installation instructions uni 8 overhead · osh a om plian t s/ z18 9.2 ... n o. / eri numme...

T H E U LT I M AT E I N F A L L P R O T E C T I O N MANUAL

INSTALLATION INSTRUCTIONS

UNI 8™

OVERHEAD

2 Uni 8™ Overhead Uniline™ Installation Instructions

Uni 8™ OverheadContents

COntents 2

GUidelines fOr installatiOn 3

impOrtant infOrmatiOn 4

system installatiOn 5

Hex swaGinG 8

tHese instrUCtiOns are an aid tO traininG. Only trained persOnnel sHOUld attempt tO install a Uni 8™ OverHead system.


Uni 8™ OverheadGuidelines for installation

Diagrams for reference only. Refer to system data sheets for more information.

typical Uni 8™ Overhead system

B

A

C E G

HF

D I

EN795:1996 Class COSHA COMPLIANTAS/NZS 1891.2

Installation Date / Installatiedatum / Fecha de instalación / Montagedatum /Date d’installation / Data da instalação / Data installazione / Installationsdatum

Installed By / Geïnstalleerd door / Instalado Por / Montiert durch / Installateur / Instalado por / Installato da / Installerad av

Contact Number / Contactnr. / Tel. de contacto / Kontakttelefon / Téléphone / Nº de Contacto / Numero contatto / Kontaktnummer

Min. Ground Clearance (m) / Min. vrije valruimte (m) / Distancia minima hasta el suelo (m) / Mindestabstand zum Boden (m) / Hauteur libre minimale (m) / Altura mínima livre (mt) / Distanza libera minima da terra (m) / Min. höjd ovanför marken

Max. Users Per System / Max. aantal gebruikers per systeem / Máximo de usuarios por sistema / Maximale Benutzer pro System / Nombre maximal d’utilisateurs par système / Nº máximo de utilizadores por linha / N. utenti max. per sistema / Max. användare per system

Max. Users Per Span / Max. aantal gebruikers per overspanning / Máximo de usuarios por vano / Höchstzahl der Benutzer pro Spannweite / Nombre maximal d’utilisateurs par portée / Nº máximo de utilizadores por vão / N. utenti max. per sezione / Max. användare per skena

Next Service Date / Datum volgende keuring / Próxima fecha de revisión / Termin der nächsten Wartung / Prochaine date d’entretien / Data da próxima Inspecção / Data prossima manutenzione / Nästa servicedatum

System Serial No. / Serienummer / Número de serie del sistema / Seriennummer des Systems / Numéro de série / Nº de série do sistema / N. di serie sistema / Systemets serienr.

Use Energy Absorbing Lanyards / Gebruik energie-absorberende verbindingslijnen / Utilice acolladores de absorción de energía / Verwenden Sie falldämpfende Sicherheits-/Anschlagseile / Utilisez des longes à absorption d’énergie / Usar cordas com amortecedor de energia / Utilizzare funi ad assorbimento d’energia / Använd energiupptagande taljerep

www.capitalsafety.com

5A Merse RoadNorth Moons MoatRedditchWorcestershireB98 9HL

2013 INTERTEK ITS10ATEX17038

Technical File No. 70802

Capital Safety Group

II 2 G c IIC T3

TM

MAX 100 ft (30m)

a

B C d e G

f H

typical Uni 8™ evolution™ Overhead system

B C E

HF

D I

EN795:1996 Class COSHA COMPLIANTAS/NZS 1891.2

Installation Date / Installatiedatum / Fecha de instalación / Montagedatum /Date d’installation / Data da instalação / Data installazione / Installationsdatum

Installed By / Geïnstalleerd door / Instalado Por / Montiert durch / Installateur / Instalado por / Installato da / Installerad av

Contact Number / Contactnr. / Tel. de contacto / Kontakttelefon / Téléphone / Nº de Contacto / Numero contatto / Kontaktnummer

Min. Ground Clearance (m) / Min. vrije valruimte (m) / Distancia minima hasta el suelo (m) / Mindestabstand zum Boden (m) / Hauteur libre minimale (m) / Altura mínima livre (mt) / Distanza libera minima da terra (m) / Min. höjd ovanför marken

Max. Users Per System / Max. aantal gebruikers per systeem / Máximo de usuarios por sistema / Maximale Benutzer pro System / Nombre maximal d’utilisateurs par système / Nº máximo de utilizadores por linha / N. utenti max. per sistema / Max. användare per system

Max. Users Per Span / Max. aantal gebruikers per overspanning / Máximo de usuarios por vano / Höchstzahl der Benutzer pro Spannweite / Nombre maximal d’utilisateurs par portée / Nº máximo de utilizadores por vão / N. utenti max. per sezione / Max. användare per skena

Next Service Date / Datum volgende keuring / Próxima fecha de revisión / Termin der nächsten Wartung / Prochaine date d’entretien / Data da próxima Inspecção / Data prossima manutenzione / Nästa servicedatum

System Serial No. / Serienummer / Número de serie del sistema / Seriennummer des Systems / Numéro de série / Nº de série do sistema / N. di serie sistema / Systemets serienr.

Use Energy Absorbing Lanyards / Gebruik energie-absorberende verbindingslijnen / Utilice acolladores de absorción de energía / Verwenden Sie falldämpfende Sicherheits-/Anschlagseile / Utilisez des longes à absorption d’énergie / Usar cordas com amortecedor de energia / Utilizzare funi ad assorbimento d’energia / Använd energiupptagande taljerep

www.capitalsafety.com

5A Merse RoadNorth Moons MoatRedditchWorcestershireB98 9HL

2013 INTERTEK ITS10ATEX17038

Technical File No. 70802

Capital Safety Group

II 2 G c IIC T3

TM

MAX 100 ft (30m)

J K n l i

m H

a Uni 8™ Wall Mounting Plate 7234021

B Uni 8™ Straight Eye 7240122

C Uni 8™ Energy Absorber 7241073

d Uni 8™ Hex Swage Tensioner 1,124 lbs (5kN) 7240109

e Uni 8™ Overhead Intermediate Bracket 7241067

f Uni 8™ Overhead Traveler 7241074

G 0.31" (8mm) 1 x 19 Stainless Steel Cable 7240212

H Uni 8™ 0.31" (8mm) Hex Swage Toggle 7234011

i Uni 8™ System Tag 7241257

J Uni 8™ evolution™ Triple Articulated Anchorage Point 7240175

K Uni 8™ evolution™ High Capacity Energy Absorber 7240151

l Uni 8™ evolution™ Overhead Intermediate Bracket 7240118

m Uni 8™ evolution™ Traveler 7240100

n 0.31" (8mm) 7 x 7 Stainless Steel Cable 7240211


Uni 8™ Overheadimportant information

Detailed below are examples of typical components used in both a Uni 8™ and Uni 8™ Overhead System along with the tools required for installation. It is advisable to read through these instructions before beginning the installation.

The component list below shows the full range available. Your order is system specific and may not feature all of these components.

Uni 8™ OverHead COmpOnents

7240109 - Uni 8™ 0.31" (8mm) Hex Swage Tensioner - 1,124 lbs (5kN)

7240166 - Uni 8™ 0.31" (8mm) Hex Swage Tensioner - 179 lbs (0.8kN)

7240122 - Uni 8™ Straight Eye

7234021 - Uni 8™ Wall Mounting Plate

7241067 - Uni 8™ Overhead Bracket

7241074 - Uni 8™ Overhead Traveler

7234011 - Uni 8™ 0.31" (8mm) Hex Swage Toggle

7241073 - Uni 8™ Energy Absorber

7241257 - Uni 8™ System Tag

7234012 - Uni 8™ 0.31" (8mm) Hex Swage Joiner

Uni 8™ OverHead evOlUtiOn COmpOnents

7240100 - Uni 8™ evolution™ Traveler

7240118 - Uni 8™ evolution™ Overhead Intermediate

7240137 - Uni 8™ evolution™ Overhead Curve

7240127 - Uni 8™ evolution™ Overhead Short Curve

7240151 - Uni 8™ evolution™ High Capacity Energy Absorber

7240175 - Uni 8™ evolution™ Triple Articulated Anchorage Point

7240176 - Uni 8™ evolution™ Mono Attachment Anchorage Point

CaBle

7240211 - 0.31" (8mm), 7 x 7 Stainless Steel Cable

7240212 - 0.31" (8mm), 1 x 19 Stainless Steel Cable

Prior to installation of the product please ensure that:

1) You have received training from Capital Safety.

2) You have all of the appropriate personal safety equipment to complete the task safely.

dOn’t Use tOOls Until instrUCted tO dO sO

typiCal tOOl list

1 x Drill + Drill Bit for M12 & M16 Holes

1 x Tape Measure

1 x Permanent Marker/Other

2 x Adjustable Spanner

1 x Needle Nose Pliers

1 x Steel Wire Cable Cutters

1 x 7241118 - Male Torque Handle

1 x 7241116 - 0.94" (24mm) Ring Spanner Head

1 x 7241115 - 0.74" (19mm) Ring Spanner Head

1 x 7241120 - Hex Swager c/w Die Set

3 x 7241123 - Cable Grip

1 x 7241124 - 0.31" (8mm) Cable Tester Kit


Uni 8™ Overheadsystem installation

Using a marker pen or chalk, mark the positions of the holes at both ends of the system as well as intermediate positions.

Fit the intermediate brackets one at a time using M12 min A470 bolts (not supplied). (Recommended torque load 36.8 lb/ft (50 Nm)).

Drill suitable holes for M12/M16 structural fasteners as applicable. (Follow Manufacturers Guidelines).

Drill suitable holes for M12 structural fasteners as applicable. (Follow Manufacturers Guidelines).

Be sure that all intermediate brackets are orientated the same way.

Remove the split pin from the Toggle and attach it to the Eye. Refit the split pin using pliers. Use Cable Grips (7241123) to apply pre-tension to the system.

Remove the split pin from the tensioner and attach it to the Energy Absorber. Refit the split pin using pliers.

If using a wall plate, install it using M12 min A470 bolts (not supplied). Recommended max torque 36.8 lb/ft (50 Nm).

Roll the Overhead Traveler onto the cable. Check that it is in the correct orientation by aligning it with the intermediate brackets.

Screw the stud into the tensioner. Tighten the turn-buckle using adjustable spanners until the tension indicator freely spins.

Fit the Straight Eye on the wall plate using the included fasteners (if applicable) or directly onto the structure using M16 min A470 bolts (not supplied). Tighten to 36.8 lb/ft (50 Nm).

Thread the cable through the installed intermediate brackets.

At the tensioner end, remove the split pin from the Energy Absorber and throw away. Attach the absorber to the eye and using the pin that’s left, refit and secure with the use of pliers.

Tighten the lock nut against the turn-buckle to prevent it from coming loose.

01

06

02

05 07

10

14

03

11

15

04

08

12

16

end anCHOr installatiOn

intermediate/ tOGGle installatiOn

Uni 8™ OverHead traveler/enerGy aBsOrBer & tensiOner installatiOn

Hex swage the cable into the Toggle (see page 8 for details).

09

Measure and hex swage the cable into the tensioner (see page 8 for details).

13



Drill the attaching hole, and Install the intermediate and its support on the structure. (Follow Manufacturers Guidelines).

Drill the attaching hole, and Install the curve and its support on the structure. (Follow Manufacturers Guidelines).

Install the washers and nuts, then hand tighten the nut.

Install the washers and nuts, then hand tighten the nuts.

Install the chemical plugs or mechanical plugs (Follow Manufacturers Guidelines) and position the plate.

Position and hand-tighten until contact, then tighten as specified: Torque load 44.3 lb/ft (60 Nm). Adjust the swivel to the axis of the lifelines cable.

Installation complete.

Tighten the nut as specified: Torque load 44.3 lb/ft (60 Nm).

Tighten the nut as specified: Torque load 44.3 lb/ft (60 Nm)

Install the washers and nuts, then tighten as specified: Torque load 44.3 lb/ft (60 Nm).

Install the protection cover by ‘‘clipping’’ it in place to complete.

Install the protection covers by ‘‘clipping’’ them in place to complete.

Adjust the swivel to the axis of the lifelines cable to complete the installation.

01

01

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02

02

02 03

03

03

03

04

04

04

standard Uni 8™ OverHead evOlUtiOn™ intermediate installatiOn

standard Uni 8™ evOlUtiOn™ OverHead COrner BraCKet installatiOn

Uni 8™ evOlUtiOn™ triple artiCUlated anCHOraGe pOint installatiOn

Uni 8™ evOlUtiOn™ mOnO anCHOraGe pOint installatiOn

Drill the 3 attaching holes in the structure using the plate as a drilling template. (Follow Manufacturers Guidelines).

01

Install the fixing in the structure M16 5/16" (7.9mm) (chemical plugs or mechanical plugs). (Follow Manufacturers Guidelines).

01



Position the absorber on the triple attachment end anchorage.

Insert the remainder of the cable and close the cover.

Connect the components and tighten. Insert cable through the absorber.

Connect the components and tighten. Insert cable through the absorber.

Swage the absorber sleeve onto the cable.

Swage the absorber sleeve onto the cable.

Cut the cable.

Cut the cable.

01

05

02

02

03

03

04

04

standard Uni 8™ evOlUtiOn™ enerGy aBsOrBer installatiOn (triple anCHOraGe)

standard Uni 8™ evOlUtiOn™ enerGy aBsOrBer installatiOn (mOnO anCHOraGe)

Position the absorber on the triple attachment end anchorage.

01

Insert the remainder of the cable and close the cover.

05


Uni 8™ OverheadHex swaging

Remove the split pin from the tensioner and attach it to the Energy Absorber or system eye.

If required, uninstall the swage and insert the cable into the tube and mark with tape/marker. Check it inserts to full depth 3" (78mm).

Unscrew the stud by hand to fully expose the threads.

Using the hex swager, make the first bite immediately after the solid section (A) (see below). Each bite is approximately 0.39" (10mm) wide.

Mark the tube at the depth of the hole (3" (78mm) from the end of the tube).

Following the table dimensions below, ensure the 6th bite finishes short of the chamfer section (B) (see below).

Pull the cable tight and mark the cable where it lines up with the mark on the tube and then cut using appropriate steel wire cable cutters.

Using a caliper, check the swage bite dimensions against the specified tolerance on the part.

01

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03

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04

08

measUre & CUt CaBle

swaGinG

Only 0.31" (8mm) 1 x 19 or 7 x 7 construction stainless steel wire cable supplied by Capital Safety may be used for Uni 8 Overhead™ applications. The hex swage data is based on the results from an Izumi EP410 model hex swager with 7241122 0.39" (10mm) bite dies. For any other hex swaging system/machine the installer needs to verify that the minimum strength of the hex swage is 8,543 lbs (38kN). Capital Safety offers a testing service, please contact us for more information.

CaBle Hex swaGinG taBle

swaGe dies swaGe Bites Bite Gap dimensiOn aCrOss flats

7 x 7 CaBle 7241122 6 discontinuous 0.04" - 0.06" (1mm - 1.5mm) See etched markings on part

1 x 19 CaBle 7241122 6 discontinuous 0.04" - 0.06" (1mm - 1.5mm) See etched markings on part

Part number, batch number and swage bite dimensions are etched on the side of the swage part.

Key:

Etching - (xxxxxx xxxxxx) 3.14" (80mm)

Dimension across flats

Bite Gap

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©2014, Capital Safety Form: 9700910 rev: A

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installation instructions uni 8 overhead · osh a om plian t s/ z18 9.2 ... n o. / eri numme...

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