Harken R32 User Manual

Page 1

R32 ACCESS RAIL SYSTEM

Certified

User Manual – Intended for specialized personnel or expert users

4393 09-18

WARNING! This product is part of a personal fall-arrest system. Manufacturer's instructions must be provided for each component of the system. The user must read and understand these instructions before using this equipment. They provide proper use, inspection and maintenance information. Alterations or misuse of this equipment, or failure to follow these instructions, may result in a fall or failure to arrest a fall leading to serious injury or death.

Please read these instructions carefully before installing, servicing, or operating the equipment.

This manual may be modified without notice. See: http://www.harkenindustrial.com for updated versions.

PLEASE SAVE THESE INSTRUCTIONS

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TABLE OF CONTENTS

Page

Introduction and safety precautions ........................... 3

1Parts ........................................................................... 4

1 Applications ........................................................5-6

a Purpose b Standards c Limitations d Load angle limitations e Training

2 System requirements 7 a Dual trolley assembly description b Other system requirements

3 Requirements for planning installation .............. 8

a Drawings by architect b Base materials c Resources d Avoiding sharp edges

4 Proof testing - unknown structure ......................8-9

a Test objective b Approving authority c New build representative testing d Retrofit full testing

e Testing rail high-risk locations f Testing procedure g After testing, ball bearing replacement

5 Rail installation guidelines ............................ 10-12

a General comments and responsibility b Rail and fastener specifications c Fastener material d Fastener spacing

e Joining rail segments f Horizontal rail mounting defined g Thermal expansion h Rail length and loading trolley assembly i Ceiling, floor, or wall mount j Angled wall mount

6 Rail Installation requirements ....................... 13-14

a Fastener distance to end of rail b Rail alignment c Drilling holes d Threadlocking fasteners e Preventing corrosion between fasteners and rail

f Installing endstops g Using removable endstops h Loading trolley assembly on rail

Page

7 Installation testing ...............................................15

a Objective b Rail test locations c Test description d Test intervals e Test scheduling and records

8 Training and access to manual ...........................16

9 Using system ................................................... 16-17

a Inspection before use b Connections to Access Rail system c Connection requirements d Operating pinstop e Using removable endstop

10 Rescue plan .......................................................18

11 After a ball, replacing equipment ..................... 18

12 Inspection before each use .......................... 18-19

a Inspect shackle b Inspect pinstop c Inspect all rail screws d Inspect endstop screws e Inspect ball bearings

13 Annual formal inspection ............................. 20-21

a Inspect trolleys for damage b Inspect ball bearings c Inspect ball bearing quantity d Replace missing or damaged ball bearings e Inspect pinstop f Inspect rail attaching fasteners g Failed Inspection

14 Maintenance ........................................................22

a Keep ball bearings and races clean b Use ball conditioner

15 Labeling ...............................................................23

16 Records ................................................................23

17 Customer declaration ..........................................24

18 Statement of vision .............................................. 25

19 Periodic and extraordinary maintenance ............26

20 Worldwide limited warranty ................................27

Appendix A .............................................................. 28-29

Reference documents, standards

Appendix B ................................................................... 30

EC Declaration of conformity

Access Rail System – R32

Service and recertification centers ............................. 32

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INTRODUCTION AND SAFETY PRECAUTIONS

INTRODUCTION

This user manual contains important information for the correct use of the Access Rail system. Read it carefully before using the system. If you do not understand an instruction, contact Harken. Do not use the Access Rail system unless you have a sufficient level of training and experience in abseiling. Harken accepts no responsibility for damage or harm caused by not observing the safety requirements and instructions in this manual. See general warnings and instructions at http://www.harkenindustrial.com/technical-information/industry-updates/.

WARNING! Strictly follow all instructions to avoid an accident, personal injury, or death. See www.harken.com/manuals for additional safety information.

WARNING! Using the Access Rail system demands a few important precautions:

• Do not use the Harken and in the use of Access Rail system equipment in particular.

• Before using the Access Rail system make sure that all people and objects are clear of the systems's moving components.

Access Rail System if you are not sufficiently trained and experienced in abseiling generally

Access Rail System – R32

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IN150.CLEAR

IN151.CLEAR

R32 COMPONENTS

IN3212.CLEAR

IN10448.CLEAR

IN185.CLEAR

IN3198

IN10459.CLR

IN10448

Pinstop rail

IN10459.CLEAR

Working

trolley

Endstop

IN185.CLEAR

IN151.CLEAR

One IN10448 assembly required

per person for CE certification

Forged stainless

steel shackle

IN10448.CLEAR

Fall-arrest

trolley

IN150.CLEAR

Forged stainless

steel shackle

Pinstop engaged

Pinstop

Splice link

For longer spans join track

sections with splice link

Removable endstop

IN3212.CLEAR

Pinstop disengaged

IN3198

R32 Trolleys

Part

No. Description IN150.CLEAR * Single trolley with pinstop 7 3/8 192 3 11/32 85 32 mm IN151.CLEAR * Single trolley 7 3/8 192 3 11/32 85 32 mm

IN10448.CLEAR * 2-trolley assembly/coupler 15 3/16 385 3 11/32 85 32 mm

*To order black hardcoat-anodized, remove .CLEAR from end of part number.

Length Width

Fits railin mm in mm

R32 Rail & Accessories

Part

No. Description IN10459.CLR * Pinstop rail for countersunk fasteners 9' 10 1/16" 3 3 15/16 100 3/8 FH 10 FH IN3212, IN185 IN3198

IN3198 Splice link 3 " 76 mm Purchase one splice link for each rail joint. IN3212.CLEAR Removable endstop 2 9/16 " 65 mm Purchase one endstop for each end of system rail. IN185.CLEAR * 32 mm rail endstop 2 9/16 " 65 mm Purchase one endstop for each end of system rail.

Use only endstops listed above. *To order black hardcoat-anodized, remove .CLEAR or .CLR from end of part number.

Access Rail System – R32

Length

Mounting

hole spacing Fasteners

Endstop Splice linkft/in m in mm in mm

Page 5

1 - APPLICATIONS

1a Purpose

Human suspension (rope access) - The rail and dual trolley system is designed for human suspension (rope access) as an adjustable anchorage point for external access to facilitate external maintenance. The system using rail and double trolley assembly is designed for rope access (human suspension). The double trolley assembly is designed for single person use. It consists of a fall-arrest trolley (1) joined to the working trolley (2), using a permanent coupler.

1. Fall arrest trolley

Used with full-body safety harness

Fall restraint - Rail plus a single trolley is designed for use as a mobile anchor point for fall restraint.

Rail

Pinstop

2. Working Trolley

Used for suspension with working harness or chair

Permanent coupler

Stainless steel shackle

Fall arrest - Rail plus a single trolley is also used for fall arrest.

Fall arrest requires a shock-absorbing lanyard so falling force is reduced.

Access Rail System – R32

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1 - APPLICATIONS (Continued)

1b Standards - Access Rail systems are CE certified and independently tested under EN795.2012 Type B/D, meet

ANSI Z359 and are OSHA compliant. See full list of standards in the appendix.

1c Limitations

Capacity - In normal use, no more than one person may be connected to a two-trolley assembly at one time. Typically, the combined load (including clothing, tools, etc) must not exceed 140 kg (310 lb). The Access Rail system has been tested and certified to CEN/TS 16415:2013 and proven capable of supporting up to four users per three (3) meter rail segment with fasteners at 300 mm (11.8") centers.

Test reports - Test reports available from Harken upon request.

Free fall - Personal fall-arrest systems used with this equipment must be rigged to limit the free fall to no more

than 1.8 m (6').

Suspension - Personal suspension system must be rigged so that no vertical free fall is possible.

Fall arrest clearance - There must be sufficient

clearance below the user to arrest a fall before the user strikes the ground or other obstruction. Height of user, plus extended safety lanyard length, must not be more than the height from rail to ground minus 2 m (6.5').

Maximum 2 m (6.5')

CORRECT

INCORRECT

1d Load angle limitations - Rail must be installed between 0° and 5° of horizontal. See below. Rail can be mounted at various angles on the horizontal mounting structure. Harken IN10448, IN150, and IN151 trolleys have the ability to handle loading at an angle up to 15° beyond vertical. Loads beyond 15° from vertical will overload trolley. See image at right.

5°

Maximum to horizontal

15°

1e Training - The user must have appropriate training in order to use this product. It is the responsibility of the purchaser, installer, and user of this equipment to assure that they are familiar with these instructions, trained in the correct care and use of the equipment, and are aware of the operating characteristics, application limits, and the consequences of improper use of the equipment. Rope access operators using this equipment must be trained to a least Irata level 1 or SPRAT level 1 equivalent.

Access Rail System – R32

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2 - SYSTEM REQUIREMENTS

2a Dual trolley assembly description

WARNING! Avoid personal injury. The Access Rail System must be used with a full body safety harness and/or working harness or chair that meets , ANSI, and OSHA support standards.

1. Full-body safety harness secured to fall arrest trolley

Use a full-body safety harness attached to Access trolley with pinstop. Full-body safety harness must meet

/ANSI and OSHA support standards.

2. Working harness secured to working trolley

Use a working harness or chair attached to access trolley. Working harness or chair must meet

/ANSI and OSHA support standards.

2b Other system requirements - Connectors (hooks, carabiners and D-rings) must be capable of supporting at least 22 kN (5000 lb), in accordance with EN362.

Personal fall-arrest systems used with this equipment must meet controlling regulations for the country of use. Personal fall-arrest systems include, but are not limited to: a shock-absorbing mechanism, lanyard and a full body harness to limit the maximum arresting force to 4 kN (900 lbf).

WARNING! Consult Harken when using this equipment in combination with components or subsystems other than those described in this manual. Altering or intentionally misusing this equipment may cause the system to fail which can cause a fall which could result in severe injury or death.

Access Rail System – R32

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3 - REQUIREMENTS FOR PLANNING INSTALLATION

3a Drawings by architect - Consider all factors that will affect safety during use of this equipment. Rail must be

laid out and positioned strictly in accordance with drawings and specifications supplied by the project authorized architect or other suitably qualified person. System must meet controlling work at height regulations for country of use.

3b Base materials - Installer shall ensure suitability of base materials and structural materials into which rail is fixed follows controlling work at height regulations for country of use, and that it is capable of sustaining a proof test force as detailed in section 4 below.

3c Resources - See list of standards in Appendix A. Consult with work at height regulations for country of use.

3d Avoiding sharp edges - Avoid attaching system components where suspension and/or fall arrest rope may

come in contact with, or abrade against, unprotected sharp edges.

4 - PROOF TESTING - UNKNOWN STRUCTURE

The following is the good faith interpretation by Harken of the standards that we understand are the current methods that will meet the many test procedures to assure a safely installed Harken Access Rail system.

Harken is not responsible for any future changes, alternate interpretations, or other requirements imposed by inspection officials. Harken does not accept any responsibility for the consequences of failed installations, including but not limited to personal injuries, costs or any related damages, or from failed alternative installation methods.

The Harken Access Rail system is fully tested and certified as a fall arrest anchor device. However, we have had a number of requests to approve alternative methods of fastening due to different construction and building techniques.

Regrettably, it is simply not possible for us to approve all these alternatives without detailed engineering, testing, and surveying of every individual case.

Therefore, the purpose of this guidance is to illustrate how alternative methods of attachment can be considered by the installer as suitable.

To be 100% explicit, this guidance pertains to the installation of the product and has nothing to do with the product itself.

Any safety equipment or lifting device must have its installation inspected and surveyed as per standard industry practice. Likewise, periodic inspection is necessary to ensure nothing has deteriorated due to age, wear or corrosion. There are well established systems and protocols in place to ensure this is done. This is nothing special or unique to the Harken Access Rail system.

The installer carries the full responsibility for a proper and safe installation that is tested to meet all relevant standards. Normally this would be verified by an independent safety engineer/surveyor.

Access Rail System – R32

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4 - PROOF TESTING - UNKNOWN STRUCTURE (Continued)

The following Code of Practice details the maintenance and testing regime of anchor devices for fall protection. It recommends an initial sample proof test of 12kN (1200 kgf) for three (3) minutes if the installation is into a base material that the installer has no information on or has never installed into before. After proof testing at this load, destroy trolley and rail. Do not use for service or clearly label as "not fit for use". If the samples tested pass, the rest of the anchor points shall be tested to 6kN (600 kgf), for 15 seconds.

If the anchor device is only used for fall protection, the device should be thoroughly examined and tested annually to 6kN (600 kgf) for 15 seconds and torque tested per the post installation inspection procedure to follow.

Refer to local codes or regulations for standards that offer guidance on testing of any new or retrofit rail installation. Our interpretation in practical application is explained in 4a to 4f below.

4a Test objective - The test objective is for the installer to prove their individual installation methodology for each type of base material/fastener type, or where working with unknown factors.

4b Approving authority - The engineer/surveyor will have to approve the individual test regime and be satisfied it was done correctly. In practice this normally means overseeing the test.

4c New build representative testing - For new builds or for identical constructions, the proof test can be done on representative sample pieces. These should be long enough to hold a pair of trolleys and end stops in normal configuration.

4d Retrofit full testing - In the case of retrofits where the construction is not necessarily known (due to modifications, corrosion or aging), the proof testing is done in situ.

4e Testing rail high-risk locations - If done in place, then we recommend testing the highest risk locations such as where personnel gain access to the system, or at the ends of the rails.

4f Testing procedure - Subject to engineer/surveyor approval, the proof test procedure is:

- Insert the trolley in the rail and achieve a load of 1200 kg (2654 lb)

- Hold for three (3) minutes without deformation, paying attention to system stability

- Remove the load and repeat the same in two (2) other locations (or sample pieces)

- The system should remain functional

Note: This is a static test. There is no drop load. The trolley is not expected to move under these conditions.

4g After testing, removing from service - Purchase a separate trolley and rail for proof testing. After testing carefully remove rail without causing damage to the structure and anchors. If structure is damaged or test has failed, consult with engineer/surveyor or Harken to determine how to remedy the situation.

WARNING! Do not use trolley for human suspension after testing to 1200 kg (2654 lb). Do not use for service. Destroy trolley or clearly label as test only, not ﬁt for use.

Access Rail System – R32

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5 - RAIL INSTALLATION GUIDELINES

5a General comments and responsibility - Installers are responsible for planning, installing and testing installation. Following are guidelines related to the assembly of Harken parts.

The fastening of the rail must be made by the installer in the manner defined by the designer (engineer enabled) who is responsible for the design of the system and the related certification. It is not possible to define a standard number and type of fasteners, as this is dependent on the material into which the rail is installed, the intended purpose, and the subsequent maximum load requirement of that purpose.

5b Rail and fastener specifications - IN10459 rail uses M10 (3/8") countersunk fasteners.

5c Fastener material - All rail listed in this manual is designed to use stainless steel fasteners with Grade A4 70

(316) or Grade A2 70 (304) specification or greater. Harken does not recommend using aluminum fasteners for installation. The installer is responsible for the use of non-stainless steel fasteners and could be held liable. Fasteners must be designed to meet the requirements of controlling work at height regulations for country of use. IMPORTANT! Use an anti corrosion paste on the fastener head to prevent galvanic corrosion between fastener and rail. Do not use for nuts on fastener.

5d Fastener spacing - Rail is supplied with mounting holes every 100 mm (3.94"). The Access Rail system has been tested and certified to EN795-2012 and CEN/TS 16415:2013 and proven capable of supporting up to four (4) users per three (3) meter rail segment with fasteners at 300 mm (11.8")centers.

5e Joining rail segments - Fasten each rail segment in the last fastener hole near the splice link IN3198. The splice link is not structural and is used only to maintain alignment and linearity of the individual rail segments.

5f Horizontal rail mounting - The rail must be mounted horizontally, with a maximum angle of 5° to the horizon.

Fastener

Splice link

5°

Access Rail System – R32

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5 - RAIL INSTALLATION GUIDELINES (Continued)

5g Thermal expansion - It is the responsibility of the system designer (qualified engineer) to carefully evaluate the thermal expansion which will be submitted to the system, particularly with respect to the rail.

It is not possible for Harken to predict the effects of thermal expansion on rail, especially with two (2) dissimilar materials, where the material of the mounting surface and anticipated temperature the system is subjected is not known.

The system designer must analyze the relative coefficient of thermal expansion of rail and mounting material and decide on the appropriate method of mounting, sealing fasteners, and gaps between rail sections. Consult manufacturers for information regarding thermal expansion.

As a general rule, leave a space between the end of one rail segment and the next to allow for thermal expansion. Spacing of 3 mm (.118") is appropriate and will allow the trolley assembly to roll smoothly over the gap. Use the O-ring supplied with the IN3198 splice link as a spacer tool to set the gap between rails. Be sure to follow mounting instructions for alignment and fasteners at splice links.

5h Rail length and loading trolley assembly - Leave room at the rail end to load trolley assembly. The trolley assembly is 385 mm (15 3/16") in length.

385 mm (15 3/16")

Plan on room at end of rail to load trolley assembly.

Access Rail System – R32

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5 - RAIL INSTALLATION GUIDELINES (Continued)

5i Ceiling, floor, or wall mount - Rail must run within 5° of horizontal, but can be mounted at various angles on the horizontal mounting structure. Rail can be ceiling mounted, floor mounted, or wall mounted.

Ceiling mount

Floor mount

5j Angled wall mount - An angled wall mount must be

limited to a maximum of 15° off vertical. It must be mounted so that the load on the shackle is taken no more than 15° beyond vertical.

Wall mount

15°

Angled wall mount

OVER 15°

Access Rail System – R32

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6 - RAIL INSTALLATION REQUIREMENTS

Installers are responsible for planning, installing and testing installation. Following are guidelines specifically relating to assembly of Harken parts.

6a Fastener distance to end of rail - Limit fastener distance to endstop or joint. At joints, use uncut rail ends and use fastener holes located closest to joint. At endstops, limit distance from endstop to first fastener to 50 mm (2").

6b Rail alignment - Precise rail alignment at joints is critical for smooth-running trolleys. Use IN3198 splice link and round rods held in the rail groove. Use spring clamps to align rails during installation.

6c Drilling holes - Use transfer punch to mark hole centers. Hold rail in alignment, until secured, with spring or "C" clamps when marking and drilling holes.

When marking and drilling holes, use transfer punch to mark hole centers. Hold rail in alignment using spring or "C" clamps until secured.

6d Threadlocking fasteners - Always use threadlocking solution or locknuts.

6e Preventing corrosion between fasteners and rail -

Use an anti corrosion paste on the fastener head to prevent galvanic corrosion between fastener and rail. Do not use for nuts on fastener.

6f Installing endstops - To prevent trolley assemblies from rolling off rail, fasten endstops to rail ends using M8 (5/16") stainless steel fasteners. Drill and tap into the rail to mount end stop. Note hole center locations at right and plan endstop location on rail to avoid interference from the predrilled mounting or pinstop holes.

Load trolley assembly before installing second endstop. Alternatively use removable pinstop.

Use an anticorrosion paste on the endstop fastener head to prevent galvanic corrosion between fastener and rail.

Access Rail System – R32

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6 - RAIL INSTALLATION REQUIREMENTS (Continued)

6g Removable endstops - The removable endstop may be used instead of fixed endstops. They allow user to easily remove trolley assemblies for storage away from the elements and for switching trolley assemblies from one rail to another. You must follow instructions and heed warnings:

A. Retain all ball bearings and replace any balls lost during transfer.

B. Make sure pinstop is securely locked into one of the rail pinstop holes.

C. Be sure to use a tether to securely attach pinstop to rail or suitable anchor to prevent equipment drop.

6h Loading trolley assembly on rail - Carefully align

trolley assembly with rail and gently roll into place. If balls are lost, trolley assembly must not be used. See 13c.

Access Rail System – R32

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7 - INSTALLATION TESTING

7a Objective - This test objective is to ensure that the system has been installed correctly in practice and remains sound as it ages.

7b Rail test locations - We recommend that each rail is tested in at least three (3) locations;, typically at both ends, at any rail joint, and in the middle..

7C Test description - Subject to engineer/surveyor approval, each rail should be tested upon installation:

- Insert the trolley in the rail and achieve a load of 600kg

- Test for 15 seconds per locations

- Remove the load and repeat the same in 2 further locations

- The system should remain functional; repeat as necessary for each separate rail

7d Test intervals - Normal safety equipment operations require testing post-installation and then annual inspections each year thereafter. Follow careful inspection procedures of trolley assemblies as previously.. Additionally, perform torque testing of rail fasteners on an annual basis. Use a torque wrench and test five (5) percent of the fasteners spread out across a broad location spectrum. Test to the fastener manufacturer's recommended torque specification. If torque test fails, rail should be decommissioned until the exact cause of the torque test failures are determined. Chemical anchors for fasteners must be pull tested every five (5) years. Mechanical anchors for fasteners must be pull tested every 10 years. Follow the installation pull test procedure "7C" above.

7e Test scheduling and records - Further testing and inspection of the Access Rail system should be incorporated into standard operating practices and into the EXAMINATION/REPAIR HISTORY in section 16.

Access Rail System – R32

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8 - TRAINING AND ACCESS TO MANUAL

It is the responsibility of the user and the purchaser of this equipment to assure they are familiar with these instructions, trained in the correct care and use, and are aware of the operating characteristics, application limits, and the consequences of improper use. Installer is responsible for certification and user training and must ensure the instructions and limitations of use are clearly displayed close to system. This should include a statement that it is designed exclusively for use with personal protective equipment.

9 - USING SYSTEM

9a Inspection before use - Always perform inspection before using system. See section 12: inspection procedure and consult examination and repair history.

9b Connections to Access Rail system

The system has two anchorage points:

1. Fall arrest trolley

2. Working trolley

9c Connection requirements - When using a hook with positive locking mechanism to connect to trolley shackle, ensure roll-out cannot occur. Roll-out occurs when interference between hook and mating connector causes hook gate to unintentionally open and release.

Use self-locking snap hooks and carabiners to reduce possibility of roll-out. Hooks or connectors must completely close over attachment object.

Do not attach a connector that will impact the side of the trolley when in use.

WARNING! Connecting hooks, lanyards, and safety harnesses are part of a personal fall-arrest system. Manufacturer's instructions must be provided for each component of the system. The user must read and understand these instructions before using this equipment. They provide proper use, inspection and maintenance information. Alterations or misuse of this equipment, or failure to follow these instructions, may result in a fall or failure to arrest a fall leading to serious injury or death.

Access Rail System – R32

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9 - USING SYSTEM (Continued)

9d Operating pinstop - Lift pinstop and rotate to lock

it out. Trolley will roll freely. To secure trolley, position pinstop over rail hole and rotate knob until pin drops into hole.

9e Pinstop tether - Always use a tether to secure the removable pinstop.

WARNING! Protect against dropped parts. Use a tether to securely attach removable pinstop to rail or suitable anchor.

9f Using removable endstop - If using removable

endstop, always be sure the pinstop is inserted into one of the stop holes in the rail. The bottom of the knob must be flush with the body of the endstop.

Pinstop up and unlocked

Pinstop down and locked

CORRECT

WARNING! Always be sure the removable pinstop is securely fastened to a pinstop hole in the rail. Failure to seat in a pinstop hole can result in a fall which could result in severe injury or death.

Access Rail System – R32

INCORRECT

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10 - RESCUE PLAN

When using this equipment, the employer must have a rescue plan and the means at hand to implement it. The plan must be communicated to authorized persons and rescuers. With rescuer working from safe area or on their own trolley, the casualty's trolley can be used as an anchor point for recovery of a casualty, either horizontally along the rail if the trolley can still move freely, or as an anchor point for lowering/raising the casualty during rescue.

11 - AFTER A FALL, REPLACING EQUIPMENT

Any equipment which has been subjected to the forces of arresting a fall must be immediately removed from service and destroyed by user or an authorized person.

12 - INSPECTION BEFORE EACH USE

Before use, perform system ins

specific inspection procedures.

12a Inspect shackle - Check for signs of corrosion, cracks, or elongation. If damaged, do not use. Damaged shackles can indicate that trolley was overloaded. Return complete trolley assembly to one of the service centers/ recertification centers listed on back of manual for advice.

pection on all components per manufacturer’s instructions. Following are Harken

12b Inspect pinstop - Check for spring degradation, cracks or wear that may affect locking strength and operation.

12c Inspect all rail screws - Check to make sure screws have not loosened and are flush with top of rail so trolleys roll smoothly. Loose screws can also compromise system safety.

Inspect the rail length by running the trolley assembly the entire length without load. Ensure the trolley assembly runs freely. Check rail for dirt (salt) buildup before each use. If the rail has visible dirt or feels gritty, clean the rail ahead of your travel as part of your maintenance. Use soapy water and flush thoroughly with water, directing spray away from trolleys.

WARNING! If all screws are not fastened securely, rail can separate from mounting surface resulting in a fall, severe injury, or death.

Access Rail System – R32

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12 - INSPECTION BEFORE EACH USE (Continued)

12d Inspect endstop screws - Check to make sure that end

stop screws have not loosened. They must be flush with the top of the endstop.

WARNING! If endstop screws loosen, trolleys can roll off end of rail resulting in a fall, severe injury or death.

12e Inspect ball bearings - If trolley assembly has been removed from rail, make sure each trolley contains all 72 balls. Do not load trolley onto rail and use trolley assembly if balls are missing.

IMPORTANT! - If transferring trolley assemblies from one rail to another, be sure to have extra balls on hand.

WARNING! If trolley has been removed from rail, some balls may be lost. Do not use trolleys if balls are missing. Trolleys with missing balls can come off rail, resulting in a fall, severe injury,or death.

Missing balls

Access Rail System – R32

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13 - ANNUAL FORMAL INSPECTION

A formal inspection of rail for cracks, deformation or wear and its connection to structure must be performed annually by a competent person.

13a Inspect trolleys for damage - Remove and inspect trolleys for damage, corrosion, strength, and operation.

Inspect all parts of

Inspect shackles carefully, especially the ends inside the trolley. Replace trolley assembly if there is any sign of corrosion, cracks, or elongation.

Note: Trolley connections and shackle installation are permanent. The only components that can be replaced are balls or ball retaining clips. Replace entire trolley assembly if any other components are damaged. Always replace entire trolley assembly after a fall.

shackles carefully

13b Inspect ball bearings - Confirm that balls are

Torlon

material. Color must be brown. Do not use balls that are white or black. Make sure there are no flat surfaces as they will impede trolley movement. Damaged balls may indicate high load or high wear. Return complete trolley assembly to one of the service/recertification center listed on the back of this manual for advice.

Inspect shackle ends from trolley underside

Use Torlon balls only

Torlon is a registered trademark of Solvay Advanced Polymers L. L. C.

Access Rail System – R32

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13 - ANNUAL FORMAL INSPECTION (Continued)

13c Inspect ball bearing quantity - Make sure that all

trolley ball races have the correct number of balls (see chart below). Do not load trolleys on rails if balls are missing. Do not use system until missing balls have been replaced.

IMPORTANT! - If transferring trolley assemblies from one rail to another, be sure to have extra balls on hand.

WARNING! Missing balls weaken trolley. Trolleys with missing balls can come off rail resulting in a fall, severe injury, or death. Do not use trolleys if balls are missing.

13d Replace missing or damaged ball bearings - Use

only Harken replacement 10 mm (3/8") Torlon

balls. To replace lost or damaged ball bearings, position trolley assembly on edge with retaining clip in place. Do not remove retaining clip. Gently push one ball at a time into trolley from center of clip. Allow balls to roll into return race and insert remaining balls. Do not overfill. Each trolley must have 72 ball bearings!

13e Inspect pinstop - Check for spring degradation, cracks or wear that may affect locking strength and operation.

Missing ball bearings

Trolley

assembly

IN10448 72

Balls per

trolley

Balls Order Balls/Set Ball Ø

Torlon

547 25 10 mm (3/8")

Retaining clip

13f Inspect rail attaching fasteners - Check for loosening, damage, or corrosion that may affect strength.

13g Failed inspection - If inspection reveals an unsafe or defective condition, remove item from service and destroy it. If in doubt, please contact manufacturer for further advice.

Torlon is a registered trademark of Solvay Advanced Polymers L. L. C.

Access Rail System – R32

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14 - MAINTENANCE

14a Keep balls and races clean - Flush trolleys

frequently by squirting a detergent/water solution into the sides of the rail and into center openings. Roll trolley assembly back and forth to distribute evenly, then flush bearings with fresh water.

Cleaning and flushing points

Check rail for dirt (salt) buildup before each use. If the rail has visible dirt or feels gritty, clean the rail ahead of your travel as part of your maintenance. Use soapy water and flush thoroughly with water, directing spray away from cars.

14b Use ball conditioner - After trolley dries, apply

one or two drops of McLube

OneDrop™ ball conditioner. Use a small screwdriver to circulate the balls to distribute OneDrop ball conditioner. Do not use spray lubricants because ball bearings may skid not roll. It is important to clean trolley as excessive build-up of grease, dirt, and salt will restrict trolley movement.

Cleaning and flushing points

McLube is a registered trademark of McGee Industries, Inc.

OneDrop is a trademark of McLube, a division of McGee Industries, Inc.

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15 - LABELING

Description

Serial number EN certification

Manufacturer CE certification

Item number Read the manual

16 - RECORDS

A record must be kept for each component, subsystem and system, with the following details (see example record log below). It is the responsibility of the user organization to provide the record and to enter onto the record the details required.

EQUIPMENT RECORD

Product:

Model/Type Description Serial Number

Manufacturer

HARKEN

Year of Manufacture Purchase Date Date First Put Into Use

Other important information (i.e. document number):

N15W24983 Bluemound Rd.,

Address

Pewaukee, WI USA

Tel/Fax/Email/Website

(262) 691-3320 / (262) 701-5780

harken@harken.com / www.harken.com

EXAMINATION/REPAIR HISTORY

Date

Reason for Entry

(Periodic exam or repair)

Defect notes, repairs carried out and

other important information

Name and signature of

competent person

Date of next periodic

examination

Type examination and ongoing production control carried out by SATRA Technology Center (Notified body number

0321), Wyndham Way, Telford, Kettering, NN16 8SD, United Kingdom.

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17 - CUSTOMER DECLARATION

The undersigned……………………………………………………………………………………………

acting as the main contractor of the fall arrest system, to which this manual refers, installed at building site:

Street…………….………………………………………………………………….. n°………………….

Cit y……………………………………………………. Prov……….……………… Zip…………………

DECLARES to have received

from the installing company:

The manual of use and maintenance of the system, together with the attachments provided

Provided end user training

The as-installed drawing of the final system

Place and date

……………………………………………

The Customer (Stamp and signature)

…………………….……………………….…………………

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18 - STATEMENT OF VISION

Please note that every access to the building where the Harken Access Rail system is installed should be made by authorized and qualified personnel ONLY.

It is therefore necessary, before using the Harken Access Rail system, that the user read this Use and Maintenance manual and complete the register below.

It is mandatory to complete the register below, in order to:

- Regulate and record access on the roof

- Equip users with the necessary PPE

- Work in complete safety

WORKER (Name and surname) SIGNATURE for acknowledgement

DATE COMPANY

COMMENTS

I HAVE READ AND UNDERSTAND THIS MANUAL

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19 - PERIODIC AND EXTRAORDINARY MAINTENANCE

To ensure conformity to local codes and regulations, the Access Rail system, must be periodically inspected according to the instructions provided by the manufacturer as described in this manual. Extraordinary maintenance goes beyond normal maintenance and includes component replacement, fastener tightening or testing which are not included as periodic maintenance.

All periodic and extraordinary maintenance must be recorded in the following register:

MAINTENANCE REGISTER

MAINTENANCE COMPANY

RESPONSIBLE (Name and Surname) DESCRIPTION OF THE WORK OUTCOME

DATE

COMMENTS

Positive

Negative

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20 - Worldwide Limited Warranty

COVERAGE. HARKEN® warrants that each HARKEN product, when properly used and maintained, will be free from defects in material and workmanship from the date of receipt of the product by the final customer.

THE LIMITED WARRANTY. This limited warranty applies to all Harken products purchased. The sole and exclusive remedy under this LIMITED WARRANTY for original defects in materials or workmanship of a HARKEN product shall be the repair or replacement, at HARKEN’s sole discretion, of the defective part or component, in accordance with the terms of this warranty.

WARRANTOR. For products originally sold in the Unites States, the limited warranty for the products are supplied by HARKEN, INC.. For products originally sold in the European Union, the limited warranty for the products is supplied by the dealer who sold the product through the Harken Distributors in that country. For products originally sold in the rest of the World, the limited warranty for the products is supplied directly by the Harken Distributors in that country. When “HARKEN” is mentioned throughout this Limited Warranty, it refers to the entity as defined in this paragraph.

OWNER – NON-TRANSFERABLE WARRANTY. This warranty is made by HARKEN with the original purchaser of the product and does not extend to any third parties. The rights of the original purchaser under this warranty may not be assigned or otherwise transferred to any third party.

WARRANTY TERM. The LIMITED WARRANTY covers any original defects in material or workmanship manifested within 10 years of the date of receipt of the product by the final customer for use in non-marine applications such as built environments. The same coverage for marine use and corrosive applications is limited to a 12 month term.

NOT COVERED. The LIMITED WARRANTY does not apply to, nor shall HARKEN have any liability or responsibility for, damages or expenses relating to defects caused by misuse, abuse, failure to install, use, maintain or store the HARKEN product as specified in the warranty booklet, service booklet, manuals, catalogue or other literature available from HARKEN.

The LIMITED WARRANTY does not apply to, and neither shall HARKEN have any liability or responsibility in respect to, damages or expenses relating to:

• defects in material or workmanship that did not exist when the product was ﬁrst delivered;

• defects in material or workmanship that are manifested outside the warranty period;

• defects which are not reported to HARKEN within sixty (60) days of discovery;

• a product that has been altered or modiﬁed from factory speciﬁcations;

• damage or deterioration of cosmetic surface ﬁnishes, including cracking, crazing, discoloration or fading;

• accidents, misuse, abuse, abnormal use, improper use, lack of reasonable or proper maintenance or storage;

• installation, service or repairs improperly performed or replacement parts or accessories not conforming to HARKEN’s speciﬁcations;

• use exceeding the recommended and permitted limits or loads of the product and/or the product on which the product is installed;

• normal wear or deterioration occasioned by the use of the product or its exposure to the elements;

• ropes, lines, buckles and webbing;

• loss of time, loss of use, inconvenience, travel expense, costs related to procuring any substitute product, transportation costs, any incidental or consequential damages arising out of the non-use of the product, or compensation for inconvenience or loss of use while the product is being repaired or otherwise not available, or other matters not speciﬁcally covered hereunder;

• the costs to remove, disassemble or re-install the product;

• removal, storage and replacing of the product on which the product has been installed, even where this is necessary to carry out the warranty service.

The LIMITED WARRANTY does not cover, nor shall HARKEN have any liability or responsibility in respect of, damages or expenses relating to, the following products and/or components:

• washers and spacers;

• ball bearings, roller bearings, thrust bearings.

Online warranty registration. Registering this product online at www.harken.com is critical to receive product updates or any recall information. Harken will not sell this information or use it for solicitation.

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Appendix A

Reference Documents for Harken Access Rail Installation, Operation and Maintenance

The following publications give detailed information to ensure a safe and legally compliant installation while offering guidance when designing, installing, testing, maintaining and using a comprehensive fall protection system:

Testing and Certification – (Harken Certification Completed)

EN795:2012 - Protection against falls from a height – Anchor devices – Requirements and Testing.

CEN/TS 1641: 2013 - Personal fall protection equipment – Anchor devices – Recommendations for anchor devices for use by more than one person simultaneously.

ANSI Z359 - Fall Protection Code

System Design and Best Practices

ANSI Z359 – Fall Protection Code.

OSHA 29CFR - Laws and Regulations.

EN358 - Personal protective equipment for work positioning and prevention of falls from a height. Belts for work positioning and restraint and work positioning lanyards.

BS7883 2005 - Code of practice for the design, selection, installation, use and maintenance of anchor devices conforming to BS EN 795.

Personal Protective Equipment (PPE)

ANSI Z359 – Fall Protection Code.

OSHA 29CFR - Laws and Regulations./TS 16415

EN813 - Personal protective equipment for prevention of falls from a height - Sit harnesses.

EN355 - Personal protective equipment against falls from a height - Energy absorbers.

EN361 - Personal protective equipment against falls from a height - Full body harnesses.

EN362 - Personal protective equipment against falls from a height – Connectors.

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Appendix A

Essential Reading

BS 7985: 2009 British Standard Code of Practice The use of rope access methods for industrial purposes.

BS7883:2005 Code of practice for the design, selection, installation, use and maintenance of anchor devices conforming to BS EN795.

This British Standard provides information relating to anchor devices and recommendations for their installation and use in conjunction with personal protective equipment (PPE) for protection against falls from a height. It is intended to complement BS EN795 by recommending good, accepted practice as followed by competent practitioners. It also gives guidance on what should be done in the case of base materials of unknown strength.

Harken R32 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual