Fly France

Original
OPERATING
INSTRUCTIONS
SKY FLY
GLOBAL VILLAGE
2177-99-SF12_13-GlobVill_Operating_Instructions-2017-10-24.pdf
2177-99-SF12_13-GlobVill_Maintenance-Lists-2017-10-09.pdf
About the instructions:
This documentation is essential for your own safety!
Furthermore it includes detailed information to guarantee the safety of the passengers and the
customers and also to prevent damage to the ride. One copy must be kept close to the ride.
The observance of this operator manual, the delivered appendix, operator and operations manual of
the installed components and maintenance manual are the conditions for a trouble-free operation and
the fulfilment of possible guarantee-claims.
This operation instructions is intended for the operating company, the operator who daily works with
the ride while passengers are in the ride and the maintenance personnel working at the ride.
Conventions used in this guide:

“Ride” stands for FLY FRANCE
Operating company of the Ride is GLOBAL VILLAGE DUBAI LLC
Manufacturer of this ride is: Gerstlauer Amusement Rides GmbH

Industriestraße 17
86505 Münsterhausen
Germany
 A text within squared brackets is the name of a button, e. g. the [start] button.
 A number within round red brackets, e.g. (1), stands for a button of a panel.
 A number within round black brackets, e.g. (1), stands for a mark on a picture.
 A blue text refers to a specific figure, table, heading or page number.
 Specific technical data are be found in the circuit plans and mechanical drawings
 An overview of the ride and its given names can be found as an appendix in “ride description”
Information on damage to property

Warns against possible damage to the ride.
Information
Additional useful information.
Safety related signs are described in chapter 1 “Safety Messages”,
section “Representation of safety instructions”
Passing on as well as copying these documentation, utilization and communication of its contents
aren't allowed as far as not granted particularly. Contraventions lead to compensations. All rights
reserved particularly in case of the patent issue or GM entry. Technical changes, respectively,
additions, reserved. We have checked the contents of the documentation for agreement with the
described hard- and software. Nevertheless deviations cannot be excluded so that we don't take on
any liability for the complete agreement. The details in this documentation are checked regularly and
necessary corrections are in the following expenditure. We are grateful for suggestions or for
improvement.
Further processing of the documentation:
It must be taken care absolutely at take-over of the documentation into the customers’ possession and
that in possible further processing the safety technical notes remain present and visible.
Scope of technical documentation
amount copies
description language
[x] [y]
Ring binder with the original Operating Instructions

English 1 2
including maintenance instructions and checklists
Ring binder with electrical and pneumatic documents English 1 2
Ring binder with technical descriptions of the

partly multilingual 4 1
components + software
Ring binder with mechanical drawings + spare part

English 1 2
lists
CD with Original Operating Instructions + technical

partly multilingual 1 1
descriptions + mechanical drawings (optional)
Safety instructions
Representation of safety instructions
General safety instructions
Component related safety instructions
Normal Mode related safety instructions
Maintenance related safety instructions
Emergency related safety instructions
Safety instructions for a longer downtime
General conditions
Duties of the operating company
Terms and conditions
Ride description
Tabular
Intended use of ride
visual overview/ block explanation
Block descriptions
Panels
Operation
Operation with passengers (Normal Mode)
Operation without passengers (Maintenance Mode)
Ride shutdown
Evacuation
Behaviour in case of emergency
Evacuation actions
Switching into maintenance mode
Take the main arm into 6 oćlock position
Lower the gondolas
Open restraints
Restart after evacuation
Maintenance
Instructions
1 Safety Messages for the
Sky Fly “FLY FRANCE” ....2
1.1 Representation of safety instructions ................................. 2

1.2 General safety instructions ................................................ 3
1.3 Component related safety instructions ............................... 5
1.4 Normal Mode related safety instructions ............................ 6
1.5 Maintenance related safety instructions ........................... 11
1.6 Emergency related safety instructions ............................. 14
1.7 Safety instructions for a longer downtime ........................ 18
The observance of the following safety instructions – as well as of the other safety
instructions in the documentation of this ride - is an elemental part of the intended use
of the ride.
Safety Messages for the Sky Fly “FLY FRANCE”
FLY FRANCE
1 Safety Messages for the Sky Fly

“FLY FRANCE”
1.1 Representation of safety instructions
This manual shows the following signs used as safety advices:
DANGER indicates a hazardous situation which, if not avoided, will

result in death or serious injury
WARNING indicates a hazardous situation which, if not avoided,
could result in death or serious injury
CAUTION indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury
Prohibition sign
= a safety sign that prohibits a behaviour by which a danger can occur
Warning sign
= a safety sign to advise against a risk or a danger
Sign giving orders

= a safety sign to instruct a certain behaviour
Arrow
Orders with this arrow have to be fulfilled in the given order.
Representation of safety instructions Global Village

page 2 / 18 2177-99_01-Safety_Messages-2017-10-09.docx
FLY FRANCE
1.2 General safety instructions

All safety messages in this documentation shall be observed by the operating
company especially the issues mentioned in chapter 2 “Conditions”, section
“ALL THE TIME MAKE SURE THAT”
Risk of personal injury or ride damage caused by incorrect use of

equipment!
 Use the equipment only for its specific use at the ride
according to the operating instruction of the
manufacturer. The technical documentation is to be
observed
 Objects (e.g. spare parts for maintenance and repair of
the ride, loose, pointed or spacious items, bags and
backpacks belonging to passengers) are prohibited to
be transported with the ride.
Risk of personal injury or ride damage through incorrect installation

or operation!
 Installation must be done by qualified personnel of the
manufacturer.
 Local and national laws and regulations regarding work
and accident safety are to be followed.
 The ride must not be operated with passengers in the
maintenance or test run operation.
 The ride must be in home position during maintenance
or repair works.
 The ride may only be operated according to the
operation instruction.
Risk of personal injury or ride damage caused by dismantling of

covers and housings!
 Do not operate the ride without covers and housings! All
terminal boxes must be closed to prevent the risk of
electrical shocks.
Global Village General safety instructions

2177-99_01-Safety_Messages-2017-10-09.docx page 3 / 18
FLY FRANCE
Risk of personal injury or ride damage caused by maintenance or

repair works during operation!
 Unauthorized people have no access to the ride area
during operation.
 During operation, the platform must be cleared, no
personnel are allowed in the ride area.
 The ride area must be safeguarded and labelled clearly
with prohibition and information signs.
Weather hazards and fire warning!
 The ride must not be operated during thunderstorms,

strong winds or storm of a certain wind force, imminent
floods, heavy snowfall or hail or fire in the ride or
adjacent rides.
 In these cases a running ride is to be stopped
immediately and the passengers have to be evacuated
safely!
Risk of personal injury or ride damage caused by lightning and

overvoltage exists!
 The main electrical power connection must be in
accordance with the electrical manual, national
guidelines and the regulations of the electrical supply
company.
 The operating company may have to install measures
against lightening and overvoltage:
- Measures for grounding and potential equalization
must be created by the operator according to the local
laws. This applies also for the construction phase.
- Installation of lightning arrester in the main distribution
board in order to avoid direct lightning strikes.
- Medium protection to be installed into the distribution
control.
General safety instructions Global Village

FLY FRANCE
1.3 Component related safety instructions
Orders of the operator personnel must be obeyed.

Entering and exiting the gondolas is allowed only when ride is stationary. This
should be a calm and orderly procedure.
 The passengers must be notified prior to the ride, that the rolling motion
of the gondola can be stopped at any time when they do not operate the
wings. For this, the wings need to be put in their horizontal neutral
position.
Global Village Component related safety instructions

FLY FRANCE
1.4 Normal Mode related safety instructions
Risk of injury for the passengers during ride!

 The passengers get burdened with a multiple of their
own body weight throughout the course of the ride.
Persons with health problems may not ride. This
applies for persons that:
- Have back injuries or vertebrae,
- are suffering from hypertension,
- are under medical care,
- are suffering from cardiovascular disease,
- have had eye surgery,
- are pregnant
 The restraint must be closed in such a way that the
restraint pad has contact to the rider’s body.
 The wings of the gondola may only be moved with the
provided handgrips
 It is prohibited to stick out arms or legs or to lean out of
the gondola during the ride.
 Obviously drunken people or those who are under the
influence of mind-altering substances are not permitted
to enter the ride.
 Fire, open lights and smoking are strictly prohibited.
 Body jewellery should be taken off if this could cause
injury.
 Long hair and scarves should be kept within clothing.
 Riding with loose footwear (e.g. flip-flops) is not
permitted
Normal Mode related safety instructions Global Village

FLY FRANCE
Passengers can fall out of the gondolas during ride!

 All passengers are seated properly;
 The restraints must be closed as tight as possible.
 The following people must be excluded from ride:
- children and people shorter and younger than

mentioned in the Intended Use of Ride – Chapter 3
- people who cannot be held safely by the existing

restraints due to their physique or because of
disability,
- people who can take no normal sitting position due to

their body size,
- people whose heads cannot be placed on the

headrest in normal position.
 If a restraint opened up overnight, put the gondola out
of operation and analyse the reason for the self-
opening.
 If a drawback of the restraint is detected during regular
checks, measures for elimination of the drawback must
be taken immediately (replacement of the cylinder-
accumulator drive) or the gondola must be put out of
operation.
 The indicator on the HMI displays only the proper
function of the mechanical switch. It’s not warranted that
the restraint is correctly fitted and close to the
passenger’s body!
 The restraints must be checked by the operating
personnel by hand to ensure a correctly fitting and close
to the passenger’s body
Global Village Normal Mode related safety instructions

FLY FRANCE
Risk of injury for the waiting customers at station!

 Fire, open lights and smoking are strictly prohibited.
 Animals, umbrellas and other sharp, bulky or loose
objects (mobile phone, photo camera, bags, backpacks
etc.) are prohibited to be taken into the gondolas.
 Eating and drinking is forbidden during the ride.
 It is prohibited to throw items out of the gondola.
 Obviously drunken people or those who are under the
influence of mind-altering substances are not permitted
to enter the ride area.
 It is prohibited to enter the ride area during ride
operation.

FLY FRANCE
Risk of injury for the personnel, passengers and customers at ride

start!
 During operation of the ride, no one (this includes
qualified personnel, park guests) is permitted to enter
the ride area, stairs; catwalk or platform.
 All areas in which visitors are staying must be absolutely
visible by the operator. Methods for a better visibility
must be taken for this areas if necessary (mirrors,
cameras, etc.).
 No people may stay in the dangerous areas.
 The operating personnel must help the passengers to
enter and exit the gondolas if necessary.
 All passengers must have properly sat down in their
seats.
 The restraints must be closed and fastened securely as
tight as possible to the upper thigh
 The operation personnel must test the correct positions
of every restraint.
 The passenger must sit upright against the back of the
seat.
 The passenger must be safely contained by the
restraints – i.e. the restraint must be as tight as possible
to the body. Also the function to keep the passenger in
the seat may not be affected by clothes or something
similar (e.g. backpacks, bags etc.).
 The operation personnel must make sure that the
restraint locking is effective by pulling the passenger
restraint into opening direction
Global Village Normal Mode related safety instructions

FLY FRANCE
Risk of injury for the personnel, passengers and customers at ride

start!
 The operation personnel must check the function of the
spring reset of both gondola wings according to the
maintenance instructions.
 Before the start of the ride, the operation personnel must
ensure that no persons are in the immediate vicinity of
the gondolas.
 The stations entrance and exit, the station area, the
escape and rescue ways and the pedestrian pathways
must always kept free and accessible according to the
local laws and regulations;
 The ride must be secured against unauthorized start up
if the operator personnel leaves the control panel or the
operating room.
 By pressing the push button to start the ride, the
operating personnel also confirms that notes and
requirements of the manufacturer`s operating
instruction as well as the requirements of superior
organizations are duly adhered to.

FLY FRANCE
1.5 Maintenance related safety instructions

Falling hazard at high-placed work areas!
 Fall arrestors must be used. The operating company is
responsible that the local safety and health instructions
are followed and obeyed during installation, test runs,
operation, maintenance and repair work.
 While working on high areas, safety scaffolding or
elevated structure, personal safety equipment must be
used to prevent the danger of falling off.
 The ride must be in home position during maintenance
or repair works.
 All works on the ride have to be done and supervised by
qualified specialists.
Warning of hot surfaces! The gear unit motors can heat up during
operation.
 Do not touch the motors or brake resistors after
operation!
 Before any maintenance and repair work wait until the
motors are cooled down.
Global Village Maintenance related safety instructions

FLY FRANCE
Risk of electrical shock!

 When working inside the ride area, be sure that the main
power switch is turned off and protected against
unauthorized switching on.
 All works on the ride have to be done and supervised by
qualified specialists.
 While working on the ride, all safety and accident
precaution, rules and regulations of technical issue,
according to local and federal laws, must be obeyed.
 All works on or nearby the electrical installation can
only be carried out if:
- the ride power is shut off and secured against restart

(i.e. locked out) before working at active electrical
parts;
- power off is tested;
- additional electrical components for control and safety

installations are installed.
 Disconnect the ride from the supply system prior to

removing protective covers. Dangerous voltages may
still be present for up to 10 minutes after mains
disconnection. Just because the operation LED’s and
other display elements have gone out does not mean
that the ride has been disconnected from the supply
system and is de-energized.
Risk of injury by air pressure!

 The hydraulic and pneumatic system must be free of
pressure before working on it.
Maintenance related safety instructions Global Village

FLY FRANCE
Risk of personal injury through maintenance or repair works at the

hydraulic ride!
 The commissioning, maintenance and repair works
must be done through qualified personnel only.
 Change of components during standstill.
 DO NOT CHANGE ANY COMPONENTS WHEN RIDE
IS RUNNING!!!
 When working inside the ride area, be sure that the main
power switch is turned off and protected against
unauthorized switching on.
 Load which can move or fall down uncontrolled while
operation or tubing must be supported or blocked.
 Components for general overhaul should be sent to the
manufacturer. Do only controllable works.
Global Village Maintenance related safety instructions

FLY FRANCE
1.6 Emergency related safety instructions

Risk of injury for passengers and personnel during emergency
evacuation!
 Fall arrestors must be used. The operator is responsible
that the local safety and health instructions are followed
and obeyed during installation, test runs, operation,
maintenance and repair work.
 All operating staff must regularly practice the measures
for emergency situations and emergency rescue of
passengers.
 The safety system of the ride is not operating after any
shut down!
 All applicable staff must practice regularly the measures
for emergency situations and emergency rescue of
passengers.
 For evacuations, the ride must be switched off and it
must be ensured that it cannot be switched on again
(lock main switch)
 For evacuations, the gondolas must be secured and
ensure that passengers can safely disembark
 To prevent the evacuation personnel and passengers
from being hit, the ride must be secured against free
movement during evacuation.
 If the arm is out of area between 8 o’clock and 4 o’clock,
the arm is sliding slowly to direction 6 o’clock as long as
the brake has enough torque to hold the arm. The brake
torque is too low to hold the arm in each position. This
can cause a dangerous situation for the passengers at
evacuation. The arm must be moved to position 6
o’clock as far as possible before evacuation. If this is not
possible the arm must be secured mechanically (tension
belt, chains, etc.).
Emergency related safety instructions Global Village

FLY FRANCE
 If an evacuation is possible from a great height only, e.g.

due to a power failure, suitable rescue vehicles with
turntable ladders must be requested (fire-brigade etc.)
or rescue ladders with a sufficient large walk area must
be provided. The passengers are to secure before their
evacuation e.g. by means of a safety harness or a safety
jacket and lifelines
 The emergency release of the restraints must be done
by qualified persons only.
 The associated operation manual and the safety
regulations of the location have to be followed anyway.
Risk of injury in the event of guest panic and jostling in the entrance
area!
 Do not start the ride.
 Calm down the passengers, call them to order and
resolve any crush.
 Inform passengers that loading will only be allowed
when everything is calmed and well organized.
Risk of injury in case of unacceptable behaviour of the passengers

during the ride!
 Push the E-stop button if it doesn’t cause more danger
in the emergency situation.
 Inform the passengers about the situation and inform
them to stay in the gondola and not to try to exit the
gondola without help.
 Evaluate the necessary emergency evacuation and
evacuate the passengers.
 Test runs after the emergency situation must be
accomplished to sufficient extent before
recommissioning the ride.
Global Village Emergency related safety instructions

FLY FRANCE
Risk of injury in case of panic caused by disaster and accidents in

the vicinity!
 Do not start the ride.
 Stop immediately a current ride.
 Shut down the ride after all passengers left the ride.
 Test runs after the emergency situation must be
accomplished to sufficient extent before
recommissioning the ride.
Risk of injury in case of safety shut down caused by the control

system!
 Inform authorized and qualified personnel.
 Find reason for the safety shut down and check the ride.
 For further information to a safety shut down and
proceedings see chapter 11 - Ride Start-up.
 Test runs -empty and with dummies- after the
emergency situation must be accomplished to sufficient
extent before recommissioning the ride.
Emergency related safety instructions Global Village

FLY FRANCE
Risk of injury in case of power failure!

 Find reason for the power failure and check the ride.
 For further information to a power failure and
proceedings see chapter 4 – Operation
 Test runs –empty and with dummies- after the
Risk of injury case of accident on the ride!

 Push the E-stop button if it doesn’t cause more danger
in the emergency situation.
 Inform, according to operator regulations, the
emergency team.
 Test the ride.
 Test runs –empty and with dummies- after the
Global Village Emergency related safety instructions

FLY FRANCE
1.7 Safety instructions for a longer downtime

Risk of personal injury or ride damage through winterizing and
dismounting works!
 Unauthorized people have no access to the ride area
during the works!
 The ride area must be safeguarded and labelled clearly
with prohibition signs and information signs!
 All work must be done by qualified specialists only!
Safety instructions for a longer downtime Global Village

2 General Conditions .......2
2.1 Duties of the operating company ....................................... 2

2.1.1 Prepare an Operation and Use Risk Assessment ......................... 2
2.1.2 Personnel ...................................................................................... 3
Qualified and reliable supervisor ......................................................................... 3
Qualified operating personnel (operator) ............................................................. 3
Qualified specialist ............................................................................................... 3
2.1.3 ! WARNING ALL THE TIME MAKE SURE THAT ................... 4
2.1.4 Inform about faults and malfunctions ............................................ 6
2.1.5 Cleaning ........................................................................................ 7
2.1.6 Disposal ........................................................................................ 7
2.2 Terms and Conditions........................................................ 8
2.2.1 Intended Use of Ride .................................................................... 8
2.2.2 Warranty and Liability.................................................................... 8
2.2.3 Revision index chapter 2 general conditions ................................. 9
General Conditions
FLY FRANCE
2 General Conditions
2.1 Duties of the operating company
Thank you for purchasing this Gerstlauer ride!
This state-of-the-art ride corresponds to all valid standards and regulations. We have done our best to
manufacture this ride to your complete satisfaction and the pleasure of your guests.
Due to the nature of an amusement ride several aspects are to be observed which we would like to
specify in the following:
2.1.1 Prepare an Operation and Use Risk Assessment

The operating company needs to prepare an operational concept which includes risks to be considered
which could occur during all operational states of the ride as well as measures for their reduction. The
operational concept must be used to help the user and operator to make the right decisions regarding
the complete ride (e.g. age and size restrictions/entering and exiting of passengers/ foreseeable misuse
etc.) in order that an acceptable residual risk is created for every analysed risk. If necessary, this concept
is to be updated and required reports to be written.
At least the following points must be included – but not limited to:
 Securing of safe operation in complete compliance with all laws, regulations and provisions of
local and national authorities;
 Securing that emergency plans and procedures, including evacuation of passengers, are
prepared, well documented and practiced regularly;
 Procedure for shutting down the ride in case of emergency or for controlled shutting down;
 Restrictions regarding the transport of passengers, e.g. size and weight, health conditions,
restricted accessibility (passenger behaviour);
 Appropriate and competent staff requires selection, training, examination of knowledge and
learning ability, monitoring, examination and keeping of records;
 Appropriate trainings must be offered to all members of staff and documented accordingly.
Trainings must be suitable regarding the risks and conducted in such a way that all training
participants can comprehend them;
 Installation, operating and maintaining processes – also for individual phases – need be
described.
If necessary, the operating company must compile operating directives for all
works on the ride.
Duties of the operating company Global Village

page 2 / 9 2177-99_02-General_Conditions-2017-10-09.docx
General Conditions
FLY FRANCE
2.1.2 Personnel
Any person working at this ride or involved in the transport, set-up, operation,
maintenance or repair thereof must have received instruction and must be aware
of the potential risks. This means that the operating manual, and especially the
safety instructions, must be carefully read, understood and observed. A lack of
or inadequate knowledge of the operating manual will result in the loss of any
liability claims against the manufacturer. It is therefore recommended that the
operator obtains written confirmation that persons have received the necessary
instruction.
Operation of the ride is only allowed if the following personal is available:
Qualified and reliable supervisor

The operating company must name a responsible, qualified and trustworthy supervisor to make the final
approval of the ride and inform the manufacturer of his/her name as contact person. This person will be
trained to operate and maintain the ride, trained for safety and accident regulations and all necessary
special rules of the ride. He/She will also receive all necessary information, documents and all keys of
the ride and has to observe respectively to guarantee that the requested laws and rules for operating
this ride according to this manual are adhered.
The qualified and reliable supervisor must meet the minimum age prescribed in the respective national
law!
Qualified operating personnel (operator)

Qualified operating personnel (operator) are persons who are instructed and trained to operate the
ride and who are also instructed in the safety regulations of the ride.
The qualified operating personnel must be at least 18 years old.
(in accordance with latest DIN EN 13814)!
Qualified specialist
Qualified specialist is a person, which has the specific qualification, knowledge, and experience, also
the knowledge of the specific regulations to see and to foresee the possible danger on the work he /she
is about to do. This person is to be determined by the qualified and responsible supervisor and is familiar
with the execution of the work he /she is about to do. This personnel has to be named by the authorized
and qualified supervisor of the ride.
work mentioned above. These inspectors must be decided by the qualified and reliable person.
Global Village Duties of the operating company

2177-99_02-General_Conditions-2017-10-09.docx page 3 / 9
General Conditions
FLY FRANCE
2.1.3 ! WARNING ALL THE TIME MAKE SURE THAT

 All areas which are accessible to the park and ride customers and endangers them (except the
entrance and exit in the station area) are fenced and secured against falling objects. [DL1]
 Suitable barriers for waiting or queuing passengers are mounted so they do not fall off the station
or topple in lower areas of the station. In addition, the surface in load/unload area must be of non-
skid material to prevent slipping of passengers. Areas and parts of the ride, which may not be
entered or touched, must be clearly identified.
 Suitable fire protection measures and escape routes are provided and usable.[DL2]
 mark clearly all emergency and escape routes & exits and to keep them free – escape routes and
exits must not be used to store or stable any objects!
 sufficient illumination for the station corresponding to the on-site location is provided
 All measures for the security of the customers, the operators, park visitors, spectators and the
ride are selected and dimensioned in such way that they resist respectively come up to extreme
conditions (e. g. panic)
 A fast accessible emergency and first-aid kit is provided. Stairs, ladders and steps in the ride area
used as entrance and exits correspond to national and local laws.
 The operating company has to decide whether and what type of a provided and receivable starting
signal (e.g. signal horn) is necessary at the start of the ride.
 Information on the behaviour and restrictions regarding the age, size and weight of passengers
and customers, safety signs and information, escape routes and emergency exits must be
identified clearly by adequate signage, preferably by pictograms. Pictograms are to be chosen
and placed according to national norms.
 A pictogram is installed which informs the passengers to keep arms and legs inside the gondola
at all times.
 The passengers are notified prior to the ride, that the rolling motion of the gondola can be stopped
at any time when they do not operate the wings. For this the wings need to be put in their
horizontal neutral position.
 all passengers and operators are informed that due to different centre of mass it could be possible
that passengers without complete legs may ride upside-down[DL3]
 Passengers are informed that the seats can be hot in strong sunlight.
 The ride is shut down if wind is stronger than stated in the Intended Use of Ride. At the onset of
strong winds, the air speed indicator must continuously be observed and evaluated. Strong winds
during operation causes permanent damage to ride structure which possibly leads to breaking
apart of the ride or leads to falling objects – ride breaking or falling objects will cause irreversible
injury including death to passengers.
 Operation is stopped by any sign of thunderstorm due to possible electric shock to passengers
by lightning strikes. Electric shock due to a lightning strike can cause irreversible injury including
death to passengers. Re-start only after thunderstorm is passed. The same applies for hail or
strong rainfalls. The ride must be stopped immediately in case of hail as passengers might be
injured by hail.
 In case of other special natural phenomenon, e.g. earthquake or storm, the ride is stopped
immediately. Before re-start up, the ride needs to be checked for any damage. Especially all
mountings are to be checked for their proper fitting.

General Conditions
FLY FRANCE
 After a lightning strike the complete electric equipment (devices at control cabinets, operator
panels and at the ride) must be tested for their correct function, especially the safety relevant
parts. Defective devices must be replaced immediately. Defect deflectors of the overvoltage
protection F21 in the control cabinet need to be exchanged
 For recommissioning the ride after special occurrences (like storms, emergency stops. etc.) all
safety relevant operations are tested. This also includes test runs with empty gondolas and
afterwards with dummies.
 A ring folder for maintenance work with test and maintenance instructions is kept at the ride. This
folder is for any control, which is done by the operating company, manufacturer and national
and/or local authorities. Also for correct performance of the maintenance works, all necessary
documents are to be hold ready at the ride.
 All carried out work is documented and signed by the personnel.
 Should this operating instruction not be available to the operator, a new operation instruction is
requested at the manufacturer immediately.
 Customary technical maintenance and monitoring are performed for the maintenance and safety
of the entire ride (even when they are not specified in detail)
 Electrical components are kept safe against foreign bodies, moisture and rodents
 Overspeed of the ride is avoided because of permanent damage to the ride equipment. Collapsing
of ride structure will cause irreversible injury including death to multiple passengers.
 Not only this documentation but also local and national laws and regulations regarding work and
accident safety are adhered.
 The applicable provisions of the „Directives for the Construction and Operation of Amusement
Rides“ (DIN EN 13814 as amended from time to time) and any superseding local requirements
are observed. A regular inspection by a specialist for amusement rides must be made according
to this directive.
 Additional requirements, operating rules, maintenance or reparation regulations are obeyed

carefully. This includes all regulations, laws and requirements which are supplied at a later date
through the manufacturer, governing bodies and authorities, which are included in the ride
acceptance.
 the clearance envelope is adhered
 The ride is used as intended (refer “Intended Use of Ride” in chapter “ride description”)
 Installation, operation and service work which is done on and nearby the electrical equipment is
done by a qualified electrical specialist with a certification in accident prevention according the
valid national regulations.
 Before ride operation all maintenance and operator duties as indicated in this operator and
maintenance manual are checked and carried out.
 Before ride operation daily test runs have been done.
 Faults and failures during operation are repaired immediately. To do this the ride must be shut
down.
 If faults and failures cannot be removed, the ride has to be shut down and also secured against
switching on.

General Conditions
FLY FRANCE
2.1.4 Inform about faults and malfunctions

The operating company must inform the manufacturer immediately, if it is of the opinion this operating
manual is not complete or not clearly understandable.
The manufacturer of the ride must be informed of any faults encountered during the warranty period. To
do this, send a precise description of the faults to the manufacturer. The manufacturer can then make
modifications, if necessary, and further optimize the ride.
You must also immediately inform the manufacturer in writing of any faults/malfunctions which may have
an impact on the operational safety of the ride, even after the warranty period has expired. This
information is used for product monitoring. The manufacturer can then make design modifications to
new rides and modify the maintenance specifications for existing rides, if necessary. This facilitates the
prevention of malfunctions. The information does not oblige the manufacturer to provide consultation or
other measures, unless owed for other reasons, in particular when arising from warranty obligations or
a maintenance contract.
During the warranty period the manufacturer of the ride must be notified of all faults and failure functions.
A list of these failures and faults must be sent to the manufacturer to ensure the ride’s safety.
The manufacturer must be informed in writing immediately by the operating company – even after expiry
of the warranty period – if any faults or failures have occurred which can have an impact on the
operational safety of the ride. This information will help the manufacturer to improve its product and to
prevent any faults or failures by changes in the maintenance and operation manuals. This can prevent
ride failures.
This information is only for the manufacturer. It will not oblige the manufacturer to do further training or
to inform the operating company unless otherwise stated in the warranty contract.
General technical maintenance and observation are not listed but should be considered and done in
order to keep a safe ride.[DL4]

General Conditions
FLY FRANCE
2.1.5 Cleaning
Clean the ride with non-aggressive cleaning solvents. Sensitive components (e.g., electric drives, etc.)
must be protected against the penetration of cleaning agents.
2.1.6 Disposal
The ride parts and auxiliary materials such as lubricants and solvents etc. must be discharged and
disposed of according to the applicable statutory and local jurisdictional.
According to existing regulations and depending on the material consistency the waste should be
separated e.g.:
 steel scrap (columns, tracks),
 electronic scrap (conducting plates),
 copper,
 plastic
Please confirm with national applicable laws.

General Conditions
FLY FRANCE
2.2 Terms and Conditions

2.2.1 Intended Use of Ride
Can be found in Chapter 3 “Ride description”
2.2.2 Warranty and Liability

The manufacturer warrants for new rides starting with the date of handover to the operating company.
In case of non-observance of the specifications of this operating instruction, negligence in the operation,
wrong maintenance and implementing unapproved changes to the ride are reasons for voiding the
guarantee by the manufacturer guaranteeing for the ride.
In particular, guarantee and warranty claims in case of personal injuries and/or material damage which
can be traced back to one or more of the following reasons will expire:
 wrong start-up, operation and maintenance of the ride;

 wrong, faulty and unreasonable operation of the ride;
 interference by unauthorized personnel;
 implementing unapproved changes to the ride;
 installation of additional components which were not checked together with the ride during the
acceptance inspection
 operating the ride after a fault and/or error;
 incorrectly executed repair and/or maintenance work
 insufficient and inadequate control and maintenance of ride components.
 usage of other than original components as spare parts, construction kit, accessories and optional
equipment;
 reasons of force majeure
In addition, the manufacturer refuses any liability in case of non-observance of the specifications in this
operating instruction. [DL5]
The operating company is responsible for injuries, damage or other faults due to incorrect installation or
operations, or non-observance of the operating instruction.[DL6]
This applies in particular to damage or other negative consequences, which result from:
 Ignoring or not obeying the rules of the manufacturer`s specifications, official authorities or other
officials involved in the ride project.
 Disregarding of the maintenance instructions and/or repair instructions given by the manufacturer,
local official authorities or other officials involved in the ride project.
Unqualified personnel maintaining or operating the ride or personnel who has not read or understood
the instructions in this operating manual.[DL7]
Terms and Conditions Global Village

General Conditions
FLY FRANCE
 The manufacturer will not pay any compensation for damage and the
resulting consequences due to ignoring rules or changes on the ride. [DL8]
The final acceptance of the ride is made together with the operating company
and the manufacturer. The manufacturer prepares an acceptance report.
2.2.3 Revision index chapter 2 general conditions
page description Index date
Global Village Terms and Conditions

3 Ride Description ............2
3.1 Technical data ................................................................... 2

3.2 Intended Use of Ride ......................................................... 3
3.3 Overview ........................................................................... 4
3.3.1 Electric .......................................................................................... 5
3.3.2 Pneumatic ..................................................................................... 5
3.4 Gondola (G) ....................................................................... 6
3.4.1 Restraint system ........................................................................... 7
Limit switch .......................................................................................................... 8
3.5 Rotation (R) ....................................................................... 9

3.6 Lift (L) .............................................................................. 10
3.7 Hydraulic ......................................................................... 10
3.8 Control cabinet ................................................................ 10
3.8.1 PLC (programmable logic controller)........................................... 10
3.8.2 Power Monitoring Device ............................................................ 11
3.8.3 Remote monitoring ...................................................................... 11
3.9 Station ............................................................................. 12
3.9.1 Touch Display ............................................................................. 12
3.10 Panels ............................................................................. 12
First read this operator manual, the delivered appendix and operator manuals of the
installed components before you start working with the ride!
The technical documentation includes important information for the maintenance;
therefore it must be kept close to the ride.
Ride Description
FLY FRANCE
3 Ride Description
3.1 Technical data
Model-Type Sky Fly 12

Ride No
Drawing no.: 2177
Physical
Flying circle 26x30 m
Height (home position): ~ 19 m
Height (during ride): ~ 22 m
Max. revolutions per hour: ~ 6,5 rpm
Seats per gondola: 1
Theoretical capacity: ~ 240 persons/h
moved weight (arm + gondolas) 22000 kg
Electrical
Main power supply: 3x400 VAC 3/N/PE
Frequency: 50 Hz
Electrical power: ~110 kW
Main fuse: 250 A
Pneumatic
Capacity FAD: max. 2 m³/h compressed air
Working pressure: min. 8 bar
max.10 bar (e) (145 psi)
Passenger
Passenger per ride: 12
Minimum passenger height: 130 cm
Average passenger weight per Ø 75 kg
gondola:
Maximum passenger weight per 900 kg
ride:
Environmental
conditions
see intended use of ride
Technical data Global Village

page 2 / 12 2177-99_03-Ride_Description-2017-10-24.docx
Ride Description
FLY FRANCE
3.2 Intended Use of Ride

The ride is built according to actual technical standard, valid norms and laws.
The intended use of this ride is given if the following aspects are given:
Passengers:
 The ride is empty or humans are sitting in the gondolas who have a minimum height of 130 cm
and have the physical and psychical conditions to secure them against falling out of the ride.
For example any leg amputations must be below the knee.
 One Passenger per restraint.
 Max. 12 passengers per ride. They have to be equally distributed.
 The ride is loaded with maximum 900 kg (12 Passengers at 75 kg).
 No passengers, staff or objects on the outside of the gondola.
 No animals and items (spare parts for maintenance and repair of the ride, loose (e.g. glasses,
flip-flops, prosthetics), pointed or spacious items, bags and backpacks belonging to passengers
etc.) are transported with the ride.
 No passengers
o With back injuries or intervertebral discs or/and
o With hypertension or/and
o under medical care or/and
o with pacemakers or/and
o heart disease or/and
o who are pregnant or/and
o are drunken or/and
o intoxicated by mind-altering substances
are riding
Environmental requirements:
 Outside air temperature is +5 °C to +45 °C (41 °F up to 113 °F).
 Air temperature inside control room is +5°C to +35°C
 Humidity in control room Max. 50% at 40°C1
 No extreme weather conditions
 Wind force under 7 Beaufort (~ 15 m/s, high wind, whole trees in motion. Effort needed to
walk against the wind.)
 Absolute altitude up to 2000 m
 Nonconductive pollution inside control room
 Environmental conditions of the other manuals are adhered
Treatment:
 stationary operation in an amusement park
 original spare parts according to the actual spare parts lists are used
 All parts are in accordance with the local laws and engineer standards
 operating time beneath 20 years
 Operator panels must be covered if they are not in use.
 All parts are proper maintained and checked within the required interval
 Not only this documentation but also local and national laws and regulations regarding work and
accident safety are adhered
Any other use is not as agreed and prohibited.
The adherence of all safety instructions in this operating manual is an

elemental part of the intended use of the ride!
1
The relative humidity of the ambient air does not exceed 50% at a maximum temperature of +40°C.
At lower temperatures, higher values may be admitted, for example 90% at +20°C
Global Village Intended Use of Ride

2177-99_03-Ride_Description-2017-10-24.docx page 3 / 12
Ride Description
FLY FRANCE
3.3 Overview
The ride is a stationary carousel consisting of a main mast with a swivel unit and a rotation unit and a
rotating arm with counterweight. The arm is carrying the twelve gondolas which are designed as aircraft.
These aircraft are occupied with each one person and can be moved manually into rotation around its
centre line by the joysticks at the wings. Using this joystick the passenger can create his own ride
experience. Complete rolls around the centre line are possible with the corresponding method. The arm
rotation is effected by three drive units and the raise and lover of the arm by a hydraulic control unit.
After all passengers have taken place and the restraints and safety belts are closed, the arm will be
lifted about 20°. The arm starts to rotate and the gondola locking will be released. While the main arm
rotates, the passengers can change the position of the gondola move up to complete rolls by adequate
body shifting and actuation of the wings. The passenger can use the wings for stabilize the gondola, if
a calmer ride is requested.
If the gondola rotation shall be stopped, the passenger only has to move the wings to the horizontal
position manually. The gondola is rotating until the passenger is sitting with his feet downwards. The
number of rotations is counted and can be displayed at the end of the ride.
Fig. 3.3-1 SKY FLY 12 – Complete Ride
Overview Global Village

Ride Description
FLY FRANCE
3.3.1 Electric
The documentation of this ride includes a separate ring folder with a detailed electric diagram.
The electrical equipment of the ride is based on the following norms in the currently valid version.
Bestimmungen für das Errichten von Starkstromanlagen mit

Nennspannungen bis 1000 V ( betreffende Teile )
DIN VDE 0100
Safety of Electrical Installations up to 1000 Volts (relevant parts)
Allgemeine Festlegungen für Niederspannungs-Schaltgerätekombinationen

DIN EN 61439
General agreement of low voltage assembly
Sicherheit von Maschinen – Elektrische Ausrüstung von Maschinen

Teil 1: Allgemeine Anforderungen
DIN EN 60204-1
Safety of machinery – Electrical equipment of machines
Part 1: General requirements
Sicherheit von Maschinen –

Sicherheitsbezogene Teile von Steuerungen –
Teil 1: Allgemeine Gestaltungsleitsätze
DIN EN ISO 13849-1
Safety of machinery –
Safety-related parts of control systems –
Part 1: General principles for design
3.3.2 Pneumatic
The documentation of this ride includes a separate ring folder with a detailed electric diagram.
 An air dryer which works below 0°C is required.
Global Village Overview

Ride Description
FLY FRANCE
3.4 Gondola (G)
2
1
5
6
Fig. 3.3-1 Gondola
The gondola consists of one seat. The moveable wings are installed there, where the passengers can
control the rotation of the Gondola. The wings are made of fiberglass parts. Inside the wings is a spring
steel element (1) which turns back the wings. The structure of the gondola is a robust and welded steel
system. It consists of square tubes and metal sheets on what the components are installed. The
gondolas are pivot-mounted by the kingpin (4) at the gondola attachment. Spring loaded cylinders (3)
for locking while load/unload are mounted at the backside of each gondola. If an electrical or air pressure
power loss appears, the spring-loaded cylinders keep the gondolas locked.
The single foam seats are designed and formed, to prevent forward and sideways motions of the
passengers. The rotation speed of the outer gondolas is limited by a brake disk (5).
The passenger will be secured by a restraint which is locked by side-mounted hydraulically cylinder-
accumulator drives (6). The restraints tube is produced integral and mounted on the gondola bearing
over a cross tube.
An additional bracket is mounted on the restraints tube through that the restraint can be closed by a
pneumatically cylinder (2). This cylinder is only for an automatically closing and is not safety-related.
The pneumatic closing of the restraints is only a support for the operator and not
an automatic closing without an operator check.
Each single restraint must be checked visually and manually by pushing

and pulling for its closed position. They must be as tight as possible to the
passenger’s body.
Gondola (G) Global Village

Ride Description
FLY FRANCE
3.4.1 Restraint system

Each passenger is held safe into the seat by a restraint system. Two independent cylinder-accumulator
drives are used for the restraint locking. This guarantees redundant restraint locking.
The restraints can be opened electrically by

the operator. It is possible to open the
restraints at all gondolas or only at one
gondola via the operator panel (HMI).
Furthermore it is possible to open the
restraints at several gondolas.
Fig. 3.4-2 Restraint System – Hydraulic cylinder-accumulator-drives
In case of power failure the restraints can be opened electrically by the battery
box via sockets at the gondolas or mechanically by adequate tools. (refer chapter
5 “evacuation”)
The cylinder-accumulator drives are equipped with an emergency release system for safety reasons. If
the installed valve does not switch (e. g. power failure or too high internal pressure), the valve can be
released by an emergency release system. Thereby a connection gets created between the piston and
the piston rod area of the cylinder and the piston rod extends.
When stored overnight, the restraints should not be completely closed! A

vacuum can be formed in the cylinder by variations in temperature, which
prevents the opening at the next morning. So the restraints should be closed with
an extra distance to the seat back of about 5 – 10 cm
Global Village Gondola (G)

Ride Description
FLY FRANCE
Limit switch
A mechanical limit switch is mounted at each gondola to control the move of the restraints. The limit
switch detects only the minimum closed position of the restraints.
The distance between the restraint and the seat back is adjusted as mentioned in the actual drawing.
The installed restraints limit switches are mounted in such way, that they will actuate at this distance.
Fig. 3.4-3 Restraints - Limit Switch
A start of the ride is only possible if all restraints are closed.
HOWEVER, THE MANUAL CHECK BY THE OPERATOR IS ALWAYS

NECESSARY!
In automatic mode all restraints can be opened by the operator at the operator panel. Furthermore the
operator can open the restraints of one or several gondolas by the Touch-Display.
Gondola (G) Global Village

Ride Description
FLY FRANCE
3.5 Rotation (R)
Fig. 3.5-2 Sky Fly schematic clock Fig. 3.4-1 touch panel display
Three motors rotate the arm. To describe the position of the arm/gondolas the control system uses the
dial of a clock.
2
1
Fig. 3.5-4 3D model of rotation part Fig. 3.5-3 slewing ring
One Motor is equipped with a brake (1). This brake fixes the arm when the passengers enter/exit the
gondolas. For safety reason this motor brake has not enough force to fix the arm in any position.
So the arm will swing back if the gondolas are too far away from ground.
The Rotation is provided by a slewing ring (2).
Global Village Rotation (R)

Ride Description
FLY FRANCE
3.6 Lift (L)

The Lift sections contains all parts which are used to lift the arm.
3.7 Hydraulic
The documentation of this ride includes a separate manual for the hydraulic system.
3.8 Control cabinet

The control cabinet is installed in the electrical room. Therewith the rotation and the hydraulic will be
controlled. In the right side of the cabinet the power components are installed and in the left side of the
cabinet the controls are installed. On the door to the power cabinet the main switch and electric
instruments are installed (see folder “ELECTRICAL and PNEUMATICAL DOCUMENTS”, page
=LO+MCC/1).
If someone is working on the ride, the main power switch must be turned off and
locked out to prevent powering up
3.8.1 PLC (programmable logic controller)
In the left side of the control cabinet, the PLC (programmable logic controller) is installed.
The ride is controlled by a modular plc system which whose components are installed at different
positions of the ride. The red groups are the “fail safe” with I/O-elements. The additional grey groups
are standard elements with I/O-elements.
Lift (L) Global Village

Ride Description
FLY FRANCE
3.8.2 Power Monitoring Device

The power monitoring device attends for inspection of the energy values of the ride. It is mounted above
the main switch at the front door of the control cabinet +MCC.
It is also possible to check the data at the HMI
Fig. 3.8-1 Power monitoring device
For detailed information see manufacturer manual, which is part of our documentation.
3.8.3 Remote monitoring

Components for the remote monitoring by the manufacturer are
installed inside the control cabinet. The remote monitoring
system is only activated for maintenance by the manufacturer
and should be disabled while normal operation.
Thereby the manufacturer is enabled to check the current status

of the ride, the single messages and faults of the plc system and
the parameter of different ride components. These Information
allows the manufacturer to give an optimum of support to solve
occurred ride problems. The operating and maintenance
personnel can be delivered with useful support on site.
A DSL line, alternatively a broadband router has to be provided

by the customer. The control cabinet has to be connected with
the DSL line by the operator.
For the remote monitoring the following network conditions has

to be prepared by the operating company:
A broadband router with minimum the following specifications is

preferred.
min. downstream: 2MByte/s
min. upstream: 1MByte/s
IP-Address: xxx.xxx xxx.xxx
xxx.xxx xxx.xxx: this information must come from the operating

company to Gerstlauer before installation!
Fig. 3.8-2 Remote Monitoring –

only for maintenance
Global Village Control cabinet

Ride Description
FLY FRANCE
3.9 Station
3.9.1 Touch Display
The TFT-Touch-Display is installed at the operator panel and shows the operator and maintenance
personnel certain functions about operating conditions. The display is not a part of the safety control but
essential for the ride operation.
Risk of damage of the touch screen exists in cause of incorrect handling!

For detailed information see maintenance instructions
 Do not hit or operate the TFT Touch Display with a hard or heavy object;
do not press the TFT-Touch-Display with too much force, as this might
damage the surface of the display or may cause irreparable defects.
 The outside air temperature during the operation is +5 °C to +40 °C (41
°F up to 104 °F).
 Do not pour any liquids over the touch monitor and insert any objects into
the touch monitor. This may cause a malfunction or a short circuit.
 Protect the monitor unit from strong vibration and shocks.
 Protect the monitor unit from direct sunlight and dust.
 Avoid the use of chemicals in the surrounding area of the touch monitor.
Do not use thinner or organic solvents to clean the unit and the display.
3.10 Panels
The following pages show all panels within this ride. These pages are folded in such a way that they are
readable when unfolded while this ring folder is opened at another page.
Station Global Village

PANELS
(1) OPM
(2) OPE
(3) OPW
(4) Battery Box
(5) OPWB
OPM
(1) OPM
No. Type Name Description Function
Red Stops the ride immediately and takes off all Button pressed: cuts immediately all power to motors on the ride
(1) E-Stop
Mushroom Button power to motors on the ride Button released: Ride ready to become reset
Basically all push button lamps have the same function:

Light off: Light flashing slow: Light steady on:
No effect if button is pressed Button ready to execute function Executing function
Other meanings of the light signals will be explained
Yellow lighted Initiate For stopping the ride before the ride program
(2) finished. Afterwards only lowering is Button pressed:Ride stop will be initiated
push button Stop
possible.
Main operating push button of this ride, Button pressed: Executes the selected function
(3) always both have to be pressed
Green lighted Light of: Buttons not active
& Start Maintenance Mode: executes the selected
push button Light flashing slow: Ready to execute selected function
(7) maintenance function on the touch screen
Normal Mode: ride dispatch Light steady on: Executing the selected function
White lighted Close Close all restraints after the ride has
(4) Button pressed: Closes the restraints
push button Restraints completely stopped
Green lighted Lower

(5) Lowers gondolas Button pressed: Gondolas will be lowered
push button Gondola
White lighted Open Opens all restraints after the ride has
(6) Button pressed: Opens the restraints
push button Restraints completely stopped
(7) see (3) Start see (3) see (3)
Button pressed: Resets in case of a fault the pending fault or

activated the emergency stop circuit (maintenance mode required)
Red lighted Light off: No faults pending or ride is off

(8) Fault Reset For fault indication and fault reset
push button Light flashing slow: Indicates a Message
Light flashing fast: Indicates a ZoneStop or Warning
Light flashing very fast: Indicates an EmergencyStop
Position On: Control voltage is switched on

(9) Selector Switch Ride On/Off Switch on this selector switch to switch the
control voltage on or off Position Off: Control voltage is switched off
Panel Enable the operator panel functions of this Position On: Operator Panel OPM is enabled
(10) Key Switch panel by choosing the on position of this key
Enable Position Off:Operator Panel OPM is disabled
switch
Position 1 Maintenance Mode: Ride is in maintenance mode and

Operating Select with this key switch the required ready to operate the ride (for maintenance mode only)
(11) Key Switch
Mode operating mode Position 2 Normal Mode: Ride is in normal mode and ready to
operate the ride with guests
Green lighted Activate Button pressed: Selected Mode will be activated

(12) For activating the Operation Modes
push button Mode Light steady on: Mode is Activated
OPE
(2) OPE

Red Stops the ride immediately and takes off all Button pressed: cuts immediately all power to motors on the ride
(1) E-Stop
Mushroom Button power to motors on the ride Button released: Ride ready to become reset
Green lighted Start Confirms that the ride is ready for dispatch,
(2) Button pressed: Confirms that ride is ready for dispatch
push button Enable which is shown on the main operator panel.
OPW
(3) OPW
Red mushroom Stops the ride immediately and takes off all Button pressed: Cuts immediately all power to motors on the ride
(1) E-Stop
button power to motors on the ride Button released: Ride ready to become reset
(2) Push button Raise As long as the button is pressed the hydraulic
Button pressed : Gondolas raise
cylinders retract
(3) Push button Lower As long as the button is pressed the hydraulic
Button pressed: Gondolas lower
cylinders extend
(4) Push button forward As long as the button is pressed the arm
Button pressed: Arm with gondolas jogs forward/clockwise
rotates clockwise
(5) Push button reverse As long as the button is pressed the arm
Button pressed: Gondolas jogging backwards/counterclockwise
rotates counterclockwise.
(6) Push button open As long as the button is pressed the restraints
Button pressed: All restraints open
are opening.
(7) Push button close As long as the button is pressed the restraints
Button pressed: All restraints close
are closing.
lock/ Enables/disables the rotation of the gondolas Button pressed: Switch between enabled and disabled rotation of the
(8) Push button
unlock around their longitudinal axis gondolas around their longitudinal axis
As long as the button is pressed the greasing

(9) Push button grease Button pressed: Activates the ball bearing slewing ring greasing
system at the ball bearing slewing ring is
system
active
(10) Push button enable After turning on the panel this button has to be
Button pressed: Ride reacts to the signals of the panel
pressed for enabling the panel
(11) Push button ---- without function Button pressed: Nothing happens
I: Panel is ON
(12) Selector switch ON/OFF Turns the panel (radio transmitter) on/off 0: Panel is OFF
Maintenance mode: see Abitron manual
(13) Selector switch ---- without function Nothing happens
(14) Selector switch OPW enable Enables the panel Left: OFF Right: ON
Activating the OPW panel:

First switch the OPM to Maintenance Mode [Operating Mode] and disable OPM by switching OPM selector switch [Panel Enable] to “0”.
Now switch OPW Enable (14) to ON and take the OPW out of the box. There is a touch switch inside the box to check if the OPW is at its place. When the
OPW is not at its place and not on then the ride cuts the power from the motors via e-stop.
Now turn the OPW selector switch ON/OFF (12) to ON and press the OPW push button enable (10).
Push and pull once E-Stop (1). After that, the ride is ready for use with the OPW.
For deactivation: First put the OPW in its box and then turn the OPW selector switch ON/OFF (12) to OFF.
BATTERY BOX
(4) Battery Box
(1) Push button open restraints Opens the restraints of the connected gondola by
Button pressed: Restraints open
activating both locking devices
locking device left Energises the left (direction of travel) locking device.
(2) Push button So the internal valve opens and the right locking Button pressed: the left locking device opens
activate
device holds the restraints alone
locking device right Energises the left (direction of travel) locking device.
(3) Push button So the internal valve opens and the left locking Button pressed: the right locking device opens
activate
device holds the restraints alone
The battery box consists of a rechargeable battery inside the box and a small operator panel with three push buttons.
The battery box has one plug connector to connect the box at the required position at the gondola and one plug connector to connect the box at the battery
charger. The 24V DC-battery voltage may not be used for the normal ride operation!
The corresponding battery charger is installed inside the control cabinet. While normal mode is activated the
battery box has to be connected to the plug-in box at the control cabinet. Otherwise the ride operation is not
possible. This guarantees, that the batteries always are charged. Thereby it will be prevented, that the unit will
be forgotten at the gondola.
Check the battery box

Pre-conditions
 Battery box nowhere plugged
Executed by: Skilled and trained Maintenance Personnel

Human action: Press any of the three push buttons (1), (2) or (3) at the panel
Ride reaction: All three push buttons light up.
Human action: If none of the push buttons light up, check if the battery is loaded or the fuse is broken.
OPWB
(5) OPWB
Opens the brake at motor M3
Risk of banging and squeezing through the movement of the arm!

 To be activated only by qualified and skilled operating personnel with utmost caution.
 The emergency stop button has NO function! The movement of the arm can only slowed by the key switch
 The corresponding manual and the national safety regulations must be followed in any case.
4 Operation........................2
4.1 Operation with passengers (Normal Mode) ....................... 2

4.1.1 Allowed passengers .................................................................... 3
4.1.2 Switching into Normal Mode ....................................................... 3
4.1.3 Start function ............................................................................... 4
4.1.4 Lower function............................................................................. 5
4.1.5 Stop function ............................................................................... 6
4.1.6 Restraints functions .................................................................... 7
4.1.7 Leak test for valve ..................................................................... 10
4.2 Operation without passengers (Maintenance Mode) ........ 11
4.2.1 Ride Start-up ............................................................................. 12
4.2.2 Ride Start-up after power loss................................................... 14
4.2.3 Switching into maintenance mode ............................................ 15
4.2.4 Rotation function ....................................................................... 18
4.2.5 Open the motor brake (OPM).................................................... 19
4.2.6 Raise/lower function.................................................................. 20
4.2.7 Fault handling ........................................................................... 21
4.2.8 Restraints functions .................................................................. 27
4.2.9 Greasing the outer slewing ring ................................................ 37
4.2.10 Hydraulic oil heating.................................................................. 38
4.2.11 Over speed test......................................................................... 39
4.2.12 Adjusting the numbers of rotation ............................................. 41
4.3 Ride Shutdown ................................................................ 42
4.3.1 Regular Shutdown .................................................................... 42
4.3.2 Irregular Shutdown after power loss ......................................... 42
4.4 Revision index Operating Instruction ............................... 43
4.5 Revision index PLC ......................................................... 43
Operation
FLY FRANCE
4 Operation
Advice:
 The safety and control devices shall never be shut off for any reason. Covers,
cabinet doors and fencing should be closed at all times.
 Movement of the ride should only be done by control of the PLC. This allows
you to follow the positions of the ride on the control O.
 First read this operator manual, the delivered appendix and operator manuals
of the installed components before you start working with the ride!
 The technical documentation includes important information for the operator
and maintenance; therefore it must be kept close to the ride.
4.1 Operation with passengers (Normal Mode)

According to the number of passengers a sufficient amount of qualified operating personnel is needed
to ensure a safe ride.
The Normal Mode is for daily operation with passengers and in this mode all movements of the ride are
fully automatic.
Before ride operation daily test runs must be done. All functions regarding security devices must be
tested in accordance with our safety guidelines.
The operator personnel has to pay attention to changes in driving behaviour of the ride while operating
– the maintenance staff must be informed if necessary. Especially while slowing down the ride, the
operator personnel must ensure a gentle and pleasant ride for the passengers.
You can prevent emergency situations by watching the ride and by acting quickly.
The start of ride respectively the ride needs to be stopped immediately if nausea,
unconsciousness or death of passengers occurs.
The ride must be stopped immediately if there is any fire in the station area or in the
adjacent rides. Fire inside the ride building or in the adjacent rides might cause panic
among passengers and in the waiting queues. The passengers must instantly be evacuated
safely.
Animals and items (spare parts for maintenance and repair of the ride, loose (e.g. glasses,
flip-flops), pointed or spacious items, bags and backpacks belonging to passengers etc.)
are prohibited to be transported with the ride.
Entering and exiting the gondolas is allowed only when ride is stationary. This should be a
calm and orderly procedure.
In case of power failure or defect entrance gates (loss of the lock pressure) the access to
the entrance gates and the ride area has to be prevented to prevent injuries of the
customers
Operation with passengers (Normal Mode) Global Village

page 2 / 43 2177-99_04-Operation-2017-10-09.docx
Operation
FLY FRANCE
4.1.1 Allowed passengers
The operating company of the ride decides who is allowed to go on the ride. It is vital for the
passenger´s life that this decision is observed. In chapter 3 “Ride description”, section
“intended use of ride” it is defined who would be allowed to ride (e.g. age, height, weight,
and physical condition).
4.1.2 Switching into Normal Mode
Human action: Switch OPM key switch [Operating Mode] (11) into position
NORMAL MODE
Ride reaction: OPM touch panel indicates that the NORMAL MODE is selected.
OPM push button [Activate Mode] (12) will start flashing
Human action: Press the flashing OPM push button [Activate Mode] (12)
Ride reaction: OPM push button [Activate Mode] (12) lights up steady and the
OPM HMI touch panel indicates that the NORMAL MODE is
activated.
The ride is ready for normal operation.
Fig. 4.1-1 screen "normal - mode"
Global Village Operation with passengers (Normal Mode)

2177-99_04-Operation-2017-10-09.docx page 3 / 43
Operation
FLY FRANCE
4.1.3 Start function

Pre-conditions
 No E-Stop or fault or warning pending

 Normal mode is active
 Restraints closed and locked (after all were opened)
 No Dispatch Inhibit condition pending
Executed by: Skilled and trained Maintenance or Operations Personnel

Human action: Make sure all guests are safely seated and each single restraint
was manually checked by the operators!
Human action: Press flashing OPE push button [Start Enable] (2)
HOWEVER, THE MANUAL CHECK BY THE OPERATOR IS ALWAYS

NECESSARY!
Ride reaction: both OPM-push buttons [Start] flash.

Make sure that only allowed passengers sit inside the ride and all
restraints are as tight as possible to the passenger´s body.
Human action: Press and hold both flashing OPM push buttons [Start] (3) & (7)
at once
Ride reaction: Gondolas will raise to the top position and the gondola interlock
will be released.
The arm will start to rotate the adjusted number of rounds when
the top position is reached.
After the ride time is over the rotation will be stopped in the top
position and the gondolas interlock get locked automatically.

Operation
FLY FRANCE
4.1.4 Lower function

Pre-conditions
 Ride time is over or Stop initiated by the operator

 Rotation has stopped
 Operator ensured that
 All wings are horizontal
 All passenger´s heads are upwards
Fig. 4.1-1 right position for lowering

Ride reaction: OPM push button [Lower Gondola] (5) will start flashing.
Human action: Ensure that all gondolas are in right position for lowering
(horizontal, head upwards)
Press the flashing OPM push button [Lower Gondola] (5)
Ride reaction: The gondolas will be lowered until it reaches their home position.

Operation
FLY FRANCE
4.1.5 Stop function

Pre-conditions
 None
Note:
After the ride time is up, the rotation stops and the gondola´s interlock will be
locked. The ride can also be stopped manually by the operator before the ride
time is over.
stop the ride manually

Human action: Press OPM push button [Initiate Stop] (2)
Ride reaction: OPM push button [Initiate Stop] (2) is flashing.
The ride will stop rotation, as soon as possible and the gondolas
interlock will be locked.
OPM touch panel indicates that the ride has stopped. Push button
lights up.
Note:
For lowering of the ride into home position see chapter
Lower function; page 5!

Operation
FLY FRANCE
4.1.6 Restraints functions

Pre-conditions
 No E-Stop
 These function is available at all operating modes
 No dispatch request pending, motor de-energized, ride is standing still in home position
Open all restraints

Ride reaction: OPM push button [Open Restraints] (6) flashes.
Human action: Press the flashing OPM push button [Open Restraints] (6)
Ride reaction: OPM push button [Open Restraints] (6) is illuminated for a
certain time.
All enabled restraints get unlocked and open automatically.
OPM HMI-Touch indicates that the restraints are opened.

Operation
FLY FRANCE
Open single restraints

Human action: Select the gondola for “Single Opening” on the OPM HMI touch
panel.
Ride reaction: The selected gondola will be marked on HMI touch panel.
OPM push button [Open Restraints] (6) flashes.
Human action: Press the flashing OPM push button [Open Restraints] (6)].
certain time (few seconds).
The restraints of the selected gondola are unlocked and open
automatically.
OPM touch panel indicates that the restraints are opened.
Open several restraints

Human action: Select the gondolas for “Several Opening of Restraints” on the
OPM touch panel.
Ride reaction: The selected gondolas will be marked on OPM touch panel.
OPM push button [Open Restraints] (6) flashes.
certain time.
The restraints of the selected gondolas are unlocked and open
automatically.
HMI touch panel indicates that the restraints are opened.
Note:
The single / several opening of restraints is not an emergency opening.
The emergency release by the battery box is always possible.

Operation
FLY FRANCE
Close restraints
Ride reaction: OPM push button [Close Restraints] (6) flashes.
Human action: Make sure that the restraints of all enabled gondolas are once in
their open positions.
Press the flashing OPM push button [Close Restraints] (6).
Ride reaction: All restraints close.
OPM touch panel indicates that one or more restraints are in
minimum closed position.
Human action: All restraints have to be checked manually and visually by the
operator personnel.
Each single restraint must be checked visually and manually by pushing

and pulling for its closed position. They must be as tight as possible to the
passenger’s body.
The restraints limit switches monitors only a minimum dwell angle and not
if the restraints are tight to passenger’s body!
The restraints of all enabled gondolas must be opened and closed after each ride
cycle (cyclic test of the restraints limit switches for change of state).
The safety function of the restraints and its monitoring devices are checked
before each cycle. The ride can only started if the restraints are closed and no
fault or warning is pending.

Operation
FLY FRANCE
4.1.7 Leak test for valve

Pre-conditions
 This function is available in the NORMAL MODE
This test is started automatically every time the OPM key switch [OPERATING MODE] (11) is switched
to “NORMAL MODE” and repeats itself automatically after every 100 starts.
Ride reaction: After the rotary drive stops in Home Position the OPM push button
[Lower Gondola] flashes
Human action: Press OPM push button [Lower Gondola] (5)
Ride reaction: Lowering starts and test is activated automatically
Ride reaction: Message leak test appears on HMI
Fig. 4.1-2 Valve Test Pop-Up
Ride reaction: Lowering hydraulic pump and release valve is activated for 5 sec.
During this time the pressure in both valves on cylinder 1+2 may
not fall below 70bar. After a testing time of 5 sec. lowering is
started.
As soon as the gondola arm is back in Home Position and the
hydraulic aggregate is turned off, a corresponding fault indication
appears if the test is failed.

Operation
FLY FRANCE
4.2 Operation without passengers

(Maintenance Mode)
All actions described in this section are only allowed without passengers in the gondolas.
Some safety functions are disabled in maintenance mode.
Animals and items (spare parts for maintenance and repair of the ride, loose (e.g. glasses,
flip-flops), pointed or spacious items, bags and backpacks belonging to passengers etc.)
are prohibited to be transported with the ride.
 Faults and failures during operation must be repaired immediately. To do this the ride must be
shut down.
Fix the arm to the ground before disassembling the gondolas
Global Village Operation without passengers (Maintenance Mode)

Operation
FLY FRANCE
4.2.1 Ride Start-up

Ride Start-up after regular ride shutdown
Pre-conditions
 Incoming Power available for ride control +MCC

 PLC, Networks & touch panel powered
 Key switch [Operating mode] on NORMAL MODE
 No faults pending

Human action: Turn OPM-key switch [Ride On/Off] (9) into position ON.
Ride reaction: Field sensor devices get powered.
Pop-up appears on the HMI-Touch
Human action: Pop-up must be read and confirmed.
a status bar shows the progress of the start-up procedure
Step 1: Select and activate maintenance mode

Human action: Turn OPM key switch [Operating Mode] (11) into position
MAINTENANCE MODE.
Ride reaction: OPM touch panel indicates that the MAINTENANCE MODE is
selected.
Human action: Do maintenance works according to the maintenance instruction.
If any of the pre-conditions is not met, the OPM touch panel indicates this with an
according text message (e.g. main circuit breaker in OFF position).
Step 2: Activate main operator panel

Human action: Turn OPM key switch [Panel Enable] (10) into position
ENABLE.
If the Key switch already is on, switch it off and on again
Ride reaction: OPM touch panel indicates that panel is enabled.
Operation without passengers (Maintenance Mode) Global Village

Operation
FLY FRANCE
Step 3: Reset E-Stop

Human action: press OPM push button [Fault reset] (8).
Ride reaction: Actuator devices powered,
main switch switches on.
OPM touch panel indicates that emergency stop is being reset.
Note:
Any Emergency Stop has an effect on the entire ride independent from the
selected operating mode. All actuators are de-energized and the ride will move
to its home position by gravity only
Step 4: Wait for required pressure:

Human action: Wait until minimal pressure is reached.
Ride reaction: The ride starts the next step automatically after the required
pressure is reached.
Step 5: Reminder: “Execute at least one cycle without passengers”:

Ride reaction: Pop-up appears on the HMI touch panel
Human action: Pop-up must be confirmed.
Ride reaction: both OPM push button [Start] (3) & (7) flash
Human action: press both OPM push buttons [Start] (3) & (7)
Note:
Before daily operation (especially at low temperatures) the grease is cold.
Therefore, it might be necessary to do more test runs than usually and that the
first test runs are done with loaded gondolas. All pneumatic operated components
have to be operated free movably. No snow and ice should be on the ride
structure or on any movable parts.
Step 6: Ready for Normal Mode:

Ride Reaction: The ride is ready for normal operation
The OPM touch panel indicate the maintenance screen
Human action: Turn OPM key switch [Operating Mode] (11) into position
NORMAL MODE
Press the flashing OPM push button [Activate Mode] (12).

Operation
FLY FRANCE
4.2.2 Ride Start-up after power loss

Pre-conditions
 After a shutdown due to power loss the ride should fulfil the following pre-conditions for start-
up:
 Incoming Power available
 PLC, Networks & Touch Panel powered
Executed by: skilled and trained Maintenance Personnel
Note:
Same sequences as after a regular shut down, for detailed information see
chapter 0 Ride Start-up after regular ride shutdown page 12

Operation
FLY FRANCE
4.2.3 Switching into maintenance mode
MAINTENANCE MODE
Ride reaction: OPM HMI touch panel indicates that the MAINTENANCE MODE
is selected.
OPM push button [Activate Mode] (12) flashes
OPM touch panel indicates that the MAINTENANCE MODE is
activated.
The ride is ready for maintenance operation.
Fig. 4.2-1 screen "maintenance - mode"

Operation
FLY FRANCE
4.2.4 Time setting

Human action: Select touch button [TIME DATE] (1) on display SCREENS
Ride reaction: Pop-up (2) for settings appears
1
Fig. 4.2-1 time setting
In order to adjust the time, first press touch button [CHANGE] (3)
Note:
All changes have to be confirmed with ENT (4), then the cursor moves to the next changeable position.
 Change DATE/day and press ENT (4)

 Change DATE/month and press ENT (4)
 Change DATE/year and press ENT (4)
 Change TIME/hours and press ENT (4)
 Change TIME/minutes and press ENT (4)
After all time settings have been made, press [REWRITE] (5) in order to save the changes.

Operation
FLY FRANCE
4.2.5 Maintenance dispatch

Pre-conditions
 No E-Stop or fault or warning pending

 Maintenance mode is active
 Restraints closed and locked (after all were opened)
 No Person within the clearance envelope
1
Fig. 4.2-2 screen "maintenance - mode"

Human action: Select on the OPM touch panel screen Maintenance
[MAINT. DISPATCH] (1)
NORMAL MODE
Human action: Press both flashing OPM push buttons [Start] (3) & (7) at once
Ride reaction: Gondolas will raise to the top position and the gondola interlock
will be released.
The arm will start to rotate the adjusted number of rounds when
the top position is reached.
After the ride time is over the rotation will be stopped in the top
position and the gondolas interlock get locked automatically.
Note:
After 5 minutes the maintenance dispatch will automatically be disabled

Operation
FLY FRANCE
4.2.6 Rotation function

Pre-conditions
 No Emergency Stop or fault pending

 No passenger in any of the gondolas
 Maintenance mode selected and active
 Gondolas are lifted
Uncontrolled movement of the Arm!

The brake is not an operational brake and has not enough brake torque
to hold the arm in each position. If the manually rotation has begun, the
arm should be moved as long until it is in 6 o’clock position again. If the
arm gets stopped before it will slide to 6 o’clock position. This can cause
a dangerous situation for the maintenance personnel under these
circumstances!

Human action: Select on the OPM touch panel Maintenance screen or on the
OPM touch panel R-screen (Fig. 4.2-2 Rotation) {page 18}) the button
[JOG FORWARD] (1) or [JOG REVERSE] (2)
Ride reaction: both OPM push buttons [Start] (3) & (7) flash slowly
Human action: For activating the function, press and hold both OPM push
buttons [Start] (3) & (7) at once.
Ride reaction: The gondola arm is rotating forward in slow speed and will be
stopped as soon as one of the OPM push buttons
[Start] (3) & (7) get released or 6 oćlock position is reached.
Fig. 4.2-2 Rotation

1 2
1 2

Operation
FLY FRANCE
4.2.7 Open the motor brake (OPM)

Pre-conditions

 Nothing within the clearance envelope
Fig. 4.2-3 screen rotary drive

1

Human action: Enable OPM main operator panel
Select on OPM touch panel R-screen [Open Motor Brake] (1).
Ride reaction: Both OPM push buttons [Start] flashes slowly.
Human action: Press and hold both OPM push buttons [Start] (3) & (7) at once.
Ride reaction: The motor brake get opened and will be closed as soon as one of
the OPM push buttons [START] (3) or (7) gets released.

Operation
FLY FRANCE
4.2.8 Raise/lower function

Pre-conditions

 Arm in 6 oćlock position
1 2
1 2
Fig. 4.2-4 Lift
Human action: Select on the Maintenance Screen or on the Maintenance Screen
Lift Hydraulic the button [JOG RAISE] (1) or [JOG LOWER] (2).
Ride reaction: both OPM push buttons [START] (3) & (7) flash slowly
Human action: When lowering ensure that all gondolas are in right position
for lowering (horizontal, head upwards) and no one is within
the clearance envelope
buttons [START] (3) & (7) at once.
Ride reaction: The gondola arm is moving to the selected direction in slow speed
and will be stopped as soon as one of the OPM push buttons
[Start] get released. The arm stops when the end position is
reached. The end position cannot be overrun.

Operation
FLY FRANCE
4.2.9 Fault handling
Any malfunction or warning detected by the PLC is displayed at the upper edge of the display by an
error message and stored in the error history (except messages).
Faults are shown in this area.
Fig. 4.2-5 fault Display

Operation
FLY FRANCE
Structure of a fault message (example)
STW_ | 3007 | =0+FIELD-B311, | PRE.. SWITCH | [AIR SUPP…] | DETECTED

PCU-Part Type of fault_ | Fault number | item designation | item | location | cause
PCU-Part
FS Fault / Warning detected at a fail-safe element of the system
ST Fault / Warning detected at a standard element of the system
Type of fault
Warning
prevents start at station
W Reset only possible in maintenance mode
Exception: If warning was provoked by operator, reset in normal mode is possible.
(e.g. : clearance to start although restraints are open)
Zone-Stop (e. g.: Rotation stopped)

Z prevents start at station
Reset only possible in maintenance mode
E-Stop
E Cuts all power to all actors in the entire ride
Reset only possible in maintenance mode
Message
M Indication of not normal but not safety relevant information
Reset possible in all modes
Message
Indication of not normal but not safety relevant information
M_H
Reset possible in all modes
stored in history
fault number. A number assigned to the error messages
item designation A string associated with the component connected to the controller
item Type of faulty part
location location of faulty part
cause cause of message

Operation
FLY FRANCE
Reset a pending Emergency Stop fault
Note:
An Emergency Stop is indicated by a steady light of the OPM-Pilot Light [Fault]
and an according message on the OPM touch panel.
Human action: Select Fault screen on OPM touch panel.

Ride reaction: According window will open.
Human action: Investigate and remove cause for Emergency Stop
(e. g. remote control OPW is in “stand by”*).
Release the according Emergency Stop Button by twisting.
Press OPM push button [Fault Reset] (8).
Ride reaction: If cause of Emergency Stop is eliminated then fault message is
removed from fault screen and all emergency stop powered
devices are re-energized.
Note:
Any Emergency Stop has an effect on the entire ride independent from the
selected operating mode. All actuators are de-energized and the ride will move
to its home position by gravity only
*OPW in “stand by”:

After an amount of time the OPW switches into “stand by” when not used and not
in the corresponding box.
To reset the E-Stop press one of the OPW push button (2)-(5). Then press OPW
push button [enable] (10).

Operation
FLY FRANCE
Reset a pending Zone Stop
Note:
A Zone Stop is indicated by a fast flashing OPM-Pilot Light [Fault] and an
according message on the OPM HMI-Touch

Human action: Investigate and remove cause for Zone Stop.
Ride reaction: If cause of Zone Stop is eliminated then fault message is removed
from fault screen and according devices are re-energized.

Operation
FLY FRANCE
Reset a pending warning
Note:
A Warning is indicated by a slow flashing OPM-PilotLight [Fault] and an according
message on the OPM-HMI

Human action: Investigate and remove cause for warning.
Ride reaction: If cause of warning is eliminated then according fault message is
removed from fault screen.
Air speed indicator warning
If an air speed indicator warning occurs, the ride will end regularly. The ride can
be restarted only after confirmation of the warning.

Operation
FLY FRANCE
Reset a pending message
Note:
A Message is indicated by an according message on the OPM-HMI
Messages do indicate useful information to operate the ride and are indicating
not critical alarms.
Human action: Select Fault screen on OPM-HMI.

Human action: Investigate and remove cause for message.
Press OPM push button [Fault Reset] (8). If necessary, some
messages does disappear by themselves if the cause has been
removed.
Ride reaction: If cause of message is eliminated then according fault message is
removed from fault screen.
Note:
The cause of a message does not affect any of the actuators and can be present
for a set amount of time. Normal Mode operation can be continued.

Operation
FLY FRANCE
4.2.10 Restraints functions

Pre-conditions
 No restraints fault pending

 No passenger on any of the gondolas
 No Dispatch request pending, motors de-energized
Note:
For unlock/open and/or close functions of the restraints see
chapter 4.1.6 Restraints functions page 7!
In case of less passengers or restraints defect the gondolas can get disabled.

Operation
FLY FRANCE
Disable restraints of a not required gondola
A disabled gondola is ignored by the control. The restraints as well

as all other functions of this gondola are NOT monitored.
A disabled gondola must be extra secured mechanically (tension
belts, ropes, locks, etc.) and visibly marked against usage and
opening of the restraints.

Human action: Select on the maintenance screen – restraints settings (Fig. 4.2-6
Restraints setting) the gondolas which restraints should be
disabled.
Ride reaction: The selected gondolas will be marked.
The restraints of the corresponding gondola do not open anymore.
It is disabled and locked for further ride cycles. The control system
identifies the restraints is not present anymore. The gondola is out
of operation.
Fig. 4.2-6 Restraints setting
Note:
The emergency release function with the emergency battery-box is always
possible
A disabled gondola must visibly secured against usage by mechanically

measurements.

Operation
FLY FRANCE
Tests

Human action: Select on the maintenance screen – screens the button [G].
Fig. 4.2-7 selectable screens
Ride reaction: The OPM touch panel displays the gondola test functions.

Operation
FLY FRANCE
Cylinder-accumulator drives (Automatic Test)
Pre conditions
 No restraints fault pending

 No Dispatch request pending, motors de-energized

Human action: The restraints needs to be open and the test devices placed in the
gondola seat (the plunger must face into direction of travel).
Note:
For unlock/open and/or close functions of the restraints see
chapter 4.1.6 Restraints functions page 7!
Human action: The restraint needs to get closed as far as possible and all other
restraints need to be closed.
Fig. 4.2-8 Test device for gondola restraints
Ride reaction: The spring and piston rod of the cylinder get pressed backwards.
The plunger pushes the restraint in opening direction.

Operation
FLY FRANCE
Human action: Select on the maintenance screen- gondola the button

[TEST 1 RESTRAINTS AUTO].
Fig. 4.2-9 Maintenance screen – Gondola
Ride reaction: Both OPM push buttons [Start] flashes slowly.

Human action: Press both OPM push buttons [Start] (3) & (7) at once.
Ride reaction: First the left restraint cylinder will be actuated for about 7 minutes,
i. e. the restraint is held closed by the right cylinder only and will
be tested by the test device.
Then the left cylinder becomes de- energised and the right restraint
cylinder will be actuated for about 7 minutes, i. e. the restraint is
held closed by the left cylinder only and will be tested by the test
device.
Human action: Inspect the piston rod
This procedure shall become repeated at all gondolas.
The indicator on the display shows execute.
If the restraint moved in direction open during this

test, then the gondola needs to become disabled
or cylinder-accumulator drive needs to become
replaced (check for leakage, damage or
corrosion).

Operation
FLY FRANCE
If only the green marked range is to see, both cylinders are

ok and the gondola can be operated further.
Fig. 4.2-10 Test device for gondola restraints As soon as the yellow range appears, the cylinders must be
– OK
checked as soon as possible (for leakage, mechanical
damage or corrosion). If necessary the test must be repeated
(manual test). If the yellow marked range is to see yet, the
cylinder must be changed.
If the red marked range is to see, the gondola must be put out
of operation and the cylinders must be changed.
Fig. 4.2-11 Test device for gondola restraints

– Not OK
Note:
Defect cylinder-accumulator drives can be checked by the manufacturer only, if
they are not damaged, clean and free of grease. To avoid damages during
transportation, take care for an adequate packing, if you send the cylinder-
accumulator drives back

Operation
FLY FRANCE
Cylinder-accumulator drives by the battery box

Executed by: skilled and trained maintenance personnel
Fig. 4.2-12 Plug in box to connect the battery box
Human action: Connect the battery box to the gondola plug-in box and press the
OPER push button [locking device right activation].
Fig. 4.2-13 Operator panel battery box (OPER)

Operation
FLY FRANCE
Ride reaction: The right cylinder-accumulator drive will be actuated, i. e. the

restraint at this gondola will be hold closed by the left cylinder-
accumulator drive only.
Human action: Pull the restraints manually by hand with a force of approx. 300N
(30kg) for several seconds in opening direction. Thereby the left
cylinder-accumulator drive will be tested.
Human action: Press the OPER push button
[locking device left activation].
Fig. 4.2-14 Operator panel battery box (OPER)
Ride reaction: The left cylinder-accumulator drive will be actuated, i. e. the

restraint at this gondola will be hold closed by the right cylinder-
(30kg) for several seconds in opening direction. Thereby the right
This procedure has to be repeated at all gondolas!
If the restraints moved in direction open during

this test, then the gondola needs to become
disabled or cylinder-accumulator drive needs to
become replaced (check for leakage, damage or
corrosion).

Operation
FLY FRANCE
Cylinder-accumulator drives by HMI selection

Human action: Select on the display gondola test functions the button
[TEST 3 CYLINDER LEFT OPEN].
Fig. 4.2-15 Maintenance screen – gondola (daily restraints test)
Human action: For activating the function press both OPM touch buttons [Start]
(3) & (7)
Ride reaction: The left cylinder-accumulator drive will be actuated, i. e. the
restraint at this seat will be hold closed by the right cylinder-
(30kg) for several seconds in opening direction. Thereby the right

Operation
FLY FRANCE
Human action: Select on the display gondola test functions the button
[TEST 4 CYLINDER LEFT OPEN].
Fig. 4.2-16 Maintenance screen – gondola (daily restraints test)
Human action: For activating the function press both OPM push buttons [Start]
Ride reaction: The right cylinder-accumulator drive will be actuated, i. e. the
restraint at this seat will be hold closed by the left cylinder-
(30kg) for several seconds in opening direction. Thereby the left
If the restraints moved in direction open during

this test, then the gondola needs to become
disabled or cylinder-accumulator drive needs to
become replaced (check for leakage, damage or
corrosion).
Note:
You find a detailed description of the test, the test procedure, and “how to do” in
the Help Topics” by pressing the button [Test Help].
Please follow the described procedure!

Operation
FLY FRANCE
4.2.11 Greasing the outer slewing ring
Pre-conditions
 No E-Stop or no fault of greasing unit


Human action: First select on the display the button [Menu]. Then Select on the
display Screen “Menu” the button [Greasing system] (1)
3 4 5 6
Fig. 4.2-17 Screens 1 2
Fig. 4.2-18 adjusting greasing system
Ride reaction: The OPM touch panel opens the display for the adjustments of the
greasing system.
Human action: The amount of rotations within two greasing actions can be
adjusted by [Down] (2) and [Up] (3) buttons.
Ride reaction: The OPM touch panel panel displays the adjusted rotation amount
(3) and the number of greasing impulses (4)
Human action: The greasing system can also be switched on manually by
pressing the button [Greasing System manual] (5) timeout five
seconds.
[GREASING SYSTEM INCHING]

is only available in maintenance mode and greases the gear rim
as long as the touch button is activated. This also works while the
Sky Fly stands still.

Operation
FLY FRANCE
4.2.12 Hydraulic oil heating

Pre-conditions
 For proper heating of the hydraulic oil the following pre-conditions have to be fulfilled:
 None
 This function is available at all operating modes
Human action: Select on the display Maintenance or Lifthydraulic the button

[OIL HEATER AUTO] (1)
Fig. 4.2-19 Screens

Operation
FLY FRANCE
4.2.13 Over speed test

Pre-conditions
 In order to execute a rotation over speed test the following pre-conditions have to be fulfilled:

Human action: Select [maint dispatch] on the maintenance screen.
Switch OPM key switch [Operating Mode] (11) into position
NORMAL MODE
Human action: Select on the screen – rotary drive the button
[TEST 1 OVERSPEED].
Fig. 4.2-20 Rotary Screen
buttons [Start] (3) & (7) at once.
For aborting the test press the OPM push button [Initiate Stop]
(2)
Ride reaction: The OPM touch panel indicates if the test was successful.

Operation
FLY FRANCE
Fig. 4.2-21 Test screen – Rotary drive
Note:
You will find a detailed description of the test, the test procedure, and “how to do”
in the help topics by pressing the button [Test Help]. Please follow the described
procedure.

Operation
FLY FRANCE
4.2.14 Adjusting the numbers of rotation

Pre-conditions
 No E-Stop or fault pending

 Maintenance mode is active
The numbers of rotation can be adjusted from minimum 4 rounds until 18 rounds per dispatch.
Executed by: skilled and trained maintenance personnel

Human action: The numbers of rotation can be adjusted by the [Up] (1) and
[Down] (2) buttons.
Fig. 4.2-22 Adjustment of the numbers of rotation
Ride reaction: The new adjusted numbers of rotation is active for the next ride cycle.
Note:
The numbers of rotation can only be adjusted when ride cycle is NOT started.

Operation
FLY FRANCE
4.3 Ride Shutdown

4.3.1 Regular Shutdown
Pre-conditions
 Ride is empty
Executed by: skilled and trained Maintenance or Operations Personnel

Human action: Make sure that all passengers have left the gondolas.
Human action: Turn OPM selector switch [Ride On/Off] in position OFF.
Ride reaction: All devices outside control cabinet de-energized with the exception
of OPM touch panel.
Persons can lock themselves into the seat!
 The restraints must be closed overnight, so no person can lock

themselves into the seat.
 Observe the operation manual of the hydraulic locking devices!
Note:
The restraints may not be closed completely overnight. By thermal fluctuation
a vacuum can accrue inside the cylinder overnight which prevents the opening
of the restraints next morning. The restraints should be closed with an
additional distance (5 cm up to 10 cm) to the seat back.
Note:
 The gondolas should be secured against uncontrolled rotation (i. e. by
strong winds) during shut down times.
 Alternatively the ride can be raised up, so the gondolas can rotate.
 Operator panels must be covered if they are not in use.
4.3.2 Irregular Shutdown after power loss
An irregular shut down due to power loss can happen at any time.
The arm will oscillate until the gondola is below. By the installed UPS the motor
brake will kept open until the arm finished the oscillation.
Ride Shutdown Global Village

Operation
FLY FRANCE
4.4 Revision index Operating Instruction
4.5 Revision index PLC
part description CRC date

Check -
sum
Global Village Revision index Operating Instruction

5 Evacuation .....................2
5.1 Behaviour in case of emergency........................................ 2

5.2 Evacuation actions ............................................................ 3
5.2.1 Switching into maintenance mode ................................................ 4
5.2.2 Take the main arm into 6 oćlock position ..................................... 5
With main panel ................................................................................................... 5
Open the motor brake (OPM) .............................................................................. 7
Without main panel .............................................................................................. 8
5.2.3 Lower the gondolas ....................................................................... 9
With main panel ................................................................................................... 9
Without main panel ............................................................................................ 11
5.2.4 Open restraints ........................................................................... 12
With main panel ................................................................................................. 12
By battery box .................................................................................................... 13
Mechanically ...................................................................................................... 14
5.3 Restart after evacuation................................................... 15

Evacuation
FLY FRANCE
5 Evacuation
5.1 Behaviour in case of emergency
Stay calm
 Interact always with the passengers and keep them calm!
 Inform the passengers about the situation and inform them to stay in the
gondola and not to try to exit the gondola without help.
Behaviour in case of emergency Global Village

page 2 / 15 2177-99_05-Evacuation-2017-10-09.docx
Evacuation
FLY FRANCE
5.2 Evacuation actions

Before starting any emergency evacuations, find out the cause of the failure. Then decide how the
evacuation should be done without endangering any passengers. This chapter contains possible actions
which have to be done in this order:
1. Take the main arm into 6 oćlock position

2. Lower the gondolas
3. Open the restraints
The brake torque is too low to hold the arm in each position.
If the arm is out of area between 8 o’clock and 4 o’clock, the arm is sliding slowly
to direction 6 o’clock as long as the brake has enough torque to hold the arm.
This can cause a dangerous situation for the passengers at evacuation. The arm
must be moved to position 6 o’clock as far as possible before evacuation. If this
is not possible the arm must be secured mechanically (tension belt, chains, etc.)
(refer 2141-99-00-00-00 retaining security Sky-Fly).
In case that the arm is not settled out after a defect/ E-Stop:
(e.g. due to a mechanical issue)
 Secure each gondola while evacuation, against movement

around its longitudinal axis!
 the passengers must be evacuated by proper ladders,
scaffoldings or cherry picker.
Global Village Evacuation actions

2177-99_05-Evacuation-2017-10-09.docx page 3 / 15
Evacuation
FLY FRANCE
5.2.1 Switching into maintenance mode
MAINTENANCE MODE
Ride reaction: OPM HMI touch panel indicates that the MAINTENANCE MODE
is selected.
OPM push button [Activate Mode] (12) flashes
OPM touch panel indicates that the MAINTENANCE MODE is
activated.
Evacuation actions Global Village

Evacuation
FLY FRANCE
5.2.2 Take the main arm into 6 oćlock position
After a total power failure the arm will oscillate until the gondolas stand below.
With main panel

Pre-conditions

Uncontrolled movement of the Arm!

The brake is not an operational brake and has not enough brake torque
to hold the arm in each position. If the manually rotation has begun, the
arm should be moved as long until it is in 6 o’clock position again. If the
arm gets stopped before it will slide to 6 o’clock position. This can cause
a dangerous situation under these circumstances!

Human action: Select on the OPM touch panel Maintenance screen or on the
OPM touch panel R-screen (Fig. 5.2-1 Screens to rotate page 6) the
button
[JOG FORWARD] (1) page 6 or
[JOG REVERSE] (2) page 6
buttons [START] (3) & (7) at once.
Ride reaction: The gondola arm is rotating forward in slow speed and will be
stopped as soon as one of the OPM push buttons [START] (3) &
(7) get released or arm reaches 6 oćlock position.

Evacuation
FLY FRANCE
1
2
Fig. 5.2-1 Screens to rotate
If it is not possible to turn the arm motorized, you can try to loosen the
motor brake, so that the arm turns itself downwards.

Evacuation
FLY FRANCE
Open the motor brake (OPM)
Fig. 5.2-2 screen rotary drive

1
Human action: Enable OPM main operator panel
Select on OPM touch panel R-screen
[OPEN MOTOR BRAKE] (1).
Ride reaction: Both OPM push buttons [Start] flash slowly.
Human action: Press and hold both OPM push buttons [Start] (3) & (7) at once.
Ride reaction: The motor brake get opened and will be closed as soon as one of
the OPM push buttons [Start] (3) or (7) gets released.

Evacuation
FLY FRANCE
Without main panel
Risk of banging and squeezing through the movement of the

arm!
To be activated only by qualified and skilled operating personnel with utmost
caution.
The emergency stop button has NO function! The movement of the arm can only
slowed by the key switch
The corresponding manual and the national safety regulations must be followed
in any case.
Pre-conditions
 In order to execute rotation functions the following pre-conditions have to be fulfilled:
Gondolas are lifted
No person within the clearance envelope
Gondolas can crash into ground!

Make sure that the hydraulic cylinders which
lift the arm are retract (the arm is up) and
secured against extraction. Otherwise the
gondolas will crash into the ground.
Fig. 5.2-3 Crash!

Executed by: Skilled and trained Maintenance Personnel with utmost caution
Human action: Turn key switch [brake Motor M3 manual release]
Ride reaction: The arm will rotate/oscillate until the gondolas are in their home
position

Evacuation
FLY FRANCE
5.2.3 Lower the gondolas

With main panel
Pre-conditions

 Gondolas are in right position
Executed by: Skilled and trained Fig. 5.2-4 right positions for lowering
Maintenance Personnel
Human action: Select on the Maintenance Screen or on the Maintenance Screen
Lift Hydraulic the button [JOG LOWER] (2) page 10.
Human action: When lowering ensure that all gondolas are in right
position for lowering (horizontal, head upwards)
and no one is within the clearance envelope
Human action: For activating the function, press and hold both OPM push buttons
[START] (3) & (7) at once.
Ride reaction: The gondola arm is moving to the selected direction in slow speed
and will be stopped as soon as one of the OPM push buttons
[START] (3) & (7) get released. The arm stops when the end
position is reached. The end position cannot be overrun.

Evacuation
FLY FRANCE
Fig. 5.2-5 screen lift

Evacuation
FLY FRANCE
Without main panel

In case of total power failure the arm can be lowered by the two installed hand valves at the cylinders.
Pre-conditions

 Gondolas are in right position
Executed by: skilled and trained Maintenance

Personnel
Human action: When lowering ensure that all
gondolas are in right position for Fig. 5.2-6 right positions for lowering
lowering (horizontal, head upwards) and no one is within the
clearance envelope
Fig. 5.2-7 Hand valves for emergency release
Human action: 1.Close both throttle valves (1)

2.Turn the levers of both hand valves (2) to position OPEN.
3.Open carefully and simultaneosly both throttle valves (1)
Ride reaction: the arm will lower slowly down by its own weight.
Note:
After the arm is in its home position, both hand valves must be switched back
to position CLOSED. Otherwise the ride cannot be commissioned

Evacuation
FLY FRANCE
5.2.4 Open restraints
Before you open the restraints, be aware that the passengers

can get up and fall out.
 If the gondolas are NOT in the load / unload position, only the gondola
should be opened from which the passenger can safely disembark.
 Secure each gondola against movement around its longitudinal axis!
With main panel

Pre-conditions
 No E-Stop
 No dispatch request pending, motor de-energized, ride is standing still in unload position
 Executed by: Skilled and trained Maintenance or Operations Personnel
 Ride reaction: OPM push button [Open Restraints] (6) flashes.
Passengers can fall out of gondolas!

The next step will open ALL restraints.
certain time.
All enabled restraints get unlocked and open automatically.
OPM HMI-Touch indicates that the restraints are opened.

Evacuation
FLY FRANCE
By battery box
If the emergency opening of the restraints by control system is impossible, e.g. in case of a power failure,
open the restraints by using the battery box.
Fig. 5.2-8 battery box
1. Connect the battery box to the plug

in box at the gondola.
(refer Fig. 5.2-9).
Fig. 5.2-9 Plug in box to connect the battery box
Press the push Button [Open Restraints]
This procedure must be repeated at all occupied gondolas.
Fig. 5.2-10 Operator panel

battery box (OPER)
After evacuation the battery box has to be connected to the charging plug-in
box at control cabinet. Otherwise the ride cannot set into commission!
The 24V DC battery voltage cannot be used for the normal operation!

Evacuation
FLY FRANCE
Mechanically
The cylinder-accumulator drives are connected with the restraints at both sides.
For emergency release both split pins must be removed

first.
After this the nuts must be unscrewed and removed with an

adequate tool (provided socket key and flat spanner with
wrench size 24). After the bolt is removed at both sides the
piston rods of the cylinder-accumulator drives can be
disconnected from the restraint. The restraint is open now.
Before the gondola gets set into operation with passengers,

the piston rods must be connected with the restraints again.
The bolts must be connected with the nuts, tightened with
the correct torque (80Nm, MoS2 lubricated) and secured
with the split pin.
Fig. 5.2-11 bolt restraints
Once loosened nuts may not be used anymore!

Evacuation
FLY FRANCE
5.3 Restart after evacuation

Eliminate the fault before restarting the ride.
Before operating with passengers, test runs after the emergency situation must be accomplished to
sufficient extent before recommissioning the ride.
Global Village Restart after evacuation

6 Maintenance ...................2
6.1 General advices................................................................. 2
6.2 Gondola ............................................................................. 4
6.3 Ball bearing slewing ring .................................................... 5
6.3.1 Lubrication .................................................................................... 5
6.3.2 Checking the tilting clearance ....................................................... 5
Procedure Gerstlauer .......................................................................................... 6
6.3.3 Checking the backlash .................................................................. 7
6.4 Electrical ............................................................................ 8
6.4.1 Slip ring transformer ...................................................................... 9
6.4.2 Touch panel – SD Card change or removal ................................ 10
Eject SD-Card .................................................................................................... 10
Insert SD-Card ................................................................................................... 11
6.5 Pneumatic ....................................................................... 12

6.6 Hydraulic ......................................................................... 13
6.7 Rotation drive unit ............................................................ 14
6.8 Other maintenance work and checks ............................... 14
6.9 Non-destructive tests NDT ............................................... 15
6.10 Check of the Torque ........................................................ 15
6.11 Preparing the ride for a shutdown period ......................... 15
6.12 Additional maintenance in winter ..................................... 16
6.13 Revision index chapter 6 maintenance ............................ 17
6.14 Maintenance lists ............................................................. 17
Before working at this ride you have to understand chapter 1 “Safety”

to avoid injury!
Maintenance
FLY FRANCE
6 Maintenance
This chapter is for detailed information about the maintenance tasks.
It essential for a proper maintenance.
Section 6.14 Maintenance lists is a tabular view of all maintenance tasks for this ride.
6.1 General advices

First read this operator manual, the delivered appendix and operator manuals of the installed
components before you start working with the ride!
For correct performance of the maintenance works, all necessary documents (drawings, operating
instruction, operation instructions of the used components, maintenance protocols of former tests,
possible requirements or secondary regulations, documentation on changes or repairs, etc.) are to be
hold ready at the ride.
For maintenance work on the ride, you must switch off the main switch at the control cabinet and lock it
out.
Welding at the structure is not allowed. Before welding confer with the seller. The maintenance
personnel must pay attention that a sufficient ground connection is not created in the vicinity of electrical
cables.
All connections must be checked and tested according to the actual operator manual.
If defects are detected on a single component/part then all components/parts of the same type must be
checked.
The used self-locking nuts (DIN 985 und DIN 982) are equipped with a slot at one side in which a plastic
ring is inserted. This ring is snug to the screw while tightening and prevents an independent loosening,
e. g. by vibrations. These nuts are limited in temperature and only useable once.
Quality screw connections with a defined torque must be put for a sufficient visual inspection before
each installation. At any rate only proper, cleaned and pre-treated (e. g. light greased with MoS2) screws
and nuts may be installed.
In case of operation in saline (near the coast) or aggressive atmosphere all movable components are
to be protected with anti-corrosion fluid. Especially for longer shut down times.
Change intervals of safety relevant components with an operating life (TM) < 20 years are listed in the
maintenance instruction. After the end of their operating life, these components have to be checked and
replaced if necessary according to the requirements of the relevant standards.
After an operation life of 20 years, all further safety relevant components have to be checked and
replaced if necessary according to the requirements of the relevant standards.
Use only original spare parts according to the actual spare parts list.
For new parts (spare parts) material certificates according to EN 10204 3.1 are required. The certificates
are to be added to the test book.
Only components and material identical with the original parts respectively parts that are approved by
the manufacturer may be used.
All used parts have to be free of internal and external defects. The parts (axles, bolts etc.) with signs of
wear and scratches have to be replaced immediately. The roughness of the surfaces have to be
General advices Global Village

page 2 / 17 2177-99_06-Maintenance-2017-10-09.docx
Maintenance
FLY FRANCE
observed, according to the fatigue evaluation. Damaged and worn parts have to be replaced
immediately
Only original ride equipment which is adjusted and checked according to the specification of the
manufacturer, is allowed to be used.
Note:
The components of the ride (e. g. covers of the Gondolas) are partly fitted and
mostly not interchangeable.
We suggest before disassembling to mark each component corresponding to its
installation point.
After reaching the wear limit at e.g. wheels, brakes, brake components, restraints paddings etc. those
are to be removed and replaced immediately.
All work regarding transport, storage, installation, electrical connection, operation, handling, ,
maintenance and repair, must be done by qualified specialists (refer chapter 2 General conditions,
Personnel) only.
Pay Attention to:
 All necessary technical documentation;
 Warning signs and marks on the ride;
 Specific rules and needs;
 Local and national laws and regulations regarding work and accident safety;
 Guidelines for manufacturing and operating rides in the momentary valid laws.
 An Overview of all safety regulations gives chapter 1 –Safety Instructions
 To avoid injury to persons and material damage handle the ride parts carefully.
Global Village General advices

2177-99_06-Maintenance-2017-10-09.docx page 3 / 17
Maintenance
FLY FRANCE
6.2 Gondola
Fix the arm to the ground before disassembling the gondolas.
Control and maintenance lists are in the attachment. Responsible and qualified personnel must do the
work. After adjustment test runs must be made.
All drawings are in the attachment and necessary to maintain and to check correctly.
The tests for the restraints can be found in chapter 4 “Operation” -> 4.2.8 “Restraints functions” -> tests
Gondola Global Village

Maintenance
FLY FRANCE
6.3 Ball bearing slewing ring

For lubrication instructions refer drawing.
Nominal lifetime is a minimum of 5000h.
Refer statistics screen on HMI touch
after the expiry of nominal lifetime, the service intervals must possibly be shortened and/or if the wear
is out of tolerance contact manufacturer
6.3.1 Lubrication
Be aware that the greasing system greases only the ring gear of the slewing ring. The race way of the
slewing ring has to be greased manually. For further information refer the technical drawings.
6.3.2 Checking the tilting clearance

From the “Assembly and Maintenance Instructions for Slewing Bearings” by DV-B:
“Large‐diameter slewing bearings are generally delivered with a bearing clearance that ensures good
operating characteristics and functional reliability. After a prolonged operating time, the clearance can
increase through wear to the slewing ring raceways. It is necessary to check the tilting clearance in
specified time intervals.
1. After mounting the bearing in a system, permanently mark 4 measuring points on the circumference
of the upper and lower structures, if possible in the main load direction.
2. Measure the initial clearance between the structures at every measuring point and record the
values.
3. Repeat the measurement after 1000 operating hours, making sure that the measuring conditions
are the same.
4. Shorten the time intervals to 200 operating hours between the measurements if the measured
increase of the tilting moment is about 75% of the permitted increase. As wear increases further, the
inspection interval should be shortened once again (to 50 –100 operating hours).
5. The slewing ring must be changed if the maximum clearance (1.9 mm) is exceeded.”
Global Village Ball bearing slewing ring

Maintenance
FLY FRANCE
Procedure Gerstlauer
Ride is off and in 6 oćlock position and lowered.
A point is marked where the dial gauge can be set as near as
possible to the slewing ring.
A lift cylinder is placed near the dial gauge (place also marked).
The pressure in the lift cylinder gets carefully increased until the
dial gauge´s indicator stops moving. The shown value gets noted.
All annually measures have to be performed in the same way at
the same marked point.
Fig. 6.3-1 placed lift cylinder
Ball bearing slewing ring Global Village

Maintenance
FLY FRANCE
6.3.3 Checking the backlash
For the measurement of the backlash, the

marking/prick-punch of the ball bearing slewing
ring needs to be at the corresponding
position/motor (refer illustration).
Fig. 6.3-2 Measurement of the backlash
Global Village Ball bearing slewing ring

Maintenance
FLY FRANCE
6.4 Electrical
Control and maintenance lists for the electric equipment are in the attachment. Responsible and
qualified specialists must do the work. After adjustment test runs must be made.
All drawings are in the attachment and necessary to maintain and to control correctly.
 All electrical components must be serviced and tested regularly.
 Clean all dirty parts.
 Check auxiliary contact at/on conductors for dirt and oxidation. (dirt and oxidation can lead
to malfunction, especially at low current and voltage levels)
 If parts of the components are changed and repaired, you need to test the new parts
according to DIN EN 60204 part 1 and according to local laws and regulations.
 The electrical safety of the ride must be checked and tested in regular time intervals
according to local laws.
 You must observe the electric technical rules.
The electrical equipment of the ride includes the main switch cabinet, operator panel, Touch-Display
and the components installed in the ride.
Safety against electrical shock according to IEC 364-4-41/DIN VDE 0100 part 410,
the following measures are used:
Against direct contact: Safety isolation on active parts
Against indirect contact: Failure Voltage Safety switch

Voltage is also present, when master switch is turned off!
Nevertheless all metal parts must be connected/grounded according to stringent law.
Protective measures against a static charging:

 Most synthetic materials are strongly chargeable and they must be
kept away from endangered components (circuit boards, electronic
equipment etc.).
 When working on electrostatically endangered components make
sure that everything is grounded in a proper way.
Electrical Global Village

Maintenance
FLY FRANCE
Contact with voltage-carrying parts can result in death or serious

injuries!
If someone is working on the ride, the main power switch must be

turned off and locked out to prevent powering up
By mandatory reasons the power off of the ride can get deviated if:
 The sort of devices or tools for this works excluding an endangerment by body flow through or
arc;
 The operating company mandates only persons who are able to work under energized parts;
 The operating company defines and effects more technical, organizational and personal
security measures which make sure that a sufficient security against endangerment by body
flow through or arc.
Note:
 Do not change the position of the proximity switches; they are adjusted
to the ride.
 Do not place metal items, steel-toed booths, etc. close to this proximity
switches; they could cause faults and malfunctions.
 The electrical equipment of the ride is to be inspected and checked at
regular intervals. Defects such as loose connections or scorched cables
must be rectified immediately.
 Compare all electrical specifications with the locally available facilities
and the required conditions, i.e. voltage, frequency, protection class,
insulation class, pole reversibility etc.
High-frequency, electromagnetic faults can be caused by the usage of radio technology (e.g. mobile
phone, radio unit) in the system control (safety SPC).
The usage and/or operation of radio units is only sensible if the control cabinet is closed or, if the doors
of the control cabinet are open, with a distance of at least 2m to the control system.
6.4.1 Slip ring transformer
 Please use residue-free switch cleaner (e.g. Loctite 7063) and wait at least 5 minutes for a
dried surface.
 The dust from the contacts can blow of by air pressure.
 The carbon brush must move free back in position by themselves. If not, adjust.
 Every carbon brush must be checked for completeness. It is possible that bolts or springs
are missing after an amount of time.
Global Village Electrical

Maintenance
FLY FRANCE
6.4.2 Touch panel – SD Card change or removal
Series SP5000
Eject SD-Card
Before the SD-Card is ejected the LED “CARD ACCESS“ of the SD-Card at the backside of the HMI
will be illuminated.
Alternatively (one after another) touch the two opposite corners of touch panel (either left top and right
bottom or left bottom and right top).
If you have done this for a few times then, you can see a toolbar in the display (either on top or at
bottom)
On the toolbar displayed, select the blue symbol which looks like a SD-Card
After this confirm yes to the question if you want to remove the SD-Card
Electrical Global Village

Maintenance
FLY FRANCE
Check the LED status of the SD-Card before you remove it. The LED “CARD ACCESS” must be off
Now you can remove the SD-card.
Insert SD-Card
To insert the SD-Card nothing must be observed. Insert the SD-Card and the LED “CARD ACCESS“
will be illuminated.
Global Village Electrical

Maintenance
FLY FRANCE
6.5 Pneumatic
The pneumatic system must be free of pressure before working on it.
Note:
 The ride must be operated with regular prepared oiled compressed air
without aggressive media.
 Do not oil too much.
 Dirty or incorrectly oiled compressed air shortens the operating life of the
pneumatic elements.
 Check all lines, hoses and screwed connections regularly for leaks and
obvious damage. Repair damage immediately. Splashed oil may cause
injury and fire.
 All pneumatic components must be serviced and tested regularly.

 All dirt particles must be cleaned from the parts.
Control and maintenance lists for the pneumatic equipment are in the attachment. Responsible and
qualified personnel must do the work. After adjustment test runs must be made.
All drawings are in the attachment and necessary to maintain and control correctly.
Pneumatic Global Village

Maintenance
FLY FRANCE
6.6 Hydraulic
The hydraulic system must be free of pressure before working on it.
Failures while commissioning can affect the operating behavior, operating costs and the product life of
hydraulic unit significant. We suggest doing the following procedures for commissioning. The
commissioning should be executed by skilled persons.
 Check the oil tank for contamination before infilling the hydraulic oil. Do not use fibrillate cleaning
rag.
 Check the tubing between hydraulic unit and actor. The pressure range of the used tubes and
fittings have to be conform to the hydraulic unit. The use of tubes whose inner diameter is too
small, or that are longer than those required, leads pressure losses which affect the
performance of the entire system. After installation the tubes may not be welded or soldered.
All tubes have to be installed accurate, carefully and free of tension. They have to be short and
straight as possible. Avoid the use of unnecessary angles and bending. All hydraulic tubes have
to be clean inside, free of rust and dirt. Check the correct connection of each actor according to
the hydraulic schema.
 Check the oil level at the tank. Refill with clean oil according to the technical specifications if
necessary.
 The ride has to be bled before commissioning. The bleed screws have to be open until foam
free oil is leaving. Check all fittings for leaks.
 Check the stated values at the electric pump and the electro-hydraulic parts for correct current
and voltage.
 To avoid dry run fill the hydraulic pump with oil if necessary. Check the direction of rotation.
Heavy damages can occur, if the direction of rotation of the hydraulic pump is not correct.
 It could be work around to oil leaks, gumming and formation of rust, if the hydraulic parts are
stored more than 6 month. In that case the hydraulic system has to be checked and cleaned by
skilled personal.
 Check if the electric motor is displaced on the pump (by transport etc.) because some pump
types do not allow radial and lateral load.
 Control system and actors should be commissioned with low flow rate and pressure to avoid
damages by faulty operations.
 All parts have to be flushed well before the ride get commissioned with full operating pressure
and operating speed.
 Take care that the ride can start safe and no operating personnel stay inside dangerous areas.
The following values have to be checked all the time:
 oil level
 oil temperature
 outer leakages at the entire ride
 noise emission
 temperature of hydraulic pump and motor
 pollution of the installed filters
Control and maintenance lists for the electric equipment are in the attachment. Responsible and
Some kind of maintenance works depends on the number of operating hours. The operating hours of
the hydraulic can be reviewed at the statistic screen in maintenance mode.
Global Village Hydraulic

Maintenance
FLY FRANCE
6.7 Rotation drive unit

 All rotation drive units must be serviced and tested regularly.
 All dirt particles must be cleaned from the parts.
A control and maintenance lists for the rotation drive units are in the attachment. Responsible and
6.8 Other maintenance work and checks

Check and maintenance lists are in the attachment. Responsible and qualified personnel must do the
work. After adjustment test runs must be made.
Some kind of maintenance works (rotary joint, etc.) depends on the number of operating hours. The
operating hours of the hydraulic can be reviewed at the screen.
Fig. 6.8-1 Statistics
Rotation drive unit Global Village

Maintenance
FLY FRANCE
6.9 Non-destructive tests NDT

Depending on the construction, material and potential fault different methods and procedures are
applied.
Check and maintenance lists for the ND-test are in the attachment. Responsible and qualified personnel
must do the work. After adjustment test runs must be made.
6.10 Check of the Torque

After about 100 operating hours or 14 days respectively all screws have to be tightened again with the
torque defined in the drawings to compensate the compression set. Pretension needs to be checked in
further intervals. These intervals increase later on to one month, 3 months, 6 months and annually. If
compression set is detected, the checks are to be done more often.
All connections, which are bolted, need to be tightened with the correct torque. Any connections without
torque must be secured with Loctite.
The specifications on the drawings

have absolute priority!
Pretension method of torques according to DIN EN 13814
6.11 Preparing the ride for a shutdown period

Necessary maintenance work for the start of the season can be also realized at the end of the season.
The purchasing time of the spare parts resp. the testing period must be taken into account.
If you shut the ride down for a longer time period (i. e. wintertime), you must protect the ride against:
 corrosion
 frost
 contamination
 moisture
 wind
 rodent infestation
 vandalism
The manufacturer is not liable for any damage caused by improper or incomplete
protection during the wintertime on the part of the operator of the ride!
Control and maintenance lists are in the attachment. Responsible and qualified personnel must do the
work. After adjustment, test runs must be made.
Global Village Non-destructive tests NDT

Maintenance
FLY FRANCE
6.12 Additional maintenance in winter

Operating the ride below +5°C is NOT the intended use of the ride!
Should the ride anyway used under the stated temperature here are some information we do not want
to hide from you:
ATTENTION!
In case of operation below indicated operating temperatures, the following
measures are to be taken :
Before daily operation and after breaks:
Remove ice. People could get hurt by falling ice.
All movable parts, guidance and bearings must be free of ice. These parts can
be restricted in their function due to formation of ice. Further equipment is to
be checked for their proper functioning.
The pneumatic system must be dry and drained – an appropriate air dryer is to
be used
Sufficient test runs (if necessary with dummies) and functioning tests are to be
carried out in order to heat up grease and oil to the operating temperature.
Additional maintenance in winter Global Village

Maintenance
FLY FRANCE
6.13 Revision index chapter 6 maintenance

6.14 Maintenance lists

This following pages are a tabular view of all maintenance tasks for this ride.
Global Village Revision index chapter 6 maintenance


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Conventions used in this guide:

Manufacturer of this ride is: Gerstlauer Amusement Rides GmbH

Information on damage to property

Ring binder with the original Operating Instructions

Ring binder with electrical and pneumatic documents English 1 2

Ring binder with technical descriptions of the

Ring binder with mechanical drawings + spare part

CD with Original Operating Instructions + technical

1.1 Representation of safety instructions ................................. 2

1 Safety Messages for the Sky Fly

DANGER indicates a hazardous situation which, if not avoided, will

Sign giving orders

Representation of safety instructions Global Village

1.2 General safety instructions

Risk of personal injury or ride damage caused by incorrect use of

Risk of personal injury or ride damage through incorrect installation

Risk of personal injury or ride damage caused by dismantling of

Global Village General safety instructions

Risk of personal injury or ride damage caused by maintenance or

Weather hazards and fire warning!

 The ride must not be operated during thunderstorms,

Risk of personal injury or ride damage caused by lightning and

General safety instructions Global Village

1.3 Component related safety instructions

Orders of the operator personnel must be obeyed.

Global Village Component related safety instructions

1.4 Normal Mode related safety instructions

Risk of injury for the passengers during ride!

Normal Mode related safety instructions Global Village

Passengers can fall out of the gondolas during ride!

- children and people shorter and younger than

- people who cannot be held safely by the existing

- people who can take no normal sitting position due to

- people whose heads cannot be placed on the

Global Village Normal Mode related safety instructions

Risk of injury for the waiting customers at station!

Normal Mode related safety instructions Global Village

Risk of injury for the personnel, passengers and customers at ride

Global Village Normal Mode related safety instructions

Risk of injury for the personnel, passengers and customers at ride

Normal Mode related safety instructions Global Village

1.5 Maintenance related safety instructions

Global Village Maintenance related safety instructions

Risk of electrical shock!

- the ride power is shut off and secured against restart

- additional electrical components for control and safety

 Disconnect the ride from the supply system prior to

Risk of injury by air pressure!

Maintenance related safety instructions Global Village

Risk of personal injury through maintenance or repair works at the

Global Village Maintenance related safety instructions

1.6 Emergency related safety instructions

Emergency related safety instructions Global Village

 If an evacuation is possible from a great height only, e.g.

Risk of injury in case of unacceptable behaviour of the passengers

Global Village Emergency related safety instructions

Risk of injury in case of panic caused by disaster and accidents in

Risk of injury in case of safety shut down caused by the control

Emergency related safety instructions Global Village

Risk of injury in case of power failure!

Risk of injury case of accident on the ride!

Global Village Emergency related safety instructions