HEADRUSH ZSIR150-20A, ZS125-08 Installation, Operation & Maintenance Manual

ZIPSTOP ZIP LINE BRAKE

Installation, Operation & Maintenance Manual

Models: ZS125-08 / ZSIR150-20A

NOTE TO INSTALLERS

Always Read Instructions Before Use

Leave this manual attached to the zipSTOP Brake unit. The Installation, Operation and Maintenance manual contains information relating to the proper use of the zipSTOP and includes all product registration and warranty information. This document may only be removed by the end user prior to operation. Ensure that this manual is readily available to operators at all times.

Head Rush Technologies zipSTOP Zip Line Brake Installation, Operation & Maintenance Manual P/N 01170006604

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.

TABLE OF CONTENTS

1. SAFETY INFORMATION 7

1.1 Symbols Used in this Manual

2. EMERGENCY ARREST DEVICE EAD CONFIRMATION 8

3. SAFETY & INFORMATION LABELS 9

3.1 Location of Safety Labels

4. WARRANTY INFORMATION 10

4.1 Warranty Conditions

4.2 Customer Responsibility

5. SPECIFICATIONS 11

5.1 Introduction

5.2 zipSTOP Brake Unit, ZS125-08

5.3 zipSTOP Brake Unit, ZSIR150-20A

5.4 zipSTOP Brake Trolley, ZS125-08 and ZSIR150-20A

6. OPERATING PRINCIPLES 15

6.1 General

7. ZIPSTOP BRAKE ASSEMBLY 16

7.1 General

7.2 Unpacking the zipSTOP

7.3 Long Term Storage

7.4 Supplied Parts

7.5 General and Additional Parts Required

7.6 Redirection Pulleys

7.7 Traveler Assembly

7.8 Minimum Hardware Requirements

7.9 Redirection Line

7.9.1 Redirection Line Speciﬁcations: ZS125-08/ZS150-20A

8. ZIPSTOP BRAKE ASSEMBLY CONFIGURATION 22

8.1 General

8.2 Setup Variables, ZS125-08/ZSIR150-20A

8.3 Rider Arrival Speed

8.4 Rider Weight

8.5 Redirection Line Ratio

8.5.1 1:1 Ratio

8.5.2 2:1 Ratio

8.6 POSSIBLE SYSTEM CONFIGURATIONS (INFORMATIVE ONLY)

8.6.1 3:1 Ratio

8.6.2 Other Conﬁgurations

8.7 Zip Line Slope

8.7.1 Positive Slope Line

8.8 Flat Line

8.9 Negative Slope Line

8.10 Calculating zipSTOP Braking Distances

8.10.1 Deﬁnition of Terms

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8.11 zipSTOP Braking Distance Charts

8.12 Conﬁguration Notes

8.13 zipSTOP Conﬁguration Worksheet

9. ZIPSTOP BRAKE ASSEMBLY INSTALLATION 34

9.1 General

9.2 Safety Precautions

9.3 Primary Anchor Point

9.4 Secondary Anchor Point

9.4.1 Position of the Secondary Anchor Point

9.5 Redirection and Support Lines

9.6 Fitting zipSTOP Brake Unit

9.7 Fitting the Brake Trolley

9.8 Fitting Type I Pulley

9.9 Fitting Type II Pulley

9.10 Fitting Redirection Line

9.11.1 1:1 Redirection Ratio

9.11.2 2:1 Redirection Ratio

10. OPERATION OF ZIPSTOP 49

10.1 Safety Precautions

10.2 zipSTOP Operation as a Primary Brake

10.3 zipSTOP Operation as an EAD

10.4 Landing Areas

10.5 Operation During Extreme Weather Conditions

10.6 Resetting the Brake

10.7 Operational Retraction Spring Cycle Limit

11. TROUBLESHOOTING 53

11.1 Before You Call

12. RECERTIFICATION AND MAINTENANCE 58

12.1 General

12.2 Annual Recertiﬁcation

12.3 Maintenance Service Schedule

12.4 Daily Inspections

12.4.1 Safety Precautions

12.4.2 Webbing Wear

12.5 Braking Line Replacement Procedure

12.6 Brake Trolley Inspection and Maintenance

12.7 Brake Unit Casing Inspection

12.8 Webbing Line Inspection

13. BRAKING DISTANCE CHARTS 67

13.1 How to Read Braking Distance Charts

13.2 1:1 Ratio – Metric, ZSIR150-20A

13.3 1:1 Ratio – Imperial, ZSIR150-20A

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13.4 1:1 Ratio – Metric ZS125-08

13.5 1:1 Ratio – Imperial ZS125-08

13.6 2:1 Ratio – Metric, ZS125-08

13.7 2:1 Ratio – Imperial, ZS125-08

13.8 3:1 Ratio – Metric

13.9 3:1 Ratio – Imperial

14. APPENDIX A: EAD WARRANTY/REGISTRATION FORM 72

14.1 Warranty Registration Form

15. APPENDIX B: ACCESSORIES AND REPLACEABLE PARTS 73

15.1 Accessories and Replacement Parts

15.2 Brake Trolley Catch Accessory

15.2.1 Speciﬁcations

15.2.2 Composition

15.2.3 Mounting/Installation

15.2.4 Operation

15.2.5 zipSTOP Brake Unit Side Cover Replacement

15.2.6 zipSTOP Brake Unit Nozzle Replacement

15.2.7 Removing Nozzle Assembly

15.2.8 To Reﬁt the Nozzle Assembly:

15.2.9 Brake Trolley Bump Stop Replacement

15.2.10 Service Life

15.3 zipSTOP Pivot Mount

15.3.1 Composition

15.3.2 Mounting

15.3.3 Installation

15.3.4 Performance

15.3.5 Service Life

15.3.6 Inspection Procedures

16. APPENDIX C: EXAMPLE INSPECTION LOGS 88

17. MANUFACTURER’S DETAILS 90

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IMPORTANT SAFETY NOTICE

Zip Lining is a Dangerous Activity

Read Before Installation & Operation

Failure by the installer or operator to heed any and all instructions, warnings and cautions for the correct installation, operation, care and maintenance of the zipSTOP may result in serious injury or death.

The zipSTOP Brake assembly, including zipSTOP Brake Unit Model ZB125-08B and ZSIR150-20A, zipSTOP Brake Trolley Model ZT125-17 and all associated equipment are designed and speciﬁed for use in the recreational zip line industry as components of a well designed zip line brake system. Use of the zipSTOP components for any purposes other than that intended by the manufacturer is not permitted.

The zipSTOP is designed to be utilized as a Primary Brake or Emergency Arrest Device (EAD). When using the zipSTOP as a primary brake, the installer MUST utilize an independent EAD to protect against operator error and third party equipment failure. Design and installation of the zip line, including the complete braking system, is the responsibility of the installer or operator.

Owners and Operators of zipSTOP devices are responsible for the safety and supervision of any person using the zipSTOP and are required to assure that proper installation and operation procedures are followed at all times. Proper installation requires careful design and planning using zipSTOP and non-zipSTOP components. Owners and Operators are encouraged to seek the advice of their zip line installer or a proper engineering professional regarding the instructions in this Manual.

These instructions must be made readily available to the operator at all times. Prior to installation and use, all owners, installers and operators must have read and shown to have understood all instructions, labels, markings, and safety information pertaining to the installation, operation, care, and maintenance of the zipSTOP brake, its component parts, and all associated hardware. Failure to do so may result in equipment damage, serious injury and death.

1. SAFETY INFORMATION

1.1 Symbols Used in this Manual

The following safety symbols are used throughout this manual to highlight potential danger to operators and equipment. 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 equipment damage, serious injury and/ or death.

Ensure that you read and understand all safety related procedures related to the working environment and the task you are undertaking.

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 safety and prevent damage to property or equipment.

CARE FOR THE ENVIRONMENT

Take care to minimize impact on the environment when carrying out this procedure.

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2. EMERGENCY ARREST DEVICE (EAD) CONFIRMATION

Zip lines using the zipSTOP Brake are required to use both primary and emergency arrest devices functioning together to arrest the motion of passengers. The EAD must engage with no input from the passenger upon failure of the primary arrest device.

This form must be initialed by the performing EAD installation technician, signed by a separate party and attached when mailing in the Warranty Registration Form; failure to do so may void your warranty .

I have read this manual prior to zipSTOP installation and use. INITIAL:

I am aware that an approved EAD is required prior to system use. INITIAL:

I certify that an approved EAD has been correctly installed prior to system use. INITIAL:

I have inspected the installation of the EAD and certify its functionality.

SIGNED: DATE:

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3. SAFETY & INFORMATION LABELS

Safety and Information Labels located on the zipSTOP components are not to be removed. Ensure labels are in place and remain legible at all times.

3.1 Location of Safety Labels

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Location of Labels – Brake Unit

Location of Labels – Brake Trolley

4. WARRANTY INFORMATION

4.1 Warranty Conditions

Manufacturers sole warranty. The zipSTOP Brake assembly will be sold free from defects in materials and workmanship, excluding ﬁeld replaceable wear parts, for a period of one (1) year from date of purchase. This warranty only applies to the original purchaser, and is contingent upon the owner/operator using and maintaining the device in accordance with the zipSTOP instructions, including the requirement to maintain annual recertiﬁcation as described in the Installation, Operation and Maintenance Manual.

THIS WARRANTY IS EXPRESSLY IN LIEU OF OTHER WARRANTIES, EXPRESS OR IMPLIED, AND ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE IS HEREBY EXPRESSLY EXCLUDED.

The sole remedy for breach of said warranty or for any claim in negligence or strict liability in tort is the repair or replacement of any defective parts at the discretion of the manufacturer. Such parts claimed to be defective shall be returned to the Head Rush Technologies Service Center, transportation prepaid, for inspection by zipSTOP to determine to its satisfaction that said part(s) are defective.

This warranty is null and void if other than genuine parts are used, or if any modiﬁcations are carried out to the zipSTOP Brake assembly or zipSTOP components without the expressed written permission of the manufacturer. No person, Agent or Distributor is authorized to give any warranty, other than the one herein expressed, on behalf of the zipSTOP Company or to assume for it any liability pertaining to such products. The company makes no warranties in respect to trade accessories or component parts which are not manufactured by the company, same being subject only to such warranties, if any, as may be made by their respective manufacturers.

4.2 Customer Responsibility

The following items are considered to be the responsibility of the Customer and, therefore, are non-reimbursable under the terms of the warranty:

 Correct installation of an EAD.

 Sucient unmanned testing of the entire system.

 Normal maintenance/routine services.

 Normal replacement of service items.

 Replacements required because of abuse, misuse or incorrect operation of equipment by the installer or

operator.

 Field replaceable wear parts such as the nozzle, braking line, quick links, redirection line and pulleys,

brake trolley sacriﬁcial bump stops, and sheaves supplied as zipSTOP branded parts.

 Normal wear and tear due to use and exposure.

Strict adherence to the Installation, Operation and Maintenance Manual supplied, manufacturer’s instructions and advice given by zipSTOP service technicians is also a condition of warranty (see Appendix A: EAD Warranty/Registration Form).

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5. SPECIFICATIONS

5.1 Introduction

The zipSTOP Brake assembly is a controlled braking force device designed speciﬁcally for use in the zip line industry as a Primary or EAD at the end of zip line runs. The zipSTOP caters to a range of rider weights and approach speeds, and oers a smooth, consistent braking force for all riders. The brake is designed to be mounted to a primary and/or secondary anchor point to slow the decent of riders on a zip line. The primary anchor point is exactly what it sounds like; it is the main attachment point for the brake. The secondary anchor point is the support point for the redirection lines and pulleys.

The zipSTOP Brake Unit is installed at the end of the zip line, usually on or adjacent to the terminal end. A Secondary Anchor Point is normally required upstream of the landing area to provide support for the Redirection Line pulleys. Alternately a full-length secondary cable of sucient capacity can be installed to provide support for the Redirection Line and associated pulleys.

The design of the zipSTOP allows for simple installation, and incorporates both an advanced self-regulating brake unit and an automatic line reset. The patented braking mechanism delivers smooth deceleration and is designed to minimize variations in the deceleration rate and stopping distance of both children and adults. There are no friction parts in the brake mechanism, ensuring reliability remains high while maintenance and operating costs are kept to a minimum.

Installation, inspection, operation and maintenance must be carried out in accordance with the instructions in this manual to protect the longevity of the zipSTOP components.

Pictures in this manual are for reference purposes in terms of geometry and proposed redirection setup conﬁguration only. Mandated EAD may or may not be shown.

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5.2 zipSTOP Brake Unit, ZS125-08

zipSTOP Mount

Top Mounting Pin

Fully Retracted - 400 mm (16”)

Side Cover

MODEL ZS 125-08B

CLASSIFICATION Zip Line Braking Device

zipSTOP Brake Unit

Nozzle Assembly

Braking Line

Pulley

DIMENSIONS 380 x 320 x 216 mm (15 x 12.6 x 8.5 in)

NET WEIGHT 23.5 kg (52 lbs)

OPERATING TEMPERATURE -10°C (14°F) to 40°C (104°F)

STORAGE TEMPERATURE -20°C (-4°F) to 60°C (140°F)

MATERIALS CASING Aluminium alloy

INTERNAL PARTS Zinc plated and stainless steel

NOZZLE Modiﬁed Acetal plastic with stainless insert

LINE 20 mm Nylon Spectra Braking Line

MAXIMUM LINE EXTENSION 12.5 m (41 ft)

RIDER WEIGHT RANGE 15 to 150 kg (33 - 330 lbs)

MAXIMUM SPEEDS 1:1 REDIRECTION RATIO 36 km/h (22 mph)

2:1 REDIRECTION RATIO 60 km/h (37 mph)

3:1 REDIRECTION RATIO* Contact Head Rush Tech

CUSTOM RATIO* Contact Head Rush Tech

*Higher speeds may be utilized with the custom Redirection Ratios, however braking distances will increase. When planning a custom ratio, note that the automatic line reset may become compromised, requiring the necessity for either manual reset or supplementary reset.

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5.3 zipSTOP Brake Unit, ZSIR150-20A

zipSTOP Mount

Top Mounting Pin

zipSTOP Brake Unit

Nozzle Assembly

Braking Line

Fully Retracted - 400 mm (16”)

Side Cover

MODEL ZSIR150-20A

CLASSIFICATION Zip Line Braking Device

DIMENSIONS 380 x 320 x 216 mm (15 x 12.6 x 8.5 in)

Pulley

NET WEIGHT 23.5 kg (52 lbs)

OPERATING TEMPERATURE -10°C (14°F) to 40°C (104°F)

STORAGE TEMPERATURE -20°C (-4°F) to 60°C (140°F)

MATERIALS CASING Aluminium alloy

INTERNAL PARTS Zinc plated and stainless steel

NOZZLE Modiﬁed Acetal plastic with stainless insert

LINE 20 mm Nylon Spectra Braking Line

MAXIMUM LINE EXTENSION 20 m (65 ft)

RIDER WEIGHT RANGE 15 to 150 kg (33 - 330 lbs)

MAXIMUM SPEEDS 1:1 REDIRECTION RATIO 60 km/h (37 mph)

ZSIR15020A  THIS PRODUCT CAN ONLY BE USED WITH 1:1 REDIRECTION SETUPS

The zipSTOP IR (ZSIR150-20A) is NOT compatible with external redirection setups in any way. Installing a redirection setup with the zipSTOP IR can create a very dangerous set of braking conditions that could result in abnormally abrupt late braking.

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5.4 zipSTOP Brake Trolley, ZS125-08 and ZSIR150-20A

Redirection Line

Mounting Point

Upper Sheave

Lower Sheaves

MODELS ZT 125-17-1/2 – For use with 12.7 mm (½”) zip lines

ZT 125-17-3/4 – For use with 19 mm (¾”) zip lines

ZT 125-17-35/8 – For use with 15.9 mm (5/8”) zip lines

CLASSIFICATION Zip Line Brake Trolley

Bump Stops

DIMENSIONS 235 x 100 x 115 mm (9.3 x 3.9 x 4.5 in)

NET WEIGHT 1.3 kg (2.8 lbs)

MATERIALS CASING Aluminium alloy

WHEELS Steel

BUMP STOP Polyurethane

MAXIMUM SPEED 72 km/h (45 mph)

MINIMUM RIDER WEIGHT 15 kg (33 lbs)

MAXIMUM RIDER WEIGHT 150 kg (330 lbs)

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6. OPERATING PRINCIPLES

6.1 General

The zipSTOP Brake assembly is a controlled braking force device designed speciﬁcally for use as a Primary or EAD at the end of zip line runs. The zipSTOP caters to a range of rider weights and approach speeds and oers a smooth, consistent braking force for all riders. zipSTOP Brake performance relies on operators using the correct equipment and operating the system in accordance with the instructions contained within this manual.

The zipSTOP Brake assembly consists of a zipSTOP Brake Unit, zipSTOP Brake Trolley, redirection pulleys and associated Redirection Lines.

Pictures in this manual are for reference purposes in terms of geometry and proposed redirection setup conﬁguration only. Mandated EAD may or may not be shown.

Cable Clamps &

Primary Mount

Redirection

Line Support

Quick Links

Redirection Line

Overhead Line

Redirection Pulley

Brake Line Extension

zipSTOP Brake Line

zipSTOP Brake Unit

Arrest Zone

Typical zipSTOP Installation

Zip Line

Brake Trolley

Rest Position

 The zipSTOP Brake Unit is located at the zip line terminal end, normally adjacent to the landing area. It is

connected via a redirection pulley and Redirection Line setup to the zipSTOP Brake Trolley.

 The Brake Trolley is located on the zip line and when idle (zipSTOP Braking Line fully retracted) will be

positioned at the start of the rider Arrest Zone (Reset Position). The approaching rider trolley contacts the Brake Trolley, moving it down the zip line. As the Brake Trolley moves into the Arrest Zone it extends the Braking Line out of the zipSTOP Brake Unit via the Redirection Line. As the Braking Line extends out of the zipSTOP Brake Unit, the eddy current brake in the unit is activated, controlling the rate of deceleration and slowing the rider in a smooth manner.

 Once the load is removed from the Brake Trolley, the return mechanism in the zipSTOP Brake Unit

retracts the Braking Line, automatically returning the Brake Trolley to the start of the Arrest Zone (Reset Position) on the zip line, ready for the next rider.

When higher Redirection Ratios are employed retraction force is reduced and a manual reset of the Brake Trolley may be necessary.

Ensure brake is reset before rider starts down zip line, every time.

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7. zipSTOP BRAKE ASSEMBLY

7.1 General

The zipSTOP Brake assembly will be supplied as a kit of parts. Additional components are required to complete the braking system. Refer to Section ”Appendix B: List of Accessories and Replaceable Parts” for part number information.

Pictures in this manual are for reference purposes in terms of geometry and proposed redirection setup conﬁguration only. Mandated EAD may or may not be shown.

7.2 Unpacking the zipSTOP

SAVE PACKAGING FOR REUSE

Keep all zipSTOP packaging for reuse when returning the zipSTOP Brake Unit for annual recertiﬁcation. Damages caused by shipping in improper packaging are not covered under warranty and will result in additional repair charges to the owner.

1. Upon receipt of the zipSTOP Brake Assembly Kit, inspect all parts and operation (pull out line) for signs of shipping damage or contamination. If any components show signs of damage or mishandling, contact your zipSTOP distributor.

2. Check that all information and safety labels axed to the zipSTOP are present and legible. Refer to Section “Location of Safety Labels”.

Brake Assembly Kit

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Do not use the zipSTOP after date shown here

3. Check the Certiﬁcation Label on the zipSTOP Brake Unit for the ‘Next Recertiﬁcation Required’ date. If the date shown has passed or the label is missing or illegible then the zipSTOP Brake Unit must not be put into service.

4. Register online at www.thezipshop.com/registration or ﬁll out the Product Registration Card included with the zipSTOP Brake Assembly Kit, and return it to your zipSTOP distributor.

5. The EAD Conﬁrmation form and the Warranty Registration form (see Sections “Emergency Arrest Device (EAD) Conﬁrmation” and “Warranty Registration Form” respectively) are required to be detached, ﬁlled out, and mailed to: Head Rush Technologies 1835 38th Street , STE C Boulder, CO 80301

PRODUCT REGISTRATION MUST BE COMPLETED

The Product Registration must be completed, either by registering online or by ﬁlling out and returning the Product Registration Card. This is critical for receiving product notiﬁcations and up-to-date information for the proper use of the zipSTOP Brake assembly.

6. Read this entire Installation, Operation and Maintenance Manual supplied with the zipSTOP, and familiarize yourself with all aspects of installation, operation, care and maintenance.

7.3 Long Term Storage

If the zipSTOP Brake Unit is to be placed into storage or left unused for longer than two weeks, ensure the unit is clean and dry and protected from the environment. Ensure the Braking Line is fully retracted into the unit. Always store in a clean and dry environment, preferably in the original packaging

DO NOT STORE BRAKE UNIT IN A WET CONDITION

After exposure to water or damp conditions, thoroughly clean and dry the zipSTOP prior to storage. Ensure that the zipSTOP Brake Unit is not left with a wet Braking Line retracted inside the casing as this may result in corrosion of the unit and deterioration of the Braking Line. In a clean and dry environment, remove the side covers and fully extend the wet Braking Line and allow to completely dry prior to storing the Brake Unit. Ensure that debris does not enter the unit and reattach the side covers prior to storing or using the unit.

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When returning the zipSTOP Brake assembly to operation after an extended period of inactivity, always carry out a

ZIPSTOP ZIP LINE BRAKE

Installation, Operation & Maintenance Manual

Models: ZS125-08 / ZSIR150-20A

NOTE TO INSTALLERS

Always Read Instructions Before Use

Head Rush Technologies zipSTOP Zip Line Brake Installation, Operation & Maintenance Manual P/N 01170006604

full inspection and operational check of all components in the assembly. Refer to Section “Operation of zipSTOP” for Inspection procedures.

7.4 Supplied Parts

The following parts will be included in each Brake Assembly Kit:

 1 x zipSTOP Brake Unit

 1 x zipSTOP Mounting Bracket, Rattle Stop, Mounting and Lynch Pins

 1 x zipSTOP Brake Trolley

 zipSTOP Installation, Operation and Maintenance Manual

7.5 General and Additional Parts Required

Additional lines and equipment will be required to successfully install a zipSTOP Brake assembly within individual zip line installations. All hardware, fasteners and accessories used in the installation of zipSTOP must meet or exceed the required loads and speciﬁcations, and must be made of materials compatible with all-season outdoor use.

Head Rush Technologies developed speciﬁc redirection pulleys and the Gorilla rope to maximize the performance of a zipSTOP Zip Line Brake. The redirection pulleys oered by Head Rush Technologies are light-

Brake Unit Brake Unit Mounting Bracket

Brake Trolley Installation, Operation, & Maintenance Manual

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weight, corrosion resistant, and engineered to be virtually resistant to snagging. Head Rush Technologies also oers the Gorilla Rope, a 6mm rope speciﬁcally designed for used as a redirection line.

7.6 Redirection Pulleys

The following parts are not supplied as part of the zipSTOP kit and may be purchased separately from your zipSTOP distributor.

The Type I Pulley is ﬁtted to the Secondary Anchor Point, and provides both support and a means of redirection for the Redirection Line. The Type I Pulley is required for both 1:1 and 2:1 Redirection Ratio setups.

A Type II Pulley is ﬁtted between the zipSTOP Brake Unit and the Type I Pulley as required to provide support and redirection for the Redirection Line and connections to the Braking Line. The Type II Pulley is only required on the 2:1 Redirection Ratio set-ups.

Example of Type I Redirection Pulley Example of Type II Redirection Pulley

7.7 Traveler Assembly

Sling

Oval Quicklink

zipSTOP Brake Line

The Traveler Assembly is a recommended support for a 2:1 ratio conﬁguration. It is used to support the weight of the Redirection Line and associated hardware in order to ensure that the Redirection Line does not contact any surface other than the pulley sheaves. A sling of proper length should be used to ensure that the Braking Line feeds straight out of the device, without twist, and centered within the Nozzle. A swivel is recommended to ensure that the Braking Line remains free of twists.

Pulleys

Triangular Quicklink

Swivel

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7.8 Minimum Hardware Requirements

All required hardware is to be purchased separately. The following are minimum requirements for all hardware used for zipSTOP installation:

DESCRIPTION SIZE QTY NOTES

Grade 4.6 (M12)

ZIPSTOP BRAKE UNIT MOUNTING

BOLTS, WASHERS & LOCKNUTS

M12 or 1/2”

ASTM A307 Grade A or B (1/2”)

Length to suit installation

Suitable for all-season outdoor use

TYPE I PULLEY MOUNTING

HARDWARE

CARABINERS, SNAPS, RINGS,

THIMBLES, CLEVISES

To suit To suit Suitable for all-season outdoor use

Minimum load rating 15 kN

To suit

Suitable for all-season outdoor use

7.9 Redirection Line

The Redirection Line is required to connect the zipSTOP Brake Unit to the Brake Trolley and will transfer the braking force from the Brake Unit. The Redirection Line passes through the redirection pulleys and must meet minimum speciﬁcation. The following list provides several Redirection line options.

Head Rush Technologies developed the Gorilla Rope speciﬁcally for use as a redirection line with the zipSTOP Zip Line Brake It features a high strength-to-weight ratio, is designed to be highly resistant to abrasion, UV resistant, and water repellent. The 6mm Gorilla Rope maximizes performance because it is lighter, smaller in diameter, minimizes resistance, and maximizes reliable reset.

Spectra - Spectra/Dyneema is one of the recommended materials because it has sucient strength while minimizing size and diameter. Spectra/Dyneema is known for high strength and superior abrasion, water, and UV resistance. The spectra line should be jacketed with an abrasion-resistant, temperature-tolerant material to avoid possible degradation of the line due to friction. Gorilla Rope, a Head Rush Technologies product, is designed speciﬁcally to provide high strength, a long life span, and minimal stretch for applications where a small diameter rope is necessary. It is made for maximum durability and high performance in any application. It is perfect for use as a reduction line with the zipSTOP Zip Line Brake but can also be used for many other industrial or recreational applications where these qualities are critical.

Technora® - Technora, while the strongest of the synthetic ﬁbers, is particularly sensitive to UV wear. Only Technora core lines with UV protective jackets should be used. Technora lines are also slightly stier which can increase retraction drag when used as a Redirection Line. The drag is usually oset by the fact that a smaller diameter Technora line can be employed compared to another material.

Nylon and Other materials - Nylon or other materials can be used provided they meet the minimum requirements for strength, UV, and wear resistance. However, these lines may necessitate much larger diameter ropes to attain the necessary strength which can have an adverse eect on Redirection Line performance.

Typical Technora Termination

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7.9.1 REDIRECTION LINE SPECIFICATIONS: ZS12508/ZSIR15020A

MAXIMUM DIAMETER 10.0 mm/0.394 in (6mm/0.236 in recommended)

MINIMUM STRENGTH 13 kN, Stretch <3% at 13 kN

STRETCH <4% at 15 kN

WEAR RESISTANCE High abrasion resistance and UV resistance

WATER RESISTANCE Dry, non-absorptive

TYPE Kernmantle or single braid construction

TYPICAL Redirection LINE EXAMPLE

ZS125-08

TYPICAL Redirection LINE EXAMPLE

ZS150-20A

ALWAYS USE THE SPECIFIED REDIRECTION LINE

Failure to utilize a Redirection Line of speciﬁed strength and quality can compromise zipSTOP brake operation, resulting in equipment damage, serious injury or death.

REDIRECTION LINE WILL BE SUBJECT TO WEAR AND ABRASION

Any Redirection Line selected for use will wear and must be replaced from time to time. Lines must be carefully inspected prior to use each day, and failure to do so may result in serious injury or death.

When selecting a Redirection line, the following considerations apply:

 The line must meet the speciﬁcations described above.  A lighter, smaller diameter line is preferred, to minimize resistance and weight, and maximize reliable

reset.

 A waterproof line is required. Water absorption can add signiﬁcant weight, allowing the line to sag

which increases the likelihood of incomplete reset for Brake Unit and Brake Trolley.

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8. zipSTOP BRAKE ASSEMBLY CONFIGURATION

8.1 General

The zipSTOP Brake assembly is designed to be utilized as part of a complete zip line braking system, and can be used for a wide range of zip line installations. The zipSTOP Brake assembly is suitable for use in both existing and new zip line installations.

Setup information contained within this manual relates only to the zipSTOP Brake assembly – The design, installation and set-up of other components comprising the complete braking system are the responsibility of the installer and/or operator.

COMPATIBILITY TESTING IS THE RESPONSIBILITY OF THE INSTALLER OR OPERATOR

The zipSTOP Brake is designed to work with most pulleys and zip lines but may not work with all. Compatibility is to be determined by the installer or operator based on experience and unmanned testing.

ALWAYS CARRY OUT UNMANNED TESTING TO DETERMINE ACTUAL BRAKING DISTANCE

The information contained in this manual is intended for guidance only. Calculated braking distances for the zipSTOP Brake assembly are estimates only and may dier from actual braking distances achieved on individual zip lines.

As there are inﬁnite possibilities regarding participant weights and arrival speeds, line slopes and environmental conditions, a safe and functional installation can only be achieved after careful consideration and unmanned testing of all factors in advance of the zipSTOP installation.

The zipSTOP Brake is required to use both primary and emergency arrest devices functioning together to arrest the motion of passengers. The EAD must engage with no input from the passenger upon failure of the primary arrest device, and all required Conﬁrmation and Warranty registration forms must be ﬁlled out and returned; failure to do so may void your warranty (see Sections “Emergency Arrest Device (EAD) Conﬁrmation” and “Warranty Registration Form” respectively).

Pictures in this manual are for reference purposes in terms of geometry and proposed redirection setup conﬁguration only. Mandated EAD may or may not be shown.

8.2 Setup Variables, ZS125-08/ZSIR150-20A

A number of variables will inﬂuence the ﬁnal braking distance and level of rider comfort, these include:

 Rider arrival speed

 Rider weight

 Redirection Line Ratio (Only a 1:1 Applies with the ZSIR150-20A)

 Zip line slope in the landing area

 System friction

 Environmental conditions (wind, rain, temperature)

 Rider trolley used

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8.3 Rider Arrival Speed

Rider arrival speed is unique to each zip line installation and is a factor of line slope, zip line length, rider weight, rider descent position, wind and friction. It is necessary to know the acceptable minimum and maximum rider velocities prior to conﬁguring the zipSTOP.

8.4 Rider Weight

Suitable rider weight ranges will need to be determined by individual zip line operators. The zipSTOP Brake unit will accommodate riders between 15 and 150 kg (33 and 330 lbs). It is necessary to know the acceptable rider weight range before conﬁguring the zipSTOP.

8.5 Redirection Line Ratio

The Redirection Ratio is the most inﬂuential factor in the braking characteristics of the zipSTOP. The Redirection Ratio is the ratio between the Brake Trolley travel and the zipSTOP Braking Line extension.

The Redirection Ratio is achieved by passing the Redirection Line around a series of pulleys. This alters the ratio of Brake Trolley travel to Braking Line extension, allowing the installer to tailor the braking distances and deceleration rates, accommodating a wide range of arrival speeds and rider weights.

ZSIR15020A  THIS PRODUCT CAN ONLY BE USED WITH 1:1 REDIRECTION SETUPS

Various Redirection Ratios are possible:

 1:1 Ratio

 MUST be used for model ZSIR150-20A

 Can be used for model ZS125-08

 2:1 Ratio

 Can be used for model ZS125-08 only

 CANNOT be used for model ZSIR150-20A

 3:1 and higher ratios – contact your zipSTOP Distributor, model ZS125-08 only

The recommended conﬁguration orients all elements (zipSTOP Brake Unit, Redirection Pulleys, Brake Trolley) in the vertical plane.

When higher Redirection Ratios (3:1 and higher) are employed (for model ZS125-08 only), retraction force is reduced and a manual reset of the Brake Trolley will be necessary.

ALWAYS USE THE SPECIFIED REDIRECTION LINE

Failure to utilize a Redirection Line of speciﬁed strength and quality can compromise zipSTOP brake operation, resulting in equipment damage, serious injury or death.

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REDIRECTION LINE WILL BE SUBJECT TO WEAR AND ABRASION

8.5.1 1:1 RATIO

Attach zipSTOP braking line to redirection

line with a quicklink and recommended

swivel, support pulley and sling

Attach redirection pulley

to overhead line

Overhead Line

Zip Line

Brake Trolley

The 1:1 Redirection Ratio directly connects the zipSTOP Brake Unit to the zipSTOP Brake Trolley via a single Type I Redirection Pulley. For every unit of Brake Trolley travel, the Braking Line extends an equal distance.

Characteristics of the 1:1 ratio are:

 Suitable for low speeds

 Strongest braking force

 Short braking distances

 Higher rate of rider deceleration

 Maximum rider approach speed of 36 km/h (22 mph) – model ZS125-08

 Maximum rider approach speed of 60 km/h (37 mph) – model ZSIR150-20A

In the case of the model ZS125-08: A 1:1 Redirection Ratio is used for zip line installations where low arrival speeds are common. Although suitable for speeds up to 36 km/h (22 mph), typically a 1:1 ratio would be employed when approach speeds are less than 20 km/h (12 mph).

*EAD not shown but it is mandated*

Overhead Cable – 1:1 Redirection Ratio

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8.5.2 2:1 RATIO

redirection line with a quicklink and

recommended swivel, support pulley

Attach zipSTOP braking line to

and sling

Attach redirection pulley

to overhead line

Overhead Line

Zip Line

Brake Trolley

*EAD not shown but it is mandated*

Overhead Cable – 2:1 Redirection Ratio

The 2:1 Redirection Ratio connects the zipSTOP Brake Unit to the zipSTOP Brake Trolley via both Type I and Type II pulleys. With a 2:1 ratio the Brake Trolley travels twice the distance that the zipSTOP Braking Line extends.

Characteristics of the 2:1 ratio are:

 Suitable for medium to high speeds

 Optimal combination of stopping distance, braking force and reliability in reset

 Optimum rider comfort

 Longer braking distances than a 1:1 setup

 Overhead support line (redirection point) recommended

 Maximum approach speed of 60 km/h (36 mph)

A 2:1 Ratio is used on zip line installations where medium to high approach speeds are common but a soft stop for the rider is desired. Although suitable for approach speeds up to 60 km/h (36 mph), typically a 2:1 ratio is employed when approach speeds are less than 40 km/h (24 mph).

A 2:1 Ratio is speciﬁcally PROHIBITED in any installation of the ZSIR150-20A. Utilizing an external redirection will lead to potentially dangerous and harmful braking dynamics.

ZSIR15020A  THIS PRODUCT CAN ONLY BE USED WITH 1:1 REDIRECTION SETUPS

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8.6 Possible Conﬁgurations (Informative Only)

8.6.1 3:1 RATIO

3:1 installation formats are a unique situation and the following information should be used to develop an appropriate site plan.

The 3:1 ratio connects the zipSTOP unit to the braking trolley via redirection pulleys and supplementary line. With a 3:1 ratio the braking trolley travels three meters for every meter of zipSTOP line. This will result in a longer stopping distance for the rider.

Characteristics of 3:1 ratio setup are:

 Max. Approach Speed = 72 km/h.

 Suitable for high arrival speed.

 Softer stopping force from higher speeds

 Longer stopping distances

 More complex set-up.

A 3:1 ratio is commonly used on zip lines with high arrival speeds and when a longer braking distance is available. The 3:1 ratio is suitable for approach speeds up to 72 km/h (45 mph) allowing a softer stop after thrilling high speed runs.

Primary Anchor

zipSTOP

Support Wheel

Secondary

Pulley

Redirection Line

Cable Tidy

zipSTOP

Brake Trolley

Support Line

Start of

Braking Zone

Double

Pulley

Block

Locate Secondary

Anchor Upstream

of Braking Zone

Secondary

Anchor

Line

Locate Pulley

Block Above Zip

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8.6.2 OTHER CONFIGURATIONS

The zipSTOP Brake assembly may be used with other zip line conﬁgurations and higher rider velocities. Conﬁgurations shown are based on a single line zip line. Dual zip lines and side-by-side conﬁgurations may also be accommodated. Please contact your zipSTOP Distributor for information on alternate set-ups.

When higher Redirection Ratios (3:1 and higher) are employed (for model ZS125-08 only), retraction force is reduced and a manual reset of the Brake Trolley will be necessary.

Pictures in this manual are for reference purposes in terms of geometry and proposed redirection setup conﬁguration only. Mandated EAD may or may not be shown.

Some examples of alternative conﬁgurations are shown below:

Beam Mounted Pulley - 2:1 Redirection Ratio

8.7 Zip Line Slope

Three zip line conﬁgurations at the end of the line are possible: ﬂat line, positive line slope and a negative line slope. The slope of the line will inﬂuence the braking distances as well as allowing the rider to roll slowly up or down the line once decelerated.

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Oset Redirection Pulley – 1:1 Redirection Ratio

NOTE: Oset redirection pulleys should only be used with highly

tensioned zip lines. Slack zip lines may cause binding and excessive

wear on the brake trolley.

8.7.1 POSITIVE SLOPE LINE

This is the ideal conﬁguration when designing a zip line incorporating the zipSTOP Zip Line Brake. The positive line slope conﬁguration equalizes the braking distance between heavy and light riders, therefore minimizing the length needed for the arrival platform.

zipSTOP

Primary Mount

Secondary Mount

Landing Area

Brake Trolley

Minimum Braking Distance

Roll Forward

Maximum Braking Distance

Arrest Zone

Reset Position

Positive Line Slope

On positive line installations riders will decelerate within the Arrest Zone but may continue to slowly roll forward on completion of braking.

It is recommended that the platform is positioned to allow all riders to roll forward on to the platform for a safe dismount.

8.8 Flat Line

On a ﬂat line participants will decelerate within the Arrest Zone at the completion of braking but typically don’t roll forward or backward.

It is recommended that the platform is positioned to allow all riders to safely dismount.

zipSTOP

Primary Mount

Secondary Mount

Landing Area

Brake Trolley

Minimum Braking Distance

Maximum Braking Distance

Arrest Zone

Reset

Position

Flat Line

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HEADRUSH ZSIR150-20A, ZS125-08 Installation, Operation & Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual