Summary of Contents for Bosch REXROTH ActiveShuttle 1.0
- Page 1 ActiveShuttle 1.0 Transport vehicle 3 842 560 431 3 842 560 106 3 842 560 422 Operating manual Replaces: 2020/02 3 842 560 101 3 842 560 593/2020-07 ENGLISH...
- Page 2 Our products are subject to natural wear and aging. © All rights reserved by Bosch Rexroth AG, also for the registration of industrial property rights. This document may not be reproduced or distributed to third parties without our consent.
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Page 3: Table Of Contents
Symbols used Unpacking the charging station Positioning/preassembling the charging station 7.5.1 Connecting the charging station electrically Unpacking the ActiveShuttle Commissioning Emergency measure Pressing emergency stop device Emergency measure Removing lithium-ion battery 3 842 560 593/2020-07 ActiveShuttle: ActiveShuttle 1.0, Bosch Rexroth AG... - Page 4 Load distribution on the loading area 16.7 Scanning levels of the personal protection systems (laser scanner) 16.8 Protective fi elds 16.8.1 Front protective fi elds 16.8.2 Rear protective fi elds Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07...
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Page 5: About This Documentation
Be sure to observe all safety precautions. 3 842 560 593/2020-07 ActiveShuttle: ActiveShuttle 1.0, Bosch Rexroth AG... -
Page 6: Symbols
If this information is not observed, the product cannot be used and/or operated as designed. Single, independent action Numbered steps: The numbers indicate that the action steps are subsequent. Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07... -
Page 7: Designations
The charging station is used exclusively for charging the ActiveShuttle 1.0. The product is strictly intended for professional use and not for private use. The intended use also includes having read and understood these instructions, especially section 2 "Safety instructions". 3 842 560 593/2020-07 ActiveShuttle: ActiveShuttle 1.0, Bosch Rexroth AG... -
Page 8: Improper Use
Any use other than that described in the section "Intended use" is considered improper and is not permitted. Bosch Rexroth AG is not liable for any damage resulting from improper use. The user alone bears any risks associated with improper use. -
Page 9: Product-Specifi C Safety Instructions
Secure the system against being switched back on. • Dispose of the product in accordance with the regulations in your country. During disposal 3 842 560 593/2020-07 ActiveShuttle: ActiveShuttle 1.0, Bosch Rexroth AG... -
Page 10: Activeshuttle
Risk of serious injury due to a speed not adapted to the situation. The speed of the ActiveShuttle must be reduced in narrow corridors, curves, intersections and areas with passenger traffi c. Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07... - Page 11 If the ventilation slots of the ActiveShuttle are covered, there is a risk of overheating and thus damage to the ActiveShuttle. The ventilation slots of the ActiveShuttle must always be free and uncovered to ensure suffi cient cooling. 3 842 560 593/2020-07 ActiveShuttle: ActiveShuttle 1.0, Bosch Rexroth AG...
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Page 12: Lithium-Ion Batteries
Do not use lithium-ion batteries with a defective connection cable or defective contacts. To charge the lithium-ion battery in the ActiveShuttle, use only the charging station supplied by Bosch Rexroth or the charger supplied by Bosch Rexroth. Only operate lithium-ion batteries and accessories in perfect condition. ... -
Page 13: Handheld Controller 1.0
The responsibility for vehicle control in "Manual" mode lies entirely with the operator. Also observe the operating manual of the manufacturer: KEBA AG Gewerbepark Urfahr Reindlstraße 51 4041 Linz Austria www.keba.com 3 842 560 593/2020-07 ActiveShuttle: ActiveShuttle 1.0, Bosch Rexroth AG... -
Page 14: Charging Station 1.0
Do not use the charging station 1.0 as a stepladder or climbing aid. • The emergency stop function is carried out on the charging station by pulling out the mains plug. Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07... -
Page 15: Personal Protective Equipment
• The driveways must be kept clear of objects that cannot be detected by the protective fi eld (see chapter 16.7 Scanning levels of the personal protection systems (laser scanner)). • Driveways must be free of projecting obstacles. 3 842 560 593/2020-07 ActiveShuttle: ActiveShuttle 1.0, Bosch Rexroth AG... -
Page 16: Minimum Marking
The ActiveShuttle is marked with the following safety labels: LASER Complies with 21 CFR 1040.10, 1040.11 & IEC 60825.1 Make sure that these safety labels are present and legible. Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07... -
Page 17: Training Of The Operating Personnel
• The distance to the intersecting paths must be large enough that a person will not enter the track of the ActiveShuttle in the area of the protective fi eld (protective fi eld length max. 970 mm). 3 842 560 593/2020-07 ActiveShuttle: ActiveShuttle 1.0, Bosch Rexroth AG... -
Page 18: General Notes On Property And Product Damage
• Prevent cleaning agents from getting into the system. • Never use solvents or corrosive cleaning agents. • Do not use a pressure washer for cleaning. Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07... -
Page 19: Scope Of Delivery
– max. stacking height of 1,200 mm. Handheld controller 1.0 To control the ActiveShuttle 1.0 in the "Manual" operating mode Charging station ActiveShuttle 1.0 To charge the lithium-ion battery in the ActiveShuttle 1.0. 3 842 560 593/2020-07 ActiveShuttle: ActiveShuttle 1.0, Bosch Rexroth AG... -
Page 20: Product Description
LED off LED on fl ashing 1) To avoid permanent damage, 560 592-01 recharge after 2 days at the Fig. 1: ActiveShuttle 1.0 latest. 2) Contact the manufacturer. Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07... - Page 21 0 … 15 Green 16 … 33 Green 34 … 50 Green 51 … 67 Green 68 … 83 Green 84 … 100 560 592-02 Fig. 2: Control panel ActiveShuttle 1.0 3 842 560 593/2020-07 ActiveShuttle: ActiveShuttle 1.0, Bosch Rexroth AG...
- Page 22 (ActiveShuttle is shut down) +/– Speed ± Lifting the loading area Lowering the loading area Source position Dip position Charging station position Parking position 560 592-03 Fig. 3: Handheld controller 1.0 Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07...
- Page 23 The forward speed is set to 1.0 m/s. 1,0 m/s Connection to handheld controller lost. Loading area moves downwards. Loading area moves upwards. The maximum forward speed in "Manual" mode is set (1.0 m/s). 3 842 560 593/2020-07 ActiveShuttle: ActiveShuttle 1.0, Bosch Rexroth AG...
- Page 24 24/68 About this product Charging contacts Charging compartment Detection sensor for ActiveShuttle Connection for operating voltage 560 592-04 Fig. 4: Charging station ActiveShuttle 1.0 Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07...
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Page 25: Safety And Warning Devices
"Release brake" buttons Bluespot Warning signal lamps Personal protection system (laser scanner) Not visible: • Acoustic signal transmitter 560 592-09 Fig. 5: Safety devices and warning signs 3 842 560 593/2020-07 ActiveShuttle: ActiveShuttle 1.0, Bosch Rexroth AG... -
Page 26: Signaling
(see Table 7) - ActiveShuttle is in the charging station, the battery is charging (see Table 8) ON/OFF button Green fl ashing (1 Hz) ActiveShuttle is started or shut down Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07... -
Page 27: Protective Fi Elds
Equipment used in or near the area of the ActiveShuttle travel path must be identifi able at the level of the scanning planes. 3 842 560 593/2020-07 ActiveShuttle: ActiveShuttle 1.0, Bosch Rexroth AG... -
Page 28: Identifi Cation Of The Product
Make sure the lifting gear is correctly fastened before lifting the product! Secure the product against tipping over when lifting! Make sure that no one but the operator is in the danger zone during lifting and lowering! Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07... -
Page 29: Mounting/Removing Lift Aid
• Observe the ambient conditions, see page 59. • When storing lithium-ion batteries, observe the safety instructions on Page 12 and the recommendations of the VdS data sheet 3103 (Association of Property Insurers). 3 842 560 593/2020-07 ActiveShuttle: ActiveShuttle 1.0, Bosch Rexroth AG... -
Page 30: Assembly
Keep the transport packaging for further use (e.g. return shipment to the manufacturer). Dispose of the packaging material (fi lm, cardboard boxes etc.) in accordance with the applicable regulations in your country. Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07... -
Page 31: Positioning/Preassembling The Charging Station
Do not use the charging station 1.0 as a stepladder or climbing aid. guide lines. ≥300 mm ≥300 mm ≥300 mm ± 1 mm ± 1 mm ± 1 mm ± 1 mm 560 592-11 Fig. 8: Positioning the charging station 1.0 3 842 560 593/2020-07 ActiveShuttle: ActiveShuttle 1.0, Bosch Rexroth AG... - Page 32 Mount the lateral housing parts. = 5,7 Nm SW13 M = 25 Nm Ø 8 ≥ 20 SW13 =25 Nm 560 592-17 Fig. 9: Mounting the charging station 1.0 Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07...
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Page 33: Connecting The Charging Station Electrically
The charging station has a GST plug-in system. Further details on the connection can be found in the enclosed document "General safety instructions for electrotechnical installation of MPS components" 3 842 358 820. 3 842 560 593/2020-07 ActiveShuttle: ActiveShuttle 1.0, Bosch Rexroth AG... -
Page 34: Unpacking The Activeshuttle
Dispose of the packaging material (fi lm, cardboard boxes etc.) in accordance with the applicable regulations in your country. Before moving the ActiveShuttle, put it into proper operation (see chapter 8). Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07... -
Page 35: Commissioning
The warning signal lamps light up permanently in red. Unlock the emergency stop device by turning the mushroom knob. 560 592-13 Fig. 11: Emergency measure Pressing emergency stop device 3 842 560 593/2020-07 ActiveShuttle: ActiveShuttle 1.0, Bosch Rexroth AG... -
Page 36: Emergency Measure Removing Lithium-Ion Battery
Do not use lithium-ion batteries with a defective connection cable or defective contacts. To charge the lithium-ion battery in the ActiveShuttle, use only the charging station supplied by Bosch Rexroth or the charger supplied by Bosch Rexroth. Only operate lithium-ion batteries and accessories in perfect condition. ... - Page 37 During transport, observe the relevant hazardous goods requirements for lithium-ion batteries. Observe the operating manual of the manufacturer: BMZ Battery Assembly Centre GmbH Am Sportplatz 28 63791 Karlstein Germany www.bmz-group.com 3 842 560 593/2020-07 ActiveShuttle: ActiveShuttle 1.0, Bosch Rexroth AG...
- Page 38 LED off LED on fl ashing 1) To avoid permanent damage, recharge after 2 days at the latest. 2) Contact the manufacturer. 560 592-08 Fig. 12: Emergency measure Removing lithium-ion battery Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07...
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Page 39: Initial Commissioning
The driving range of the ActiveShuttle must have suffi cient traction. The driving range of the ActiveShuttle must be level, dry, clean and free of objects lying around. 3 842 560 593/2020-07 ActiveShuttle: ActiveShuttle 1.0, Bosch Rexroth AG... - Page 40 Check that all safety and warning devices function in accordance with the following descriptions when switching on and off. For initial commissioning, proceed chronologically as described in the chapters 8.3.1 to 8.3.5: Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07...
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Page 41: Switching On The Activeshuttle
The ActiveShuttle is in "Automatic" operating mode. When the emergency stop device (Q) is actuated, the ActiveShuttle is stopped. The warning signal lamps (F) light up permanently in red. 3 842 560 593/2020-07 ActiveShuttle: ActiveShuttle 1.0, Bosch Rexroth AG... -
Page 42: Switching To "Manual" Operating Mode
Stage 2 Approval, ON Stage 3 Panic function, OFF (ActiveShuttle is shut down) The warning signal lamps (F) light up permanently in yellow. 560 592-14 Fig. 14: Switching to "Manual" operating mode Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07... -
Page 43: Move Activeshuttle To The Charging Station Using The Handheld Controller
ActiveShuttle and the charging station do not match, readjust the height of the charging station (see chapter 7.5 Fig. 9). 560 592-06 Fig. 15: Drive unlocking 3 842 560 593/2020-07 ActiveShuttle: ActiveShuttle 1.0, Bosch Rexroth AG... -
Page 44: Fully Charge The Activeshuttle
The activation key (O) fl ashes green. The ActiveShuttle switches off. 8.4 Re-commissioning after a standstill Follow the steps for initial commissioning and the instructions in the ActiveShuttle Management System (AMS). Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07... -
Page 45: Preparing The Supermarket
Blue guide line, roll 25 m, 3 842 560 612 Dollies Blue guide line Supermarket ± 1 mm ± 1 mm Attach the guide lines. 560 592-10 Fig. 16: Supermarket 3 842 560 593/2020-07 ActiveShuttle: ActiveShuttle 1.0, Bosch Rexroth AG... -
Page 46: Permissible Dollies
1 + brake" possible. Lean Dolly Type V HDLL 10011 + DOS-1334 D.2 ESD version 4 castor wheels All confi gurations apart from "Wheel position 1 + brake" possible. Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07... -
Page 47: Operation
When a loaded vehicle starts up/restarts, there is a danger of crushing the rear wheels of the load. • Do not put your feet between the wheels. • Observe start-up warning. • Always wear safety shoes. 3 842 560 593/2020-07 ActiveShuttle: ActiveShuttle 1.0, Bosch Rexroth AG... - Page 48 The ActiveShuttle can be damaged by obstacles outside the protective area. Keep the driving range free of obstacles, especially fl at objects or objects protruding into the driving range. Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07...
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Page 49: Lithium-Ion Batteries
Do not use lithium-ion batteries with a defective connection cable or defective contacts. To charge the lithium-ion battery in the ActiveShuttle, use only the charging station supplied by Bosch Rexroth or the charger supplied by Bosch Rexroth. Only operate lithium-ion batteries and accessories in perfect condition. ... -
Page 50: Handheld Controller 1.0
The responsibility for vehicle control in "Manual" mode lies entirely with the operator. Also observe the operating manual of the manufacturer: KEBA AG Gewerbepark Urfahr Reindlstraße 51 4041 Linz Austria www.keba.com Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07... -
Page 51: Charging Station 1.0
– Liquids that thicken as they evaporate and become highly viscous or adhesive (sticky) can lead to malfunctions. In such instances, special care must be taken when planning the system, and the maintenance intervals must be correspondingly shortened. 3 842 560 593/2020-07 ActiveShuttle: ActiveShuttle 1.0, Bosch Rexroth AG... -
Page 52: Maintenance And Repair
Carry out a test of the safety devices at least every 6 months. Take vehicles with non-functional safety and warning devices out of service and contact the Bosch Rexroth Service. Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07... -
Page 53: Periodic Inspection - Minimum Requirements
If an inspection reveals an error, the ActiveShuttle must be shut down immediately. In this case, have the vehicle and its safety devices checked by the Bosch Rexroth Service. 3 842 560 593/2020-07 ActiveShuttle: ActiveShuttle 1.0, Bosch Rexroth AG... -
Page 54: Procedure For Testing The Personal Protection Systems (Laser Scanner)
fi eld is active over the entire required width. 10.4 Maintenance Bearings The bearings have lifelong lubrication and are maintenance-free under normal conditions of use. Gear The gears are maintenance-free. Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07... -
Page 55: Replacement Of Wear Parts
Decommissioning 55/68 10.5 Replacement of wear parts Check the following components regularly for wear. Have the Bosch Rexroth Service replace it if necessary: • Drive rollers • Cam rollers • Rubber mat on the loading area • Holding brake (see chapter 10.2.1) 11 Decommissioning This product is a component which does not need to be decommissioned. -
Page 56: Disposal
– According to the Directive, the product may not contain any foreign substances or foreign components when it is recycled. • Dispose of the product in accordance with the regulations in your country. Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07... -
Page 57: Upgrading And Modifi Cation
14 Upgrading and modifi cation • Do not modify the product. • The Bosch Rexroth warranty only applies to the confi guration as delivered, and to approved upgrades. The manufacturer will not accept any warranty claims for systems with unapproved modifi cations or upgrades. -
Page 58: Technical Data
• Input voltage: 90-305 VAC • Rated output voltage: 48 VDC (SELV) • Nominal power: 600 W • External fuse protection: Circuit breaker ≤ 16 A with triggering characteristic B or C Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07... -
Page 59: Ambient Conditions
• Surface fi nish: 0.8 ≥ µ ≥ 0.6 (wheel material: Vulkollan) • Electrical conductivity: R < 1 x 10 Ω (ESD applications) • Joints: max. 6 mm high, max. 15 mm wide 3 842 560 593/2020-07 ActiveShuttle: ActiveShuttle 1.0, Bosch Rexroth AG... -
Page 60: Load Distribution On The Loading Area
16.7 Scanning levels of the personal protection systems (laser scanner) Scan levels each measured above the fl oor: • Front: Scan level 130 mm • Rear: Scan level 87 mm Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07... -
Page 61: Protective Fi Elds
16.8 Protective fi elds 16.8.1 Front protective fi elds Table 13: When driving forward Zone Vreg Vmax Protective fi eld Protective fi eld [mm/s] [mm/s] Width Length [mm] [mm] 1000 1050 3 842 560 593/2020-07 ActiveShuttle: ActiveShuttle 1.0, Bosch Rexroth AG... - Page 62 Protective fi eld [mm/s] [mm/s] Width Length [mm] [mm] 1000 1150 Table 15: In the danger area Zone Vreg Vmax Protective fi eld Protective fi eld [mm/s] [mm/s] Width Length [mm] [mm] Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07...
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Page 63: Rear Protective Fi Elds
Table 18: In the danger area Zone Vreg Vmin Protective fi eld Warning Protective fi eld [mm/s] [mm/s] fi eld Width Length Length [mm] [mm] [mm] -100 -110 0.5m Warning fi eld Protective fi eld 3 842 560 593/2020-07 ActiveShuttle: ActiveShuttle 1.0, Bosch Rexroth AG... - Page 64 Table 20: Forward Zone Vreg Vmin Protective fi eld Warning Protective fi eld [mm/s] [mm/s] fi eld Width Length Width [mm] [mm] [mm] 0.5m Warning fi eld Protective fi eld Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07...
- Page 65 65/68 3 842 560 593/2020-07 ActiveShuttle: ActiveShuttle 1.0, Bosch Rexroth AG...
- Page 66 66/68 Technical data Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07...
- Page 67 Technical data 67/68 3 842 560 593/2020-07 ActiveShuttle: ActiveShuttle 1.0, Bosch Rexroth AG...
- Page 68 Bosch Rexroth AG Postfach 30 02 07 70442 Stuttgart Germany Fax +49 711 811–7777 info@boschrexroth.de www.boschrexroth.com Subject to modifi cations 3 842 560 593/2020-06...