Lad-Saf Powered Climb Assist System

Transcription

1 Instructions for the following series products: Lad-Saf Powered limb ssist System Model Numbers: (See Figure 1) WRNING: These instructions must be provided to the user and installer of this equipment. The user and installer of this equipment must read and understand these instructions before use or installation. Follow the manufacturer s instructions for safety equipment used with this system. Follow these instructions for proper use, inspection, and maintenance of this equipment. This equipment is intended to be used as part of a complete Powered limb ssist System. lterations, substitutions, or misuse of this equipment, or failure to follow instructions, may result in serious injury or death. IMPORTNT: If you have questions on the installation, use, maintenance, or suitability of this equipment for your application, contact apital Safety. IMPORTNT: efore using this equipment, record the product identification information from the ID label in the Inspection and Maintenance Log (Section 9). description: User Instruction Manual Lad-Saf Powered limb ssist System This manual is intended to meet the Manufacturer s Instructions, and should be used as part of an employee training program as required by OSH. The Lad-Saf Powered limb ssist System (Figure 1) provides fall protection and powered climbing assistance for individuals ascending and descending interior fixed ladders like those used in wind turbine towers. The Powered limb ssist System (PS) is comprised of sheaved Top racket and ottom racket assemblies that attach to the ladders rungs and support a Wire Rope able routed on both sides of the ladder. n Motor on the ottom racket assembly provides the assist force for climbing up or down the ladder. portable ontrol Panel and integrated Proximity Switch control assist force and stop/start functions of the Motor. n optional Intermediate racket assembly is available for installation on ladders where the cable might abrade on platforms or other structural elements. Figure 1 - Lad-Saf Powered limb ssist System - Top racket ssembly Model: Portable ontrol Panel (220V) Models: (US Plug), (European Plug) E - able ssembly Models: 617xxxx (Last 4 digits indicate cable length in feet.) E D - ottom racket ssembly Model: D - Lad-Saf Detachable Sleeve Length = 2 x Ladder Length + 20 ft. (6m) (US Sleeve) (E Sleeve) Intermediate racket ssembly Model: (optional) Model Lad-Saf 220V PS comprised of: - Top racket - ottom racket & 220V Motor Form: Rev: opyright 2009, D Industries, Inc.

2

3 1.0 pplication 1.1 PURPOSE: The Lad-Saf Powered limb ssist System (PS) provides fall protection and climb assistance while ascending or descending a ladder. Should the user fall, the PS will sense the fall and lock; stopping movement of the cable. The PS is intended to be installed on interior fixed ladders such as those used in wind turbine towers. 1.2 LIMITTIONS: The PS is not intended to be installed on portable ladders or ladders exposed to the environment. This system is designed for use on ladders that are generally vertical. Ladders must be at least 75 degrees from horizontal for proper system operation. The following application limitations must be considered before installing or using the PS.. LDDER STRUTURE: The ladder structure to which the system is installed must be capable of withstanding the loads applied by the system in the event of a fall (see Section 2.3).. System capacity: The PS is designed to be used by one user at a time. Multiple users are required to climb sequentially so only a single user is on the PS at any time. System capacities are based on a maximum user s weight, including tools and clothing, of 310 lbs (141 kg).. Environmental Hazards: Use of this equipment in areas with environmental hazards may require additional precautions to reduce the possibility of injury to the user or damage to the equipment. Hazards may include, but are not limited to: high heat caused by welding or metal cutting; caustic chemicals; seawater; high voltage power lines; explosive or toxic gases; moving machinery; sharp edges. D. omponent ompatibility: The PS is designed for use with DI-SL approved components and subsystems (see Section 2). The use of non-approved components and subsystems may jeopardize compatibility of equipment, and could affect the safety and reliability of the complete system. IMportant: The PS should not be used in combination with another fall protection system or sub system, except if authorized by apital Safety. E. Training: This equipment is intended to be installed and used by persons who have been trained in its correct application and use. F. Locking Speed: void using the PS in situations where the climbing path is obstructed. Working in cramped spaces may not allow sufficient speed to lock the PS when a fall occurs. clear path is required to ensure positive locking of the system. 1.3 Standards: Refer to local, state, and federal (OSH) requirements governing this equipment for more information on ladder safety systems and associated components, including OSH , NSI Z359 series, and NSI System Requirements 2.1 Ladder Safety sleeve: Only a Lad-Saf Detachable able Sleeve suitable for use with 5/16 in (8 mm) cable may be used with this system (see Figure 1). 2.2 ody Support: full body harness must be used with the PS. The harness must have a frontal connection suitable for frontal fall arrest when ladder climbing. The harness connection point must be above the users center of gravity. body belt is not authorized for use with the PS. If a fall occurs when using a body belt it may cause unintentional release and possible suffocation because of improper body support. Substitutions of equipment or system components must not be made without the written consent of apital Safety. 2.3 ompatibility of onnectors: onnectors used with this system (hooks, carabiners, D-rings) must be capable of supporting a minimum of 5,000 lbs (22.2 kn). Use caution to assure compatibility of hooks and the connection point. See section 4.4 on making connections. Non-compatible connectors may unintentionally disengage (roll-out). onnectors must be compatible in size, shape, and strength. Self closing/self locking connectors are highly recommended by apital Safety. 2.4 Load requirements for Structure and racket onnections: The ladder to which the PS is installed must be capable of supporting the loads imposed by the system. For calculation purposes the required bracket load may be assumed to be distributed evenly between the number of rung attachments. ecause the system forms a closed loop, the top bracket will receive double the in-line load. In the event of a fall, the load on the top bracket will be 5,500 lb (25 kn); including a safety factor of 2. The top bracket is attached with two clamps and one hook which distribute the load equally on three rungs. The load required for each rung would equal 5,500 lb (25 kn) divided by 3 or 1,800 lb (8 kn). The load for the bottom bracket should be calculated using only the in-line load. Since the bottom bracket is held with two clamps (the hook is not a strength member), the requirement for each rung would equal 2,750 lbs (12 kn) divided by 2 or 1,375 lbs (6 kn) including a safety factor of 2.

4 3.0 System Installation 3.1 Planning: Installation requirements for the Powered limb ssist System will vary based on the physical characteristics of the ladder/climbing structure to which the PS is attached. Planning the installation can minimize the amount of time on the ladder and improve safety. The following items should be considered prior to installation:. Mounting orientation: Figure 2 illustrates mounting of the Powered limb ssist System on a ladder. Preferred mounting orientation for the PS is with the motor on the back side of the ladder to avoid obstructing the climber s path. Where space is limited behind the ladder, the PS can be mounted with the motor on the front climbing side of the ladder. Space considerations should be evaluated prior to installation so bracket assemblies get mounted on the appropriate side of the ladder.. Rung lamp ssemblies: The PS ships with assorted hardware for securing the PS Top racket and ottom racket to round or square rungs on the ladder. omponents used will vary with the shape and size of the rungs. Figure 3 illustrates typical Rung lamp ssemblies and defines required hardware based on rung shape and size: important: When securing Powered limb ssist System components to the ladder rungs, fasteners on the Rung lamp ssemblies should be torqued to ft-lbs (27-34 Nm).. Tools: The following tools are required or recommended for installation of the PS: Torque Wrench: 9/16, 3/4, 1/2 Deep Sockets Steel Hammer Phillips Head Screwdriver Wrenches: 1/2, 9/16, 3/4, 7/8, 15/16, 1-1/8, 15 mm Wire Rope utter -lamp Ratchet Wrench: 1-1/4 Socket utting Pliers Tape Measure Drive Punch: 1/8 Figure 2 - Mounting Orientation Figure 3 - Rung lamp ssemblies E D E D Item Description Round Rungs (Diameter) 3/4 ( 20 mm) >3/4 1-5/8 (>20 mm 41 mm) Square Rungs (Length per Side) 9/16 ( 14 mm) >9/16 1-5/8 (>14 mm 41 mm) lamp Plate U-olt 2 2 Hex Head olt 4 4 Motor ottom racket Top racket D Lock Washer E Hex Nut Installation: fter determining appropriate mounting orientation and selecting the correct Rung lamp ssemblies (see Section 3.1), install the Powered limb ssist System as follows: warning: Exercise caution when installing the Powered limb ssist System. Wear personal protective equipment, including safety glasses and steel-toed shoes. Use personal fall arrest or restraint systems when exposed to a fall hazard. e careful when installing the system near electrical power lines. PS cables are conductive. Never connect to a partially installed Powered limb ssist System. Step 1. Install the Top racket: Figure 4 illustrates installation of the Top racket ssembly. Hang the Top racket Hook () on the ladder rung immediately below the top rung. Position the Top racket so the able Ports () on the Sheave over are centered horizontally on the ladder (Figure 4). When the Top racket is positioned correctly, secure the bracket to the ladder rungs with two Rung lamp ssemblies (). See Figure 3 for correct clamp assembly sizing and configuration. Verify that the Top racket Hook is resting securely on the ladder rung before tightening the clamps completely. The bolts on the clamps should be torqued to ft-lbs (27-34 Nm). 4

5 Figure 4 - Top racket Installation Figure 5 - able Installation, Top racket Top racket Hook able Port Rung lamp ssembly able able Port Sheave djustment olt Step 2. Feed the able through the Top racket Sheave: WRNING: The cable is very stiff and may spring out of the coil unexpectedly. Exercise caution when unrolling the cable. Wear appropriate safety gear (gloves, safety glasses, etc.) when unrolling the cable. Pass one end of the able () through the able Ports () in the Plastic over that protects the Top racket Sheave (see Figure 5). Feed the cable through the Sheave until both ends of the cable are reachable from ground level. The Sheave can be adjusted horizontally to allow proper clearance between the cable and ladder. To reposition the Sheave on the Top racket ssembly, loosen the 1/2 diameter Sheave djustment olts (Figure 5, Item ), slide the Sheave to the desired position, and then retighten the djustment olts to ft-lbs (54-61 Nm). Important: Inspect the cable for shipping damage before proceeding. Do not install damaged cable. Important: Keep the cable free of grease during installation. Step 3. Install the ottom racket: Hang the ottom racket Hook (Figure 6, Item ) on the third rung from the bottom of the ladder. Position the ottom racket so the able Ports () on the Sheave over are centered horizontally on the ladder. When the ottom racket is positioned correctly, secure the bracket to the ladder rungs with two Rung lamp ssemblies (). See Figure 3 for correct clamp assembly sizing and configuration. Verify that the ottom racket Hook is resting securely on the ladder rung before tightening the clamps completely. The bolts on the clamps should be torqued to ftlbs (27-34 Nm). Figure 6 - ottom racket Installation ottom racket Hook able Port Rung lamp ssembly 5

6 Figure 7 - able Installation, ottom racket D E Motor on climbing side of ladder Motor on back side of ladder -lamp D Tensioning olt E Drive Sheave over olts Step 4. Feed the able through the Motor Sheaves: Figure 7 illustrates passage of the cable through the Motor Sheaves. The two cable ends will need to be terminated and connected on the climber side of the ladder in the next step. e sure to thread the cable through the Motor Sheaves in the direction illustrated in Figure 7 for your PS mounting orientation ( or ). Prior to threading the cable through the Motor Sheaves: 1. Loosen up 3/4 Tensioning olt (D) so the end of the bolt is up as high as possible in the tube. 2. Slide the Motor/Fall rrest ssembly up and temporarily secure it at the highest possible position on the Tension Indicator Tube with a -clamp () or similar device. 3. Loosen the five 5/16 diameter bolts (E) on the Drive Sheave over and remove the Drive Sheave over. Feed the cable through the Motor Sheaves as illustrated in Figure 7. fter the cable is routed through all four Motor Sheaves, reattach the Drive Sheave over and torque the five 5/16 diameter bolts to 10 ft-lbs (13.6 Nm). Step 5. ut the able to length and then terminate and connect able Ends: Two Swageless able Eyes and a Quick Link are provided for connecting the ends of the cable to each other (see Figure 8). Prior to terminating the cable ends, cut off a portion of the top cable end so a 5 inch (12.7 cm) gap is present between the two ends (Figure 8). Terminate each of the able Ends as follows: 1. Slide the Urethane umper () over the able End. 2. Loosen the Eye (F) slightly. Insert the able End into the assembled Swageless Termination and then unscrew the Eye. 3. djust the able End so it protrudes 1/4-3/8 (.63 cm -.95 cm) beyond the Wedge Set (). e sure the three Wedges on the Wedge Set remain level with each other and the Washer (D) remains in place in the one (). 6

7 4. Slide the one () back over the Wedge Set () so the Wedge Set seats in the one without altering the alignment of the three Wedges. 5. Screw the Eye (F) by hand all the way into the the one and then unscrew the Eye and inspect the Wedge Set. ll three Wedges must be level with each other and set completely in the one. 6. Screw the Eye (F) all the way into the the one and tighten thoroughly with a wrench. 7. Tighten the Lock Nut (E) firmly. fter both ends are terminated, insert the Quick Link (G) between the two terminated cable ends as illustrated in Figure 8. Tighten the arrel Screw (H) and insert the provided Spring Pin (I) to secure the terminated cable ends in the Quick Link. Step 6. Step 7. Position the ontrol Panel: Position the ontrol Panel in the immediate vicinity of the ladder in a location that: 1. Does not obstruct the user s path; 2. Provides easy access to the Emergency Stop utton on the front of the panel. onnect the ontrol Panel to the Motor: Figure 9 illustrates electrical connections for the Powered limb ssist System. Plug the Motor Power ord () exiting the Motor Junction ox () into the ontrol Panel Power Receptacle ord (). Important: The wire connections in the Motor Junction ox () determine which direction the Motor spins. The wires are color coded and numbered with alpha (One, Two, etc.) or numeric (1, 2, etc.) labels. The Powered limb ssist System is factory wired for operation with the motor on the opposite side of the ladder from the climber. If the motor is on the same side of the ladder as the climber, the black wires in the lue (1)/ lack (One) and Orange (3)/lack (Three) wire pairs should be swapped (see Figure 9): 1. Loosen the four screws and remove the junction box cover Locate the lue (1)/lack (One) and Orange (3)/lack (3) wire pairs. Twist the wire nuts off the wire pairs and separate the wires. Pair up the lue (1) and lack (Three) wires, twist stripped ends together, and secure with a wire nut. Pair up the Orange (3) and lack (One) wires, twist stripped ends together, and secure with a wire nut. Reposition the cover on the junction box and screw in the four screws. Figure 8 - able Terminations D E F H G I a Urethane umper one Wedge Set D Washer E Lock Nut F Eye G Quick Link H arrel Screw I Spring Pin 7

8 Step 8. Step 9. onnect the ontrol Panel to the Proximity Switch: Remove the Protective ap (D) and plug the Proximity able (E) into the Proximity Switch (F) on the Motor/Fall rrest ssembly (see Figure 9). onnect the ontrol Panel to the Power Supply: Plug the ontrol Panel Power ord (G) into a V, Single Phase,, Hz, 10 Power Outlet (H). Figure 9 - System Electrical onnections D E H F G Motor Power ord Motor Junction ox ontrol Panel Power Receptacle ord D Protective ap E Proximity able F Proximity Switch G ontrol Panel Power ord H V, Single Phase,, Hz, 10 Power Outlet Factory Default Motor Wiring (motor opposite climber) Wire olor Wire Label Wire olor Wire Label lue 1 TO lack One Orange 3 TO lack Three Orange (3) lack (Three) lue (1) lack (One) Wire olor Wire Label Wire olor Wire Label lue 1 TO lack Three Orange 3 TO lack One 8

9 Step 10. Tension the able: The ottom racket is equipped with a Tension djustment Tube for monitoring and adjusting cable tension (see Figure 10). Remove the vice grip or clamp so the Motor/Fall rrest ssembly slides down under its own weight and removes excess slack from the cable. Tighten the 3/4 diameter Tensioning olt () until the Red Line () on the Tension Indicator Tube is centered in the OK range. Once the cable is properly tensioned, tighten the Lock Nut () on the Tensioning olt until it is snug against the top of the Tension Indicator Tube (TIGHTEN SEURELY). Important: efore each use of the Powered limb ssist System, inspect the Tension Indicator Tube to ensure that the Red Line is within the OK range. Insufficient cable tension can prevent the climb assist system from functioning correctly and may prevent the fall arrest system from functioning correctly in the event of a fall. Excess cable tension can cause premature wear of the sheaves, cable, etc. Figure 10 - Tension djustment Important: Depending on the length of the system and environment in which the system is installed, it may be necessary to periodically re-tension the system. Extreme temperature ranges and longer cable lengths will likely necessitate periodic re-tensioning. Step 11. Test and Inspect the system installation: Figure 11 identifies key components on the PS ontrol Panel. fter installation, test the PS without a climber to ensure proper operation: Warning: void turning the ontrol Panel ON and OFF several times in rapid succession. Doing so may damage the electronic components of the ontrol Panel. Wait a minimum of 1 minute before restarting the system. 1. Turn the ontrol Panel MIN POWER Switch () to the ON (7) position to power up the PS. 2. Verify that the EMERGENY STOP utton () is pulled out and then press the STRT utton () to turn on the ontrol Panel. The red light on the EMERGENY STOP button will illuminate. 3. Press the RETURN THE LINE utton (D) and verify that the cable moves down on the climbing side of the ladder and up on the back side of the ladder. llow the cable to travel down the climbing side of the ladder until the Urethane umper below the cable end terminations contact the Motor/Fall rrest ssembly. fter 4 seconds, the motor should stop running and remain stopped. 4. Pull the cable up or down a minimum of 14 inches (36 cm) to test operation of the Proximity Switch. The cable should begin moving up the climbing side of the ladder and down the back side of the ladder. llow the cable to travel up the climbing side of the ladder until the Urethane umper above the cable end terminations (Figure 8) contacts the Top racket. fter 4 seconds, the motor should stop running and remain stopped. 5. Press the RETURN THE LINE utton (D) to return the cable end terminations to the bottom of the ladder. In addition to the above functional tests, a thorough inspection should be performed on the entire Powered limb ssist System after installation. See Section 5 for details. Step 12. Record the Installation Date: Record the date of installation on the Identification and Inspection Label located on the Motor/Fall rrest ssembly Sheave over (see Section 8). 3.3 Intermediate bracket Installation: Intermediate rackets (Figure 12) may be installed to prevent the cable and/or cable terminations from abrading on ladder rungs or other structural elements (platforms, walls, etc.). Intermediate rackets are typically needed for curved or angled ladder sections. Single or multiple Intermediate rackets should be installed around the rungs closest to the area of abrasion in the following manner: 9

10 Figure 11 - ontrol Panel omponents Figure 12 - Intermediate racket E D E D Main Power Switch Emergency Stop utton Start utton D Return the Line utton E ssistance Force djustment Knob ack Plate Front Plate Threaded Rod D & E Roller Warning: lways use a secondary Fall Protection System when climbing on the ladder before the Powered limb ssist System is fully installed and inspected. Step 1. Step 2. Determine the best location for installing the Intermediate racket(s): The Intermediate racket is designed to install around the ladder rung(s) closest to the area of abrasion. Secure the Front and ack Mounting Plates to the Ladder Rails: Position the ack Plate () and Front Plate () on each side of the ladder rail. The Front Plate should mount on the inside of the ladder rail with the notched portion surrounding the ladder rung (see Figure 12). Insert the provided 3/8 diameter bolts through the mounting plate holes that fit snuggest to the rail width. Secure the plates to one another with 3/8 diameter lock washers and nuts. Torque fasteners to the following values: On Steel or Solid luminum Ladder Rails: Torque Plate Fasteners to 25 ft-lbs (27 Nm). On Hollow luminum Ladder Rails: Torque Plate Fasteners to 10 ft-lbs (13.6 Nm). Install a second pair of Front and ack Plates on the opposite Ladder Rail in the manner described above. Plate pairs should be aligned level so the Threaded Rods () installed in the next step run parallel with one another and the ladder rungs. Step 3. Install the Threaded Rods in the Mounting Plates: The Threaded Rods () should be installed so the cable rides outside the Roller (D) on the front of the ladder and inside the Roller on the back of the ladder (E). eginning with the climbing side, install the Threaded Rods as follows: Remove the outer Hex Nuts from each end of the Threaded Rod. Thread the remaining Hex Nuts further onto the Threaded Rod so they are closer to the Roller. NOTE: The Threaded Rods should be installed in the holes on the Front Plate that best protect the cable from abrasion while ensuring that the Intermediate racket does not obstruct climbing. When installed with the Face Plates surrounding the ladder rung, the Intermediate racket can be used as a rung/step during ascent or descent of the ladder. 10

11 Starting from the inside face of one of the Front Plates (), insert the Threaded Rod () through the desired hole in the Front Plate until the Hex Nut contacts the Front Plate, and then pull the Threaded Rod back through the corresponding hole in the opposite Face Plate. Position the Threaded Rod () horizontally so the cable rides on the middle of the Roller (D) and then thread the two Hex olts outward until they contact the Front Plates and hold the Threaded Rod in place. Thread Hex Nuts on each end of the Threaded Rod () and tighten firmly. Install the remaining Threaded Rod () on the back side of the ladder in the same manner. 4.0 System Operation 4.1 efore Each Use: Inspect the system according to Section 5. Do not climb a structure that is not in good condition. Verify from the label markings that the system has been formally inspected within the last year. Do not use a defective or improperly maintained Lad-Saf Powered limb ssist System. Inspect the Lad-Saf Detachable able Sleeve according to manufacturer s instructions. Inspect the full body harness according to manufacturer s instructions. 4.2 Plan: Plan your use of the Powered limb ssist System system before starting work. onsider all factors that will affect your work. Important points to consider include the following: onsider hazards associated with connecting and disconnecting from the system. Ensure adequate anchor points, landing platforms, or other means are available at connection and disconnection points to allow safe transitions to and from the system. e aware of hazards in the work area that could cause injury to the user or damage to the system, such as; high heat, electrical hazards, chemical hazards, or moving machinery. Use caution when climbing. void carrying tools or equipment that do not allow your hands to be free for climbing. Ensure items carried are secure to avoid dropping them on climbers below. limb within your ability. Long climbs may require several rest stops during ascent or descent to avoid exhaustion. void climbing in high winds or severe weather whenever possible. Important: Do not use the Powered limb ssist System to lift equipment or materials. In the event of a power outage or motor failure; resulting in loss of powered climb assistance, The Lad- Saf Powered limb ssist System can still be used to climb up and down the ladder. onnect the Lad- Saf Detachable Sleeve to the harness front D-ring, then secure the sleeve on the stationary cable. The Lad-Saf Sleeve will follow the user up or down the ladder while the cable remains stationary. If a fall occurs the user (employer) must have a rescue plan and the ability to implement it. 4.3 TRINING: It is the responsibility of the user and purchaser of this equipment to assure they are familiar with the instructions, operating characteristics, application limits, and the consequences of improper use of this equipment. Users and purchasers of this equipment must be trained in the correct care and use of this equipment. ontact apital Safety for additional training guidelines. 4.4 Use: Steps for operating the Powered limb ssist System are as follows: SYSTEM PREPRTION: Step 1. Step 2. Step 3. Step 4. Step 5. onnect the ontrol Panel to Power: Plug the ontrol Panel Power ord into a V, Single Phase,, Hz, 10 Power Outlet (refer to Figure 9). onnect the ontrol Panel to the Motor: Plug the Power ord exiting the Motor Junction ox into the ontrol Panel Power Receptacle ord (refer to Figure 9). onnect the ontrol Panel to the Proximity Switch: Plug the Proximity able from the ontrol Panel into the Proximity Switch on the Motor/Fall rrest ssembly (see Figure 9). Turn on Main Power: Turn the ontrol Panel MIN POWER Switch to the ON ( ) position to power up the PS. Turn on the ontrol Panel: VerifY that the EMERGENY STOP utton is pulled out and then press the STRT utton to turn on the ontrol Panel. The red light on the EMERGENY STOP button will illuminate. Æ Æ 11

12 Step 6. djust the ssistance Force: The SSISTNE FORE DJUSTMENT Dial indicates the Relative Lifting Force with 1 representing the lowest approximate value; 45 lbs (20 kg) and 10 representing the highest approximate value; 120 lbs (55 kg). Turn the dial to adjust the Relative Lifting Force of the PS. Test the adjustment by climbing a ft. (3-5 m) section and descending back down prior to climbing the entire ladder. FIRST USER: Warning: It is recommended that the Lifting Force not exceed 2/3 of the users weight. In no case should the PS lift the user entirely off the ground. Step 7. onnect the Lad-Saf Detachable Sleeve to the front D-ring on the Full ody Harness: apital Safety requires a Full ody Harness with a front attachment for ladder climbing. body belt is not recommended for use with the PS. If a fall occurs when using a body belt it may cause unintentional release and possible suffocation because of improper body support. Substitutions of equipment or system components must not be made without the written consent of apital Safety. See the Full ody Harness manufacturer s instructions for connection instructions. IMportant: Only recommended Lad-Saf Detachable Sleeve models compatible with 5/16 (8 mm) wire rope should be used with the Powered limb ssist System (see Figure 1). Step 8. Step 9. ttach the Lad-Saf Detachable Sleeve to the PS able: The Detachable Sleeve should be attached to the Powered limb ssist System cable just above the terminations connecting the two cable ends. See the Lad-Saf Detachable Sleeve User Instruction Manual for connection instructions. egin Power ssisted limbing: The Proximity Switch on the Motor/Fall rrest assembly stops and starts the motor based on cable displacement. To begin assisted ascent or descent, move the cable up or down a minimum of 14 inches (36 cm) to activate the PS. The motor will begin pulling the cable up the front of the ladder and down the back of the ladder. To stop the PS, stop climbing and remain motionless for a minimum of 4 seconds and the Proximity Switch will stop the motor. important: In emergency situations where the user is unable to stop the PS with the Proximity Switch, the system can be stopped by pressing the EMERGENY STOP utton on the ontrol Panel. To resume Power ssisted limbing, move the cable up or down a minimum of 14 inches (36 cm) until the Proximity Switch starts the motor. Step 10. When finished climbing, disconnect the Detachable Sleeve: Disconnect the Lad-Saf sleeve per the instructions in the Lad-Saf Detachable Sleeve User Instruction Manual. Warning: Where fall hazards exist, always connect to a backup fall arrest system (e.g., Full ody Harness and Lanyard) before disconnecting from the Powered limb ssist System. n energy absorber, limiting forces to 1,800 lbs (8 kn), should be used. The Top racket ssembly on the PS is equipped with D-Ring which can be used to connect the backup fall arrest system. DDITIONL USERS: Warning: Only one user may be connected to the Powered limb ssist System at any time. Multiple users can connect to the the system successively to ascend or descend the ladder, but only one person should be connected to the system at any time. Step 11. Return the cable for use by the next person: For each additional person ascending or descending the ladder, the cable should be returned to its original position so the next person can attach their Detachable Sleeve in the proper location above the joined cable ends. warning: lways ensure that the previous climber is fully disconnected from the cable before returning the cable to its original position for use by the next climber. 12

13 To return the cable to the ottom of the Ladder for the next person to ascend: Press the ontrol Panel RETURN THE LINE button. llow the cable to travel downward until the bottom Urethane umper (see Figure 8) contacts the Motor/Fall rrest ssembly. fter 4 seconds, the motor will stop. important: The ontrol Panel RETURN THE LINE utton should only be pressed after confirming that the previous climber is safely disconnected from the PS. To return the cable to the Top of the Ladder for the next person to descend: Move the cable up or down a minimum of 14 inches (36 cm) so the Proximity Switch starts the motor. llow the cable to travel upward until the top Urethane umper (see Figure 8) contacts the Motor/Fall rrest ssembly. fter 4 seconds, the motor will stop. Step 12. onnect to the Powered limb ssist System and climb the ladder: onnect to the cable on the PS with a Lad-Saf Detachable Sleeve and climb the ladder in the desired direction. See Steps 7 thru 10 for specific instructions. SYSTEM SHUTDOWN: Step 13. Turn off the Powered limb ssist System: When work is completed and all users have descended the ladder, turn the MIN POWER Switch to the OFF ( ) position to power down the PS. Important: void turning the ontrol Panel ON and OFF several times in rapid succession. Doing so may damage the electronic components of the ontrol Panel. Wait a minimum of 1 minute before restarting the system. Step 14. Prepare the ontrol Panel for transport to another PS: Disconnect the Power ord, Power Receptacle ord, and Proximity ord (see Figure 9). fter disconnecting the Proximity ord, place the Protective ap over the connector on the Proximity Switch. oil and secure the cords with the provided Velcro Strap. 5.0 inspetion 5.1 FREQUENY: Important: void shocks and impacts to the ontrol Panel during transport to ensure the panel remains in good working condition. efore Each Use: Visually inspect the Lad-Saf Powered limb ssist System, Lad-Saf Detachable Sleeve, and ladder structure. Use the guidelines provided in Section 5.2 to check the PS. heck the system label (Section 8) to verify that annual inspection is current. If the condition of the system is in doubt, do not use. nnual Inspection: formal inspection of the Powered limb ssist System, Detachable Sleeve, and ladder structure must be performed at least annually by a competent person other than the user. fter a Fall: If a fall occurs while using the Lad-Saf Powered limb ssist System and Lad-Saf Detachable Sleeve, a formal inspection of the entire system must be performed by a competent person other than the user. separate fall protection system (not the PS) should be used while inspecting the system. See Section 5.2 and Section 5.3 for details. 5.2 Inspection Guidelines: To ensure safe efficient operation, the Lad-Saf Powered limb ssist System, Sleeve, and ladder structure should be inspected per the following guidelines: ottom racket: Reference Figure 13. Step 1. Step 2. Step 3. Inspect the ottom racket for damage, corrosion, or rust. Look for cracks, bends, or wear that could affect strength and operation of the system. Inspect for loose or missing fasteners. Retighten and replace fasteners as necessary. heck fasteners on all Rung lamp ssemblies () for proper torque. Recommended torque range is ft-lbs (27-34 Nm). efore Each Use Every Year fter a Fall X X X X X X X X 13

14 Figure 13 - Inspection, ottom racket Figure 14 - Inspection, Motor Fall rrest ssembly F E E G F H D J I M L K Motor/Fall rrest ssembly: Reference Figure 14. Step 1. Step 2. Step 3. Step 4. Step 5. Step 6. Inspect the Motor/Fall rrest ssembly for cracks, bends, or wear that could affect the strength and operation of the system. Inspect for loose or missing fasteners; including fasteners holding the Proximity Switch (). Retighten and replace fasteners as necessary. Inspect all labels (see Section 8). ll labels must be present and fully legible. Remove the five 5/16 diameter bolts on the Drive Sheave over (), remove the Drive Sheave over, and inspect as follows: Inspect the Pawls () and Ratchet am (D) for signs of damage or wear. Verify that the Pawls rotate freely on their Pivot Studs (E). Inspect the Pawl Springs (F) to ensure they are tight. Inspect the groove in the Drive Sheave (G) for signs of wear. Replace the Drive Sheave if wear is excessive. Verify that the 5/16 Diameter Set Screw (H) holding the Drive Sheave on the Motor Shaft (I) is tight and the Retaining Ring (J) is still in place on the end of the Motor Shaft. djust positioning of the Drive Sheave and tighten the Set Screw as needed. Remove the overs (K) from the three Guide Sheaves (L) and inspect as follows: Inspect the Guide Sheaves for wear. Inspect the plastic Sheave Guards (M) for signs of wear and excessive grooving. ttach all Sheave overs. Torque Sheave over fasteners to the following values: 5/16 Diameter olts & Nuts - Torque to 10 ft-lbs (13.6 Nm) #10 Screws - Torque to 20 in-lbs (2.3 Nm) 1 >500: If estimated annual use exceeds 500 climbs. 2 <500: If estimated annual use does not exceed 500 climbs. efore Each Use Every Year Every 3 Years fter a Fall X X X X X X X X >500 1 <500 2 X >500 1 <500 2 X >500 1 <500 2 X 14

15 Top racket: Reference Figure 15. Step 1. Step 2. Step 3. Step 4. Inspect the Top racket for damage, corrosion, or rust. Look for cracks, bends, or wear that could affect strength and operation of the system. Inspect for loose or missing fasteners. Retighten and replace fasteners as necessary. heck fasteners on all Rung lamp ssemblies () for proper torque. Recommended torque range is ft-lbs (27-34 Nm) Unscrew the six #10 Screws and remove the Sheave over (). Inspect the Sheave () and Sheave Guard (D) as follows: Inspect the Sheave for signs of wear. Inspect the plastic Sheave Guard for wear and excessive grooving. Reattach the Sheave over. Torque #10 screws securing the cover to 20 in-lbs (2.3 Nm). 1 >500: If estimated annual use exceeds 500 climbs. 2 <500: If estimated annual use does not exceed 500 climbs. efore Each Use Every Year Every 3 Years fter a Fall X X X X X X X X >500 1 <500 2 X able ssembly: Reference Figure 16. Step 1. Step 2. Step 3. Step 4. Inspect the Wire Rope able () for cuts, kinks, burns, broken wires or strands, chemical damage, and severe abrasion. If necessary, replace the damaged cable. Inspect the entire system for areas of abrasion against the ladder or structure. Install Intermediate rackets if needed (see Section 3.3). Verify that the Swageless Terminations () and Quick Link () joining the cable ends are fully tightened. Verify that the Spring Pin (D) is securely in place in the Quick Link. Inspect the Tension Indicator Tube (E) for correct cable tension. The Indicator (Red Line) should be within the OK range. efore Each Use Every Week Every Year fter a Fall X X X X X X X X X X X X Figure 15 - Inspection, Top racket Figure 16 - Inspection, able ssembly D D E 15

16 Figure 17 - Inspection, Intermediate racket Figure 18 - i-safe RFID Tag Intermediate rackets: Reference Figure 17. Step 1. Step 2. Inspect the Intermediate racket(s) for damage, corrosion, or rust. Look for cracks, bends, or wear that could affect strength and operation of the system. Inspect for loose or missing fasteners. Retighten or replace fasteners as necessary. Fasteners on Front Plates () and ack Plates () should be torqued to the following values: 1. On Steel or Solid luminum Ladder Rails: Torque Plate Fasteners to 25 ft-lbs (27 Nm). 2. On Hollow luminum Ladder Rails: Torque Plate Fasteners to 10 ft-lbs (13.6 Nm). Step 3. Inspect Rollers () for signs of wear. Verify that Rollers rotate freely. X X Every Year X X fter a Fall X X Ladder Structure: Inspect the entire Ladder Structure for damage, rust, or deterioration that could affect the strength and safety of the ladder. Every Year X fter a Fall X Lad-Saf Detachable Sleeve: Ispect the Lad-Saf Detachable Sleeve per the inspection steps defined in the Lad- Saf Detachable Sleeve User Instruction Manual. efore Each Use Every Year fter a Fall X X X 5.3 unsafe or defective conditions: If inspection reveals an unsafe or defective condition, remove the PS component or Detachable Sleeve from service and destroy it or contact an authorized service center for repair. 5.4 I-Safe RFID Tag: The Powered limb ssist System includes an i-safe Radio Frequency Identification (RFID) tag (Figure 18). The RFID tag can be used in conjunction with the i-safe handheld reading device and web based portal to simplify inspection and inventory control and provide records for your fall protection equipment. If you are a first-time user, contact a apital Safety ustomer Service representative (see back cover); or if you have already registered, go to Follow the instructions provided with your i-safe handheld reader or on the web portal to transfer your data to your web log. 6.0 Maintenance, Storage, and troubleshooting 6.1 Maintenance: The Lad-Saf Powered limb ssist System requires no scheduled maintenance. See Section 5 for inspection related maintenance issues. Recommendations for periodic cleaning are as follows: Wire Rope able: If the Wire Rope able becomes soiled with oil, grease, paint, or other substances; clean it with appropriate cleaning solutions. Do not use acid or caustic chemicals that could damage the cable. Lad-Saf Detachable Sleeve: The Lad-Saf Sleeve may be cleaned using commercial parts-cleaning solvents and rinsed with warm, soapy water. 6.2 Storage: When not in use, store the ontrol Panel and Lad-Saf Detachable Sleeve in a cool, dry, clean environment; out of direct sunlight. void areas where chemical vapors exist. Thoroughly inspect the sleeve after extended storage. 6.3 Trouble shooting: If the Powered limb ssist System is not operating correctly, Table 1 can be used to diagnose and correct common problems. 16

17 Table 1 - Lad-Saf Powered limb ssist System Troubleshooting Symptom: What to heck: orrective ction: The motor does not start and provide climb assistance when the cable is pulled up or down a minimum of 14 in. (36 cm). The cable is not traveling downward when the RETURN THE LINE button is pressed. The motor starts, but no/little assistance force is provided. Is the ontrol Panel Power ord plugged in to a power outlet (Figure 9)? Is the Motor Power ord plugged in to the ontrol Panel Power Receptacle ord (Figure 9)? Is the ontrol Panel Proximity able connected to the Proximity Sensor on the Motor/Fall rrest assembly so the male and female connectors are fully engaged (Figure 9)? Is the ontrol Panel plugged into a correct power source? Is the ontrol Panel plugged into a working power outlet? Is the ontrol Panel MIN POWER Switch fully engaged in the ON ( ) position (Figure 11)? Is the EMERGENY STOP utton pulled out (Figure 11)? Has the STRT utton been pushed (Figure 11)? Is the SSISTNE FORE DJUSTMENT knob (Figure 11) adjusted correctly (Section 44, Step 6)? Is the light at the back of the Proximity Switch (Figure 9) flashing when the lifeline is moved up or down a minimum of 14 in. (36 cm)? Plug in the ontrol Panel Power ord. Plug the Motor Power ord into the ontrol Panel Power Receptacle ord. onnect the Proximity able to the Proximity Sensor. e sure the male and female connectors are fully engaged. heck power outlet specifications against the ontrol Panel power specifications in Section 7.3. heck the power outlet voltage with a voltmeter or operate other electrical equipment from the outlet to verify the outlet is working. Switch the ontrol Panel MIN POWER Switch to the ON ( ) position. Make sure the switch is fully engaged. Pull out the EMERGENY STOP utton. Push the STRT utton. djust the SSISTNE FORE DJUSTMENT knob. lean Proximity Switch and Proximity able connections. Re-position the Proximity Switch. If all else fails, replace the Proximity switch. If none of the above resolve the problem, reset the ontrol Panel: Switch the MIN POWER Switch to OFF. Wait 1 minute and switch the MIN POWER Switch to ON. Pull out the EMERGENY STOP utton and then press the STRT utton. If the problem is still not resolved, send the ontrol Panel to apital Safety for repair. heck all of the above items. re the cable or cable terminations (Figure 8) catching on the ladder or structure? Is the SSISTNE FORE DJUSTMENT knob (Figure 11) adjusted correctly (Section 44, Step 6)? Is the cable tensioned correctly (Figure 10)? djust the Top racket Sheave so the cable and cable termination clear the ladder or structure during travel (Figure 5) or install an Intermediate racket (Figure 12) to guide the cable and cable terminations clear of the ladder or structure. djust the SSISTNE FORE DJUSTMENT knob. djust the cable tension (Section 3.2, Step 10). 17

18 7.0 Specifications 7.1 Standards: When installed per the requirements and recommendations in the instruction manual, the Lad-Saf Powered limb ssist System meets OSH and NSI requirements, including Motor and ontrol Panel are UL recognized. 7.2 mterils: OTTOM RKET: Tube: Shaft: Springs: Hook: Fasteners: Galvanized Steel Plated lloy Steel Steel Galvanized Steel Plated Steel MOTOR/FLL RREST SSEMLY: Plates: Sheaves: Sheave Guards: Pawls: Pawl Springs: Sheave overs Fasteners: Plated Steel Plated Steel luminum or Plastic Stainless Steel Stainless Steel luminum Plated Steel or Stainless Steel TOP RKET: Tube: Hook: Plate: Sheave: Sheave Guard: Sheave over: Fasteners: D-Ring ssembly: Galvanized Steel Galvanized Steel Plated Steel Plated Steel Plastic luminum Plated Steel Painted or Plated Steel LE SSEMLY: able: Swageless Terminators: Quick Link: umpers: Fasteners 5/16 (8 mm) Diam. 7 x 19 Galvanized Wire Rope Stainless Steel Stainless Steel Urethane Galvanized Steel INTERMEDITE RKET: Threaded Rod: Roller: Fasteners: Plated Steel Nylon Plated Steel, Stainless Steel, or Galvanized Steel 7.3 ONTROLS: Motor: ontrol Panel: (See also Figure 19 Schematic) Power able: 3/8 HP, 0-70 RPM, Totally Enclosed, Fan ooled, Insulated-lass F, Inverter Duty Nema 12 Enclosure, V, Single Phase, Hz, Full Load mps 6.6, Fused 10-J lass PN : US Male Plug Type Nema 6-10P, 14 Gauge Wire PN : European Male Plug Type EE 7/7, 16 Gauge Wire 7.4 Noise emissions: irborne Noise Emissions from the PS do not exceed 70 db(). 18

19 Figure 19 - ontrol Panel Electrical Schematic 19

20 8.0 Labeling The following labels must be securely attached and fully legible: ontrol Panel Instruction & Warning Label Tension Indication Label Warning Label 20 ID & Inspection Label

21 9.0 INSPETION ND MINTENNE LOG SERIL NUMER: MODEL NUMER: DTE PURHSED: DTE OF FIRST USE: INSPETION DTE INSPETION ITEMS NOTED ORRETIVE TION MINTENNE PERFORMED 21

22 9.0 INSPETION ND MINTENNE LOG SERIL NUMER: MODEL NUMER: DTE PURHSED: DTE OF FIRST USE: INSPETION DTE INSPETION ITEMS NOTED ORRETIVE TION MINTENNE PERFORMED 22

23

24 apital Safety ompany SG US 3833 Sala Way Red Wing, MN Toll Free: Phone: Fax: SG anada Ltd. 260 Export oulevard Mississauga, Ontario L5S 1Y9 anada Toll Free: Phone: Fax: SG Northern Europe Ltd. 7 hristleton ourt Stuart Rd. Manor Park Runcorn heshire W7 1ST UK Phone: +44 (0) Fax: +44 (0) csgne@csgne.co.uk SG EME (France) Le roc enter Z.I. 1ère venue-5600 M P arros edex Phone: +33 (0) Fax: +33 (0) information@capitalsafety.com Germany: Phone: +49 (0) Fax: +49 (0) SG sia Pte Ltd. No. 6, Tuas venue 18 Singapore Phone: Fax: inquiry@capitalsafety.com SG (ust) Pty Ltd. 20 Fariola Street Sliverwater Sydney, NSW 2128 ustralia Phone: +61 (2) Fax: +61 (2) sales@capitalsafety.com.au I S O 9001 ertificate No. FM 39709