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Product version 01-2017.06

User andMaintenance ManualTrolley Rope Return System with Traffic Control

for Rollglider Attraction Lines

111 V, Tsarigradsko shose blvd., Sofia 1784, Bulgaria | Phone: +359 2 448 57 44 | [email protected] | www.adventure.walltopia.com

Power unit mounted above the

STARTING PLATFORM

Pulling link

Tensioning mechanism mounted above the Finishing PLATFORM

1General Information

The Rollglider Trolley Rope Return System is designed to retrieve the Rollglider Trolley from the finishing to the starting platform of the Rollglider facility. At the end of each ride, participants are detached from the trolley and dismounted from the finishing platform.

A system of steel cables and pulleys pulls the trolley from the finishing to the starting platform by hauling it along the Rollglider line. The system is powered by an electric motor and can be controlled from two independent positions.

SPIRALS

TURNS

DIP S

1. ROLLGLIDER LINE

2. TROLLEYS4. TROLLEY

TRANSITION SYSTEM

3. TRAFFIC CONTROL SYSTEM

5. HYDRAULIC PLATFORM

START

FINISH

ATTENTION! The system is designed to move only empty trolleys and should never be used for carrying people. Attempts to transport people using the trolley return system can lead to serious or fatal injuries.

!

User Manual FOR USE AND MAINTENANCE OF THE TRS AND TCS

1.1 Components

The Trolley Rope Return System consists of: • Main switchboard• Smaller switchboard• Power unit with electric motor• Tensioning mechanism• Trolley towing link

1

2

1. Limit Switch 2. Inductive proximity sensor

The Traffic Control System is designed to prevent risk of collision and optimize operations by giving a light signal and locking the output gate, when the line is free to be used by the next participant.

Both the trolley return and traffic control systems are integrated into a single control module consisting of a main switchboard, a smaller switchboard, junction boxes, sensors and limit switches.

The main switchboard is usually located at the starting platform. It controls the electric motor (via automatic fuse control contactors and a frequency inverter), the smaller switchboard, and all of the limit switches and sensors. The main switchboard manages the light column, which indicates whether or not the system is working, as well as the electromagnets on the output flap and gate.

The smaller switchboard is located on the finishing platform. It controls the hydraulic platform and its light indicators.

Both switchboards have emergency stop switches. The emergency switch on the main switchboard cuts the power supply of the entire system, and the one on the smaller switchboard controls the power supply of the hydraulic platform.

The towing link’s ending position, where the trolley stops, are controlled via inductive proximity sensors - two sensors for the upper position and two for the lower one (at the starting platform). To ensure maximum safety the system is equipped with limit switches for both the upper and lower end positions.All inductive sensors and limit switches are on the power unit.

• Steel cables • Pulleys• Two remote radio controls• Remote radio control receiver• Light columns


START

FINISH

Main Safety switch Remote Radio Control (2 transmitters)

Remote Radio Control Receiver

Light Column

The main safety switch is mounted on the door of the main switchboard. It turns the power supply of the entire system on and off.

A receiver for the remote radio control is mounted on the side of the main switchboard.

A light column with red and green lights is mounted on top or near the power unitt, and shows that the engine block is supplied with power. Two additional light columns with red and green lights are mounted near the gate of the starting platform and next to the final platform. They are used to indicate signals from the traffic control system.

1.2 Used Inscriptions

Main Switchboard

Smaller Switchboard

PS1, PS3 - Inductive sensors “UP”PS1, PS3 - Inductive sensors “DOWN”LS1 - Limit Switch “UP” (light column on the starting platform gate)LS2 - Limit Switch “DOWN” (light column on the starting platform gate)LS3 - Output Flap Limit Switch LS4 - Hydraulic Platform Limit Switch “DOWN”SF1 - Safety Flap Limit Switch 1 (flap on the return line preventing trolley from

going back)


SF2 - Safety Flap Limit Switch 2 (flap on the return line preventing trolley from going back)

LM - Red / green light system performance indicator on the power unitSL1 - Red / green light that allows patrons to begin the rideLF1 - Red / green light that allows the hydraulic platform to lift at the finishing

platform M1 - Electromagnet that secures the gate at the starting platformM2 - Electromagnet that secures the output flap at the starting platformTCS - Traffic Control System.

*LS1 and LF1 work simultaneously

1.3 System Operation Overview

The system is controlled from the starting and finishing platforms via two remote radio controls for cranes - model F21-2S.

Button Descriptions

EMERGENCY STOP - mushroom shaped emergency stop button, active when the red light is on.

START - turns the system on (green light means the system is on)UP – sends the trolley from the finishing to the starting platform via towing link

(automatic)DOWN - returns the towing link to the finishing platform (manual)EAST - the hydraulic platform is raised (this button is active only on the remote

control unit labeled FINAL)WEST - the hydraulic platform is lowered (this button is active only on the remote

control unit labeled FINAL)SOUTH - controls the electromagnetic lock of the gate on the starting platform

(this button is active only on the remote control unit labeled START)NORTH - controls the electromagnetic lock of the output flap that holds the trolley

on the starting platform (this button is active only on the remote control unit labeled START)


The return of the trolley from the finishing to the starting platform is automatic. When pressing the “UP” button, the system returns the trolley in the “UP”per position at the starting platform. This process can be stopped at any time by pressing the “UP” button again or by a single press of the “DOWN” or START buttons. The trolley is returned to the finishing platform manually, by pressing and holding the “DOWN” button.

1.4 Operating Modes

The Trolley Return System has two modes - automatic and manual.Automatic: When the “UP” button is pressed, the system automatically moves the towing link from the finishing to the starting platform and stops by itself. The “DOWN” button can be used for stopping if necessary. Moving the towing link “Down” is not automated for safety reasons. The buttons “EAST”, “SOUTH” and “NORTH” are controlled by the Traffic Control System (TCS) Manual:All functions of the buttons are controlled by the operator.

Note: For instructions about the remote radio control - see the user manual of F21-2S.

2 Technical Information

Electric motor: 3~400V/ 50Hz / 1.5kW / 1400 min-1.Reducer H051M, n2=272,37 min-1; i=5,14. The electric motor is controlled by a frequency inverter Lenze ESMD152X2SFA 1(2)N PE AC 230/240V. The maximum permissible pull speed is 2m/s for the towing link.

3 Daily Checks

Make the following checks prior to beginning daily operations.

1. Visual check of the main panel and associated cables, and the electric motor for any mechanical damage.

In the case of any spotted damage, cease operations until the problem has been fixed by a competent electrician.


2. Visual inspection of the actuating mechanism for any mechanical defects:

- Check for loose bolts

- Check for cracked welds

- Make sure the rope is sitting properly into the channels of the leading and auxiliary pulleys

- Check the rope for mechanical damage

3. Check the tensioning mechanism:

- Check for loose bolts

- Check for cracked welds

- Make sure the rope sits properly into the channel of the pulley mounted inside

- Make sure the pulley mounted inside moves smoothly (Check the tension of the rope by measuring the end spring.)

4. Check the rope deflection - if necessary use the tension mechanism to adjust to the required level.

In the case of any observed damage – the rope should be immediately removed by an authorized technician.

4 System Startup

1. Release the emergency buttons and switch on the main safety switch. The red light will ignite on the light column of the Power Unit (LM).

2. Wait 10 seconds and press the START button twice on the remote radio control. The first press will turn the receiver on. The second one will turn the system on. When the power unit light column turns green, the system is ready to use.

3. Test the entire cycle of the ride using an empty trolley.3.1 Begin from the finishing platform, toward the starting platform, so that the

trolley can successfully pass through Limit Switches SF1 and SF2 (the two flaps on the return line).

3.2 Press the “DOWN” button to move the towing link to the lower end position at the finishing platform.

3.3 Attach the trolley to the towing link. Check the hydraulic platform - it should be in the lower position (LS4 is on).


3.4 Press the “UP” button and tow the trolley to the starting platform. When the trolley passes through the safety point (flaps SF1 and SF2) the green lights on the starting and finishing platforms will turn on (LS1). Hydraulic platform movement will be disabled, and the gate and output flap locks on the starting platform will be enabled. They can be unlocked using the “SOUTH” and “NORTH” buttons.

3.5 Release an empty trolley on the track. Unlock the output flap and push the empty trolley on the Rollglider line. When the trolley passes through the output flap, the RED light on the starting platform (LS1 & LS2) will turn on. This means that the TCS is working properly. *If the magnetic locks of the gate and output flap are not secured, then the red light of SL1 will blink.

4. The hydraulic platform’s movement will be enabled after several seconds (LF1 turns green); the gate and output flap on the starting platform will be locked. *Raising the hydraulic platform is prohibited when a patron is on the ride.

5. In case of an emergency press one of the Emergency mushroom buttons. The system will stop immediately; the red light on the power unit light column will turn ON.

6. After the end of the workday, stop the electrical power from the Main safety switch.

7. In the extreme case of total collapse, turn off the Main safety switch - it will put the whole system to a halt.

5 Use of the System

1. The safe use of the system requires two operators, one at the starting and one at the finishing platforms. Both operators must have constant visual contact (or via remote radio) while performing any movement procedures.

2. It is prohibited to use the trolley return system while a participant is on the Rollglider track.

3. When a user descends on the Rollglider track, the towing link should be in the “UP”per position (at the starting platform).

4. The towing link moves to the lower position only after the descending person has been dismounted from the Rollglider line and has left the finishing platform.

5. Attach the trolley towing link and move the trolley to the starting platform.6. At the end of the workday, the trolley and the towing link should be secured

at the starting platform.


The sensor sensitivity can be adjusted by increasing or decreasing the distance between the active surface of the sensor and the metal indicator

1. Nuts

2. Active surface of the sensor

1. Front sensor “DOWN”

2. Rear sensor “DOWN”

3. Metal indicator used to activate sensors

4. Front sensor “UP”

5. Rear sensor “UP”

1

2

3

5

4

2

1

6 Maintenance

6.1 Gear ReducerThe system includes a gear reducer designed to slow “Down” the gliding speed at certain points of the Rollglider line. The gear reducer does not need any maintenance - it is supplied with lubricant and has no oil plugs.

6.2 Roller BearingsThe additional roller bearings for the rolls on the engine block are pre-lubricated, if necessary, they can be further greased.

6.3 Adjustment of Proximity SensorsDistance between sensors and rope - min 16 mm.Distance between sensors and metal indicator - max 10 mm.


6.4 Adjustment of Rope Tension

Adjustment for Direction “UP”

1. Keep the metal indicator away from the front sensor.2. Mount the rear sensor approximately 20 mm from the rope.3. Adjust the rear sensor by decreasing the distance step by step between

the sensor and the metal indicator.

After every change of distance - check the end position by pressing the “UP” push button - the towing link will move “UP” and must stop when the metal indicator is close to the sensor.

4. Mount the front sensor and repeat the adjustment procedure.

Adjustment for Direction “DOWN”

Adjustment for direction “Down” is the same as the adjustment for direction “UP”

6.5 Adjustment of the Line Tension

Loosen tensioning unit

Tighten tensioning unit

To adjust the line tension,follow these steps:1. Loosen the lock nut (1)2. By rotating the tensioning nut (2) tighten the rope.3. Tighten the lock nut (1)

Tighten level C must be within limits shown below. C=A-B, mmMin C=15mm, Max C=20mm.


7 UTroubleshooting

Symptom Causes or solution

The main safety switch is turned on, but the red lamp is not on

- Check the power supply- Check the automatic fuses in the main switchboard. If they are off, turn them on and wait for a few minutes. If the fuses turn off automatically again please call an authorized electrician.

The main safety switch is turned on. The red lamp is on.The system cannot start using “On” or “Start” buttons.

- One of the EMS mushroom buttons is not released completely.

When trying to use the “UP” or “Down” button but the system doesn’t move. The green light is on.

- There might be issues with the frequency inverter. Please call an authorized electrician.

The system does not move when trying to use the “UP” or “Down” button The green light is on. When the rope is being pulled away from the sensors, the system starts to move.

Some of the sensors need to be adjusted. Start from the sensor closest to the rope.

When using the “UP” or “Down” button the system moves, but doesn’t stop in the end positions. The green light is on.

Check the sensors. The distance between the sensors and the metal indicator might be too long. The max. distance is 15 mm.

user and maintenance manual - adventure.walltopia.com · sf2 - safety flap limit switch 2 (flap on...

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