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HEADRUSH ZSIR150-20A Installation, Operation & Maintenance Manual

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ZIPSTOP
ZIP LINE
BRAKE
Installation, Operation & Maintenance Manual
Models: ZS125-08 / ZSIR150-20A
NOTE TO INSTALLERS
Always Read Instructions Before Use
Leave this manual attached to the zipSTOP Brake unit. The Installation, Operation
and Maintenance manual contains information relating to the proper use of the
zipSTOP and includes all product registration and warranty information. This doc-
ument may only be removed by the end user prior to operation. Ensure that this
manual is readily available to operators at all times.
Head Rush Technologies zipSTOP Zip Line Brake Installation, Operation & Maintenance Manual
P/N 01170006604
Head Rush Technologies products are covered by a number of patents, including
U.S. Patents 8,490,751; 8,851,235; 9,016,435; 8,851,235 and D654,412 & corresponding patents/applica-
tions in the USA and in other countries worldwide.

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Summary of Contents for HEADRUSH ZSIR150-20A

  • Page 1 ZIPSTOP ZIP LINE BRAKE Installation, Operation & Maintenance Manual Models: ZS125-08 / ZSIR150-20A NOTE TO INSTALLERS Always Read Instructions Before Use Leave this manual attached to the zipSTOP Brake unit. The Installation, Operation and Maintenance manual contains information relating to the proper use of the zipSTOP and includes all product registration and warranty information.

  • Page 2: Table Of Contents

    4.1 Warranty Conditions 4.2 Customer Responsibility 5. SPECIFICATIONS 5.1 Introduction 5.2 zipSTOP Brake Unit, ZS125-08 5.3 zipSTOP Brake Unit, ZSIR150-20A 5.4 zipSTOP Brake Trolley, ZS125-08 and ZSIR150-20A 6. OPERATING PRINCIPLES 6.1 General 7. ZIPSTOP BRAKE ASSEMBLY 7.1 General 7.2 Unpacking the zipSTOP 7.3 Long Term Storage...
  • Page 3 12.6 Brake Trolley Inspection and Maintenance 12.7 Brake Unit Casing Inspection 12.8 Webbing Line Inspection 13. BRAKING DISTANCE CHARTS 13.1 How to Read Braking Distance Charts 13.2 1:1 Ratio – Metric, ZSIR150-20A 13.3 1:1 Ratio – Imperial, ZSIR150-20A www.headrushtech.com +1-720-565-6885...
  • Page 4 13.4 1:1 Ratio – Metric ZS125-08 13.5 1:1 Ratio – Imperial ZS125-08 13.6 2:1 Ratio – Metric, ZS125-08 13.7 2:1 Ratio – Imperial, ZS125-08 13.8 3:1 Ratio – Metric 13.9 3:1 Ratio – Imperial 14. APPENDIX A: EAD WARRANTY/REGISTRATION FORM 14.1 Warranty Registration Form 15.
  • Page 5 The zipSTOP Brake assembly, including zipSTOP Brake Unit Model ZB125-08B and ZSIR150-20A, zipSTOP Brake Trolley Model ZT125-17 and all associated equipment are designed and specified for use in the recre- ational zip line industry as components of a well designed zip line brake system.

  • Page 6: Safety Information

    1. SAFETY INFORMATION 1.1 Symbols Used in this Manual The following safety symbols are used throughout this manual to highlight potential danger to operators and equipment. One or more precautions may be associated with practices and procedures described within this manual.

  • Page 7: Emergency Arrest Device (Ead) Confirmation

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

  • Page 8: Safety & Information Labels

    3. SAFETY & INFORMATION LABELS Safety and Information Labels located on the zipSTOP components are not to be removed. Ensure labels are in place and remain legible at all times. 3.1 Location of Safety Labels Location of Labels – Brake Unit Location of Labels –...

  • Page 9: Warranty Information

    4. WARRANTY INFORMATION 4.1 Warranty Conditions Manufacturers sole warranty. The zipSTOP Brake assembly will be sold free from defects in materials and workmanship, excluding field replaceable wear parts, for a period of one (1) year from date of purchase. This warranty only applies to the original purchaser, and is contingent upon the owner/operator using and main- taining the device in accordance with the zipSTOP instructions, including the requirement to maintain annual recertification as described in the Installation, Operation and Maintenance Manual.

  • Page 10: Specifications

    5. SPECIFICATIONS 5.1 Introduction The zipSTOP Brake assembly is a controlled braking force device designed specifically for use in the zip line industry as a Primary or EAD at the end of zip line runs. The zipSTOP caters to a range of rider weights and approach speeds, and offers a smooth, consistent braking force for all riders.

  • Page 11: Zipstop Brake Unit, Zs125-08

    5.2 zipSTOP Brake Unit, ZS125-08 zipSTOP Mount Top Mounting Pin zipSTOP Brake Unit Nozzle Assembly Braking Line Side Cover Pulley MODEL ZS 125-08B CLASSIFICATION Zip Line Braking Device DIMENSIONS 380 x 320 x 216 mm (15 x 12.6 x 8.5 in) NET WEIGHT 23.5 kg (52 lbs) OPERATING TEMPERATURE...

  • Page 12: Zipstop Brake Unit, Zsir150-20A

    ZSIR150-20A - THIS PRODUCT CAN ONLY BE USED WITH 1:1 REDIRECTION SETUPS The zipSTOP IR (ZSIR150-20A) is NOT compatible with external redirection setups in any way. Installing a redirection setup with the zipSTOP IR can create a very dangerous set of braking conditions that could result in abnormally abrupt late braking.

  • Page 13: Zipstop Brake Trolley, Zs125-08 And Zsir150-20A

    5.4 zipSTOP Brake Trolley, ZS125-08 and ZSIR150-20A Bump Stops Redirection Line Mounting Point Upper Sheave Lower Sheaves MODELS ZT 125-17-1/2 – For use with 12.7 mm (½”) zip lines ZT 125-17-3/4 – For use with 19 mm (¾”) zip lines ZT 125-17-35/8 –...

  • Page 14: Operating Principles

    6. OPERATING PRINCIPLES 6.1 General The zipSTOP Brake assembly is a controlled braking force device designed specifically for use as a Primary or EAD at the end of zip line runs. The zipSTOP caters to a range of rider weights and approach speeds and offers a smooth, consistent braking force for all riders.

  • Page 15: Zipstop Brake Assembly

    7. zipSTOP BRAKE ASSEMBLY 7.1 General The zipSTOP Brake assembly will be supplied as a kit of parts. Additional components are required to com- plete the braking system. Refer to Section ”Appendix B: List of Accessories and Replaceable Parts” for part number information.

  • Page 16: Long Term Storage

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

  • Page 17: Supplied Parts

    ZIPSTOP ZIP LINE BRAKE Installation, Operation & Maintenance Manual Models: ZS125-08 / ZSIR150-20A NOTE TO INSTALLERS Always Read Instructions Before Use Leave this manual attached to the zipSTOP Brake unit. The Installation, Operation and Maintenance manual contains information relating to the proper use of the zipSTOP and includes all product registration and warranty information.

  • Page 18: Redirection Pulleys

    weight, corrosion resistant, and engineered to be virtually resistant to snagging. Head Rush Technologies also offers the Gorilla Rope, a 6mm rope specifically designed for used as a redirection line. 7.6 Redirection Pulleys The following parts are not supplied as part of the zipSTOP kit and may be purchased separately from your zipSTOP distributor.

  • Page 19: Minimum Hardware Requirements

    7.8 Minimum Hardware Requirements All required hardware is to be purchased separately. The following are minimum requirements for all hardware used for zipSTOP installation: DESCRIPTION SIZE NOTES Grade 4.6 (M12) M12 or 1/2” ASTM A307 Grade A or B (1/2”) ZIPSTOP BRAKE UNIT MOUNTING BOLTS, WASHERS &...

  • Page 20: Redirection Line Specifications: Zs125-08/Zs150-20A

    7.9.1 REDIRECTION LINE SPECIFICATIONS: ZS125-08/ZSIR150-20A MAXIMUM DIAMETER 10.0 mm/0.394 in (6mm/0.236 in recommended) MINIMUM STRENGTH 13 kN, Stretch <3% at 13 kN STRETCH <4% at 15 kN WEAR RESISTANCE High abrasion resistance and UV resistance WATER RESISTANCE Dry, non-absorptive TYPE...

  • Page 21: Zipstop Brake Assembly Configuration

    A number of variables will influence the final braking distance and level of rider comfort, these include: ƒ Rider arrival speed ƒ Rider weight ƒ Redirection Line Ratio (Only a 1:1 Applies with the ZSIR150-20A) ƒ Zip line slope in the landing area ƒ System friction ƒ...

  • Page 22: Rider Arrival Speed

    ZSIR150-20A - THIS PRODUCT CAN ONLY BE USED WITH 1:1 REDIRECTION SETUPS The zipSTOP IR (ZSIR150-20A) is NOT compatible with external redirection setups in any way. Installing a redirection setup with the zipSTOP IR can create a very dangerous set of braking conditions that could result in abnormally abrupt late braking.

  • Page 23: 1:1 Ratio

    ƒ Maximum rider approach speed of 36 km/h (22 mph) – model ZS125-08 ƒ Maximum rider approach speed of 60 km/h (37 mph) – model ZSIR150-20A In the case of the model ZS125-08: A 1:1 Redirection Ratio is used for zip line installations where low arrival speeds are common.

  • Page 24: 2:1 Ratio

    Although suitable for approach speeds up to 60 km/h (36 mph), typically a 2:1 ratio is employed when approach speeds are less than 40 km/h (24 mph). A 2:1 Ratio is specifically PROHIBITED in any installation of the ZSIR150-20A. Utilizing an external redirection will lead to potentially dangerous and harmful braking dynamics.

  • Page 25: Possible System Configurations (Informative Only)

    8.6 Possible Configurations (Informative Only) 8.6.1 3:1 RATIO 3:1 installation formats are a unique situation and the following information should be used to develop an appropriate site plan. The 3:1 ratio connects the zipSTOP unit to the braking trolley via redirection pulleys and supplementary line. With a 3:1 ratio the braking trolley travels three meters for every meter of zipSTOP line.

  • Page 26: Other Configurations

    8.6.2 OTHER CONFIGURATIONS The zipSTOP Brake assembly may be used with other zip line configurations and higher rider velocities. Con- figurations shown are based on a single line zip line. Dual zip lines and side-by-side configurations may also be accommodated. Please contact your zipSTOP Distributor for information on alternate set-ups. When higher Redirection Ratios (3:1 and higher) are employed (for model ZS125-08 only), retraction force is reduced and a manual reset of the Brake Trolley will be necessary.

  • Page 27: Positive Slope Line

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

  • Page 28: Negative Slope Line

    8.9 Negative Slope Line On negative line installations riders will decelerate within the rider Arrest Zone and may roll backwards at the completion of braking. It is recommended that the platform is positioned to allow all riders to safely dismount. zipSTOP Negative Line Slope Reset...

  • Page 29: Definition Of Terms

    8.10.1 DEFINITION OF TERMS The following terms are used when configuring and installing the zipSTOP Brake assembly: Pivot Length Brake Line Extension zipSTOP Buffer Zone Brake Trolley Rider Arrival Speed Maximum Arrival Speed = ASmax Minimum Braking Distance (BD min) Minimum Arrival Speed = ASmin Maximum Braking Distance (BD max) Reset...

  • Page 30: Zipstop Braking Distance Charts

    Difference between maximum and minimum brak- RIDER BRAKING RANGE ing distances. NOTE: Landing Area will vary depending on rider arrival speed, stopping distances and line slope. RESET POSITION The reset position defines the start of the Arrest Zone and is the location on the zip line the Brake Trolley will return to once the rider is removed.
  • Page 31 2. LINE EXTENSION (LEX) – Line extension is the distance the Braking Line extends out of the zipSTOP brake Unit. If LEX is greater than 12.0m then reduce maximum permissible approach speed (ASmax), permissible rider weight (RWmax) or increase Redirection Ratio (RR). Exceeding 12m runs the risk of an abrupt stop when the webbing reaches its termination as well as damage to the zipSTOP, webbing and other equipment.

  • Page 32: Zipstop Configuration Worksheet

    8.13 zipSTOP Configuration Worksheet Use this worksheet in conjunction with the braking distance charts at the back of this manual. Worksheet must be completed in metric. Read the zipSTOP Brake assembly configuration notes and definitions before completing the worksheet. Distances calculated by this worksheet are based on a flat line with no outside influences such as wind, friction etc.

  • Page 33: Zipstop Brake Assembly Installation

    9. zipSTOP BRAKE ASSEMBLY INSTALLATION 9.1 General Simply put, the zipSTOP Brake is designed to be mounted to a primary anchor point to slow the decent of riders on a zip line. The primary anchor point is exactly what it sounds like; it is the main attachment point for the brake.

  • Page 34: Primary Anchor Point

    ENSURE ALL CABLES, ATTACHMENT LINES AND PULLEYS ARE CORRECTLY ATTACHED AND MAINTAINED TO PREVENT TANGLING, SNAGGING, BINDING AND ABRASION. Ensure that the Redirection Line is routed cleanly and in line through the pulley system, to prevent contact with any surface other than the pulley sheaves. ALL STRUCTURES, SUPPORTS AND ANCHORS MUST BE EVALUATED AND DESIGNED AC- CORDING TO PROPER INDUSTRY AND ENGINEERING PRACTICES.

  • Page 35: Position Of The Secondary Anchor Point

    9.4.1 POSITION OF THE SECONDARY ANCHOR POINT The Secondary Anchor Point is located in line with the start of the Arrest Zone (Brake Trolley Reset Point). It provides the location for the attachment of the Type I Pulley above the zip line and also attachment of any secondary or support lines that may be required.

  • Page 36: Fitting Zipstop Brake Unit

    9.6 Fitting zipSTOP Brake Unit The zipSTOP Brake Unit may be mounted horizontally or vertically. The mounting bracket is designed for use with a flat or curved surface. Curved surfaces must have a minimum 150 mm (6“) diameter. ONLY INSTALL THE ZIPSTOP BRAKE UNIT ORIENTED DIRECTLY INLINE WITH THE TYPE 1 PULLEY The Braking Line feeds straight out of the device, without twist, and centered within the Nozzle.
  • Page 37 Install the RattleStop washers to both sides Install the RattleStop screws to both sides. Tighten the screws on both sides ATTACH MOUNTING BRACKET TO PRIMARY SUPPORT Attach the supplied mounting bracket to the primary support with three (3) M12 or ½” hex head through bolts. The bolt holes are located 100mm (3.94in) apart on center.
  • Page 38 INSTALL ZIPSTOP TO MOUNTING BRACKET Line up zipSTOP Brake Unit with the bottom mounting hole and insert the corre- sponding retaining pin and lynch pin. Swing the zipSTOP Brake Unit up and apply a small amount of pressure against the RattleStop until upper mounting holes align. Fit the upper mounting pin and lynch pin.

  • Page 39: Fitting The Brake Trolley

    9.7 Fitting the Brake Trolley The Brake Trolley is installed on the zip line and is used to transfer the energy of the rider to the zipSTOP Braking Unit. ALWAYS USE THE CORRECT BRAKE TROLLEY SIZE FOR THE ZIP LINE Failure to use the correct size may prematurely wear the trolley or zip line.
  • Page 40 >>…Upper Sheave…>> >>…and top half of the Bump Stop from the Brake Trolley. Place the Brake Trolley on the zip line with the Bump Stop facing the direction of the approaching rider. Refit the upper half of the Bump Stop. Torque to 6 Nm (4.5 lb-ft) Refit the Redirection Line mounting point.

  • Page 41: Fitting Type I Pulley

    ZSIR150-20A - THIS PRODUCT CAN ONLY BE USED WITH 1:1 REDIRECTION SETUPS The zipSTOP IR (ZSIR150-20A) is NOT compatible with external redirection setups in any way. Installing a redirection setup with the zipSTOP IR can create a very dangerous set of braking conditions that could result in abnormally abrupt late braking.

  • Page 42: Fitting Type Ii Pulley

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

  • Page 43: 1:1 Redirection Ratio

    ENSURE THAT THE REDIRECTION LINE IS ROUTED CLEANLY & IN LINE THROUGH THE PULLEY SETUP Contact between Redirection Line and any surface other than the pulley sheaves must be prevented in order to eliminate abrasion and undue wear. The redirection line must remain free and clear of all obstacles, the Arrest Zone and rider travel path.
  • Page 44 Fixed support pulley(s) can be used to ensure that Redirection Lines are kept free and clear. The ZSIR150-20A MUST use a 1:1 redirection line ratio. Position the Brake Trolley at the start of the Arrest Zone (Reset Position) and temporarily secure it at that position.

  • Page 45: 2:1 Redirection Ratio

    FOLLOWING THE INSTALLATION OF THE REDIRECTION LINE ƒ Remove temporary restraint from the Brake Trolley. ƒ Check the Redirection Line to ensure that the Brake Trolley is in the correct Reset Position when zip- STOP Braking Line is fully retracted. ƒ...
  • Page 46 Redirection Lines are kept free and clear. 2:1 AND HIGHER RATIOS CAN ONLY BE USED WITH THE ZS125-08 DO NOT use the ZSIR150-20A in 2:1 or higher configurations. ENSURE THAT THE ZIPSTOP BRAKING LINE IS FULLY RETRACTED INTO THE ZIPSTOP DEVICE...
  • Page 47 Run the Redirection Line towards the zipSTOP Brake Unit, pass the Re- direction Line around the Type II Pulley ensuring it passes through the sheave in the direction of the Secondary Anchor Point. Tension the Redirection Line and connect to the dedicated mounting point on the Secondary Anchor Point using an approved proper termi- nation method.

  • Page 48: Operation Of Zipstop

    10. OPERATION OF zipSTOP 10.1 Safety Precautions ALWAYS CORRECTLY INSTALL, MAINTAIN AND OPERATE THE ZIPSTOP BRAKE ASSEMBLY Failure to do so may result in serious injury or death to participants. ALWAYS OPERATE A ZIPSTOP BRAKE ASSEMBLY WITH AN EMERGENCY ARREST DEVICE (EAD) ACTIVE Failure to do so may result in serious injury or death to participants ALWAYS CARRY OUT UNMANNED TESTING TO DETERMINE ACTUAL BRAKING DISTANCE...

  • Page 49: Zipstop Operation As A Primary Brake

    NSURE BRAKE TROLLEY ALWAYS RESETS TO THE START OF THE ARREST ZONE Failure to reset the Brake Trolley will compromise braking performance and may result in serious injury or death and/or equipment damage. THE BRAKE TROLLEY CANNOT BE TIED BACK IN ANY WAY, BY ANY METHOD, OR BY ANY ACTION DURING OPERATIONAL HOURS Any restriction of the brake trolley during operational hours may result in serious injury or death, or equip- ment damage.

  • Page 50: Operation During Extreme Weather Conditions

    10.5 Operation During Extreme Weather Conditions zipSTOP equipment has been designed for use in a wide range of temperature and weather conditions. Ex- treme heat and cold weather will not alter the performance of the equipment, nor will operations in wet con- ditions, however, the following should be observed: WET LINE WARNING When the line is wet it may slightly alter the performance of the zipSTOP device.

  • Page 51: Operational Retraction Spring Cycle Limit

    Repeated extensions of the webbing near the maximum line extension (12m / 39ft Model ZS125-08, 20m / 65ft Model ZSIR150-20A) will prematurely wear out the retraction spring and may void the warranty. Extremely high throughput facilities may be required to send their devices in for recertification more frequently than the annual requirement.

  • Page 52: Troubleshooting

    11. TROUBLESHOOTING Use this information to assist in troubleshooting problems that might occur during operation. If a problem can- not be resolved, remove components from service and contact your Head Rush Technologies Service Center. SYMPTOM POTENTIAL CAUSE RESOLUTION In most cases your redirection point has been established. Hopefully this distance correlates to the performance of the brake you wanted to Pivot height is too achieve.
  • Page 53 SYMPTOM POTENTIAL CAUSE RESOLUTION Check your pulleys to ensure that the sheaves are operating smoothly and without drag. Also ensure that all your angles to and from all redirection pulleys are straight and that the brake trolley angle is parallel to its im- mediate redirection point.
  • Page 54 SYMPTOM POTENTIAL CAUSE RESOLUTION Auxiliary Retraction Devices are not recommended. Occasionally extreme 2:1 installations or 3:1 or greater installations will have alternative clothes- line type reels or weight assisted retraction devices to help facilitate auto- Braking matic reset. These devices RADICALLY alter the brake application forces and add to the brake resistance of the zipSTOP.
  • Page 55 SYMPTOM POTENTIAL CAUSE RESOLUTION Check your pulleys to ensure that the sheaves are rotating smoothly and without drag. Also ensure that all your angles to and from all redirection pulleys are straight and that the brake trolley angle is parallel to its im- mediate redirection point.

  • Page 56: Before You Call

    SYMPTOM POTENTIAL CAUSE RESOLUTION If the prevailing wind is particularly a crosswind, the redirection lines can be pulled way out of alignment with the redirection points increasing friction and drag in the system. Where possible, wind should be shielded or blocked or lines shortened to minimize side wind loading on the redirection assem- bly.

  • Page 57: Recertification And Maintenance

    12. RECERTIFICATION AND MAINTENANCE 12.1 General Complete inspection and servicing of the zipSTOP unit, Brake Trolley, and associated pulleys and lines in ac- cordance with the Service Schedule. Service actions are detailed in their relevant sections. 12.2 Annual Recertification DO NOT OPERATE THE ZIPSTOP BRAKE UNIT AFTER THE DATE SHOWN ON THE CERTIFICATION LABEL Operation of the zipSTOP Brake Unit without a current Certification Label visible will render the unit not fit for use and will void all warranty.

  • Page 58: Daily Inspections

    NO UNAUTHORIZED SERVICING Do not attempt to carry out any maintenance, repair or service actions not detailed in the User Manual. ipSTOP unit, Brake Trolley, and asso- Any unauthorized maintenance, repair or modifications to the z ciated pulleys and lines will compromise safety, render the unit not fit for use, and void the warranty provisions.

  • Page 59: Webbing Wear

    The zipSTOP Brake Unit and Braking Line, Brake Trolley, Redirection Line and associated hardware must be in- spected on a daily basis for condition and correct operation. The single most important aspect of safe zip line operation is a daily inspection. Example log sheets are included in Section “Appendix C: Example Inspection Logs”.
  • Page 60 WEAR TABLES Webbing pictures outlined in in the tables below show webbing that MUST be taken out of service and replaced immedi- ately to continue using your zipSTOP. The green outlined photos show webbing that can be kept in operation. zipSTOP Degree of Wear Side Wear...
  • Page 61 WEAR TABLES Webbing pictures outlined in in the tables below show webbing that MUST be taken out of service and replaced immedi- green ately to continue using your zipSTOP. The outlined photos show webbing that can be kept in operation. zipSTOP IR Degree of Wear Side Wear...

  • Page 62: Braking Line Replacement Procedure

    The troubleshooting webbing failure table below describes the symptoms, potential causes, and potential solutions of webbing failure. TROUBLESHOOTING WEBBING WEAR Symptoms Potential Causes Potential Solutions Ensure that the zipSTOP is mounted according to Op- zipSTOP is mounted incorrectly erator Manual. Make sure that the zipSTOP is pointed at your redirection point with no large offset.
  • Page 63 To replace the Braking Line: Remove the zipSTOP Brake Unit from service and place securely on the work bench. 2. Remove the Nozzle assembly – Refer to Section “Remove Nozzle Assembly”. 3. While holding zipSTOP Brake Unit securely, pull out the Braking Line until the end of the Drum Lead and the Shackle Link are exposed.

  • Page 64: Brake Trolley Inspection And Maintenance

    9. Tighten the Shackle Pin to 2 Nm (18 lb-in), ensuring the threads are fully engaged and the end of the pin is flush with the Shackle Link as shown. 10. Remove the Holding Pin and allow the new line to slowly retract until Drum Lead and Shackle Link are inside casing ONCE SHACKLE PIN IS TIGHTENED IT MUST NOT BE LOOSENED OR RETIGHTENED This will break the locking compound and the shackle pin may become loose.

  • Page 65: Webbing Line Inspection

    12.8 Webbing Line Inspection BRAKING LINE MUST BE REPLACED IMMEDIATELY IF IT IS WORN OR DAMAGED OR AT 12 MONTH INTERVALS, WHICHEVER COMES SOONER Failure to do so may result in equipment failure, serious injury or death to participants. The Braking Line is the line that extends during the zipSTOP activation. The inside end of the Braking Line attaches to the zipSTOP Brake Unit via a Shackle Link to assist with ease of replacement.

  • Page 66: Braking Distance Charts

    13. BRAKING DISTANCE CHARTS CAUTION Always complete unmanned testing to determine actual braking distances and allowable swing up of rider at given weight and arrival speed. Riders stopping too abruptly will swing up and potentially contact the cable. Do not operate the zipSTOP with an excessive amount of rider swing up. Calculated braking distances shown on charts are for guidance use only.

  • Page 67: 1:1 Ratio - Metric, Zsir150-20A

    13.2 1:1 Ratio – Metric, ZSIR150-20A Braking Distance(m) vs. Arrival Speed(kph) vs. Rider Weight(kg) Braking Distance (m) vs. Arrival Speed (km/h) vs. Rider Weight (kg) zipSTOP IR zipSTOP IR Weight (kg) Weight(kg) Arrival Speed (km/h) Arrival Speed (kph) 13.3 1:1 Ratio – Imperial, ZSIR150-20A Braking Distance(ft) vs.

  • Page 68: 1:1 Ratio - Metric Zs125-08

    13.4 1:1 Ratio – Metric ZS125-08 BRAKING DISTANCE BRAKING DISTANCE 1:1 Reduction Line Ratio 1:1 Redirection Line Ratio BDmin BDmin Rider Weight (kg) Rider Weight (kg) Arrival Speed (kph) Arrival Speed (kph) 13.5 1:1 Ratio – Imperial ZS125-08 BRAKING DISTANCE BRAKING DISTANCE 1:1 Reduction Line Ratio 1:1 Redirection Line Ratio...

  • Page 69: 2:1 Ratio - Metric, Zs125-08

    13.6 2:1 Ratio – Metric, ZS125-08 BRAKING DISTANCE BRAKING DISTANCE 2:1 Reduction Line Ratio 2:1 Redirection Line Ratio BDmin BDmin Rider Weight (kg) Rider Weight (kg) Arrival Speed (km/h) Arrival Speed (kph) 13.7 2:1 Ratio – Imperial, ZS125-08 BRAKING DISTANCE BRAKING DISTANCE 2:1 Reduction Line Ratio 2:1 Redirection Line Ratio...

  • Page 70: 3:1 Ratio - Metric

    13.8 3:1 Ratio – Metric NOTE 3:1 braking charts are available by contacting Head Rush Tech directly. 13.9 3:1 Ratio – Imperial NOTE 3:1 braking charts are available by contacting Head Rush Tech directly. www.headrushtech.com +1-720-565-6885...

  • Page 71: Appendix A: Ead Warranty/Registration Form

    14. APPENDIX A: EAD WARRANTY/REGISTRATION FORM Correct installation procedures as well as the signed and returned registration form below is required for all warranty requests. Incorrect installation or non-registration will void the manufacturer’s warranty (see Section “Warranty Information” for details). 14.1 Warranty Registration Form zipSTOP Model #: Serial #:...

  • Page 72: Appendix B: Accessories And Replaceable Parts

    15. APPENDIX B: ACCESSORIES AND REPLACEABLE PARTS The zipSTOP Brake assembly is fitted with a number of user-replaceable parts and upgrades that may be refit- ted without returning the device to an authorized Head Rush Technologies Service Center. Always follow the manufacturer’s instructions as detailed in this manual when undertaking replacements or upgrades.

  • Page 73: Specifications

    Trolley contacts the Brake Trolley, the Catch Wire captures the Hook so that a rider arriving short of the plat- form can easily be recovered by reeling in the brake trolley. Use of this accessory eliminates the need for an operator to go out onto the line to retrieve stranded riders, increasing throughput.
  • Page 74 DO NOT REUSE NYLOCK NUTS Nylock nuts are a single use item. Reuse of the item will compromise the nuts locking power and render it susceptible to backing out. 2. Gently separate the two backing plates and slip over the zip line. Do not detach the Catch Wire from the backing plates.
  • Page 75 4. In order to function properly, the Catch Wire must be horizontal when the Brake Trolley Assembly is fully reset. If using an offset redirection point, rotate the Backing Plate and Catch Wire Assembly such that the Wire is horizontal when reset. If using a directly overhead redirection point, the Catch wire will be perpendicular to the Brake Trolley side plates.

  • Page 76: Operation

    Offset Redirection Point 5. Ensure the Catch Wire rotates freely. Do not rotate the Catch Wire past vertical to prevent damage to the torsion springs. FAILURE TO INSTALL AND INSPECT THE BRAKE TROLLEY CATCH ACCESSORY ACCORDING TO THE PROVIDED SPECIFICATIONS MAY RESULT IN SERIOUS INJURY OR DEATH OF A PARTICIPANT Any indication of the Brake Trolley Catch Accessory or associated hardware being out of specification man- dates the immediate removal of the device from service.
  • Page 77 Upon arrival at the platform, disconnect the rider from the Impact Trolley and remove the primary and backup cara- biners. Push forward, rotate the Impact Trolley and Hook to the side, then pivot up to remove the Hook from the Catch Wire.
  • Page 78 Rotate Trolley Pivot Up Remove Trolley UNSAFE OPERATION Remove the Brake Trolley Catch Accessory from service immediately if there is any concern over its correct operation or user safety. Do not return the Brake Trolley Catch Accessory to service until it has been inspected and tested by an ap- proved Head Rush Technologies Service Agent.

  • Page 79: Zipstop Brake Unit Side Cover Replacement

    ENSURE RETRIEVAL ROPE DOES NOT BECOME ENTANGLED Always ensure the retrieval rope used in conjunction with this device does not become entangled with trolley path, any fixed object, including the zip line, or the rider. Entanglement with a fixed object may prevent the brake trolley traveling over the entire braking distance.

  • Page 80: To Refit The Nozzle Assembly

    1. Nozzle Assembly 2. Remove Nozzle Pin 3. Lift out top half 4. Lift out bottom half Inspect the Nozzle assembly for: ‚ Splitting, cracking and deformation around slot and mounting flanges. ‚ Correct fitment in housing. 15.2.8 TO REFIT THE NOZZLE ASSEMBLY: ENSURE THAT THE BRAKING LINE FEEDS SQUARELY AND WITHOUT TWISTS WHEN RETRACTING BACK INTO THE BRAKE UNIT Failure to do so may result in equipment failure, serious injury, or death to participants.

  • Page 81: Brake Trolley Bump Stop Replacement

    3. Fit pin 4. Assembled Nozzle Refit the lower half of the Nozzle assembly into the recess on the casing. 2. Fit the upper half of the Nozzle assembly. 3. Insert pin into nozzle halves. 4. Check zipSTOP for correct operation. 5.

  • Page 82: Composition

    THE ZIPSTOP PIVOT MOUNT IS NOT DESIGNED OR INTENDED FOR USE WITH ANY OTHER DEVICE The zipSTOP Pivot Mount has been specifically engineered for safe use with only the zipSTOP line of devices. Both zipSTOP and zipSTOP IR Zip Line Braking devices can utilize the Pivot Mount, but the Pivot Mount must be used without any external redirection (i.e.

  • Page 83: Installation

    15.3.3 INSTALLATION The following parts are included in the zipSTOP Pivot Mount kit: 1. 1 x Left Pivot Mount Plate 2. 1 x Right Pivot Mount Plate 3. 2 x Center Plate Spacer 6. 8 x 5/8”-11 Stainless Steel 4. 4 x 3/16” O-Ring 5.
  • Page 84 Inspect all components for damage, cracks, or corrosion prior to installation. Assemble according to the fol- lowing diagram: 5. Upper Spacer 9. 3 x 5/32” Cotter Pin 1. Left Pivot Mount Plate 2. Right Pivot Mount Plate 6. 8 x 5/8” SS Washer 10.

  • Page 85: Performance

    15.3.4 PERFORMANCE Use zipSTOP Braking Distance charts in the zipSTOP Operator’s Manual and the diagram below to determine braking distances and performance. Due to the direct connection between the unit and the brake trolley in the zipSTOP Pivot Mount setup, the braking distances may be shorter than in the zipSTOP Braking Distance charts. Use the zipSTOP Braking Distance charts only as a starting point for tuning performance and braking distance as external and installation factors can change performance.

  • Page 86: Inspection Procedures

    perature and weather conditions. If a component is found to be damaged or worn during inspection, replace- ment parts are available from Head Rush Technologies and Authorized Service Centers. 15.3.6 INSPECTION PROCEDURES Weekly Inspection: Prior to installation and operation of the zipSTOP Pivot Mount, it should be fully inspected according to the procedure below.

  • Page 87: Appendix C: Example Inspection Logs

    16. APPENDIX C: EXAMPLE INSPECTION LOGS Inspections are the single most important step in ensuring correct operation and rider safety. Logging your inspections will help to ensure rider safety and provide an accurate way to track issues and determine correc- tive actions.
  • Page 88 SAFETY INSPECTION CHECKLIST SITE NAME ZIP LINE INSPECTED: INSPECTED BY: DATE: CORRECTIVE ACTION ITEM PASS FAIL / NOTES – DATE DAILY Visually inspect the zipSTOP Brake Unit for damage, corrosion, and loose fittings and fasteners. Inspect the zipSTOP Brake Unit mounting bracket and pins for damage and ensure that it remains secured correctly.

  • Page 89: Manufacturer's Details

    17. MANUFACTURER’S DETAILS Replacement parts for the zipSTOP and other related products can be purchased at store.headrushtech.com or from an Authorized Head Rush Technologies Distributor. Return the zipSTOP to the manufacturer at the address shown below for any replacement or unscheduled service or repairs.
  • Page 90 REGISTER YOUR DEVICE Get automatic updates on recertification and product information – visit headrushtech.com/register ANNUAL RECERTIFICATION IS REQUIRED Please keep the shipping box for your device. For instructions on annual recertification, visit headrushtech.com/recertification +1-720-565-6885 www.headrushtech.com info@headrushtech.com Jun 2017...

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Zs125-08

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