FIXED LINE SYSTEMS For further details on all our products contact below:-

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1 This Leaflet Contains Information on Fixed Line Systems Consisting of Vertical Life Line Systems Vertex PN 7000 Vertex PN 8000 Vertex PN 9000 Horizontal Life Line Systems Horizon PN 4000 Horizon PN 5000 FIXED LINE SYSTEMS For further details on all our products contact below:- C-35A, Phase-III, ESIP, Sitarganj, Distt. Udham Singh Nagar, Uttarakhand , India. Customer Care No. : (Toll Free) customercare@karam.in PRODUCT INFORMATION with Check Card

2 MANUFACTURING- FALL PROTECTION EQUIPMENT KARAM is the only company in the world which has a vertically integrated manufacturing set up. Starting with yarn and processing it to make premium quality of Webbing and Rope, converting hot rolled coils, flats and extrusions of Steel and Aluminium Alloys into World class Fall Arrest Components. Over the years KARAM has widened the scope of fall protection to suit workers of most industries including Telecommunications, Oil & Gas industry, Engineering industry, Power Transmission plants and Construction Industry. Constant innovation and prime focus on research and design has enabled KARAM to provide Fall protection solutions to a worker working in some of the most hazardous industrial conditions. Operations at KARAM are under constant vigilance to provide the finest in Quality of product and service. Congratulations on your Purchase! You are now a proud owner of KARAM FIXED LINE SYSTEM and CONGRATULATIONS again that you have stepped into the business of saving precious lives. To ensure the fixed line systems lives up to all expectations, it is important to read and comply with this instruction manual. Please ensure that this manual is easily accessible to all workers working on the lifeline as it is an important for all personnel installing, using and maintaining the system. The instruction manual is designed and written to be used for guidance for installation as well as tips on usage and maintenance of the system. INDEX PRODUCT CODE PAGE No. Vertical Anchorage Lifeline System on Rigid Cable Line Horizontal Anchorage Life Line System Vertical Anchorage Lifeline System on Aluminum Rail System Mounting Bracket & Rungs Horizontal Alu-Rail System Proof loading Pre-Use Checks Precautions Annual Inspection Tools Torque Chart Check Card Vertex PN 7000 Vertex PN 4000 Vertex PN 8000 Vertex PN 9000 Horizon PN If there are any questions or queries about installation, usage, inspection or maintenance our team would be Happy to Help. You may please contact us on help@karam.in Each installation can be viewed by scanning the QR Code on the respective page. Disclaimer : Illustrations may be changed without notice. All dimensions and specifications are approximate and drawings not to scale. If in doubt click on the following view the latest updated manual. Thank you, Together let us make our workforce SAFE. 01

3 VERTICAL LIFE LINE SYSTEM Ref. PN 7000 MOUNTING BRACKET Ref. PN 7000 System Ref. Vertex PN 7000 Shock Absorber Ref. PN 7000 (02) Extremity Plates for Two Ladder Rungs Ref. PN 7000 (13) Step 01 - Installation of The Mounting Bracket (Top & Bottom) The System PN 7000 is installed in the following way: Step 1A: Installation of the Mounting Bracket Ref. PN 7000 (01) on the Upper Ladder Rung: The mounting brackets can be installed on different sections of the ladder rung with or without the help of the two channel grips and fastened on the same with the help of the given fasteners. The drawings below illustrate the position of the channel grips for different sections. Recommended Torque: COMPATIBLE SUPPORT SECTION PROCESS Wire Rope (with one end having a swaged loops) Ref. PN 9XXXSL (where XXX is the length of the wire rope meters Rope Grab Ref. RG Step 1A : Installation of the Mounting Bracket Ref. SA12. on the Upper Ladder Rung Some Structures have brackets welded for fall protection. In Such cases. an eye bolt SA 12 may be used as the mounting bracket, SA12 is certified to EN 795. Intermediate Ref. PN 2001(04) Step 1B : Installation of the Mounting Bracket Ref. PN 7000 (13) on the Upper Ladder Rung Step 1A Wire Rope Cap Ref. PN 7000 (12) The PN 7000(13) brackets is fixed on two rungs of the ladder Set of U-bolts and Thimbles Ref. PN 6000 (01) Step 1C: Installation of the Mounting Bracket Ref. PN 7000 (21) on the Upper Ladder Rung Tensioner Ref. PN 7000 (05) The mounting bracket PN 7000(21) is used to hold the life line on a monopole up till 120 mm diameter. Step 1B Step 1C 02 03

4 SHOCK ABSORBER & CABLE TERMINATION Ref. PN 7000 CABLE TERMINATION Ref. PN 7000 STEP 3B: Wire Crimping Assembly PN 7000 (14): SS Thimble Step 02 - Installation of Shock Absorber Connect the shock absorber to top mounting bracket by inserting the fastener and the nylon spacer so as to pass through mounting bracket and eye of energy absorber. The spacer ensure the correct position of energy absorber. Ensure that the energy absorber is fitted with red arrow on label pointing down wards Connect the end extremity to energy absorber by inserting fastener through eye of energy absorber. Insert 2 ferrules in the wire. Insert the wire in heat shrinking tube. Loop the wire across the Stainless Steel Thimble. Insert the end of the wire back into the Ferrule. Crimp the Ferrule using a 20 Ton Hydraulic Crimping head and 2 300mm crimping dies. Ensure that the first ferrule is as close as possible to the thimble, the next ferrule should be 50mm apart from the first one. Insert the aluminum cap in the free end of wire and crimp it. Cover the entire assembly up to the bottom edge of the ferrule with a heat Shrinkable tube. Shrink the tube with a hot air gun. Aluminum Ferrules Aluminum Endcap Heat Shrink Tube Wire Crimping Assembly PN7000(14) (Step 3B) STEP 3C: Cable Swaging Step 03- Cable Termination A suitable cable termination may be selected according to the site condition u-bolts and thimbles are only Allowed at bottom termination according to EN353.1:2014 Step 3A: Assembling the Cable Extremity: Ref. PN 7000 (03) Cable\ Extrimit STEP 1 Poke\ Pi Insert the cable into the swage tube The swage tube has markings to identify exact positions of crimping Place the swage tube on the hex loc die of a hydraulic crimping tool(130kn capacity). Ensure that the mark on the swage tube is in the center of the die. Operate the machine to start the swaging operation until the green light is on. Repeat the process for all markings(5 times minimum). Open up the cable roll and then insert the cable in to the housing of the cable extremity. Open the strands of the wire. Insert the core of the cable in the poke pin. The core is the straight strand, all other strands are twisted. With a hollow Center-punch hammer the poke pin deep inside the housing of the cable extremity Tighten the connector of the extremity to the housing of the cable extremity. Connect the cable extremity to the mounting bracket (for the upper ladder rung) by a locking pin. Insert the pin ring in to the locking pin to lock. STEP 2 STEP 3 STEP 4 STEP 3D: U bolt & Thimble Loop the Cable across the thimble and ensure at least 300mm of the cable is overlapping. Next, fasten the stainless steel U bolts (Part of Ref PN 6000 (01)) approximately 50 mm apart. If the cable is in excess make a loop and tie the loop with cable ties. If it is necessary to cut the cable, seal the loose end of the cable by adhesive tape after cutting it. 50mm Ubolt & Thimbles PN 6000 (01) (Step 3D) 04 05

5 INTERMEDIATE & TENSIONER Ref. PN 7000 EXTENSION ARM Ref. PN 7000 The intermediates reduces large deflections in the cable due to wind pressure. Step 4: Installation of the Intermediate: Ref. PN 2001 (04) Place the fisher plate of the Intermediate on the back of the ladder rung. Fasten the Intermediate Plate with the fisher plate with the help of the given fasteners. Ensure that the cable is in between the two arms of the intermediate. It is recommended to install an Intermediate at an interval of every 10 m length of the Cable. Step 06- Installation of the Extension Arm: Ref. PN7000 (06) If the System has been provided with the Extension Arm, this shall be installed in place of Upper Mounting Bracket as in step: 1. The Extension Arm is provided pre-installed with the Mounting Bracket for the Upper end of the system. Follow the simple steps for easy installation-top Rung * Hold the extension arm against the upper last three rungs of the ladder. * Hold the fisher plate in front of the extension arm. * Insert the given U- bolts through the rung in to the fisher plate. Tighten the nuts of the U-bolts Repeat the exercise for the Second Rung from the top On the third rung of the ladder, from the top Insert the given U-bolt through the ladder rung in to the slot so as to pass through the extension arm tighten the nuts of the U-Bolt. Step 5: Installation of the Tensioner: Ref PN 7000 (05) The Tensioner is installed at the lower end of the system. Open the threads of the extension rod of the tensioner from both ends. Ensure that 75% of the thread is open. Insert the eye of the tensioner to the mounting bracket at the lower ladder rung. Insert the stainless steel locking pin so as to pass through the eye of the tensioner and the mountin brackets. Insert the pin ring in the locking pin to lock it. Fix the tensioner to the wire rope. Fix the thimble (part of Ref PN 6000 (01)) to the eye of the tensioner by the given fastener Loop the Cable across the thimble and ensure at least 300mm of the cable is overlapping. Next, fasten the stainless steel U bolts (part of Ref PN 6000 (01)) approximately 50 mm apart. If the cable is in excess make a loop and tie the loop with cable ties. If it is necessary to cut the cable, seal the loose end of the cable by adhesive tape after cutting it. Providing tension to the wire rope: Open both the chuck nuts and hold the tensioner eye. Insert a steel rod in the housing of the tensioner and rotate the tensioner in anti clock wise direction. Rotate it until reasonable tension is achieved in the cable. Tighten both the chuck nuts mm Step 07- Label The Label is fixed to the lower most rung of the ladder using cable ties Helpline: KARAM INDUSTRIES C-35A, PHASE-III, ESIP, SITARGUNJ, ADDRESS DISTT. UDHAM SINGH NAGAR, UTTARAKHAND PRODUCT CODE BATCH NO. YEAR OF MANUFACTURE : LENGTH MTRS. INSTALLATION DATE / / INSPECTION REPORT Date : / / REVALIDATION DUE ON 07

6 FALL ARRESTER Ref. PN 7000 RECOMMENDED PPE Ref. PN 7000 Step 08 -Installation of the Rope Grab: Ref. RG (02) Connect Rope Grab to the Cable following the given simple steps: * Hold the Rope Grab as shown in the figure. * Push the Rope Grab through the cable and rotate it counter clockwise. * Ensure the arrow on Rope Grab points up wards. * Insert the karabiner of the shock absorbing lanyard (Ref PN 2001 (02)) in the eye of the Rope Grab. * Connect the other end of the shock absorbing lanyard to the harness of the user by the other Karabiner. Once the system is installed the user can use a work positioning harness along with a shock absorbing twin lanyard to climb up. He can use the double lanyard when he needs to exit the fall arrest system while working on towers. When the user needs to exit from the fall arrest system in a horizontal plane towards the edge of the tower he may need to travel restraint lanyard model While working on the tower a work positioning lanyard helps in attaining a comfortable position. Step 9:Connect the Harness to the Rope Grab * Check the harness that all the straps are connected and buckles are secured and the harness has been adjusted to give it a snug fit. * Connect the Rope Grab to the front attachment point of the full body harness with the help of the Karabiner of the connecting lanyard (Ref PN 7000 (07)). * Ensure that the gate of the karabiner is closed and locked properly. A/2 A/

7 HORIZONTAL LIFELINE Ref. PN 4000 (O.H.) HORIZONTAL LIFE LINE Ref. PN 4000 (O.R.) Ref. HORIZON PN 4000 (Over the Head) Spring Type Shock Absorber Ref. PN 4000MU(02) Intermediate Ref. PN 4000 (10) Cable Extremity with swaged end PN 4000 (15) Ref. HORIZON PN 4000 (Over the Roof) Spring Type Shock Absorber Ref. PN 4000MU(02) Carriage Body Ref. PN 4000 (08) Roof Top Anchor Port Intermediate Ref. PN 07 (B) 7 STRANDS OF 19 WIRES Tensioner Ref. PN 4000 (03) Wire Rope Ref. PN 9XXXS (Where XXX is the length of the wire rope in meters) Corner Pice Ref. PN 4000 (06) Inspection Plate Ref. PN 4000 (20) Wire Rope Ref. PN 9XXXS Carriage Body Ref. PN 4000 (08) Intermediate Ref. PN 4000 (10) OPTIONAL Wheel Type Carriage Body Ref. PN 4000 (17) Cable Extremity Ref. PN 7000 (03) Roof Top Anchor Port Extremity Ref. PN 07 (A) 10 11

8 POSTS Ref. PN 4000 POSTS Ref. PN 4000 Step 1 : Installation of Posts on Receiving Structure The life line is now ready with shock absorber and tensioner at one end and cable extremity at the other end intermediates are inserted according to the span length. We now need to select suitable posts for different kind of recieving structure This section details extremity posts, intermediate Posts and corner Post for different structures available. TRAPEZOIDAL ROOF SHEETS The post can be fitted using water proof blind rivets. The posts are adjustable to hold difference rib profiles. Step A : Roof Top Anchor Post Extremity; Ref. SA 07A Stick the ends of the base plates of the post to the roof with double adhesive EPDM sheet. Drill 32 holes for the blind rivets. Rivet with a riveting gun. Cover the rivets with a weather proofing flash tape. Connect the eye on the junction of top and bottom brackets Step B : Roof Top Anchor Post Intermediate; Ref. SA 07B Stick the post to the bottom plate of the roof with double adhesive EPDM sheet. Drill 16 holes for the blind rivets. Rivet with a riveting gun. Cover the rivets with a weather proofing flash tape. Step C : Intermediate Bracket; Ref. PN 4000(10) Insert the cable through the intermediate. Connect the intermediate to the receiving structure with the fastener. The angle of the Intermediate may be changed by inserting the intermediate fastener to different holes provided. Standing Seam Roof Sheets Upto 430 Mm Seam Distance These posts are fitted on the seams using aluminum seam clips. The Posts are adjustable and can be fitted on standing seam roof up to 430 mm seam distance. Step A : Roof Top Anchor Post Extremity; Ref. SA 07C With grub screws fix the standing seam clips to the seam. Mount the roof post base plates on the seam clips and with fasteners. Connect the eye on the junction of top and bottom brackets. Step B : Roof Top Anchor Post Intermediate; Ref. SA 07D With grub screws fix the standing seam clips to the seam. Mount the roof post base plates on the seam clips and with fasteners. nuts. Step C : Intermediate Bracket; Ref. PN 4000(10) Insert the cable through the intermediate. Connect the intermediate to the receiving structure with the fastener. The angle of the Intermediate may be changed by inserting the intermediate fastener to different holes provided. Step D : Corner Piece Step D : Corner; Ref. PN 4000(17) Insert the cable through the Corner. Connect the Corner to the intermediate post with the fastener. FASTENERS/CONNECTOR TYPE SIZE(mm) QTY Blind Rivet Hex Bolt Nylock Nut 8 12X Install the post as described in Step 2. Insert the cable through the Corner Tube. Connect the Corner piece assembly to the post with the fastener

9 POSTS Ref. PN 4000 POSTS Ref. PN 4000 Standing Seam Roof Sheets Upto 600 Mm Seam Distance These posts are used for larger seam distance up to 600mm. Step A : Roof Top Anchor Post Extremity; Ref. SA 07E With grub screws fix the standing seam clips to the seam. Mount the roof post base plates on the seam clips and with fasteners. Connect the eye on the junction of top and bottom brackets. Trapezoidal Roof Sheets These Posts are suitable for a variety of trapezoidal roof sheet designs. It has multiple holes to suit different peak distances. Step A : Roof Top Anchor Post Extremity; Ref. SA 07G Stick the base plates of the post to the roof with double adhesive EPDM sheet. Drill 16 holes for the blind rivets, four at each corner, rotate the base 0 plate by 90 if the holes does not match the seam position. Rivet with a riveting gun. Cover the rivets with a weather proofing flash tape. Connect the eye on the junction of top and bottom brackets. Step B : Roof Top Anchor Post Intermediate; Ref. SA 07F With grub screws fix the standing seam clips to the seam. Mount the roof post base plates on the seam clips and with fasteners. Step B : Roof Top Anchor Post Intermediate; Ref. SA 07H Stick the bottom plate of the roof with double adhesive EPDM sheet. Drill 8 holes for the blind rivets. Rivet with a riveting gun. Cover the rivets with a weather proofing flash tape. Step C : Intermediate Bracket; Ref. PN 4000(10) Insert the cable through the intermediate. Connect the intermediate to the receiving structure with the fastener. The angle of the Intermediate may be changed by inserting the intermediate fastener to different holes provided. Step C : Intermediate Bracket; Ref. PN 4000(10) Insert the cable through the intermediate Connect the intermediate to the receiving structure with the fastener. The angle of the Intermediate may be changed by inserting the intermediate fastener to different holes provided. Step D : Corner Piece; PN 4000(16)A Install the post as described in Step 2. Insert the cable through the Corner Tube. Connect the Corner piece assembly to the post with the fastener. Step D : Corner Piece; PN 4000(26) Install the post as described in Step 2. Insert the cable through the Corner Tube. Connect the Corner piece assembly to the post with the fastener

10 POSTS Ref. PN 4000 POSTS Ref. PN 4000 Standing Seam Roof Sheets These Posts are suitable for a variety of trapezoidal roof sheet designs. It has multiple holes to suit different peak distances. Step A : Roof Top Anchor Post Extremity; Ref. SA 07I With grub screws fix the standing seam clips to the seam. Mount the roof post base plates on the seam clips and with fasteners. Connect the eye on the junction of top and bottom brackets. Trapezoidal Roof Sheets (Blank Posts) These are blank posts on which holes may be punched to match the roof Profile on trapezoidal roof. Step A : Roof Top Anchor Post Extremity; Ref. SA 07K Using the template identify the location of the holes to be punched in the blank base plate. Mount the template and the blank base plate on the base of the drill machine. Drill holes on the blank Base plate through the template. Connect the eye on the junction of top and bottom brackets. Step B : Roof Top Anchor Post Intermediate; Ref. SA 07J With grub screws fix the standing seam clips to the seam. Mount the roof post base plates on the seam clips and with fasteners. Step B : Roof Top Anchor Post Intermediate; Ref. SA 07L Using the template identify the location of the holes to be punched in the blank base plate. Mount the template and the blank base plate on the base of the drill machine. Drill holes on the blank Base plate through the template. Step C : Intermediate Bracket; Ref. PN 4000(10) Insert the cable through the intermediate. Connect the intermediate to the receiving structure with the fastener. The angle of the Intermediate may be changed by inserting the intermediate fastener to different holes provided. Step C : Intermediate Bracket; Ref. PN 4000(10) Insert the cable through the intermediate. Connect the intermediate to the receiving structure with the fastener. The angle of the Intermediate may be changed by inserting the intermediate fastener to different holes provided. Step D : Corner Piece; PN 4000(27) Install the post as described in Step 2. Insert the cable through the Corner Tube. Connect the Corner piece assembly to the post with the fastener. Step D : Corner Piece; PN 4000(28) Install the post as described in Step 2. Insert the cable through the Corner Tube. Connect the Corner piece assembly to the post with the fastener

11 POSTS Ref. PN 4000 POSTS Ref. PN 4000 Standing Seam Roof Sheets (Blank Posts) There are blank posts on which holes may be punched to match the roof profile on standing seam roof. Step A : Roof Top Anchor Post Extremity; Ref. SA 07M Using the template identify the location of the holes to be punched in the blank base plate. Mount the template and the blank base plate on the base of the drill machine. Drill holes on the blank Base plate through the template. Connect the eye on the junction of top and bottom brackets. Step B:Roof Top Anchor Post Intermediate: Ref. SA 07N Using the template identify the location of the holes to be punched in the blank base plate. Mount the template and the blank base plate on the base of the drill machine. Drill holes on the blank Base plate through the template. Step C: Intermediate bracket: Ref. PN4000(10) Insert the cable through the intermediate. Connect the intermediate to the receiving structure with the fastener. The angle of the Intermediate may be changed by inserting the intermediate fastener to different holes provided. for frasite roof on roof with wooden rafters, the top layer of the roof cut open and roof posts are installed on the rafter using fischer plate. The post are available in sizes of 300mm, 500mm, and 750mm and can be selected depending on the position of the rafter. For roofs having fragile sheets or metal gratings, Steel Anchor posts are used. The roof sheet is cut to expose the rafter below a suitable post is installed. SA25 is used fro rectangular hollow sections, where the section is hold using top and bottom flange plates using 4 studs. In case of an I beam the post SA56 is used which holds the top flange using two bottom flange plate. In case of grating the post is fixed on the section below which holds the grating. Step A : Extremity Roof Top Anchor Post SA25 Place the top flange of the post on the metal rafter of the roof or grating of the walkway. Hold the bottom plate on the bottom side of the structure or on the top flage in case of an I Beam. Insert the studs. Tighten the nuts on the top and bottom of the posts. Place the universal extremity plate on the top flange. Tighten the nuts and bolts to secure the universal extremity plate to the post. Step B :Intermediate Roof Top Anchor Post SA25 Place the top flange of the post on the metal rafter of the roof or grating of the walkway. Hold the bottom plate on the bottom side of the structure. Insert the studs. Tighten the nuts on the top and bottom of the posts. Insert the cable in the Intermediate. Place the Intermediate PN4000(10) on the top flange. Tighten the nut and bolt to secure the universal extremity plate to the post. SA 56 SA 25 SA 56 SA 25 Step D : Corner Roof Top Anchor Post SA24; PN 4000(21) Step D : Corner Piece; PN 4000(28) Install the post as described in Step 2. Insert the cable through the Corner Tube Connect the Corner piece assembly to the post with the fastener. Place the top flange of the post on the metal rafter of the roof or grating of the walkway. Hold the bottom plate on the bottom side of the structure insert the studs Tighten the nuts on the top and bottom of the posts. Insert the cable in the corner tube. Place the bottom flange of the corner piece on the top flange of the post. Tighten the nut and bolt to secure the corner to the post. SA 56 SA

12 CABLE TERMINATION & SHOCK ABSORBER Ref. PN 4000 TENSIONER & INTERMEDIATE Ref. PN 4000 Step 2A : Cable Extremity STEP 1 Step 4 : Mounting the tensioner on the system Insert the cable in to the housing of the cable extremity. Open the strands of the wire. Insert the core of the cable in the poke pin. The strand which is Straight is the core, the other strands are twisted. With a hollow Centre punch hammer the poke pin deep inside the housing of the cable extremity. Tighten the connector of the extremity to the housing of the cable extremity Connect the cable extremity to the universal end extremity Plate PN 4000 (09) by a locking pin. Insert the pin ring in to the locking pin to lock. Step 2B : Cable Swaging Insert the cable into the swage tube The swage tube has markings to identify exact positions of crimping Place the swage tube on the hex loc die of a hydraulic crimping tool(130kn capacity). Ensure that the mark on the swage tube is in the center of the die. Operate the machine to start the swaging operation until the green light is on. Repeat the process for all markings Step 3: Shock Absorber: Ref. PN 4000MU(02) Cable\ Extrimit STEP 2 STEP 3 STEP 4 Poke\ Pi Open the threads of the tensioner from both ends. Ensure 75% of the thread is open. Insert the locking pin so as to pass a the eye of the tensioner and the Shock Absorber, PN 4000 (07). Insert a pin ring in the locking pin to lock it. Step 5 : Applying Tension To the line Hold the tensioner eye Insert the tensioning tool in the housing of the tensioner and rotate the tensioner in clock wise direction. Rotate it until reasonable tension is achieved in the cable and the green indicator rod is visible in he shock absorber. Stop applying tension when the red indicator begins to appear in shock absorber Tighten both the chuck nuts Step 6 : Intermediate; Ref. PN 4000(10) Insert the cable through the intermediate Connect the intermediate to the receiving structure with the fastener. The angle of the Intermediate may be changed by inserting the plastic intermediate fastener to different holes provided. UPWARD PULL FOR TENSION Insert the connector to the universal extremity plate, PN 4000 (09) Connect the other connector to the tensioner PN4000(03) Apply tension to the cable until the L tension indicator plate touches the spring Take the shock absorber out of service when the spring is elongated due to an impact from a fall of the user

13 CARRIAGE BODY Ref. PN 4000 VERTICAL ANCHORAGE LIFE LINE SYSTEM Ref. PN 8000 & PN 9000 Step 7 : Carriage Body To connect the line to the user, there is a freely moving Carriage Body PN 4000 (08), which moves along the length of the line with the user, who is connected to it by using a karabiner followed by a Connecting element connected to the full body harness of the user. VERTICAL ANCHORAGE LINE SYSTEM Ref. PN 8000 & PN 9000 The carriage may be attached or detached from the line at any given point by two consecutive deliberate action. In applications on roofs, the carrier may be used on either side of the roof. Aluminium Rail Extremity PN 5000 (02) Alu.Rail Intermediate PN 5000 (01) RECOMMENDED PPE Rung Clamp PN 8000 (03) Junction PN 5000 (08) Once the system is installed the user can use a work positioning harness along with a shock absorbing twin lanyard to climb up. He can use the double lanyard when he needs to exit the fall arrest system while working on towers. When the user needs to exit from the fall arrest system in a horizontal plane towards the edge of the tower he may need to travel restraint lanyard model While working on the tower a work positioning lanyard helps in attaining a comfortable position. Rung Clamp PN 8000 (03) Ceiling Mounting Bracket PN 5000 (06) Ladder Rung PN 9000 (01) Ladder Rung PN-9000(01.1)L Ladder Rung Alu. Extension Karabiner Vertical Trolley PN-9000(01.1)R PN 8000 (02) PN 111 PN 8000 (01) 22 23

14 JUNCTION & ALU RAIL EXTREMITY Ref. PN 8000 & PN 9000 ALU RAIL EXTENSION & TROLLEY Ref. PN 8000 & PN 9000 Step 01 : Installation of Alu Rail Extremity PN 5000 (02) Step 3: Installation of Alu Rail Extension PN (8000 (03)) * Repeat step 3 to join the Alu rail Extension with the Alu Rail Intermediate. * Select the correct Alu Rail Extension Support depending upon the type of roof * Connect the Alu rail Extension support to the end of the Alurail Extension using a mounting nut. * For trapezoidal roof sheets use blind rivits to install the Alurail Extension support to the roof,for standing seam fasten the bracket using nut bolts Step 4: Vertical Trolley: Ref. PN 8000(01) * Insert the trolley in the Alu. Rail extremity. Press the termination of the extremity and pass the trolley over the termination. * After the trolley slides on the Alu. Rail the termination cones back to its original position ensuring that the trolley does not slide off the Alu. Rail. Step 02 : Junction: Ref. PN 5000 (08) Join two lengths of Alurail intermediate. Match the sections of both the Alu. Rail. Place the junction plate on either side of the Alu. Rail with the holes of junction plate matching with those of Alu. Rail intermediate. Fix both the plates by 4 sets of fasteners. Ensure that the gap between the two rails is not greater than 1.5 mm. LOCKING JIB LOCKING JIB L - CLAMP L - CLAMP SAFETY LOCKING PIN 24 25

15 MOUNTING BRACKET Ref. PN 8000 & PN 9000 RUNGS, HALF AND FULL Ref. PN 8000 & PN 9000 Step 1: Installation of Mounting Nut PN5000(03) Insert the mounting nut into the alu rail extremity. The first mounting nut must be at 300mm from the bottom edge and second needs to be 1500mm from the first mounting nut and so on. Step 03 : Installation of Ladder Rung PN9000(01) The Alu rail has two holes at regular intervals to hold the rungs, insert the bolt along with washer into the rung and tighten it Step 4: Installation of Alu Rail Extension PN (8000 (03)) * Repeat step 3 to join the Alu rail Extension with the Alu Rail Intermediate. * Select the correct Alu Rail Extension Support depending upon the type of roof * Connect the Alu rail Extension support to the end of the Alurail Extension using a mounting nut. * For trapezoidal roof sheets use blind rivits to install the Alurail Extension support to the roof,for standing seam fasten the bracket using nut bolts RECOMMENDED PPE Step 02 : Installation of Alu Rail Extremity PN5000(02) & Mounting Bracket PN5000(06) The Mounting Brackets can be installed on metal as well as concrete structure by special fasteners. Chemical fasteners are used to fix the brackets to the concrete wall and SS fasteners for metal structure. The shorter end of the bracket is mounted on alu rail by mounting nut and longer end to the receiving structure by using fasteners Forked Lanyard with Energy absorber Ref: PN 351 Work Positioning Lanyard with Grip Adjuster Ref: PN 242 Rhino Full Body Harness Ref: PN 56 Guided Type Fall Arrester System on Flexible Anchorage Line Ref: PN

16 HORIZONTAL ALU- RAIL SYSTEM Ref. PN 5000 MOUNTING NUT & MOUNTING BRACKET Ref. PN 5000 HORIZONTAL ALU- RAIL SYSTEM Ref. PN 5000 Step 01: Mounting Nut Insert the mounting nut in the channel as shown in the drawing. The mounting brackets may then be connected to the Alu Rail by a fastener. Step 2A: Wall Mounting Bracket Flush Type: Ref. PN 5000 (04) Connect the bracket to the mounting nut as shown in the drawing. To install the mounting bracket in concrete use 12 mm Chemical fasteners. Optional Accessory: Chemical Fastener SA 12(04) Concrete: 25 mpa Step 2B: Wall Mounting Bracket with Recess: Ref. PN 5000 (05) Connect the bracket to the mounting nut as shown in the drawing. To install the mounting bracket in concrete use 12 mm Chemical fasteners. Optional Accessory: Chemical Fastener SA 12(04) Concrete: 25 mpa Step 2C: Ceiling Mounting Bracket: Ref. PN 5000 (06) Connect the bracket to the mounting nut as shown in the drawing. To install the mounting bracket in concrete use 12 mm Chemical fasteners. Optional Accessory: Chemical Fastener SA 12(04) Concrete: 25 mpa 28 29

17 BEND Ref. PN 5000 TROLLEY & RECOMMENDED PPE Ref. PN 5000 Step 3A: Curved Alu. Rail (Outer Wall Mounted): Ref. PN 5000 (09A) Join the curved Alu. Rail with the Alurail intermediate. Match the sections of both the Alu. Rail. Place the junction plate on either side of the Alu. Rail with the holes of junction plate matching with those of Alu. Rail intermediate and curved alu rail fix both the plates by 4 sets of fasteners. Ensure that the gap between the two rails is not greater than 1.5 mm. Step 4A: Trolley For Wall Ref. PN 5000 (13) Insert the trolley in the Alu. Rail extremity. Press the termination of the extremity and pass the trolley over the termination. After the trolley slides on the Alu. Rail the termination cones back to its original position ensuring that the trolley does not slide off the Alu. Rail. Step 4B: Trolley For Ceiling/Floor: Ref. PN 5000 (12) Step 3B: Curved Alu. Rail (Inner Wall Mounted): Ref. PN 5000 (09B) Insert the trolley in the Alu. Rail extremity. Press the termination of the extremity and pass the trolley over the termination. After the trolley slides on the Alu. Rail the termination comes back to its original position ensuring that the trolley does not slide off the Alu. Rail. Join the curved alurail with the Alurail intermediate. Match the sections of both the Alu.rail. Place the junction plate on either side of the Alu. Rail with the holes of junction plate matching with those of Alu. Rail intermediate and curved alu rail fix both the plates by 4 sets of fasteners. Ensure that the gap between the two rails is not greater than 1.5 mm. RECOMMENDED PPE Once the system is installed the user can use a work positioning harness along with a shock absorbing twin lanyard to climb up. He can use the double lanyard when he needs to exit the fall arrest system while working on towers. When the user needs to exit from the fall arrest system in a horizontal plane towards the edge of the tower he may need to travel restraint lanyard model While working on the tower a work positioning lanyard helps in attaining a comfortable position. Step 3C: Curved Alu. Rail (Floor/ceiling): Ref. PN 5000 (10) Join the curved alurail with the Alurail intermediate. Match the sections of both the Alu.rail. Place the juncti-on plate on either side of the Alu. Rail with the holes of junction plate matching with those of Alu. Rail intermediate and curved alu rail fix both the plates by 4 sets of fasteners. Ensure that the gap between the two rails is not greater than 1.5 mm

18 PROOF LOADING PRE USE-CHECKS PROCESS OF PROOF LOADING OF HORIZONTAL AND VERTICAL LIFE LINES Checks and Precautions The cable termination may be proof loaded upto 6KN using hydra jaws testing equipment. The hydra jaws equipment pulls the wire out of the termination, using a hydraulic cylinder. The pull force is increased to 6kN, & the pressure gauge,mounted on the cylinder displays the exact tension achieved. Once 6KN is achieved the tension is released. Post Installation Inspection Once installed, it is important to inspect the complete line by moving the entire length of life line. On site testing of the receiving structure may be provided at an extra cost. Now we know that the cable termination is successful Pre Use-Checks It is mandatory for the Site Inspector/ Supervisor and the actual users of the system to perform a thorough check of the same before carrying out work. KARAM conducts a brief training of all concerned personnel on the subject of Pre-Use Inspection of the System as per a defined guideline after the system has been installed by KARAM personnel. Checking the receiving structure Do not use the system receiving structure is found weak. Checking the System Clean the system from dust/dirt. Check for any mechanical defects. Check for wear and tear in all components or unusual bending or deformation. Check for any modifications done by the user. Check for any missing component. Check for any damages that may have been caused due to welding while maintenance of other equipment. Check the Identification Plate. The system needs to be put out of service if the label is not legible or missing. Hydra Jaws Lifeline Testing Checking the Cable See that there is sufficient tension on the cable by checking the tension indicator in the shock absorber. Check the condition of the cable. Wear hand gloves and check the wire from all sides. Check for broken strands or any deformity in the cable. Report if strands are found broken

19 PRECAUTIONS WHILE USING ANNUAL INSPECTION KARE Precautions While Using the System The following points of precautions needs to be considered For safe use of the Fixed Line Systems The life line is for the purpose of fall protection while working at height. A back up fall arrest system is required when transitioning on and off the life line system. Never disengage the fall arresting lanyard from the life line while working at height. Avoid using grease to lubricate the system. If any fall is reported put the system out of use. Contact the manufacturer for repairs and re-validation. Only certified KARAM full body harness with proper attachment anchorage points should be worn while using KARAM Fixed Line Systems. Do not alter or misuse this equipment. Always take an advice from KARAM personnel while using this equipment in combination with components or subsystems other than those described in this manual. Usage of certain component/sub system may interfere with the proper functioning of this equipment and the system may not deliver the working as per its intended use. In such case KARAM may not be held responsible for any malfunction. The lifelines must be kept free from dust, grease etc., by periodic cleaning. The system can be cleaned by a soft dry cloth. Inspection and Revalidation Fall Protection Equipment is a life saving product. As per the EN 365 of PPE Directives89/686/EEC, It is mandatory to have a Competent Authority to inspect the Fall Protection Equipment at least once annually. KARAM Kare Inspection software takes care of the equipment for at least 20 years. Hazards Hazards existing in immediate environment may require additional precautions to limit the possibility of injury to the user or damage to the equipment. Hazards may include but are not limited to, extreme temperatures, caustic chemicals, corrosive environments, high voltage power lines, explosive or toxic gases, moving machinery, sharp edges, high velocity winds Etc. Do not expose the equipment to any hazard which it is not designed to withstand. Consult the manufacturer if in doubt. Rescue Plan It is mandatory to ensure that the user shall have a rescue plan and means to execute it while using this equipment. The rescue plan needs to be project specific. The employees must be trained in selfrescue or alternative means shall be provided for prompt rescue in an event of a fall. Always work in a pair to ensure that in an event of a fall your partner may help in rescue. Kare Cloud Based Online as well as off line software. Captures Geo Coordinates where the system is installed. RFID / Bar code compliant. Generates Report in real time. Reminds user of items due for inspection. Captures images of components. user customizable. Can be integrated to client software. Reports can be shared with multiple recipients in real time

20 TOOLS TOOLS Measuring Tools Ring Spanner Double End Spanner Socket Set Detect Digital Torque Wrench Distance Meter Laser Tool Vernier Tape Tensioner Tightening Tool Crimping Plier Consumables, Miscellanous Tools Dust Pump Hole Saw Cutter Bolt Cutter Allen Key MACHINES Hot Air Gun Setting Tool Blower Chemical Applicator Cordless Drill Machine Hammer Drill Machine Cordless Impact Wrinch WRENCH SIZE Paint Brush Drill Bit Impact Drill Hex Bolt Wrench Size Hydra Jaws Lifeline Testing Swaging Tool Hydraulic Crimping Head Power Bird Riveting Machine Socket Size ANCHORS ALLEN KEY SIZE Allen Bolt Size Allen Key Size Allen Grub Screw Key Size TORQUE CHART Bolt size 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm Recommended Torque: 9 Nm 22Nm 29 Nm 50 Nm 80 Nm 125Nm 36 37

21 CHECK CARD It is recommended that the equipment be inspected and examined by a competent person for any damages or failures, if the need arises.the instructions for use for the individual components need to be observed. SERVICE AND INSPECTION RECORD Date Damage Observed Repair Measures Comments The above supplied equipment is warranted against any defect arising out of faulty or defective materials or workmanship for a period of ONE YEAR from the date of purchase. in case of any defect develop in this equipment during the period of warranty, KARAM undertakes the responsibility to replace/ repair the equipment free of cost. This warranty, however, is not valid in the case of the following events. 1. The equipment is not used according to the Instructions given in the User's Manual. 2. The defects are caused by improper, reckless use or by any deliberate action. 3. Any repair work is attempted or carried out by persons other than the authorized personnel. 4. Any modification or alteration of any nature is made in the equipment. 5. The Batch number is deleted, defaced or altered. Note Year of Manufacturing Date of Purchase Date of First Use Name of User 38 39

22 Walkways, Treads and steps for Roofs Walkways, Treads and steps for Roofs FEATURES Roofer's Step Roofer's Walk Way For providing safe walking on any roof surface Meets the test requirements of EN 516:2006 Class 1-C (Prefabricated Accessories for Roofing Installations for roof access - Walkways, treads and steps) Available in pre-assembled lengths Available as steps for steep slopes with hand rails Designed for all type of roofing like trapezoidal, clip on and standing seam profiles. Flexible for installation at site and can be adjusted from 0 to 50 Easy to install at site Tailor made solutions are also available Indigenously made Fire retardant Corrosion and moisture resistant material. Long life span It can be used along with horizontal life line systems designed for over the roof. Providing SAFE WALKING on any kind of ROOF STRUCTURE Application : WALK WAYS Provided safe walking on Kind of roof structure. Material of Constructions (MOC) : FRP walkways with Hot Dipped Galvanised / SS316 Mounting Brackets Operating temperature : -30 to + 60 C Life Span : 20 Years Recommended Inspection Frequency : Annual Complies to : EN 516:2006 Class 1-C