Tornado ORBITER User manual

Tornado International Ltd Ver 3.1 Jan 14
ORBITER MANUAL
ORBITER
User Manual
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 Tornado International Ltd 2014

Tornado International Ltd Ver 3.1 Jan 14
ORBITER MANUAL
Your Serial Number is:
Please quote this number when ordering parts or
seeking telephone assistance.
Company Information:
Telephone
Technical Help (0)121-773-1827 Ask for
Technical
Parts & Accessories (0)121-773-1827 Ask for the
Parts Dept.
Unit Sales (0)121-773-1827 Katie Roberts
Comments: (0)121-773-1827 Stuart Bland
Addresses:
Head Office
Sales & Production
Tornado International Ltd
Unit 20 Stirchley Trading Estate
Hazelwell Road, Stirchley
Birmingham
B30 2PF
United Kingdom
Tel: [phone]
Fax: [phone]
Email: [email protected]
Web: www.tornado-uk.com
A Member of the Tornado International Leisure Group
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ORBITER MANUAL
1.0 Con entions used in this Manual
For clarity the following conventions are used in this manual:
Paragraph Heading Meaning
Tip! Information which will assist in the operation of
ORBITERS.
Note! Information which is important for the correct
operation of ORBITERS.
Caution! Information which is VITAL to avoid injury to
persons or damage to the ORBITERS.
Warning! Information which is VITAL to avoid serious
injury to personnel or the public.
Please take note of the information in shaded areas. If you have any questions with regard
to the correct installation or operation of ORBITER please contact Tornado International
Ltd.
Important – Please Read This!
This manual is provided in good faith and is believed to be accurate. Because Tornado
International have no control over the manner in which the product is used, users should
satisfy themselves that any information or instruction contained in this manual is
appropriate for the conditions under which the product is being operated.
In the interest of product development, Tornado International reserves the right to alter or
modify the product as necessary.
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ORBITER MANUAL
2.0 Site Requirements
2.1 Introduction
ORBITERS are designed to be operated on a flat and level hard surface. This surface may
be of tarmac or Concrete (natural, painted or sealed) Whatever material is used for the
surface it should be remembered that dust raised by the movement of the ORBITERS will
settle on the body and chassis components which will require cleaning more frequently.
To reduce tyre wear the surface should be as smooth as possible. Should you wish to use a
surface of other materials please contact the Tornado International Technical Help
Line. The area should be gently cambered (max 3 degrees) to avoid water remaining on
the surface. An area which slopes must be avoided as this leads to increased vehicle speed
down the slope with implications on safety.
2.2 Orbiter Barrier
A substantial barrier to contain the ORBITERS should be installed. Drawings of a suitable
construction method may be found at appendix A. A removable section of barrier will be
required in order that the ORBITERS may be wheeled out of the area.
2.3 Public Fence
The area should be completely fenced (with gates for the entrance and exit) to avoid
members of the public who have no intention of using the attraction straying into the path
of the cars. The construction method chosen will generally be in sympathy with existing
fencing on the site but due consideration must be given to preventing small children from
entering the area.
The entrance and exit gates should ideally be separate. This avoids any possibility of
people who are entering the area to use the ORBITERS preventing people leaving after
their ride. These gates should be adequately signed (see appendix D) and should ideally
have hinges which allow movement in the appropriate direction. It is vital that the exit
gate be prominently marked when viewed from the inside of the area so that guests may
expedite their exit after their ride. It would be prudent to paint arrows on the floor to help
guide guests to the exit.
The entrance and exit route should be at the same level as the top of the containment
barrier so that guests step down into the operating area and step up out of the area. This
reduces the possibility of guests tripping over the barrier. If this is not possible then the
ORBITER containment barrier must be painted a prominent colour where it passes the
entrance and exit gates to reduce the chances of guests stumbling over it.
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ORBITER MANUAL
2.4 Orbiter Housing
A building should be constructed to provide secure housing when the ORBITERS are not
in use. The battery chargers will also be housed in the same building. The size of the
building will depend on the number of ORBITERS purchased. Don’t forget to allow for
expansion if further ORBITERS are required. Appendix B & C show the dimensions of
the ORBITERS, batteries and chargers. If the area is secure from vandalism then the
ORBITERS may be charged out of doors during the season. This allows the ORBITER to
be moved to the edge of the track at the end of the operational day and the batteries
charged whilst still in the vehicle. If this system is used then the following points should
be considered.
1. A secure location will be needed to store the ORBITERS during the closed season.
1. The chargers will need to be housed in a well ventilated but weatherproof location. If
this is a cabinet it must have a volume of at least double the total volume of the
chargers installed. Provision for adequate cooling air flow over the charger’s heat sink
is vital. The ambient air inside any such charging area must not be allowed to exceed
30 degrees centigrade. See the section “Installation – Chargers” for more details and
appendix B for the charger dimensions.
1. Protective covers must be used to protect the ORBITER overnight. These may be
ordered from Tornado International Parts and Accessories.
2.5 Signage
In order to inform your guests of the correct and safe operation of the ORBITERS clear
and concise signage is essential. At appendix D you will find sample signage in their most
basic form. It is assumed that most locations would choose to have their own signs
manufactured in their corporate style. The wording of the signs at appendix D is provided
for your guidance.
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ORBITER MANUAL
3.0 Introduction
The Tornado ORBITER is a single rider, battery powered free roving vehicle. As
delivered it consists of three basic parts. The ORBITER, the batteries (two per Orbiter)
and the chargers.
Note!
If your ORBITERS are fitted with any optional equipment (e.g. Ridemaster, Hit & Spin)
you should read this manual in conjunction with the supplementary Owners Manual(s)
supplied with the vehicles.
3.1 T e ORBITER
The Orbiter is a single rider battery powered vehicle designed for use in amusement areas.
The chassis is manufactured from mild steel and painted with black powder coat. The
vehicle is surrounded by a pneumatic bumper. This is designed to offer protection to the
vehicle in the event of a collision but it should be noted that the vehicle is not designed as
a “bumper car”. The body is moulded in one piece in glass reinforced plastic. The vehicle
is steered using the two control sticks positioned each side of the seat. These control each
of the motors which drive the main wheels.
The principal features of the ORBITER are shown in Figures 3.1 & 3.1a below.
Fig 3.1 - Orbiter with the body closed
1 - Control Sticks 2 - Coin Entry 3 - Key entry 4 - Pneumatic Bumper
5 - Main Wheels - Castor Wheels 7 – Recessed Body Handle
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ORBITER MANUAL
Fig 3.1a - Orbiter with body open
1 – Control Electronics 2 – Batteries 3 – Battery Holders 4 – Gas Spring
5 – Main Wheels – Battery Connectors 7 – Cash Box 8 – Coin Counter
9 – Bumper Valve 10 – Body Hinge 11 – Hinge retaining Pin 12 – Drive
Gear
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ORBITER MANUAL
3.2 T e ORBITER CONTROL ELECTRONICS
The principal features of the control electronics are shown in Figure 3.2 below.
Fig 3.2 - Orbiter Control Electronics
1 – Number of Coins per Play Selector 2 – Ride Time Selector
4 – Sound Volume 4 – For Use With Ridemaster Only
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ORBITER MANUAL
3.3 T e BATTERIES
The batteries are of the sealed lead acid type. They require no topping up and give off no
gases when in use or when being charged.
The principal features of the batteries are shown in Figure 3.3 below.
Fig 3.3 - The Batteries
1 – Carrying Handles 2 – Battery Lead 3 – Battery Connector
4 – Battery Vents ( off – See Warning below!)
Caution!
The battery vents must not be removed for any reason. The battery is maintenance free and
water must not be added. Removal of the vents or the addition of water to the cells will
invalidate the warranty.
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ORBITER MANUAL
3.4 T e CHARGER
The charging unit is designed to charge four batteries. Each battery is charged
independently of the others. Each output has its own control unit and status indicator
display. The battery charger is a well known commercial unit assembled by Tornado
International into a custom designed case for convenience. The charging units are
completely automatic with no charge rate or time to be set. The charging cycle is set out
below figure 3.4. The principal features of the Chargers are shown in Figure 3.4 below.
Fig 3.4 - The Charger
1 – Battery Charger Units 2 – Battery Charging Lead 3 – Status Indicator
4 – LED Indicators (left side RED for mains power / right side RED or GREEN for
charging status 5 – Battery Station Case – Mains Input Lead
7 – Specifications 8 – Rear Case Vents 9 – Lower Case Vents
10 – Side Case Vents
Bulk Charging
The LED light will show AMBER to indicate that bulk charging is taking place.
Absorption Charging
When the battery is 5% charged the LED light will flash AMBER/GREEN to indicate
that the second stage of charging is taking place.
Float Charging
When the battery is 100% charged the LED light will turn to GREEN to indicate that the
battery is ready for use. The battery can be left connected until it is required for use. A
regulated trickle voltage of no more than 13.8 volts and less than 1 amp of current is given
to maintain the capacity.
Caution!
Connect charger to a mains outlet which has the same voltage and frequency as shown on
the specification label in fig 3.4. Battery charging station must be located in a clean dry
area free from contact with water and dirt. Re-charging must be carried out at an ambient
temperature of 0 deg C to 30 deg C. For extra cable length use only the charging lead
extension cables supplied. Do not use if dropped or damaged, contact Tornado
immediately if in any doubt about the charging operation.
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Illuminations
RED mains power on indicator light. This should always be illuminated when the unit is
connected to mains power.
Charging status indicator light:
AMBER = Bulk battery charging taking place
Flashing AMBER/GREEN = Charging 5% complete
GREEN = Battery ready for use
Caution!
Do not connect a battery to a charger if your charger(s) differ(s) from the above examples
or if you are unsure about the charging process. Please contact Tornado immediately for
assistance.
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ORBITER MANUAL
3.5 T e SEAT BELTS (Optional Equipment)
The seat belts are of identical construction to those fitted to automobiles. They are of the
inertia reel type with a unique shoulder strap aligning system to allow the belts to fit a
large range of drivers.
The principal features of the Seat Belts are shown in Figure 3.5 below.
Fig 3.5 The Seat Belts
1 – Shoulder Strap 2 – Lap Strap 3 - Buckle
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ORBITER MANUAL
4.0 Installation
Note!
If your ORBITERS are fitted with a RIDEMASTER control system you should read this
section in conjunction with the Ridemaster Owners Manual supplied with the vehicles.
4.1 Opening t e BODY
After delivery, place the ORBITERS in the operating area. Attached to the control stick of
one of the ORBITERS will be the keys. Remove these and proceed as below.
Fig 4.1 - Opening the Body
Referring to Fig 4.1 above, insert the body key into the hole at the rear of the body until
resistance is felt. At this point press down on the back of the body (1) and at the same time
push the key in to the stop (2). At this time the body may be opened by lifting (3). The
body will be supported by the gas spring. Carefully inspect the vehicles for any sign of
transit damage. If any damage is present this should be notified to the transport company
immediately and preferably whilst the driver is still present.
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ORBITER MANUAL
4.2 Fitting t e BATTERIES & TESTING
Fig 4.2 - Fitting the Batteries
1 – The Battery 2 – Lifting Handles (See note below) 3 – Battery Holders
1. Place two batteries into an ORBITER. Note the position of the cables as in Fig.4.2 and
connect the batteries.
Note:
The battery handles (2) MUST be folded flat on to the top of the battery after fitting.
1. Set the ORBITER control unit selectors (Fig 3.2) to the required settings.
2. Note the coin counter numbers. (Fig 3.1a-8)
1. Close the body by lowering gently until the body touches the chassis. Then push down
firmly at the top of the headrest until the catch is heard to click.
1. Introduce the required number of coins/tokens into the coin acceptor. Note the time.
After a short delay the sound will be heard.
6. Sit in the ORBITER and test drive around the area. This is a good time to ensure that
the barrier is correctly and substantially constructed.
6. Drive the ORBITER until it times out. Check that this corresponds with the time set on
the Ride Time Selector (Fig 3.2-2)
7. Open the body and check the coin counter has advanced by the correct number.
Tip
The counter will count ALL coins/tokens inserted irrespective of when the ride triggers.
6. Repeat for each ORBITER.
The pneumatic bumpers are shipped inflated to the maximum air pressure of 1 bar. The
pressure should now be adjusted to suit the particular conditions at each site. Using the
valve (Fig 3.1a- ) partially deflate the bumper to provide the maximum impact protection.
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The correct pressure is obtained when two ORBITERS meet head on and the bumpers
deform but do not allow the bodies to come into contact with each other.
Take this opportunity to record the pressure that you have set the bumpers to in this box:
BAR
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4.3 T e CHARGERS
The chargers (Fig 3.4) should be placed on a suitably positioned shelf and a number of
factors must be taken into consideration. The size of the chargers may be found at
appendix B.
1. The chargers are designed to operate indoors only and if not placed in the ORBITER
storeroom they must be protected against any ingress of water.
Warning!
If the chargers are to be located in a position where an operator who may be wet from rain
can touch the case then the chargers must be protected by a residual circuit breaker. If in
doubt contact Tornado International Technical Help.
1. At all times t ere must be a free flow of cooling air over t e c arger case! It is vital
that this precaution is observed. The top of the charger case must not be within 300mm
of any horizontal surface.
1. If chargers are mounted one above the other then a gap of 600mm must be allowed.
1. If the chargers are mounted in any type of box or housing then the volume of the box
must exceed twice the volume of the chargers installed. In addition the minimum
ventilation required is as follows. For convection cooling the vents in the housing must
each be at least equal to the total area of the vents respectively in the chargers
themselves (Fig 3.4). For fan assisted cooling the top and bottom vents in the housing
should be equal to 75% of the total area of the top and bottom vents respectively in the
chargers themselves.
Note:
The volume of a charger is approximately 12 litres. The area of the top and bottom vents
in a charger case is 132 square centimetres each.
5. Attention must be paid to the length of the battery leads (Fig 3.4 items 2) fitted to the
charger. The charger should be positioned in such a manner that the cable will reach the
battery without undue operator effort or strain on the cable. In particular it should be
noted that the batteries are too heavy to be lifted onto a shelf.
Tip:
Battery cable extensions are supplied for each battery charging position. These should not
be altered in any way.
6. Each charger requires either a 110 or 220/240volt 13amp socket. UK chargers will be
supplied with a 13 amp plug. Export models will be set to local voltage and will be
supplied with a local mains plug where available.
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ORBITER MANUAL
5.0 Operation
WARNING
It must be understood that ORBITER is a free running vehicle and as such all steps must be
taken to ensure that it is only used by guests who are of a suitable size and age. To
determine if a guest is large enough to drive ORBITER is easy. The guide is as follows.
With the guest seated in the car and their back against the backrest their arms must reach
the controls without leaning forward. It should be understood that the position of the body
when correctly seated is an intrinsic part of the in–built safety of the ride. To determine if
the guest is old enough to understand the principles behind safe operation of the ride is far
more difficult. It could be assumed that a child of ten or older would have sufficient
understanding to operate the vehicle correctly. However there is great latitude in children’s
development and understanding during the ages of five to twelve. It is suggested that the
decision as to whether a particular child is suitable for this ride should be left to the parent
or adult accompanying the child. It is of course vital that suitable signage is erected in
order to convey these points to such adults. See appendix D.
5.1 DAILY
At the Start of the Operating Period:
1. Check the charging indicators on the front of the charger (Fig 3.4 items 3&4). The
digital display should read 100%, with the GREEN LED illuminated when fully
charged. If the indicators do not show this then notify your supervisor and do not
disconnect the battery.
1. Disconnect the batteries from the chargers.
1. Move the ORBITERS into the playing area and polish and clean the bodies.
1. Open the ORBITER body (Fig 4.1) and carefully place the batteries into the battery
carriers (Fig 4.2). Note the position of the battery leads and ensure that the battery
lifting handles are folded flat against the top of the battery.
Caution!
Exercise care when lifting or moving the batteries. They are heavy! Lift using only
approved techniques keeping your back straight. Be aware of the battery lead and avoid
the plug becoming caught as this might cause a sudden increase in the load. Avoid putting
the battery down on the plug or lead.
5. Connect the battery leads to the ORBITER control electronics (Fig 4.2).
Note:
The ORBITER must always have two batteries connected when in service.
Tip:
Red handles are fitted to aid connecting and disconnecting.
6. Conduct a thorough visual inspection of the chassis.
7. Note the coin counter reading.
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8. Close the body by lowering it gently until it touches the chassis, then push firmly down
on the top of the headrest until a click is heard.
. If seat belts are fitted the shoulder strap (Fig 3.5-1) should be extended as far as
possible. It should then be checked visually for any signs of wear or fraying. The
buckle (Fig 3.5-3) should be checked for correct operation.
10. Coin and test drive each ORBITER.
11. If RIDE MASTER is fitted check the emergency stop function as follows.
a) Referring to t e RIDE MASTER user manual, make a note of the position of
the mode selector (Fig1 item1), and then set to “Session Play – Pay Attendant”.
b) Start all of the ORBITERS by pressing the start button (Fig 3 item 1). Wait for
10 seconds after which all of the sound effects will have started.
c) Press the red emergency stop button (Fig 3 item 4). All of the sound effects will
stop and the start and finish light (Fig 3 items 2&3) will flash.
d) With the emergency stop button still pressed move the control sticks on each
ORBITER in turn. The vehicles should not move. Release the emergency stop
button by rotating the head. All of the vehicles should now drive normally.
e) After the go has finished return the mode selector to the previously noted
position.
If any defects are found notify your supervisor.
At the end of the operating period:
1. Move each ORBITER close to the storage area and open the body.
2. Disconnect the batteries from the ORBITER control electronics and remove from the
battery carrier for charging.
Caution!
Exercise care when lifting or moving the batteries. They are heavy! Lift using only
approved techniques keeping your back straight. Be aware of the battery lead and avoid
the plug becoming caught as this might cause a sudden increase in the load. Avoid putting
the battery down on the plug or lead.
Tip:
The batteries may be charged in the ORBITERS. See section 2.4. Extension leads are
provided.
3. Place the batteries close to the chargers and connect to the charger leads. Note that each
charger unit feeds four batteries but that each battery is charged independently.
Caution!
The battery plug is grey with a red handle and the charger plug is black or black with a red
handle if the extension leads are being used. As you connect the batteries to the chargers
check that each connection consists of one grey and one black plug. Failure to do so may
result in damage to the charger and batteries.
4. Check that there is a reading on each charger status indicator. (Fig 3.4 item 3). If there
is an indicator without a reading, investigate the cause. The chargers are fully automatic
so there are no settings to adjust.
5. Empty the cash box (Fig 3.1a-7) and note the coin counter readings (Fig 3.1a-8). Return
the body to the closed position.
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Caution!
If the batteries are to be charged inside the ORBITER, ensure that the charging leads are
positioned in such a manner that they will not be damaged by closing the body.
6. Remove the ORBITERS to the storeroom or fit the covers if left outside overnight.
5.2 Batteries and Battery C arging
It must be understood that batteries are an expendable item and in this respect are similar
to the tyres and brakes on your car. They will benefit from correct use and be permanently
damaged by misuse or inappropriate charging regimes. There are three areas where you
can have a direct effect on the overall life of the battery. These are, Charging Use and
Storage.
Before we examine the factors relating to battery life, this vital fact must be appreciated.
E ery rechargeable battery lea es the manufacturer with a finite life!
This life is usually expressed in terms of charge/discharge cycles. Each time a battery is
charged and discharged a part of the battery life is used up and cannot be replaced.
5.3 Charging.
Caution!
The battery vents (Fig 3.3-4) must not be removed for any reason. The battery is
maintenance free and water must not be added. Removal of the vents or the addition of
water to the cells will invalidate the warranty.
It is vital to use a quality charger. The charger supplied is a well known commercial
product and is purchased from a respected, proven and worldwide manufacturer. It has
been chosen by us to be used with the dry-fit batteries supplied. Do not charge the
batteries with any other charger and do not use the Tornado chargers on other batteries.
The batteries should be charged at the end of each operating period even if the ORBITER
has only had a little use.
Repeated under charging will lead to reduced battery capacity and premature failure. With
this in mind it is important to charge the battery fully after each use and this will normally
be achieved by overnight charging. Incomplete charging can be diagnosed by charger
displays which are not at 100% at the start of the operating period and a gradual and
progressive reduction of the batteries capacity as evidenced by a reduction in the number
of rides the batteries achieve. If these symptoms are accompanied by late closing and early
opening times then steps must be taken to avoid the premature failure of the batteries due
to undercharging. If the reasons for the undercharging are of a temporary or spasmodic
nature then it is permissible to charge the batteries for a full 24 hours each week of
operation. This can be achieved by charging the batteries in rotation, removing one of the
ORBITERS from service, or by purchasing one pair of spare batteries and a spare charger.
If the reasons for undercharging are continuous then the best solution is to purchase spare
batteries and chargers for each ORBITER.
5.4 Use
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When fitting and removing the batteries handle them with care. Avoid dropping them into
the ORBITER or onto the floor. Dropping the battery will cause the plates to deform with
the result that some cells will become useless. Do not allow the ORBITER to be used with
discharged batteries. Customer satisfaction will be reduced as will the battery life. Charge
the batteries or remove the ORBITER from service as soon as the vehicle speed is visibly
reduced. Do not part charge and re-use the batteries as this will lead to premature failure.
5.5 Storage
If the ORBITERS are to be removed from service the correct storage of the batteries is
vital. As soon as the batteries are removed from service they should be charged for
24hours. They should then be stored in a FROST-FREE place and be charged for 24hours
each month of storage. Failure to follow these instructions will result in permanent
damage to the batteries.
5.6 Summary
1. Only use the chargers supplied.
2. Charge the batteries at the end of each operating period.
3. Do not allow repeated undercharging.
4. Remove batteries from service before they are completely discharged and recharge
immediately.
5. Charge for 24hours before storage and recharge for 24hours for each month of storage.
6. Store in a FROST-FREE place.
7. Handle the batteries with care.
8. Keep the terminals and plug clean.
. Do not remove the vents, or add water to the cells.
The batteries are expensi e. It pays to look after them!
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