Installation Information

This section contains articles and information regarding the proper mounting,  installation and servicing of the zipStop zipline brake system.

Easy To Follow Brake Assembly Instructions

 

ZipStop Assembly Instructions

General

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

Safety Precautions

Professional Design, Engineering and Testing of the complete braking system is always required. The Complete Brake System for zip Lines consists of all brakes employed, including Primary and Emergency Brakes. Any braking installation, including the implementation of zipSTOP, must be professionally designed, inspected and tested prior to the system being put into operation. Failure to do so may result in serious injury or death to participants.

Failure to correctly install or maintain a zipSTOP Brake Assembly may result in serious injury or death to participants.

Always install an emergency brake. An independent primary arrest device is required to safely stop riders in the event of operator error or third party equipment failure.

Avoid contact between rider and rider trolley and/or Brake Trolley. Serious injury may result if rider contacts the rider trolley or Brake Trolley during the braking phase. Always design zipSTOP Brake Assembly installation to ensure rider cannot make contact with, or have any part of their body caught between, the rider trolley and Brake Trolley.

Ensure all cables, attachment lines and pulleys are correctly attached and maintained to prevent tangling, snagging, binding and abrasion. Ensure that the Reduction 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 evaluated by a suitably qualified professional engineer. The act of decelerating a rider at the termination of a zip line can generate extreme loads.

Primary Anchor Point

Always employ the services of a qualified professional engineer to design all anchor points used to support the zipSTOP Brake Assembly. The Primary Anchor Point provides support for the zipSTOP Brake Unit. The anchor point and associated fittings must be of sufficient strength to provide a secure mount and to support all applied loads sustained during zip line operation.

Loads specified are for the zipSTOP Brake Assembly installation only and do not allow for any additional equipment or other loadings applied to the primary mount. The zipSTOP Brake Unit is attached to the Primary Anchor Point using three M12 or ½” fixing bolts.

Secondary Anchor Point

Always employ the services of a qualified professional engineer to design all anchor points used to support ZipSTOP Brake Assembly.

The Secondary Anchor Point provides support for redirection pulleys and hardware used in the Reduction Line system. The design of the Secondary Anchor Point must be sufficient to withstand all applied loads experienced during zip line operation.

Loads specified are for zipSTOP Brake Assembly installation only and do not allow for any additional equipment or other loadings applied to the secondary mount.

Position of Secondary Anchor Points

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.

Ensure the Secondary Anchor Point and any supporting structure is a sufficient distance from the zip line to prevent contact with the rider.

Always install pulleys so as to prevent any prevent tangling, snagging or binding with other lines or objects, Ensure that the Reduction Line is routed cleanly and in line through the pulley system, to prevent contact with any surface other than the pulley sheaves.

Reduction and Support Lines

Only use a double Figure - Eight knot or approved termination system for all rope connections (sewn eye or swaged eye). Secure all rope ends so they cannot untie. All Reduction Lines and support lines are to be manufactured of specified strength and suitable for all-season outdoor use.

When installing reduction and support lines, use a cable tidy or route lines to ensure that:

  • All lines are installed in such a way as to prevent loose or sagging lines, tangling, snagging or binding with other zip line components.
  • Lines are to be routed to eliminate abrasion and undue wear.
  • All lines are laid out so as not to present a tripping or injury hazard to zip line staff or riders. If necessary use cable tidies.
  • All lines are to be thimbled and whipped or tied with a Double Figure Eight knot.

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 I Pulley. The Braking Line must feed from the device linearly, without twist, and centered within the nozzle. Accelerated Braking Line wear may occur if the line bears onto the nozzle edge.

Do not reuse self-locking nuts Always use new nuts, as reuse of self-locking nuts may compromise connection integrity.

Fit the zipSTOP Brake Unit as follows:

  • Always orient the zipSTOP Brake Unit directly in line with Type I Pulley.
  • Always use through bolts with large washers and self locking nuts.
  • It is recommended that double helix spring washers are located under mounting nuts to allow for movement in primary mount point.
  • Always mount the zipSTOP Brake Unit a sufficient distance from the zip line so that Reduction Lines and pulleys do not interfere with rider.
  • Once the installation is complete, ensure that the zipSTOP Braking Line is not twisted and feeds linearly through the nozzle.