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BASIC Series
Operator's Manual
40 pgs2.02 Mb0

DBI SALA BASIC Series Operator's Manual

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Form No: 8516182 Rev: A
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1 INTRODUCTION
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Safe, efficient and trouble free operation and maintenance for your component or system requires that you or anyone else who will be operating, maintaining or inspecting the equipment, read, understand and follow all the Safety, Installation, Operation, Maintenance and Inspection instructions contained in this manual, and in any related manuals referenced in this manual and/or supplied with the system.
This manual covers the “Basic” Series Winches manufactured by Unique Concepts. Use the Table of Contents or Index as a guide when searching for specific information.
Keep this manual handy for frequent reference and to pass to new operators. Establish a regular training program for experienced and new operators per these instructions. Establish a regular maintenance and inspection program to keep the equipment in top condition.
Modular components are labeled with the capacities and rating to which they were designed, tested, and manufactured. The rating of any system is considered to be the rating of the lowest rated component contained is the system.
Do not use the equipment if rating stickers are damaged or illegible. New stickers are available from the manufacturer. When ordering replacement stickers be sure to include:
1) The part number from the bottom right hand corner of the sticker, when available.
2) The serial number of the unit.
3) The part (item) number of the component (consult the appropriate section of this manual).
4) Any other numbers stamped on the components.
This product is a part of a Man Rated Confined Space Entry/Retrieval System. The user must read, understand, and follow the instructions contained in the manual for each component or total system before using this equipment. Establish an appropriate training, maintenance, and inspection program for your people and the equipment. Failure to follow these instructions could result in serious in
WARNING
jury or death.
2 SAFETY
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SAFETY ALERT SYMBOL
This Safety Alert symbol means
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
The Safety Alert symbol identifies important safety messages on your equipment and in the manual. When you see this symbol, be alert to the possibility of personal injury of death. Follow the instructions in the safety message.
Why is SAFETY important to you?
3 Big Reasons
SIGNAL WORDS:
Note the use of the signal words
WARNING,
messages. The appropriate signal word for each message has been selected using he following guide-lines:
CAUTION
and
DANGER,
with the safety
Accidents Disable and Kill Accidents Cost You Money Accidents Can Be Avoided
DANGER -
situation that, if not avoided, will
WARNING -
CAUTION -
situation that, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.
Indicates an imminently hazardous
result in death or serious injury. This signal word is to be limited to the most extreme situations, or for hidden or unseen hazards.
Indicates a potentially hazardous situation that if not avoided, could result in death or serious injury, and includes obvious and hidden hazards. It may also be used to alert against unsafe practices.
Indicates a potentially hazardous
SAFETY
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YOU are responsible of the SAFE operation, maintenance and inspection of your Unique Concepts Man Rated Confined Space Entry/ Retrieval System Winch. YOU must ensure that you and anyone else who is going to operate, maintain, inspect or work around the equipment be familiar with the operating and maintenance procedures and related SAFETY information contained in this manual. This manual will take you step-by-step through your working day and alerts you to all good safety and operating practices while using the equipment.
Remember, YOU are the key to safety. Good safety practices not only protect you, but also the people around you. Make these practices a working part of your safety program. Be certain that EVERYONE operating this equipment is familiar with the procedures recommended and follows safety precautions. Remember, most accidents can be prevented. Do not risk injury or death by ignoring good safety practices.
• Owners must give operating instructions to operators or employees before allowing them to use the equipment, and at least annually thereafter.
• The most important safety device on this equipment is a SAFE operator. It is the operator’s responsibility to read and understand ALL Safety and Operating instructions in the manual and to follow these. All accidents can be avoided.
• A person who has not read, been trained in using and understood all operating and safety instructions is not qualified to operate this equipment. An untrained operator exposes himself and others to possible serious injury or death.
• Do not modify the equipment in any way. Unauthorized modification may impair the function and/or safety and could affect the life of the equipment.
• Think SAFETY! Work SAFELY!
2.1 GENERAL SAFETY
1. Read, understand and follow the User Manual and all safety signs before using, maintaining or inspecting the equipment.
2. Refer to and follow applicable ANSI, OSHA, CE or other Standards and local regulations. Comply with requirements of local regulations for your applications.
3. Establish an equipment–use training program for experienced employees. Only trained, competent persons shall use the equipment. An untrained operator is not qualified to operate the system.
4. Have a first-aid kit available for use should the need arise and know how to use it.
5. Provide a fire extinguisher for use in case of an accident. Store in a highly visible place.
6. Install and properly secure all guards and shields before operating.
7. Wear appropriate protective gear. This list includes but is not limited to:
- A hard hat
- Safety glasses
- Protective shoes
with slip resistant soles
- Heavy gloves
- Protective clothing
- Face protection
8. Review and follow the Pre-Operation
Inspection before using a component in the
system or the system itself.
9. Establish a regular Maintenance and Inspection program with your equipment and maintain detailed records.
10. Review safety related items and operating instructions with all personal on a regular basis.
11. Be aware of your environmental surroundings; be sure not to use the equipment during an electrical storm. (this equipment is conductive)
12. When using our winch, the noise level does not exceed 70 d B(A).
2.2 OPERATING SAFETY
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1. Read, understand and follow the Operator’s Manual and signs on the equipment before using, maintaining or inspecting the equipment.
2. Train all operators before allowing them to use the equipment. An untrained operator exposes themselves, bystanders and workers to possible serious injury or death.
3. Visually inspect the equipment and all auxiliary components and equipment before using. Correct any problems before using the equipment.
4. Securely anchor the winch before using, where applicable.
5. Use only certified anchor and connector components in your system.
6. Use only an approved full body harness for the workers.
7. Always work in teams. One person works in the confined space and the other one pays out the line and reels it in.
8. Check the condition of the brake wear each time the winch is used. When the indicator moves into the red portion of the scale or 1 year in service (which ever comes first), remove from service and return to the factory for service.
9. Do not exceed 310lbs. (141 kg) on the line during operation.
10. Establish a regular training program for new and experienced workers.
11. Establish a detailed inspection program for your equipment and document the findings. Return the equipment to the manufacturer for rework if any problems are found.
12. Plan your work program before starting. Have the required people, equipment and procedures available to do the job.
13. Do not use the equipment around physical or environmental hazards. This list includes but is not limited to:
a. Corrosion that may affect the structural
integrity of the life line or other components .
b. Chemicals which can degrade
components and not be visible.
c. Toxic gases: Rescuers or workers can
be killed in toxic environments. d. Heat or elevated temperatures. e. Moving machinery: Workers or
auxiliary equipment can be contacted
by or pulled into moving components. f. Sharp edges: Workers or the
equipment can be injured or damaged
by sharp edges or components. g. Electrical hazards: Stay away from
power lines or components carrying
electrical power. h. Overload: Do not exceed 310 lbs. (141
kg) during operation.
Follow confined space regulations in
i.
Standards.
Noise: wear appropriate noise
j.
protection where necessary.
Environmental hazards: do not operate
k.
equipment during electrical storms.
2.3 MAINTAINANCE/ INSPECTION SAFETY
1. Read, understand and follow the User
Manual and signs on the equipment before using, maintaining or inspecting the equipment.
2. ANSI, OSHA & CE requires a regular
inspection program for all Confined Space Entry/Retrieval Equipment and to maintain documented results of these inspections. Follow the inspection procedure contained in this manual and use the inspection form to document the results.
3. Keep instructional and safety signs
clean and legible at all times. Clean or replace as required.
4. Lubricate winch as per instructions in
Section 4 of this manual.
5. Remove the equipment from service if a
problem is found during the inspection. Return to an authorized repair depot or the factory for service.
3 OPERATING, NEW
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OPERATOR OR OWNERS
The “Basic” Series Winch is designed to attach to a person (entrant) and allow them to enter a confined space and assist in exiting if required. Every new operator must read, understand and follow the instructions in all applicable manuals. No one should be allowed to use the equipment without training. The training should be reviewed with experienced operators on a regular basis. At regular intervals perform a detailed inspection of the equipment and document the results. Remove from service if deficiencies are found. Alterations or misuse of this equipment or failure to follow instructions, may result in serious injury of death.
It is the responsibility of the owner’s organization or operator to read this manual and to train all other operators before they start working with the equipment. Follow all safety instructions exactly. Safety is everyone’s business. By following recommended procedures, a safe working environment is provided for the operator, bystanders and the area around the work site. Untrained operators are not qualified to operate the equipment.
Many features incorporated into this equipment are the result of suggestions made by customers like you. Read this manual carefully to learn how to operate the equipment safely and how to set it to perform as intended. By following the operating instructions in conjunction with a good maintenance program, and diligence in annual re-certification your equipment will provide many years of trouble-free service.
OPERATING SAFETY
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1. Read, understand and follow the User Manual and signs on the equipment before using, maintaining or inspecting the equipment.
2. Train all operators before allowing them to use the equipment. An untrained operator exposes themselves, bystanders and workers to possible serious injury or death.
3. Visually inspect the equipment and all auxiliary components and equipment before using. Correct any problems before using the equipment.
4. Securely anchor the winch before using.
5. Use only certified anchor and connector components in your system.
6. All anchor points, or mounting/setup locations for permanent or portable systems must be approved to local standards by a qualified engineer.
7. Use only an approved body harness for the workers.
8. Always work in teams. One person works in the confined space and the other one pays out the line and reels it in.
9. Do not use the equipment when the winch brake wear indicators display in the red or 1 year in service (which ever comes first). Return equipment to manufacturer for service.
10. Do not exceed 310lbs. (141 kg) on the personal man rated lifeline during operation.
11. Use only retractable lifelines or shock absorber with a maximum arrest force (MAF) equal to or lower than the lowest rated component of your system.
12. Establish a regular training program for new and experienced workers.
13. Establish a detailed inspection program for your equipment and document the findings. Return the equipment to the manufacturer for rework if any problems are found.
14. Plan your work program before starting. Have the required people, equipment and procedures available to do the job.
15.
Do not use the equipment around physical or environmental hazards. This list includes but is not limited to:
a. Corrosion that may affect the
structural integrity of the life line or other components.
b. Chemicals which can degrade
components and not be visible.
c. Toxic gases: Rescuers or workers
can be killed in toxic environments. d. Heat or elevated temperatures. e. Moving machinery: Workers or
auxiliary equipment can be
contacted by or pulled into moving
components. f. Sharp edges: Workers or the
rescue equipment can be injured
by or damaged by sharp edges or
components. g. Electrical hazards: Stay away from
power lines or components carrying
electrical power. h. Overload: Do not exceed a
personal load capacity of 310 lbs.
(141 kg) or material load capacity
of 620lbs. (282 kg) during
operation. i. Follow confined space regulations
in Standards. j. Noise: wear appropriate noise
protection where necessary. k. Environmental hazards: do not
operate equipment during electrical
storms.
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3.1 PRINCIPLE COMPONENTS
The “Basic” Series Winch is designed to extend and retract a lifeline from a drum for attaching to a person who is entering or exiting a confined space. It is designed with a double redundant braking system to hold the line in any position. Line extending or retracting is controlled by the crank handle attached to the 5.1:1 driving shaft.
The winch frame back plate mates to a mounting system that attaches to various structures. Secure the winch to the mounting system with the hand tightened bolt before using the winch. Maximum of 70 feet line can be installed on the drum and a red marker is located 10 feet from the fixed end to alert the user not to pay out more line. This prevents the line from being wrapped backward on the spool and ensures effective protection during Load Limiter Clutch activation. Line extension must occur when the handle is turned counter-clockwise and clockwise for retraction to have the internal brakes properly engaged.
To prevent accidental reversal of the cable on the drum, the cable is installed and conforms to the proper cable direction on the drum. Spooling the cable entirely off the drum is forbidden in case of accidentally spooling the cable in the reverse on the drum. Spooling the cable on the drum in
reverse will cause freewheeling of the drum and cable and may cause serious injury or death.
C
M
D
H
E
F
C
A Crank Arm
B Crank Handle
C Cover
D Brake Indicator
E Drum
F Cable
G Load Indicator Snap
L
A
B
H Pressure Bar
I Cable Retainer Spring
J Load Limiter Window
K Load Limiter Tear Strip
L Annual Recertification
Date
K
J
A
F
H C
Figure 1 Winch Components
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3.2 PRE-OPERATION INSPECTION
It is necessary to perform a detailed visual inspection prior to using the winch. If deficiencies are found, remove the winch from service and return to Unique Concepts Ltd. or authorized service center for rework. This checklist should be used as a guide to determine whether the equipment is in good operating condition prior to using. Equipment that is not in good condition can endanger the safety of the entrant during use.
The visual inspection must include but is not limited to the following items:
1. Check that the winch has no structural
defects.
2. Be sure the winch is clean and the
labels are legible.
3. Be sure the crank handle moves freely.
4. Functional check:
a. Pull on cable and turn the crank
counterclockwise to extend cable.
b. Release the crank and pull hard on
the cable.
c. Pull on cable and turn handle
clockwise to retract cable.
d. Be sure that cable is threaded
through the structure pulleys and rollers as per instructions in applicable structure manual.
5. Inspect the cable:
a. Check cable for kinking, cuts, wear
and fraying.
b. Check that the thimble and cable
crimps are in good condition.
c. Check that the snap lock is in good
condition. Be sure the gate will not open unless the lock is released to prevent rollout. Be sure the load activation indicator snap reads green according to Section 4.2.2.
6. Check brake wear indicator. Remove from service if indicator displays in the red and return winch to the factory for service.
7. Check the Annual Re-Certification date stamped into the crank handle. Remove from service if stamped date exceeds the current date of operation and return winch to factory for service. Refer to winch inspection log for details on winch servicing.
8. If the winch is not in good condition, remove from service and tag for shipment to an authorized repair depot or the factory for rework. Using a winch that is not in good condition can lead to a hazardous condition for entrant(s).
9. Go through the detailed inspection procedure on a regular basis (at least annually) per the Inspection Section of this manual. Document the results using the sample form and retain for your files.
10. A detailed inspection is required after 6 months of periodic use and records kept.
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3.3 APPLICATIONS
1. General
The Unique Concepts “Basic” Series Man Rated Confined Entry/Retrieval System Winch is designed to be used in work support or rescue. It extends and retracts a line as the handle is turned. When the handle is not being turned, an internal brake holds the spool and the line will not extend or retract.
2. Scope
The winch works well in both vertical and horizontal applications. However, different mounting, anchoring and support systems are required for each type of application. The user has the
responsibility of reading and following the instructions for the other systems in addition to the winch. Misuse or abuse of any
component can create hazards for personnel.
3. Work Support
The winch works well for supporting workers in a boatswains chair or a full body harness (single point suspension). In some applications, a back-up fall arrest system is also used. In these applications, a swing angle of less than 5° is recommended. Use only an approved mounting or anchoring system at all times. Use only approved connectors that are equipped with an anti rollout device.
4. Emergency Rescue In emergency situations, use the winch to remove personnel from a hazardous or an unsafe environment. In these situations, a back-up fall arrest system is generally not required. Be sure to use the proper mounting and anchoring system for the winch. Use only a full­body harness for personnel. Always be aware of the system limitations and follow the instructions.
5. Limitations Operators must be aware of several limitations on the use of the winch whenever it is used and plan their work accordingly. Limitations include but are not limited to:
a. Corrosion:
Do not keep the winch in an area that has a corrosive atmosphere. Corrosive vapors can be released by sewage plants or in fertilizer plants. Sea water or spray can also cause corrosion to the case, lifeline or other components. Long term exposure to these types of environment will require more frequent inspections to insure that the function of the unit has not been effected.
b. Chemical or Toxic Environments:
Work environments that contain strong acids, bases or other corrosive chemicals in solutions, sprays or vapors may damage the winch or auxiliary components. Inspect the unit frequently to detect any damage. Chemical damage may be difficult to detect visually and periodic lifeline replacement is recommend to insure safety.
c. Electrical Hazards:
Stay away from power lines or other components carrying electrical power. The metal lifeline can conduct electricity if it gets close to or contacts a power line or electrified component. Remember electricity can jump across an air gap and electrocute personnel using the winch. Contact your local utility to remove or disconnect the power before working around these components. Contact Unique Concepts for synthetic rope options for reduced conductivity.
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d. Load Capacity:
Do not exceed the winch capacity of 310 lbs. (141 kg) (includes people, harness, tools etc). Do not carry more than one person at a time on the lifeline. Overloading the winch can exceed the design safety factors and could create hazards.
e. Training:
Do not allow anyone to use this winch unless they are trained in its limitations and use. Untrained operators can expose themselves and others to hazards. Train new operators before using the unit. Review operating procedures on a regular basis with experienced personnel.
3.4 SYSTEM REQUIREMENTS
The Unique Concepts “Basic” Series Winch is a component in a Confined Space Entry/Retrieval System. The winch and all auxiliary components must be compatible to prevent creating unexpected hazards. A list of system compatibility requirements includes but is not limited to:
a. Anchorage
The winch is designed to be attached to a mounting and support system that provides the required anchorage strength. Anchorage strength requirements are defined by ANSI and OSHA Standards or local regulations and must be met to insure the safety of the entrant. If Unique Concepts has reviewed and approved the mounting or anchorage system, it has sufficient strength to fulfill the ANSI and OSHA requirements. If the winch will be used with a non-factory approved mounting or anchorage system, a qualified person must review and approved the application prior to use.
b. Connectors
Use only approved connectors with sufficient capacity that have an anti rollout device designed into the snap. Non-approved connectors can open during use and create unexpected hazards. Do not use them.
c. Personnel Harness
Use only an approved full body harness. Do not use a single belt or strap system. Only a full body harness can provide the required support for the body to prevent injury.
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