Alert for ZIGZAG®,ZIGZAG®PLUS, ZILLON

Updated 1/1/2023 - CLOSED

Download PDF Alert Notice from Petzl Australia

Petzl have received reports from users experiencing rope slippage while using the ZIGZAG®, ZIGZAG® PLUS and ZILLON. Following these reports, they have identified two defects causing the slippage. Petzl, therefore, ask users to do a manual inspection and a function test of your product to detect any possible slippage. In case your product slips, we are providing details on the Australian after-sales returns service.

Products involved:

ZIGZAG (D022AA00), ZIGZAG PLUS (D022BA00), ZILLON (L22A 025, L22A 040, L22A 055) with serial numbers between 18L 0000000 000 and 21G 0000000 000.

Customer returns alerted us to slippage with new or slightly used ZIGZAG / ZIGZAG PLUS / ZILLON products. Following our technical investigations, we were able to identify the causes of the slippage. They related to a variance in our production process, resulting in two types of defects in the release levers on ZIGZAG, ZIGZAG PLUS and ZILLON:

• random malfunction of the spring effect of the upper release lever,
• variance in the surface treatment resulting in a modification of the geometry of the release lever.

This production variance causes premature wear on the release levers, resulting in slippage that can be observed after a few months of use, or even on new products.

Petzl has advised three actions:

1. Stop sales of current products. Petzl are working to solve the problem and we are now receiving updated products.
2. A request for inspection by end users of their product by following the two specific points of the PPE inspection procedure.
3. An Exchange offer to redress the inconvenience caused by the slippage of your product after user performs the tests detailed herein. In Australia we now offer end users an exchange of their product via petzl.com.au 

Note: devices must fail the following inspection and test, and will not be replaced if slipping occurs due to excessive wear and tear from use.

PPE Inspection points to carry out on your ZIGZAG / ZIGZAG PLUS / ZILLON product: 

1. Inspecting the release levers
   
   
   
   
   
   Check the effectiveness of the upper release lever return spring (1) and the mobility of the lower release lever (2) for ZIGZAG, ZIGZAG PLUS. Repeat the test at least ten times. The levers should move freely without friction.
   
   If the results of these tests are not satisfactory, immediately stop using your product and return your product via the methods described above. If the levers work, proceed to the next inspection point.
   
   
   
2. Function Test
   
   ZILLON: Hang on to the lanyard in single mode at a very low height: there should be no slippage. When used in double mode, verify that pressure on the release lever allows smooth and controlled sliding of the rope.
   
   
   ZIGZAG / ZIGZAG PLUS: perform a function test with your rope (compatible ropes: 11.5 to 13mm ø).
   Install the ZIGZAG in double mode. Suspend yourself at a very low height.
   
   

   When hanging from the ZIGZAG in double mode, there should be no slippage. Verify that pressure on the release lever allows smooth and controlled sliding of the rope.

   If the results of these test are not satisfactory, immediately stop using your product and return your product by contacting using the relevant method, if the devices passes the tests there is no need to return and it can be continued to be used.

If you have any doubt about the results of these tests, contact us by lodging a Support Request. These inspection points are in no way a substitute for a complete PPE inspection of your product following the procedure available on www.petzl.com.

• ZIGZAG / ZIGZAG PLUS PPE inspection procedure (PDF)
• ZILLON PPE inspection procedure (PDF)

To find your serial numbers:

As mentioned this Inspection Request is for the below products with serial numbers in the range 18L 0000000 000 and 21G 0000000 000.

To download a copy of this information:

Please click here to download this Alert Information for 🇦🇺 end users. 

Australian Return Process:

NOTE: In order to return the device it must fail the (1) inspection and (2) function test detailed in this notice. Devices will not be replaced if slipping occurs due to excessive wear and tear from use.

It has come to our attention that some units returned are slipping not due to the faulty manufacturing in the top two levers. We have found heavy usage where high rates of use on contaminated, unclean, ropes will wear out the friction areas and creates slippage. This is particularly the case when using the thinner Ø ropes like 11.5 and 11.7mm due to the smaller friction area.

If your device looks similar to the images below highlighting the wear, then your device is not faulty and is worn out and needs to be replaced.

This is a limited time exchange offer, If your product’s serial number is between 18L 0000000 000 and 21G 0000000 000 and slips when tested as requested in our information, devices worn by excessive use will not be replaced. You have until December 31, 2022 to return your product.

For more questions, see Petzl FAQ's on petzl.com.au - this offer expired 31/12/2022. Original post from petzl.com