shall not
be deemed suitable for use until it is ensured that the entire system complies
with the requirements of appropriate regional, state, and federal directives/
standards.
The TRUBLUE and TRUBLUE XL Auto Belays conform to Regulation (EU)
2016/425 and comply with the following prevailing Safety regulations:
AS/NZS 1891: Industrial fall-arrest systems and devices – Part 3: Fall
arrest devices
CSA Z259.2.3-99: Descent Control Devices
EN 341: 2011 Class 1A: Personal protective equipment against falls from
a height – Descender devices
ANSI/ASSE Z359.4: Safety Requirements for Assisted-Rescue and
Self-Rescue Systems, Subsystems and Components.
EN 360:2002: Personal protective equipment against falls from a height
- Retractable type fall arresters
Section 4.5: Maximum force <6kN for 150kg capacity
EU Declaration of Conformity:
EU Declaration of Conformity can be downloaded at this website address:
https://headrushtech.com/resources/declarations-of-conformity.html
Body controlling the manufacture of this PPE:
TÜV SÜD Product Service GmbH
Ridlerstraße 65
80339 München, Germany
Notified body performing the CE type exam:
TÜV SÜD Product Service GmbH
Ridlerstraße 65
80339 München, Germany
9
www.headrushtech.com |[phone]

4.0 DESCRIPTION
The TRUBLUE Auto Belay is a controlled descent device designed specifically
for use in the climbing/aerial adventure industry. The TRUBLUE oers a maxi-
mum descent height of 12.5 m (41 ft), and the TRUBLUE XL oers a maximum
descent height of 20 m (65.6 ft). TRUBLUE Auto Belays are suitable for user
weights ranging from 10 - 150 kg (22 - 330 lbs) depending on model.
The design of the TRUBLUE permits simple installation and removal and
incorporates an advanced self-regulating brake system and automatic line
retraction. The patented braking mechanism oers users a smooth descent
with a minimal variation in descent rate of both children and adults. There are
no wearing parts in the brake mechanism, ensuring that reliability remains high
while maintenance and operating costs are kept to a minimum.
To protect the longevity of the TRUBLUE, installation, care and use of the
TRUBLUE Auto Belay must be carried out in accordance with the instructions
in this manual. The theoretical lifespan of the TRUBLUE and TRUBLUE XL Auto
Belay is unlimited with proper care and performing the required annual service
maintenance. For planning purposes, we recommend a planned lifespan of 15
years.
10 www.headrushtech.com |[phone]

MODELS TRUBLUE: TB150-12C
TRUBLUE XL: TBXL150-20A
CERTIFICATION IN ACCORDANCE WITH EN 341:2011-1A AND
EN 360:2002
DIMENSIONS 380 x 320 x 216 mm (15 x 12.6 x 8.5 in)
NET WEIGHT 19.75 kg (44 lbs)
MATERIALS CASING Aluminum Alloy
INTERNAL PARTS Zinc plated steel
NOZZLE Modified Acetal plastic
NOZZLE INSERT 304 Stainless Steel
LINE TB: Polyamide/UHMWPE
TBXL: UHMWPE/Polyamide
MODEL MINIMUM MAXIMUM
MOUNTING HEIGHT
(NOZZLE TO
GROUND)
TB150-12C (7.5m) 3.5m (11.5 ft) 7.5m (24.6 ft)
TB150-12C (12.5m) 7.5m (24.6ft) 12.5m (41.0 ft)
TBXL150-20A 12.0m (39.4 ft) 20.0m (65.6 ft)
USER WEIGHT TB150-12C 10 kg (22 lbs) 150kg (330 lbs)
TBXL150-20A 10 kg (22 lbs) 136kg (300 lbs)
OPERATING
TEMPERATURE
ALL MODELS -4° C (25° F) 60° C (140° F)
ALL MODELS (DRY) -10° C (14° F) 60° C (140° F)
STORAGE
TEMPERATURE ALL MODELS -20° C (-4° F) 60° C (140° F)
DESCENT SPEED ALL MODELS ------------- 2.0 m/s (6.5 ft/s)
METRIC UNITS ARE THE CONTROLLING UNITS OF MEASURE IN THIS
MANUAL. IMPERIAL UNITS ARE PROVIDED AS A COURTESY AND HAVE
BEEN ROUNDED. IF THE OWNER/OPERATOR/INSTALLER MUST MAKE
ANY UNIT CONVERSIONS, THE METRIC UNITS SHOULD BE REFER-
ENCED.
5.0 SPECIFICATIONS
11
www.headrushtech.com |[phone]

6.0 AUTO BELAY PARTS
PRIMARY MOUNT
HANDLE
WEBBING LINE
CARABINER
SECONDARY
MOUNT
(UNLOADED)
COVER
(FRONT)
CASING
COVER
(BACK)
NOZZLE
6.1 Label
TB150-12C SN#######
Model number
Unit serial number
EN standard and
device classification
Notified body
for CE type
examination
IN ACCORDANCE WITH EN 341:2011-1A
AND EN 360:2002
0123
12 www.headrushtech.com |[phone]

6.2 Location of Safety Labels
INFORMATION LABEL
SERIAL LABEL
TB150-12C SN0000000
TBXL150-20A SN0000000 SPECIFICATION LABEL
COVER LABEL (Both Sides)
CERTIFICATION LABEL
10015-03
MODEL: TBXL150-20A
RATED BODY WEIGHT:
10 to 136kg (22 to 300lbs)
DEVICE WEIGHT:
19.7 kg (43.5 lbs
MOUNTING HEIGHT*:
20.0 m purple webbing end: Max. 20.0
m (65.6 ft)
20.0 m purple webbing end: Min. 12.0
m (39.4 ft)
* Mounting heights are measured from nozzle to ground
MAXIMUM DESCENT RATE:
2.0 m/s (6.6 ft/s)
TEMPERATURE RANGE:
Operating: -4°C to 60°C (25°F to
140°F)
Operating (Dry): -10°C to 60°C (14°F
to 140°F)
HEAD RUSH TECHNOLOGIES
1835 38th Street
Boulder, Colorado 80301, USA
www.headrushtech.com
0123
11762-02
10015-05
IN ACCORDANCE WITH EN341:20111A AND EN 360:2002
MODEL: TB150-12C
RATED BODY WEIGHT:
10 to 150 kg (22 to 330 lbs)
DEVICE WEIGHT:
19.75 kg (44 lbs
MOUNTING HEIGHT*:
7.5 m red webbing end: Max. 7.5 m
(24.6ft)
12.5 m blue webbing end: Max. 12.5 m
(41.0 ft)
7.5 m red webbing end: Min. 3.5 m (11.5
ft)
12.5 m blue webbing end: Min. 7.5 m
(24.6 ft)
* Mounting heights are measured from nozzle to ground
MAXIMUM DESCENT RATE:
2.0 m/s (6.6 ft/s)
TEMPERATURE RANGE:
Operating: -4°C to 60°C (25°F to 140°F)
Operating (Dry): -10°C to 60°C (14°F to
140°F)
HEAD RUSH TECHNOLOGIES
1835 38th Street
Boulder, Colorado 80301, USA
www.headrushtech.com
0123
10051-03
IN ACCORDANCE WITH EN341:2011-1A AND EN 360:2002
1. 2.
4.
6.
8.
10.
12.
13.
11.
9.
3.
5.
7.
EN 12277,
UIAA 105,
EN 361
10053-06
ALWAYS READ AND FOLLOW
THE WARNINGS AND
INSTRUCTIONS FOR USE
TBSD150-20 only
EN 362/EN 12275
10024-02
SERIAL NUMBER:
MANUFACTURE DATE:
RECERTIFICATION DATE:
NEXT RECERT REQUIRED:
BY:
WEBBING DATE OF
MANUFACTURE LABEL
(Attached to Webbing)
YYYY
Jan.
Apr.
Jul.
Oct.
Feb.
May
Aug.
Nov.
Mar.
Jun.
Sept.
Dec.
13
www.headrushtech.com |[phone]

6.3 Icon Descriptions
Device Weight Only one user at a time
Body Weight
EN 12277
,
UIAA 105
,
EN 361
Harness standards
Descent Rate
Do not alter the line. Do
not clamp, knot or tie on
additional line
Country of Manufacture Do not store the line
inside the device wet
Temperature Range
Never install the device
where the line passes
over sharp edges, high
friction areas
Minimum Height
Never permit line to wrap
around or become en-
tangled with neck, arms,
or legs
14 www.headrushtech.com |[phone]

Maximum Height
Connect the carabiner
to the designated belay
loop of your harness,
making sure the gate is
locked
Inspect the Webbing
Check descent path is
clear, Always land with
slightly bent knees to
absorb landing
Do not let TBSD150-20
(The TRUBLUE Speed
only) retract uncon-
trolled
Serial number
EN 362/EN 12275
Minimum connector
strength for installation Manufacture Date
Avoid swing falls into
objects Date
Primary connector
taught, secondary back-
up connector loose
Technician
15
www.headrushtech.com |[phone]

7.0 UNPACKING
7.1 Precautions
LEAVE THIS USER MANUAL ATTACHED TO THE AUTO BELAY
UNTIL INSTALLATION IS COMPLETE
The Operator Manual contains information relating to the safe use of the
TRUBLUE Auto Belay and includes all product registration and warranty
information. The Operator Manual document may only be removed by the
end user. Ensure this manual is readily available to Auto Belay users at all
times.
DO NOT DISPOSE OF PACKAGING
The cardboard box and internal packaging are required for the return of
the Auto Belay for the annual Certification inspection. Please keep packag-
ing in a safe place until required.
7.2 Receipt of the Auto Belay
The TRUBLUE Auto Belay is packaged in a recycled cardboard box and contains:
1 x TRUBLUE Auto Belay Model TB150-12C or TRUBLUE XL Model
TBXL150-20A
1 x 7.5m (24.6 ft), 12.5 m (41 ft) or 20m (65.6ft) Webbing Lower Line
1 x Carabiner or EN 362 connector attached to the Webbing Lower Line
1 x Operator Manual
7.3 Unpacking the Auto Belay
To unpack the Auto Belay:
1. Upon receipt of Auto Belay, inspect for signs of shipping damage or
contamination. If Auto Belay shows any signs of damage or mishandling
contact your Head Rush Technologies distributor.
2. Check all labels axed to Auto Belay are present and legible.
10024-02
SERIAL NUMBER:
MANUFACTURE DATE:
RECERTIFICATION DATE:
NEXT RECERT REQUIRED:
BY:
Do not use the Auto Belay after date shown here.
16 www.headrushtech.com |[phone]

3. Check the Certification Label for the ‘Next Recertification Required’
date. If the date shown has passed or the label is missing or illegible, the
Auto Belay must not be put into service.
4. Register your Auto Belay online at headrushtech.com/register.
PRODUCT REGISTRATION MUST BE COMPLETED
Product Registration is critical for receiving product notifications, recertifi-
cation notices, and up-to-date information for the safe use of the TRUBLUE
Auto Belay. Registration is fast and easy and can be done online at www.
headrushtech.com/registration.
5. Read the Operator Manual and familiarize yourself with all aspects of
installation, operation, care and maintenance.
7.4 Storage
If the Auto Belay is to be left unused for longer than two weeks, ensure the unit
is clean and dry and line is fully retracted into the unit.
When returning the Auto Belay to duty after an extended period of inactivity,
always carry out a full inspection and operational check.
DO NOT STORE IN WET CONDITION
After exposure to water or damp conditions thoroughly clean and dry the
Auto Belay. Ensure Auto Belay is not left with wet webbing line retracted
inside the casing. If the webbing is wet and the device is to be stored, re-
move the nozzle and pull all the webbing out until the shackle is exposed.
Insert a pin through the line to prevent retraction, and allow the webbing
to dry naturally away from open fire or heat source.
Always store in a clean and dry environment.
17
www.headrushtech.com |[phone]

8.0 INSTALLATION
8.1 Precautions
ALWAYS USE DESIGNATED MOUNTING POINTS
Never install the Auto Belay using any part of the device apart from the desig-
nated mounting points. Incorrect mounting can result in serious injury or death.
ALWAYS USE THE CORRECT MOUNTING HEIGHT
Failure to install the device at the correct mounting height could result in
damage to the device or loss in device performance.
HARD IMPACTS MAY RESULT IN STRUCTURAL DAMAGE
Dropping of, or hard impacts to, the Auto Belay can result in serious
damage to mounting points and internal parts and may compromise safety
of operation. If the Auto Belay is subject to a hard impact, remove it from
duty and return to a service agent for inspection.
HEAVY ITEM  20 KG 44.1 LBS
Take care when lifting the Auto Belay. Take care not to drop the device as
this may result in serious injury or equipment damage.
ALWAYS MOUNT VERTICALLY
Always mount the Auto Belay vertically with the nozzle pointing down-
wards and the line exiting the bottom of the device. Failure to do so will
result in incorrect operation and compromise User safety.
HARMFUL CONTACT
Do not allow solvents, acids, sharp edges etc. to get into contact with
the device, especially the webbing. If in contact, the Auto Belay must be
inspected.
8.2 Standards
Prior to installation, all Operators must be familiar with the requirements of all
relevant Standards for anchor points, hardware and equipment used with the
Auto Belay.
18 www.headrushtech.com |[phone]

8.2.1 ANCHOR POINTS
All anchor points and connectors used with a TRUBUE Auto Belay must con-
form to any federal or state requirements for such devices.
Head Rush Technologies requires anchor points to have a minimum load ca-
pacity of 10 kN (2200 lbs) in expected directions of application. Other national
and international standards for anchor points may apply and require higher
load capacity. Consult with the authority having jurisdiction for your required
load capacity.
The location and anchor points for the TRUBLUE Auto Belay should comply
with the following:
Anchor points are not to be used by additional devices or as attach-
ments for hardware not associated with the Auto Belay installation.
Anchor points should be of a suitable size to correctly install any mount-
ing hardware.
8.2.2 HARNESS
All harnesses used in conjunction with the TRUBLUE Auto Belay must be of the
correct size and fit, be in serviceable condition, and comply with one of the
following standards:
EN 361 - Personal protective equipment for prevention of falls from a
height – Full body harness.
EN 813 - Personal protective equipment for prevention of falls from a
height – Sit harness.
EN 12277 - Type A. Full Body Harness.
EN 12277 - Type B. Small Full Body Harness.
EN 12277 - Type C Sit Harness.
8.2.3 SECONDARY CONNECTORS
All secondary connectors and hardware used in the installation of the
TRUBLUE Auto Belay must conform to the requirements of:
EN 362 - Types of connectors for personal protection.
EN 12275 - Types of connectors for mountaineering.
All connectors, hooks, D-rings and shackles used to mount the TRUBLUE Auto
Belay must be of compatible size, shape and strength for the mounting point
to which they are attached.
19
www.headrushtech.com |[phone]

8.2.4 SELECTING A LOCATION
The TRUBLUE Auto Belay is to be mounted at the top of the climbing route/
descent path with the nozzle and webbing line pointed down.
When selecting a location to mount the Auto Belay, always check:
The Auto Belay will hang vertically over the climbing route with the
nozzle pointing down.
All paths that can be used by the climber when connected to the Auto
Belay are free of sharp edges and high-friction surfaces that may dam-
age the webbing line.
Ensure that the descent path and landing area are free of other climbers,
pedestrians or obstacles that may cause entanglement or restrict the
user’s ascent or descent.
The Auto Belay is free to pivot in all directions and should not bind the
mountings or be able to impact upon the surrounding structure.
8.2.5 OUTDOOR INSTALLATIONS
The TRUBLUE Auto Belay may be installed outdoors.
It is recommended that in wet or high-variable temperature environments, the
Auto Belay is protected from the direct ingress of water or foreign objects.
NOTE
Prolonged exposure to the elements will increase the risk of internal
corrosion and degradation of the webbing line, resulting in increased
operation and servicing costs. Increased inspections are required in these
types of environments.
8.2.6 MOUNTING POINTS
USE ONLY THE DESIGNATED MOUNTING POINTS
Use only the correct mounting points. Use of incorrect points can result in
equipment damage.
Ensure all mounting hardware is secure but free to pivot in mounting point.
The TRUBLUE Auto Belay is manufactured with a single central pivot mounting
point, an oset mounting point and formed handle located at the top of the cas-
ing. These mounting points are located on the central plate and are located to
ensure the unit hangs centrally and vertically with the line nozzle pointing down.
20 www.headrushtech.com |[phone]