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Tornado ORBITER, User Manual

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Tornado ORBITER User Manual Download Page 10

Tornado International Ltd

Ver 3.1 Jan 14

ORBITER MANUAL

3.4    The 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     6 – 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 95% 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.

1N00-962

Page 10

 Tornado International Ltd 2014

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Summary of Contents for ORBITER

Page 1: ...Tornado International Ltd Ver 3 1 Jan 14 ORBITER MANUAL ORBITER User Manual 1N00 962 Page 1 Tornado International Ltd 2014 ...

Page 2: ...21 773 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 0 121 773 1827 Fax 0 121 772 6056 Email sales tornado uk com Web www tornado uk com A Member of the Tornado International Leisu...

Page 3: ...ake 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 a...

Page 4: ...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 po...

Page 5: ...osed 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 Instal...

Page 6: ...e 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...

Page 7: ...1a Orbiter with body open 1 Control Electronics 2 Batteries 3 Battery Holders 4 Gas Spring 5 Main Wheels 6 Battery Connectors 7 Cash Box 8 Coin Counter 9 Bumper Valve 10 Body Hinge 11 Hinge retaining Pin 12 Drive Gear 1N00 962 Page 7 Tornado International Ltd 2014 ...

Page 8: ...L 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 1N00 962 Page 8 Tornado International Ltd 2014 ...

Page 9: ...ures 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 6 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 1N00 962 Page 9 Tornado...

Page 10: ... light will show AMBER to indicate that bulk charging is taking place Absorption Charging When the battery is 95 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...

Page 11: ...harging status indicator light AMBER Bulk battery charging taking place Flashing AMBER GREEN Charging 95 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 1N00 962 Page 11 Tornado International Ltd 2014 ...

Page 12: ...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 1N00 962 Page 12 Tornado International Ltd 2014 ...

Page 13: ...ese 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 ...

Page 14: ...uired 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 t...

Page 15: ...re 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 1N00 962 Page 15 Tornado International Ltd 2014 ...

Page 16: ...rs 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 ...

Page 17: ... 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 fr...

Page 18: ...ify 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 an...

Page 19: ... 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...

Page 20: ...f 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 ...

Page 21: ...With the body open check the following 6 2 The condition of the body hinge assembly at the front of the chassis Fig 3 1a 10 a Check for any signs of bending or deformation b That there is no sign of rust around the hinge pin c That the retaining pin is correctly in place Fig 3 1a 11 d That there is no sign of delimitation of the hinge plate from the body moulding 6 3 The condition and operation of...

Page 22: ...gas spring is noted it must be changed Proceed as in Chapter 7 9 6 4 Check the condition of the body retaining catch as follows a Close the body gently It should then take a firm push on the top of the head restraint to lock the catch An audible click should be heard After the catch is latched correctly it should not be possible to open the body by lifting If necessary the catch may be adjusted as...

Page 23: ...epeat for the other side 6 7 Check the condition and security of the castors as follows a Using a suitable block of wood raise the rear of the ORBITER so that the castor can be rotated freely b Rotate the wheel and listen for any sound of rough running A dry sound may be remedied by greasing proceed as per Chapter 7 6 c Rotate the whole castor and listen for any sound of rough running A dry sound ...

Page 24: ...e the loom passes through any securing device 6 10 Check the condition of the batteries and Battery Looms as follows a Remove the batteries from the ORBITER Do this even if the batteries are normally charged in the car 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 p...

Page 25: ...charged or part discharged battery connect to each charger in turn Note the status indicator at each position and that they are the same c If any malfunction is noted the charger should be returned to Tornado International Ltd for repair 6 12 Check the condition and operation of the seat belts if fitted as follows a Visually inspect the webbing straps Fig 3 5 items 1 2 for any signs of fraying The...

Page 26: ...quired and order them from Tornado International NOW b Thoroughly clean the body and chassis c Apply a good polish to the body and treat any damaged paint on the chassis d Deflate the bumper to 0 25 bar e Ensure that the batteries are removed from the ORBITER f Store the ORBITER in a dry well ventilated place Cover with clean sheets Do not use the overnight covers for extended storage g Store the ...

Page 27: ...irm push on the body is required to engaged the catch Proceed as follows 1 Remove the batteries from the ORBITER and close the body 2 Lift the ORBITER to the vertical position with the catch at the top have a colleague hold the ORBITER in this position 3 Loosen the chassis bar lower adjustment nuts Fig 7 1 5 4 Slide the bar in the direction A in Fig 7 1 to place the bar in the centre of the body c...

Page 28: ...m the ORBITER Leave the body open Support the ORBITER above the floor by 400mm Axle stands are ideal for this Disconnect the motor lead from the loom Fig 7 2 1 Remove the inner retaining nuts Fig 7 2 3 The bolts are welded into the axle Support the axle and remove the outer retaining nuts Fig 7 2 5 The bolts are welded into the chassis The axle assembly can then be removed from the chassis 1N00 96...

Page 29: ...ust be reapplied on reassembly 7 4 Removing the Wheel Bearing Fig 7 4 Wheel Bearing Removing and Lubricating 1 Delryn Drive Gear 2 Inner Spacer 3 Gear spacers and Bolts 4 Wheel Bearing 5 Outer Spacer 6 Gear Retaining Bolts 1 Remove the three gear retaining nuts Fig 7 4 6 Be careful to remove the correct three nuts The gear can then be separated from the wheel 2 Remove the inner and outer spacers f...

Page 30: ... Nipple 2 Wheel Bolts 3 off 3 Inner Wheel Rim 4 Outer Wheel Rim 5 Wheel Nuts 3 off 1 Unscrew the grease nipple Fig 7 5 1 2 Unscrew and remove the three wheel bolts and nuts Fig 7 5 items 2 5 3 Remove the inner and outer wheel rims Fig 7 5 items 3 4 from the tyre This may require a press 4 To re assemble apply water to the new tyre and place the inner and outer wheel rims in position 5 Using a pres...

Page 31: ... colleague hold it in this position 3 Using a standard grease gun filled with auto wheel bearing grease apply to the nipple Fig7 6 1 until fresh grease is seen at the perimeter of the bearing 4 Remove any old grease expelled during this process 5 Remove the axle retaining nut Fig7 6 2 and remove the axle The bearing and axle should then be cleaned an fresh auto wheel bearing grease applied 6 Re as...

Page 32: ...batteries from the ORBITER and close the body Place the ORBITER in the vertical position and have a colleague hold it in this position Remove the castor retaining nuts Fig 7 7 1 The bolts are welded into the chassis Remove the old castor and re assemble using its replacement and new Nyloc nuts 1N00 962 Page 32 Tornado International Ltd 2014 ...

Page 33: ... raise the ORBITER off the ground so that the drive wheel is free to rotate 2 Remove the batteries from the ORBITER 3 Loosen the motor mounting nuts Fig 7 8 1 four off 4 Slide the motor towards the drive gear to adjust the backlash to 2mm at the circumference of the wheel 5 Re tighten the motor mounting nuts 6 Rotate the drive wheel at least once and check for any tight spots 1N00 962 Page 33 Torn...

Page 34: ...ispose of carefully Do not incinerate or crush 1 Open the body and have a colleague support the body 2 Rotate and remove the lower ball joint retaining clip Fig 7 9 4 3 Rotate and remove the upper ball joint retaining clip Fig 7 9 3 4 Remove the gas spring from the ball joints 5 Fit the replacement spring with the body Fig 7 9 1 attached to the ORBITER body and the ram Fig 7 9 2 attached to the ch...

Page 35: ...x B Battery Charger Dimensions Battery Manufactured by Exide Technologies Sonnenschein Model Number GF1276V Dimensions 330mm l x 171mm w x 236mm h Weight 29Kg Charger Charging Station 4 Chargers Dimensions 285mm l x 205mm w x 170mm h Weight 6Kg 1N00 962 Page 35 Tornado International Ltd 2014 ...

Page 36: ...in Model GF1276V Battery Life 200 Charge discharge cycles Charge discharge cycle Fully charged to 100 discharge Capacity at the end of rated life 80 Motors 24vDC 2000rpm Transmission Single stage spur gears Chargers Quad station single input Automatic charge rate Output 10A at 14v per Station Recharge time 8 14 hrs Depending on the level of discharge 1N00 962 Page 36 Tornado International Ltd 2014...

Page 37: ...ho will drive these vehicles are old enough to understand the method of control and their responsibilities both to themselves and other riders A sign with this or similar wording should be placed in a prominent position where it will be seen on the approach to the ORBITER area Caution Moving vehicles Take care when entering or leaving this area 1N00 962 Page 37 Tornado International Ltd 2014 ...

Page 38: ...TER MANUAL These vehicles are designed to carry one person only No bumping at any time A sign with this or similar wording should be placed in a prominent position at the entrance to the ORBITER area 1N00 962 Page 38 Tornado International Ltd 2014 ...

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