Söll ShockFusion Installer and User Instruction Manual - EN

Sll
Horizontal Lifeline Roof System
Table of Contents
1.0 Purpose.............................................................................................................................................3
2.0 General Requirements, Warnings and Limitations.........................................................................3-5
2.1 General Fall Protection Requirements
2.2 Warnings and Limitations
3.0 Sll ShockFusion Horizontal Lifeline Roof System Components...................................................6-8
4.0 Installation of Sll ShockFusion Horizontal Lifeline Roof System.................................................9-28
4.1 Post to Base Assembly
4.2 Base Installation
4.2.1 Installation of Base to Standing Seam Roofs
4.2.2 Installation of Base to Metal Sheathing
4.2.3 Installation of Base to Membrane and Built-up Roofs
4.2.5 Installation of Base to Concrete Roofs
4.2.6 Installation of Base with Alternate Hardware
4.3 Horizontal Lifeline Assembly and Installation
4.3.1 Installation of Intermediate Brackets to Sll Fusion Roof Posts
4.3.2 Installation of Corner Brackets to Sll ShockFusion Roof Posts
4.3.3 Assembly and Installation of Lifeline and Lifeline End Fittings to Roof Post System
4.4 Installation Inspection
5.0 Use of the Sll ShockFusion Horizontal Lifeline Roof System...................................................28-29
5.1 System Capacity Ratings
5.2 Connecting to and Using the Horizontal Lifeline
6.0 Training............................................................................................................................................30
7.0

Inspection and Maintenance.......................................................................................................30-32

7.1 Inspection
7.2 Cleaning and Storage
7.3 Contact
7.4 Labels
Inspection and Maintenance Log.....................................................................................................33

www.honeywellsafety.com
Thank You
Thank you for your purchase of Miller Fall Protection equipment. Miller brand products are produced to meet the
highest standards of quality at our ISO 9001 certified facility. Miller Fall Protection equipment will provide you with
years of service when cared for properly.
WARNING
All persons installing this equipment must read, understand and follow this Instruction Maunual and any additional instructions provided during installation training
or with the system at the time of shipment. Failure to do so may result in serious
injury or death.
All system users must be provided with this Instruction Manual.
Do not install or use this equipment unless you are properly trained.
These instructions are protected by copyright!
They may not be reproduced and distributed in any ways/by any means
without prior written consent of the author according to Articles 16
and 17 of the German Copyright Act. SPERIAN FALL PROTECTION
Deutschland GmbH & Co. KG will prosecute any violations against this
under Article 106 of the German Copyright Act.
Appointed certified testing agency 0158:

DEKRA EXAM GmbH
Dinnendahlstrae 9
44809 Bochum
Germany
1.0 Purpose
The Sll ShockFusion Horizontal Lifeline Roof System is an advanced surface-mounted horizontal lifeline system for
rooftop applications. It is comprised of energy-absorbing Sll ShockFusion End and Corner Roof Posts, tip-over Sll
Fusion Intermediate Roof Posts, versatile base attachments to accommodate a variety of roof structures, and a selection
of high-quality lifeline components to suit any system configuration--straight or curved. The Sll ShockFusion Roof System minimizes deflection in the lifeline to effectively manage system forces and maintain a safe connection to a variety of
roof designs. The system installs to standing seam, metal sheathing, membrane and built-up roofs and concrete.
The Sll ShockFusion Horizontal Lifeline Roof System meets OSHA 1926.502, OSHA 1910.66 EN 795:1996 class
C and ANSI A10.32. In addition, all system components meet the design requirements as set forth in ANSI Z359.6
and CSAZ259.16-2004. Please note, however, that the system as a whole once installed must be deemed to be
in compliance with these standards by a qualified engineer. Additional documentation specific to the installation is
required. Please reference the standards for applicable requirements.
2.0 General Requirements, Warnings and Limitations

2.1 General Fall Protection Requirements
Equipment must not be altered in any way. Repairs
must be performed only by the equipment manufacturer,
or persons or entities authorized, in writing, by the
manufacturer.
All warnings and instructions shall be provided to

authorized persons/users. Warnings and instructions must
be read and understood prior to using this equipment.
All installers and authorized persons/users must
reference the regulations governing occupational
safety, as well as applicable standards.
Any product exhibiting deformities, unusual wear, or

deterioration must be immediately discarded.
Proper precautions should always be taken to remove

any obstructions, debris, material, or other recognized
hazards from the work area that could cause injuries or
interfere with the operation of the system.
Any equipment subject to a fall must be removed from

service.
All equipment must be inspected before each use

according to the manufacturers instructions.
Never use fall protection equipment for purposes other

than those for which it was designed. Fall protection
equipment should never be used for towing or hoisting.
The user shall have a rescue plan and the means at

hand to implement it when using this equipment.
All equipment should be inspected by a qualified person

on a regular basis.
Never remove product labels, which include important

warnings and information for the authorized person/user.
To minimize the potential for accidental disengagement,

a competent person must ensure system compatibility.
2.2 Warnings and Limitations

The Sll ShockFusion Lifeline roof system is designed
to be installed by Miller approved installers. The installers must have been trained and must be owning a
certificate that guaranties his capability to install these
products in a proper way.
If other personal safety equipment is used as protection against falling or as restraining or rescuing devices
and if such equipment is anchored or fixed on the Sll
ShockFusion Horizontal Lifeline Roof System, corresponding operating instructions of the respective
companies and the instructions for use/user information provided by the relevant manufacturer must be
followed.
System Compatibility
The Sll ShockFusion Horizontal Lifeline Roof System is designed for use with Miller approved components. Substitution or replacement with non-approved
component combinations, sub-systems, or both, may
affect or interfere with the safe function of each other
and endanger the compatibility within the system. This
incompatibility may affect the reliability and safety of
the total system.
Warning!
Before installation, check whether the substructure on

which the Sll ShockFusion Horizontal Lifeline Roof
System is to be fixed can withstand the stresses resulting from a fall (certificate for stability).
A qualified engineer must certify this.
Each user of the Sll ShockFusion Horizontal Lifeline

Roof System has to be equipped with a full-body harness and an approved shock-absorbing lanyard or fallarrester which reduces the maximum dynamic forces
exerting on the user in case of a fall to max. 6 kN. All
instructions and warnings provided with the body wear
and connecting device must be read and understood
before using the equipment.
Manufacturers installation instructions and installation

suggestions as per the EN 795 standard must be followed at the time of installation.
It is essential that the owner of this system has a rescue measures plan, wherein all possible emergencies
that may occur while working are taken into account.
The Sll ShockFusion Horizontal Lifeline Roof System
should only be used for the intended purpose, e.g. not
as a transport anchor or for lifting of loads.
Safety precautions
It is advised that all persons using the Sll ShockFusion Horizontal Lifeline Roof System read this instruction manual carefully before using the device. Actions
contravening this instruction manual put peoples lives
at risk!
For the users safety, it is essential that he is physically fit and not be under the influence of medicines or
alcohol.
For the users safety, it is important that the retailer
provide this manual in respective countrys language if
this system is re-sold in another country.
The operating company of the anchorage device must

ensure that this instruction manual
is either kept at a safe and dry location near the
system
or is always kept at an easily accessible location that
is known to all system users.
Limits of Use
The Sll ShockFusion End and Corner Roof Post is designed to be used within a Sll ShockFusion Horizontal
Lifeline Roof System. It must never be used as a single
anchorage point for a personal fall arrest system.
The operating company must present this instruction

manual at the request of the manufacturer (SPERIAN
FALL PROTECTION Deutschland GmbH & Co. KG or
one of its authorised dealers).
The Sll Fusion Roof Post is designed to be used as

an intermediate (non-corner) anchorage post within
a Sll ShockFusion Horizontal Lifeline Roof System
and also as a single anchorage point for a personal
fall arrest system when the D-bolt anchor is attached.
Always read, understand and follow the Sll Fusion
Roof Anchor Post instructions when using as a single
anchorage point. Do not use the Sll Fusion Roof Post
as an end anchorage in a horizontal lifeline application
unless approved by Miller Fall Protection.
The Sll ShockFusion Horizontal Lifeline Roof System

should be used only by personnel trained to handle this
device safely.
Prevailing accident prevention regulations and safety
guidelines must be followed.
The Sll ShockFusion and Sll Fusion Posts are

engineered for temporary or permanent installation and
must always be installed in an upright position.
Example:
The minimum distance from the ground required for using an EN 354 compliant lanyard having a length of 1.5
m is calculated as follows:
2x length of the coupling element
3,00 m
Maximum plastic deformation of the shock absorber 1,75 m
Safety distance
1,00 m
Maximum deflection of the anchorage device see matrix
____________________________________________
Capacity
The maximum lifeline system capacity varies by system

configuration. In addition, maximum capacity per span
is affected by the span length and connecting device
being used with the system.
Required minimum distance from the ground
Fall Arrest Forces
The Sll ShockFusion Roof System is uniquely engineered to absorb energy minimizing fall arrest forces
imposed on the worker and the structure. Refer to
Figures 12b and 12c in section 4.2.6 for further detail.
Anchorage Requirements
Permissable Direction of Loading
The roof structure that the Sll ShockFusion Roof System is installed to must be capable of supporting those
loads resulting from a possible fall of the users.
Fall Clearance
The Sll ShockFusion Roof System, depending on

base model, is compatible with most industrial roof
designs, including standing seam, membrane, built-up,
metal sheathing, trapezoidal and concrete. For additional requirements regarding specific roof types, refer
to 4.2 Base Installation.
The integrated shock absorber reduces the loads affecting the roof at the end and corner posts to maximum 10 kN.
It is permissable to work on either the inside or outside

of the lifeline system
Ensure that adequate clearance exists in the potential

fall path to avoid striking a lower level or other object.
The potential for a swing fall must be minimized.
Select the position of the anchorage device and the
method of work in such a manner that the free fall and
the fall height are restricted to a minimum.
Environmental Hazards
Use of this equipment in areas where environmental

hazards exist may require additional precautions to limit the possibility of injury to the user or damage to the
equipment. Hazards may include, but are not limited
to, extreme temperatures, caustic chemicals, corrosive
environments, high voltage power lines, explosive or
toxic gases, moving machinery, and sharp edges. Do
not expose the equipment to any hazard which it is not
designed to withstand. Consult the manufacturer in
cases of doubt.
Determine the distance required between the Sll

ShockFusion Horizontal Lifeline Roof System and
the ground or an obstacle by taking into account the
deflection of the rope which depends on the location of
the anchorage device and the type and length of the
coupling element (refer to the example). The maximum
deflection according to the matrix has to be taken into
consideration.
This Chart indicates line deflection in meters when using CE Lanyards

Span
length
[m]
Up to 3
3 to 6
6 to 9.1
9.1 to 12.2
12.2 to 15
15 to 20
Number of
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
Workers
Worker Worker Worker Worker Worker Worker Worker Worker Worker Worker Worker Worker Worker Worker Worker Worker Worker Worker Worker Worker Worker Worker Worker Worker
Max Cable
Deflection
[m]
0,85
0,89
0,92
0,96
1,10
1,14
1,18
1,21
1,30
1,33
1,37
1,41
1,46
1,50
1,54
1,57
1,60
1,77
1,83
1,91
2,10
2,47
2,76
2,91
3.0 Sll ShockFusion Horizontal Lifeline

Roof System Components
Sll ShockFusion
End and Corner Roof Post
(26385/1031362)
45 Corner Bracket
(26388/1031401)
for Connection of Lifeline

to Sll ShockFusion
Corner Posts
Roof
Post
Cable End Swage

(22609/1006701)

to Sll ShockFusion
End Posts
Coiled Shock
Absorber and
Lifeline Anchorage
Swageless Cable End

(23936/1013720)
to Sll ShockFusion
End Posts
Attachment to Base
Swage Turnbuckle with Tension

Indicator (26417/1031403)
90 Corner Bracket
(26387/1031400)
for Connection of Lifeline to

Sll ShockFusion
End Posts

to Sll ShockFusion
Corner Posts
Swageless Turnbuckle with

Tension Indicator (26482/
1031402)
Swage Turnbuckle
(23500/1010550)
for Connection of
Lifeline to Sll
ShockFusion
End Posts

to Sll ShockFusion
End Posts
Cable Lifeline
(22613/
1015900)
Swageless Turnbuckle
(23938/1013722)

Sll ShockFusion
End Posts
Xenon Automatic
Pass-Through Shuttle
(22604/1005709)
6
Sll Fusion Intermediate Roof Post (26386/1031361)

Universal Intermediate Bracket
(23496/1010609)
Attachment for lifeline

guides, D-rings, etc.
for Connection
of Lifeline to Sll Fusion
Intermediate Roof Posts
Bendable Intermediate Bracket

(23510/1010612)
Roof
Post

Sll Fusion Intermediate
Roof Posts
Universal
Intermediate Bracket
with stainless steel cable
guide (25141/1019004)
Attachment to Base

to Sll Fusion Intermediate
Roof Posts
Sll Fusion Premium

Standing Seam Kit
(26404/1031365)
Rivet Kit (26420/1031371)

with Sealing Washers
and Mastic Tape
Sll ShockFusion
Premium Standing
Seam Kit
(26405/1031366)
Sll ShockFusion and

Sll Fusion Standard
Standing Seam Kit
(26450/1031370)
Large Base (26400/1031363)
Sll Fusion Standing Seam Kit

(26407/1031367)
for Standing Seam and Membrane

Roofs
for up to 610 mm Spacing

with Extension Bars and
Clamp Assemblies
Sll ShockFusion Standing Seam

Kit (26406/1031368)
Concrete Expansion
Bolt Anchor Kit
(26447/1031375)
for up to 610 mm Spacing

with Extension Bars, Stiffeners,
Shims and Clamp Assemblies
Toggle Bolt (1 pcs)

(26421/1031372)
for Membrane Roofing
up to 150 mm thick
Multipurpose Base
(26402/1031364)
for Metal Sheathing, Trapezoidal

and Concrete Roofs
Toggle Bolt (1 pcs)

(26422/1031373)
for Membrane Roofing > 150 mm

up to 280 mm thick
4.0 Installation of Sll ShockFusion

Horizontal Lifeline Roof System
WARNING! All information contained in the Sll ShockFusion System Design
Guide must be read and understood before installation of a Sll ShockFusion
Horizontal Lifeline Roof System. Installers must be Miller certified.
Before installation, carefully inspect all components of the system according to the manufacturers instructions
(see 7.1 Inspection).
Some system components may come preassembled. Installation instructions still must be followed to ensure all
components are included and properly assembled. All fasteners and connectors must be checked for correct
alignment and installation and tightened to required specifications.
Hardware provided with product at the time of shipment must be used for proper installation. Base Model 26402
(multipurpose base) may be installed to metal decking or concrete roofs with alternative Miller approved hardware (refer to 4.2.6 Installation of Base with Alternate Hardware). Do not use alternate hardware/parts unless
approved by Miller. All installation instructions must be followed, including any installation instructions provided
with the hardware. Contact Sperian Fall Protection if there are any discrepancies.
4.1 Post to Base Assembly

Post to Base Assembly
1. Ensure that the neoprene washer is set on the bolt extruding from the bottom of the post, as shown in Fig. 1a
2. Insert the bolt of the post through the base.
3.Tighten until snug against base.
4. Use a hinged hook wrench to lock the post on the base plate (1/4 turn after locking by hand).
Fig. 1b - Completely Assembled
Fig. 1a
4.2 Base Installation

Always follow a previously approved site plan and site work rules when installing a Sll ShockFusion Horizontal
Lifeline Roof System.
The roof structure to which the system is being installed must be capable of sustaining the load requirements as
set forth in 2.2 System Warnings and Limitations.
When determining distance from roof edge to install the roof system, it must be verified that the roof structure at
the point of installation is able to sustain the potential fall arrest loads. In addition, fall clearance and the connecting device to be used on the system must be considered.
Proper precautions must be taken to ensure that the installer is not exposed to a fall hazard during the installation process.
4.2.1 Installation of Base to Standing Seam Roofs

(Model 26400)
Standing seam spacing of roof must be determined before attaching clamp assemblies to the standing seam base.
Refer to the Base Spacing Diagram (Fig. 2) for help in determining the rows needed to create the spacing required for
the standing seam roof. Remember that the clamp assemblies are designed to self-center allowing spacing to be offset slightly. Clamp assemblies may be installed to any two of the corner 8.6 mm diameter mounting holes in a row at
each of the four corner locations to accommodate the maximum number of standing seam roofs with various spacing
requirements. Optional extension bars may be used for additional spacing needs (applies to Base Model 26400 only).
Minimum thickness of the metal sheets must be 0,6 mm.
10
Large Base Spacing Diagram
This dimension is for membrane/built-up

roof installation only.
Fig. 2
This dimension is for membrane/built-up roof installation only.
Due to the large number of standing seam roof styles, the following illustrations are provided to set guidelines for
establishing a correct and secure installation. As a general rule, the clamp assemblies should always be installed
to the standing seam as far down as possible below an obstruction (the seam must not be narrower above where
the clamp is closed on the seam). Do not install to sloped portions of a standing seam as the clamp may have the
potential to slip. If in doubt about proper installation to a particular standing seam roof style, contact Sperian Fall
Protection.
Fig. 3a
Correct
Installations
Fig. 3b
Incorrect Installations
NO
If not fully tightened
to required torque
specifications
11
IMPORTANT: For installation of the base to standing seam roofs, the Sll Shock
Fusion End and Corner Roof Posts and the Sll Fusion Intermediate Roof Posts use
different roof mounting assemblies. Be sure to use the capped premium clamp assemblies (26405) for installation of bases to be used with Sll ShockFusion End and
Corner Posts, and use the basic premium clamp assemblies (26404) for installation
of bases to be used with Sll Fusion Intermediate Roof Posts.
12
Installation of Large Base - Model 26400

for Sll ShockFusion End and Corner
Roof Posts
1. Once standing seam spacing has been de
termined, attach one capped premium clamp
assembly (26405) to each of the four corners
of the base as shown in Fig. 4a. Install each
bolt completely through the washer and
base mounting hole and into the corresponding hole in the clamp assembly bar. Do not
tighten until the base is set on the standing
seam roof.
2. Place base with open clamp assemblies
over the standing seams and proceed with
closing and tightening clamp assemblies.
Premium clamp assemblies are designed to
self-center for proper alignment. Standing
seam roofs differ, but in all cases the clamps
must close below the seam obstruction to
ensure that they are properly secured and
will not slip (see Fig. 3a). Torque clamp assemblies to 54 Nm, alternating bolts until all
bolts have achieved the correct torque value.
Note: Once the first bolt has reached 54 Nm,
do not tighten the other three bolts more than
three times each.
Fig. 4a
Fig. 4b
Fig. 4c - Completely Installed
Installation of Large Base - Model 26400

for Sll Fusion Intermediate Roof Posts
Follow the above instructions except use
basic premium clamp assemblies (26404)
and torque to 27 Nm. Reference Figs. 5a, 5b
and 5c.
Fig. 5a
Fig. 5b
13
IMPORTANT: For installation of the large base using extension bars for standing
seam spacing up to 610 mm, the method of attachment and consequently the roof
mounting assemblies to be used are different for the Sll ShockFusion End and
Corner Roof Posts and the Sll Fusion Intermediate Roof Posts. Be sure to follow the
correct procedures for each roof post installed.
Using Extension Bars - Model 26406
with Large Base - Model 26400
for Sll ShockFusion End and Corner Roof Posts
For standing seam roofs with spacing greater than
540 mm and up to 610 mm, extension bars may be
added to the base.
Fig. 6a
1. Place extension bar on the underside of base, aligning holes in base with those on the extension bar.
2. Attach hardware as shown in Fig. 6a. Insert each
bolt through washer, base and extension bar and
attach washer and nut on the underside. Four bolts
must be used on each end of the extension bar (for a
total of eight bolts) for proper installation.
3. Repeat procedure for extension bar on opposite side
of base. Torque extension bar hardware to 27 Nm.
4. Once standing seam spacing has been determined,
attach clamp assemblies to extension bars using
the included stiffener bars, shims and hardware as
shown in Fig. 6b. For the clamp assemblies located
at the ends of each extension bar, install each bolt
(premium clamp assembly) completely through the
washer and corresponding holes in the stiffener bar
(placed horizontally across the ends of both extension bars), extension bar and clamp assembly bar.
For the additional two clamp assemblies attached
in the center of the stiffener bars at each end of
the base, install each bolt completely through the
washer and corresponding holes in the stiffener bar,
shim and clamp assembly bar. A total of six clamp
assemblies are required for proper installation of the
large base with extension bars. Do not tighten until
the base is set on the standing seam roof.
5. Place base with open clamp assemblies over the
standing seams and proceed with closing and tightening clamp assemblies.
Premium clamp assembly
are designed to self-center
for proper alignment.
Standing seam roofs differ,
but in all cases the clamps
must close below the seam
obstruction to ensure that
they are properly secured
and will not slip (see Fig.
3a). Torque clamp assemblies to 54 Nm, alternating
bolts until all bolts have
achieved the correct torque
value.
Note: Once the first bolt
has reached 54 Nm, do
not tighten the other three
bolts more than three times
each.
Fig. 6b
14
Using Extension Bars - Model 26407

with Large Base - Model 26400
for Sll Fusion Intermediate Roof Posts
For standing seam roofs with spacing greater than 540
mm and up to 610 mm, extension bars may be added
to the base.
1. Place extension bar on the underside of base, aligning holes in base with those on the extension bar.
2. Attach hardware as shown in Fig. 7a. Insert each
bolt through washer, base and extension bar and
attach washer and nut on the underside. Four bolts
must be used on each end of the extension bar (for a
total of eight bolts) for proper installation.
3. Repeat procedure for extension bar on opposite side
of base. Torque extension bar hardware to 27 Nm.
4. Once standing seam spacing has been determined,
attach one premium clamp assembly to each extension bar end as shown in Fig. 7b. Install each bolt
completely through the washer and extension bar
mounting hole and into the corresponding hole in the
clamp assembly bar. Do not tighten until the base is
set on the standing seam roof.
5. Place base with open clamp assemblies over the
standing seams and proceed with closing and tightening clamp assemblies. Premium clamp assemblies
are designed to self-center for proper alignment.
Standing seam roofs differ, but in all cases the
clamps must close below the seam obstruction to
ensure that they are properly secured and will not
slip (see Fig. 3a). Torque clamp assemblies to
27 Nm, alternating bolts until all bolts have achieved
the correct torque value.
Note: Once the first bolt has reached 27 Nm, do not
tighten the other three bolts more than three times
each.
Fig. 7a
Fig. 7b
Fig. 7c Completely Installed
15
IMPORTANT: For installation bases to standing seam roofs with the standard clamps,
the Sll ShockFusion End and Corner Roof Posts and the Sll Fusion Intermediate
Roof Posts use the same roof mounting assemblies (Model 26450).
Installation of large Base - Model 26400

for Sll ShockFusion End and Corner Roof Posts
and the Sll Fusion Intermediate Roof Post
Standard clamp assembly (26450) can be used for
standing seam roofs with spacing up to 600 mm.
1. Place the standard clamps (26450) on the standing
seam profile. Do not fully tighten the bolts yet.
2. Place the base plate on top of the clamps and adjust
the clamp position. Connect each standard clamp to
the base plate by installing the two bolts including
washers and nuts (see Fig. 8a). Do not fully tighten
the bolts yet.
3. Tighten the clamp bolts on the side of the clamps.

4. Tighten the bolts connecting the standard clamps to the
base plate.
5. Torque clamp assemblies to 25 Nm.
Fig. 8a
Fig. 8b
16
4.2.2 Installation of Base to Metal Sheating and Trapezoidal Roof

(Model 26402)
Model 26402 (multipurpose base) anchors to flat metal sheathing as well as trapazoid profile/ribbed metal roofs.
Use with Sll ShockFusion End and Corner Roof Posts or Sll Fusion Intermediate Roof Posts does not affect
installation of bases to metal sheathing. Minimum thickness of the metal sheats must be 0,5 mm.
Multipurpose Base - Model 26402
1. Position the base on metal decking such that a row
of 8.64 mm diameter mounting holes aligns with
decking ribs at each of the four base plate corners as
shown in Fig. 9c. Refer to spacing diagram (Fig. 9a)
if needed. Mounting holes must be centered on decking rib crowns. Never align mounting holes over the
rib valleys or on the sloped sides of the decking ribs.
2. With the base in position, drill four 6.4 to 6.6 mm
diameter pilot holes in a row through the decking ribs
at each of the corner mounting locations for a total of
16 holes.
3. Remove the base and place a length of sealing tape
over each of the set of mounting holes on the bottom
of the base plate (see Fig. 9b).
4. Reposition the base on the metal decking aligning
the pilot holes with the mounting holes on the base
plate. Install each of the 16 rivets through the correspondingbase mounting hole and into the sealing
tape and pilot holes in the decking ribs using an appropriate riveting tool.
5. Cover the rivets with the aluminium laminated sealing tape. (see Fig. 9c)
WARNING: All sixteen (16) rivets must be
used to secure the base properly.
17
Fig. 9a
This dimension is for concrete roof installation only.
This dimension is for concrete roof installation only.
Fig. 9c
Fig. 9b
Tolerances, Unless
Otherwise Specified

INCH
.XX
.02
.XXX .005 Angular 1/2
ATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF

OTECTION. ANY REPRODUCTION, IN PART OR IN WHOLE, WITHOUT
S WRITTEN PERMISSION OF SPERIAN PROTECTION, IS PROHIBITED.
Fig. 9d Completely Installed
18
THIRD ANGLE PROJ.
4.2.3 Installation of Base to Membrane and Built-up Roofs

(Model 26400)
Fig. 10a
Mounting holes for membrane/

built-up roof installation.
Base Model 26400 is

designed for installation to flat
membrane covered or builtup roofs. Model 26421 is a
toggle bolt kit for membrane/
built-up roofs with a combined
thickness of up to 150 mm,
while Model 26422 is a toggle
bolt kit for combined roof
thicknesses between 150 mm
and 280 mm. Use with Sll
ShockFusion End and Corner
Roof Posts or Sll Fusion
Intermediate Roof Posts does
not affect installation of base to
membrane or built-up roofs.
Mounting holes for membrane/built-up roof installation.
1. Position the base at the desired location on the roof.

Note: All four mounting holes must be located over the
roof decking. Be careful that mounting holes are not
located directly over a structural roof support or beam
that may interfere with toggle installation. Refer to the
spacing diagram (Fig. 10a) if needed. When ribbed
metal decking is a component in the membrane or builtup roof, the toggle bolts must be located either on the
flat crown surface or the flat valley surface, but must
not be located on the sloped rib surface.
2. With the base in position, use the base as a template
to mark the four mounting hole locations.
3. Remove base and drill test holes with a long 6 mm
drill bit to ensure proper placement of the toggle bolts
to ribbed decking. The drill will deflect if a sloped rib
surface is hit; in which case, the base must be repositioned, mounting holes remarked and new test holes
drilled until an approved installation
location is found.
4. Once test holes are successfully drilled,
set the base aside and drill four 32 mm
Fig. 10c
diamete rholes through the membrane
and into the insulation 25 mm deep.
This hole acts as a counter bore to
properly seat the roof anchor.
5. Then drill four 24 mm diameter holes
in the center of each previously drilled
counter bore hole through the insulation
and into the roof decking.
6. Assemble toggle and nut together and
place below base plate (see Fig. 10b).
Insert bolt through plate and thread into
nut until fully engaged (see Fig. 10c).
Do not leave more than one thread exposed beyond nut as that will interfere
with the toggle function. Do the same
for the other three toggles.
19
Fig. 10b
7. After toggle/nut/bolt are

assembled to plate, place
over predrilled holes and
insert into roof (see Fig.
10d).
8. Shake toggle several
times to flip into horizontal position (see Fig.
10e). Check by lifting
toggle bolt assembly
to make sure toggle is
flipped and does not
come up through holes.
9. Place magnet into 17mm
socket (see Fig. 10f).
Place socket over bolt
and use drill/driver to lift
toggle until contact is
made with the bottom of
the roof (see Fig. 10g).
10. Apply upward force to
keep toggle stationary
while tightening toggle
bolt with drill/driver.
Fig. 10d
Fig. 10e
Fig. 10f
Fig. 10g
20
11. Once toggle is fully drawn up

and seated (see Fig. 10h and
10i), torque to approximately
14-20 Nm. Repeat for other
three toggle bolt assemblies.
12. Apply sealant around each bolt
head. Fill entire open area in the
counter bore of each of the four
holes. Over filling is advised as
it will protect against wear of the
bolt into the membrane due to
foot traffic.
13. If already assembled, remove
the post from the base and
place membrane layer over the
base plate. Make sure that the
hole in the middle of the membrane is align with the hole in
the base which is used to mount
the post (see Fig. 10j)
14. Reassemble the post (refer to
4.1 Post to Base Assembly; see
Fig. 10k Completely installed)
Fig. 10h
Fig. 10i
Fig. 10j
Fig. 10k Completely Installed
21
Note: A roofing contractor

approved for servicing the
membrane should be used
to properly weatherproof
the roof anchor post once
installed.
4.2.5 Installation of Base to Concrete Roofs (Model 26402)

Base Model 26402 is designed for concrete roof installation. Concrete must have a minimum compressive strength
of 20 N/mm (C20/25 to C50/60) and a minimum thickness of 165 mm. Use with Sll ShockFusion End and Corner
Roof Posts or Sll Fusion Intermediate Roof Posts does not affect installation of base to concrete roofs.
Fig. 11a
1. Position the base at the desired

location on the roof.
2. With the base in position, use the
base as a template to mark the four
mounting hole locations as shown in
Fig. 11a.
3. Remove base and drill a 12 mm hole
with a depth of 90mm at each of the
four mounting locations.
4. Clean all debris from each hole using a blow out bulb.
5. Reposition the base on the roof
aligning the mounting holes over the
drilled holes.
6. Then drive an expansion bolt
through the base mounting hole and
into the corresponding drilled hole at
each of the four mounting locations
(see Fig. 11b).
7. Make sure the underside of the
expansion bolt head is flush with the
base plate before tightening. Torque
each bolt to 50 Nm using a 19 mm
socket wrench.
Fig. 11b
WARNING: All four (4) expansion bolt anchors must be used

to secure the base properly.
Fig. 11c Completely

Installed
22
4.2.6 Installation of Base with Alternate Hardware (Model 26402)

Base Model 26402 (multipurpose base) may be installed to metal decking or concrete roofs with alternative Miller
approved hardware. The following graphs must be referenced to ensure that the hardware selected meets the
strength requirements for the anchor application.
Notes:
Roof anchorage strength must be known.
It will be necessary for a design office to study the strength of existing roofs or the prime contractor for a new
building must supply the necessary information. It is essential to check compliance with the required force levels
before any installation takes place.
Shear and tensile strength requirements are per each corner of the base plate (or each side as is the case when
the expansion bolt anchor mounting holes are used in concrete installation.) Figure 12a shows the characteristic
shear strength required for the fasteners corresponding to the anchorage strength requirement. Figure 12b shows
the characteristic tensile strength required for the fasteners corresponding to the anchorage strength requirement
when the base is used with a Sll ShockFusion End/Corner Roof Post; while Figure 12c shows the characteristic
tensile strength required for the fasteners corresponding to the anchorage strength requirement when the base is
used with a Sll Fusion Intermediate Roof Post. Both Figures 12a and 12b must be used in selecting appropriate
fasteners to ensure safe and secure installation of the Sll ShockFusion Roof Post, and both Figures 12a and 12c
must be used in selecting appropriate fasteners to ensure safe and secure installation of the Fusion Roof Post.
If there are any questions in regard to approved hardware and/or the following graphs, Systems Customer Service
of the manufacturer must be consulted before proceeding with installation of bases to be used within the Sll
ShockFusion Horizontal Lifeline Roof System.
(kN per Corner of Base)
Fig. 12a
23
Fig. 12b
Sll ShockFusion Roof Post Distribution of Tensile Forces to Hardware
Fig. 12c
Sll Fusion Roof Post Distribution of Tensile Forces to Hardware
24
4.3 Horizontal Lifeline Assembly and Installation

4.3.1 Installation of Intermediate Brackets to Sll Fusion Intermediate
Roof Posts
Sll Fusion Intermediate Roof Posts will be fitted with either the Universal Intermediate Bracket (Model 23496),
which is designed for straight pass-through lifeline connections and curves of 5 or less, or the Bendable Intermediate
Bracket (Model 23510), which is designed for straight pass-through lifeline connections and curves of 25 or less.
1. Position the bracket over the protruding bolt on the top of the Sll Fusion Intermediate Roof Post.
2. Align the bracket with the intended direction of the lifeline and install washer and nut to bolt. Tighten until fully
engaged and securely fastened.
Fig. 13b - Bendable

Fig. 13a - Universal
Note: The Universal and Bendable Intermediate

Brackets must be set to fixed positioning when
used with the Sll ShockFusion Horizontal Lifeline
Roof System. They can be fixed in the straight up
position as shown or at an angle in 45 increments up to 90 in either direction. To fix the position of the cable support, align the star-shaped
hole in the clevis with the square hole in the cable
support (see Fig. 13c) and angle the support in
the desired fixed position. Insert the bolt completely through the aligned holes. (The bolt must
enter through the side with the star hole.) Attach
the washer and nut. Ensure that the cable support
is properly set in the fixed position; the cable support must never be free-floating when used with
this system.
Fig. 13c - Assembly of

Universal Intermediate
Bracket Set
to Fixed Positioning
Nut Washer
Clevis
Cable
Support
Bolt
Star
to
Square
Cable
Guides
25
4.3.2 Installation of Corner Brackets to Sll ShockFusion Roof Posts

To accommodate curves of 25 to 100 in the lifeline system, two corner brackets are available and attach to Sll
ShockFusion Roof Posts. The 45 Corner Bracket is designed for intermediate curves of 25 to 50, and the 90
Corner Bracket is designed for intermediate curves of 75 to 100.
1. Position the corner bracket below the protruding post attachment.
2. Align the bracket with the intended direction of the lifeline and install bolt and nut. Tighten until fully engaged and
securely fastened.
Fig. 14a
Orienting the Sll ShockFusion End and

Corner Roof Posts with the Direction of the
Horizontal Lifeline
The Sll ShockFusion Roof Post can be reoriented once installed.
The nut that holds the shock absorber component down within the
post, along with the plastic spacer, provides enough gap, to allow
the upper assembly of the post to rotate while the lower post assembly stays in position. Simply grasp the protruding post attachment
(a carabiner or other connecting device may be connected to the
post attachment to assist with the procedure) and rotate until proper
alignment is achieved.
Note:
Bending the cable has to be avoided.
This must especially be adhered to when the cable
is guided through intermediate brackets and corner
brackets.
26
4.3.3 Assembly and Installation of Lifeline and Lifeline End Fittings to

Sll ShockFusion Roof Post System
There are several lifeline end fittings available for the system: the Swage Turnbuckle with Tension Indicator, the
Swageless Turnbuckle with Tension Indicator, the Cable End Swage, and the Swage Turnbuckle. Any combination
of end fittings may be used for the horizontal lifeline roof system as long as one of the end fittings used is the
Swage Turnbuckle with Tension Indicator, which is required for proper tensioning of the lifeline and inspection.
WARNING: Always wear gloves and eye protection when inspecting or installing a cable lifeline.
Cable Swaging
Proper cable swaging is essential to the overall performance of the system. Standard Sll Xenon installer practices
apply for cable swaging. It is recommended that a Swaging Indicator Ring be used on every crimping for inspection
purposes (see 7.0 Inspection and Maintenance). If there are any questions about proper cable swaging, installers
should contact Miller System Customer Service.
Installation of End Fittings to Sll ShockFusion End Roof Posts
1. Attach the end fitting to the end roof post by aligning the clevis of the end fitting with the protruding post attachment on the roof post and installing the supplied shoulder pin (see Fig. 15a).
2. Then secure the shoulder pin by installing the split pin, folding back the ends with flat pliers.
Fig. 15a
Fig. 15b - Swage Turnbuckle

with Tension Indicator
Fig. 15c - Cable

End Swage
Fig. 15d - Swage

Turnbuckle
27
Tensioning Lifeline
IMPORTANT: It is essential that the lifeline be properly tensioned before use. Failure to do so will affect fall clearance requirements and the potential fall forces which may be imposed upon the worker and the system.
Slack must be minimized when installing lifeline throughout roof system. Once system is completely installed, the
lifeline must be properly tensioned.
Every Sll ShockFusion Horizontal Lifeline Roof System is required to have at least one Swage Turnbuckle with
Tension Indicator. Using an open end wrench to prevent the lifeline from twisting while tensioning, rotate turnbuckle
until the required tension is achieved. The tension indicator disk should begin to spin freely when the lifeline is
tensioned properly. DO NOT OVERTENSION.
4.4 Installation Inspection

Once installation is complete, the installer of the Sll ShockFusion Horizontal Lifeline Roof System must perform a
final inspection of all system components and of the system as a whole.

Check all system components for any damage that may have occurred during installation.
Ensure that all system components have been installed using the provided Miller hardware (or Miller approved
hardware) and that all fasteners meet torque specifications.
Inspect the installation of the base to the roof and ensure that the roof structure has not been damaged during
installation. The integrity and strength of the roof structure must not be compromised.
Double-check that there is no missing hardware or components.
Ensure that lifeline has been properly swaged and that swage indicator has not moved.
Check the lifeline tension and tension indicator.
Labels and system required markings and capacity ratings must be present.
Refer to 7.1 Inspection. Sll ShockFusion System installations must be approved by a qualified person.
5.0 Use of the Sll ShockFusion Horizontal Lifeline

Roof System
Before each use, carefully inspect the roof system in addition to all components of the personal fall arrest system
according to the manufacturers instructions.
Ensure that there is sufficient fall clearance below the work surface to avoid hitting a lower level or obstruction.
Avoid working where the connecting device and/or lifeline may come in contact with sharp edges or abrasive
surfaces.
Ensure that all connections within the system are compatible in regards to size, shape and strength.
Use only approved connecting devices to attach to the Sll ShockFusion Roof System.
Follow system capacity ratings.
5.1 System Capacity Ratings

MAXIMUM WORKERS PER SYSTEM:
UP TO 6 WORKERS
Maximum Number of Workers allowed per Span: 4 Workers
28
5.2 Connecting to and Using the Horizontal Lifeline

1. Properly fit the full-body harness. Refer to the donning instructions provided with the harness.
2. Ensure that the structure being worked on is properly
supported before connecting to the horizontal lifeline.
Use necessary fall protection equipment while approaching the horizontal lifeline.
3. If using the Sll Xenon Automatic Pass-Through
Shuttle, install the shuttle to the lifeline by pressing and holding the button on the side of the shuttle
while pushing in on the attachment ring to open the
cable channel jaws. Then insert the shuttle over the
lifeline and release.
Jaws
Press and hold
button
Button
WARNING: Once installed, ensure

that the cable channel jaws are
completely closed and locked.
When closed and locked, the gap
width between the jaws will be
between 1.6 mm and 4 mm maximum
without any load being applied.
Attachment
Ring
Push inward on
attachment ring
Approved Connecting devices
4. Connect one end of the shock-absorbing lanyard or

fall limiter to the back D-ring of the harness and the
other to attachment ring on the shuttle (or directly to
the horizontal lifeline if the shuttle is not being used).
Refer to the instructions provided with the connecting
device. Ensure that all connections are compatible
and that all connectors, such as snap hooks or carabiners, are closed and locked.
5. Once securely attached, the user may proceed along
the lifeline. The snap hook (or connector) of the
shock-absorbing lanyard or fall limiter must remain
connected to the shuttle (or horizontal lifeline) and
the shuttle to the lifeline at all times along the length
of the system. The Sll Xenon Shuttle will self-align
to navigate past intermediate brackets. If the shuttle
is not being used, a two-legged, shock-absorbing
lanyard is required in order to bypass intermediate
brackets while remaining attached to the lifeline at all
times for 100% fall protection.
The Sll ShockFusion System should onlybe

used in combination with the following
safety accessories
EN 355 compliant shock absorber or EN 360
compliant retractable fall arrester
Full body harness and work positioning belt
according EN 358, EN 361.
When used with the Sll ShockFusion Roof
System, the Miller Turbo T-BAK is intended to
be used as a regular retractable lanyard. Do not
"tie-back" onto the horizontal lifeline.
Read and follow all instructions and warnings
provided with the connecting device at the time
of shipment. For application specific questions,
contact Sperian Fall Protection.
Important:
Usage of retractable type fall arresters is allowed
after consulting the manufacturer of the Sll
ShockFusion lifeline only.
NOTE: The shuttle should always be removed from

the horizontal lifeline after use and cleaned and
stored according to the instruction manual of the
shuttle.
Cable
Channel
29
6.0 Training
It is the responsibility of the purchaser of this equipment, the installers, and users to ensure that they are familiar
with these instructions and are trained in the proper use, installation, operation, maintenance and limitations of this
system. Training should be conducted periodically and without exposing the trainee to a fall hazard.
Installers must attend Miller approved system installation training. Only Miller Certified Installers can design and
install a Sll ShockFusion System. Installers have been qualified and trained by Miller trainers to ensure they have
the required knowledge and competence.
If an installer wants to install Sll ShockFusion Systems, Miller by Honeywell is providing online training modules for
those who are familiar with lifeline installation and Installation training sessions for those who have no installation skills.
7.0 Inspection and Maintenance

7.1 Inspection
Sll ShockFusion Systems should be inspected frequently. Inspection interval must not exceed twelve months.
In addition to performing a thorough inspection upon completion of assembly/installation, the system must be visually inspected by the user before each use and inspected by a qualified or competent person on a regular basis, at
least annually. Replace equipment if any of the defective conditions explained in this manual are found.
Inspect entire system for any of the following: bent, cracked,
distorted, worn, malfunctioning or damaged parts; loose
fasteners or missing parts/components; deterioration; deformation; corrosion; signs that indicate the product has been
subjected to a fall arrest; or any other indications of damage/
problems that may affect the integrity and operation of the
product. If in doubt, contact the manufacturer.
Check all fasteners and corresponding torque values to ensure
that the system posts are securely attached to the roof structure (see 4.2 Base Installation). Inspect the condition of the
roof to ensure that it still meets all anchorage requirements.
Inspect the system posts for any signs of possible loading. The
protruding post attachment on the Sll ShockFusion End and
Corner Posts, which is the tongue of the coiled shock absorber
inside the post, will drop when exposed to a load (see Fig.
16a). The Sll Fusion Intermediate Post will tip over when
exposed to a load (see Fig. 16b).
Inspect cable swaging for any signs of slippage. The swaging
indicator ring moves with the cable leaving a gap between the
indicator ring and the swaged end to show when the lifeline
has been exposed to high tension or loading. If there is a gap
(see Fig. 17), the cable swaging has been compromised and
the lifeline must be taken out of service.
Inspect the cable lifeline for cuts, frays, kinks, broken strands
or other signs of unusual wearing patterns. [CAUTION:
Always wear gloves when inspecting wire rope!]
Check lifeline tension. The tension indicator should spin freely
at the proper tension.
Inspect Sll Xenon shuttle for physical damages, deformation, cracks, wear and corrosion. Ensure that the shuttle and
its parts are functioning properly. The attachment ring should
move freely, the button should depress and release to its original position, and the cable channel jaws must close and lock.
Refer to 5.2 Connecting to and Using the Horizontal Lifeline.
Inspect the components of the personal fall arrest system according to the manufacturers instructions.
If the system or any components within the
system do not pass inspection or have been
subjected to fall arrest forces, the system must be
taken out of service until the components in question can be replaced and the system is inspected
by a qualfied person.
30
Fig. 16a - Sll ShockFusion

End/Corner Post:
Exposed to Loading
OK
NO
NO
Fig. 16b - Sll Fusion

Intermediate Post:
Exposed to Loading
OK
NO
NO
Fig. 17 - Swaging Indicator Ring
7.2 Cleaning and Storage

Basic care of all Miller Fall Protection equipment will prolong the life of the unit or system and will contribute toward
the performance of its vital safety function. Periodically clean system components to remove any dirt, paint, corrosives, contaminants, or other materials that may have accumulated. When Sll Xenon shuttle is not in use, store in
a clean, dry, ventilated area, free of exposure to furmes, corrosive elements and environmental effects.
7.3 Contact
For Southern Europe: System Customer Service (Vierzon, France)
Phone: +33 248 53 00 80
mail: lignedevie@antec.fr
For Northern Europe: System Customer Service (Hof, Germany)
Phone: +49 9281 8302 0
mail: soell@sperian.com
31
7.4 Labels
The Sll ShockFusion End and Corner Roof Posts as well as the Sll Fusion Intermediate Roof Posts are labelled
as shown below. These labels contain type denomination and serial number of the posts.
Attach the identification plate at the access points of the system. This plate has to be easily visible.
The identification plate contains the following infor
mation:
Manufacturer
Type denomination: Sll ShockFusion Horizontal
Lifeline System
Refence to the European Standard
Monitoring testing agency
Reference for reading instructions for use
Maximum number of users per system
The installer must additionally fill in the site-specific

information using a permanently legible font:
The name of the installation company
The maximum number of users who can secure
themselves per span simultaneously
Maximum length of the PPE
Maximum line deflection
Next inspection
Installation number of the installer
Length of the system
32
Regular Inspections and Repairs

DATE OF MANUFACTURE:__________________________________________________________
MODEL NUMBER:_________________________________________________________________
DATE PURCHASED:_______________________________________________________________
Date
Reason for the

inspection
(e.g. regular, repair)
Noticed damages /
Stamp / Signature of the
Carried out maintenance /
competent person
Other information
33
Date for the

next regular
inspection
Sperian Fall Protection Deutschland

GmbH & Co. KG
Seligenweg 10
95028 Hof
+49 (0) 9281 83 02 0
+49 (0) 9281 36 26
Sperian is now Honeywell
SE 90
March 2012
2012 Honeywell International Inc.
34

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Sll

Horizontal Lifeline Roof System

Inspection and Maintenance.......................................................................................................30-32

Inspection and Maintenance Log.....................................................................................................33

Appointed certified testing agency 0158:

2.0 General Requirements, Warnings and Limitations

All warnings and instructions shall be provided to

Any product exhibiting deformities, unusual wear, or

Proper precautions should always be taken to remove

Any equipment subject to a fall must be removed from

All equipment must be inspected before each use

Never use fall protection equipment for purposes other

The user shall have a rescue plan and the means at

All equipment should be inspected by a qualified person

Never remove product labels, which include important

To minimize the potential for accidental disengagement,

2.2 Warnings and Limitations

Before installation, check whether the substructure on

Each user of the Sll ShockFusion Horizontal Lifeline

Manufacturers installation instructions and installation

The operating company of the anchorage device must

The operating company must present this instruction

The Sll Fusion Roof Post is designed to be used as

The Sll ShockFusion Horizontal Lifeline Roof System

The Sll ShockFusion and Sll Fusion Posts are

The maximum lifeline system capacity varies by system

Required minimum distance from the ground

Fall Arrest Forces

Permissable Direction of Loading

The Sll ShockFusion Roof System, depending on

It is permissable to work on either the inside or outside

Ensure that adequate clearance exists in the potential

Use of this equipment in areas where environmental

Determine the distance required between the Sll

This Chart indicates line deflection in meters when using CE Lanyards

3.0 Sll ShockFusion Horizontal Lifeline

for Connection of Lifeline

Cable End Swage

for Connection of Lifeline

Swageless Cable End

Swage Turnbuckle with Tension

for Connection of Lifeline to

for Connection of Lifeline

Swageless Turnbuckle with

for Connection of Lifeline

for Connection of Lifeline to

Sll Fusion Intermediate Roof Post (26386/1031361)

Attachment for lifeline

Bendable Intermediate Bracket

for Connection of Lifeline to

for Connection of Lifeline

Sll Fusion Premium

Rivet Kit (26420/1031371)

Sll ShockFusion and

Large Base (26400/1031363)

Sll Fusion Standing Seam Kit

for Standing Seam and Membrane

for up to 610 mm Spacing

Sll ShockFusion Standing Seam

for up to 610 mm Spacing

Toggle Bolt (1 pcs)

for Metal Sheathing, Trapezoidal

Toggle Bolt (1 pcs)