Automated Guided Vehicle - SEW Eurodrive · 1 General information About this documentation 5...

*23507268_1217*Drive Technology \ Drive Automation \ System Integration \ Services

Operating Instructions

MAXOLUTION® System SolutionAutomated Guided VehicleMAXO-MTS-T005-P-00-B04-04-C-VR0-A-00

Edition 12/2017 23507268/EN

SEW-EURODRIVE—Driving the world

Table of contents

Operating Instructions – Automated Guided Vehicle 3

Table of contents1 General information.................................................................................................................. 5

1.1 About this documentation ............................................................................................... 51.2 Structure of the safety notes ........................................................................................... 51.3 Rights to claim under limited warranty ............................................................................ 61.4 Exclusion of liability......................................................................................................... 71.5 Other applicable documentation ..................................................................................... 71.6 Product names and trademarks...................................................................................... 71.7 Copyright notice .............................................................................................................. 7

2 Safety notes .............................................................................................................................. 82.1 Preliminary information ................................................................................................... 82.2 Working on the system solution ...................................................................................... 82.3 Target group ................................................................................................................... 82.4 Designated use ............................................................................................................... 92.5 Functional safety........................................................................................................... 102.6 Bus systems.................................................................................................................. 102.7 Transport....................................................................................................................... 112.8 Electrical installation ..................................................................................................... 112.9 Startup and operation ................................................................................................... 112.10 Inspection and maintenance ......................................................................................... 122.11 Storage ......................................................................................................................... 12

3 Vehicle ..................................................................................................................................... 133.1 Type designation........................................................................................................... 133.2 Short designations ........................................................................................................ 133.3 Nameplates................................................................................................................... 143.4 Structure ....................................................................................................................... 153.5 Detailed drawings ......................................................................................................... 193.6 Functional principle ....................................................................................................... 203.7 Caution signs on the vehicle ......................................................................................... 213.8 Load handling device interfaces ................................................................................... 21

4 Warning and safety devices .................................................................................................. 234.1 Safety concept .............................................................................................................. 234.2 Safety functions ............................................................................................................ 234.3 Safety laser scanner ..................................................................................................... 244.4 Emergency stop button ................................................................................................. 254.5 Optical and acoustic warning signals............................................................................ 264.6 Key switch..................................................................................................................... 27

5 Operation................................................................................................................................. 285.1 Notes on safe operation................................................................................................ 285.2 Operating modes of the vehicle .................................................................................... 295.3 Control elements on the vehicle.................................................................................... 305.4 Switching on the vehicle ............................................................................................... 305.5 Switching off the vehicle ............................................................................................... 305.6 DOP operator panel ...................................................................................................... 30

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Table of contents

Operating Instructions – Automated Guided Vehicle4

6 Maintenance............................................................................................................................ 406.1 Inspection and maintenance work ................................................................................ 406.2 Failures ......................................................................................................................... 436.3 Status and error messages........................................................................................... 446.4 Replacing the battery .................................................................................................... 466.5 Transport....................................................................................................................... 486.6 Spare parts ................................................................................................................... 496.7 Electronics Service ....................................................................................................... 49

7 Technical data......................................................................................................................... 517.1 Ambient conditions........................................................................................................ 517.2 Vehicle .......................................................................................................................... 517.3 Startup parameters ....................................................................................................... 527.4 Dimension sheets ......................................................................................................... 55

8 MAXOLUTION® Competence Center ..................................................................................... 56

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1General informationAbout this documentation


1 General information1.1 About this documentation

The current version of the documentation is the original.This documentation is an integral part of the product. The documentation is written forall employees who assemble, install, start up, and service this product.Make sure this documentation is accessible and legible. Ensure that persons respons-ible for the machinery and its operation as well as persons who work on the productindependently have read through the documentation carefully and understood it. If youare unclear about any of the information in this documentation or require further in-formation, contact SEW‑EURODRIVE.

1.2 Structure of the safety notes1.2.1 Meaning of signal words

The following table shows the grading and meaning of the signal words for safetynotes.

Signal word Meaning Consequences if disregarded DANGER Imminent hazard Severe or fatal injuries

WARNING Possible dangerous situation Severe or fatal injuries

CAUTION Possible dangerous situation Minor injuries

NOTICE Possible damage to property Damage to the product or its envir-onment

INFORMATION Useful information or tip: Simplifieshandling of the product.

1.2.2 Structure of section-related safety notesSection-related safety notes do not apply to a specific action but to several actionspertaining to one subject. The hazard symbols used either indicate a general hazardor a specific hazard.This is the formal structure of a safety note for a specific section:

SIGNAL WORDType and source of hazard.Possible consequence(s) if disregarded.• Measure(s) to prevent the hazard.

Meaning of the hazard symbolsThe hazard symbols in the safety notes have the following meaning:

Hazard symbol MeaningGeneral hazard

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1 General informationRights to claim under limited warranty


Hazard symbol MeaningWarning of dangerous electrical voltage

Warning of hot surfaces

Warning of risk of crushing

Warning of suspended load

Warning of automatic start-up

No access to persons with pacemakers

Do not ride on vehicle

1.2.3 Structure of embedded safety notesEmbedded safety notes are directly integrated into the instructions just before the de-scription of the dangerous action.This is the formal structure of an embedded safety note:

SIGNAL WORD Type and source of hazard. Possible consequence(s) if disreg-arded. Measure(s) to prevent the hazard.

1.3 Rights to claim under limited warrantyRead the information in this documentation. This is essential for fault-free operationand fulfillment of any rights to claim under limited warranty. Read the documentationbefore you start working with the product.

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1General informationExclusion of liability


1.4 Exclusion of liabilityRead the information in this documentation, otherwise safe operation is impossible.You must comply with the information contained in this documentation to achieve thespecified product characteristics and performance features. SEW‑EURODRIVE as-sumes no liability for injury to persons or damage to equipment or property resultingfrom non-observance of these operating instructions. In such cases,SEW‑EURODRIVE assumes no liability for defects.

1.5 Other applicable documentationObserve the corresponding documentation for all further components.

1.6 Product names and trademarks

The brands and product names in this documentation are trademarks or registeredtrademarks of their respective titleholders.

1.7 Copyright notice

© 2017 SEW‑EURODRIVE. All rights reserved. Unauthorized reproduction, modifica-tion, distribution or any other use of the whole or any part of this documentation isstrictly prohibited.

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2 Safety notesPreliminary information


2 Safety notes2.1 Preliminary information

The following basic safety notes must be read carefully to prevent injury to personsand damage to property.The safety notes refer to the use of the system solution described in this document.This document does not replace the detailed documentation of the products and soft-ware used. You therefore have to observe the documentation of the products and soft-ware used.Ensure that all safety notes are observed.

2.2 Working on the system solutionMake sure that all work steps described in this documentation are only performed byqualified specialists.Observe the following:• National and regional safety and accident prevention regulations• Personal protective equipment, e.g. safety shoes• Caution signs on the products• All system-specific specifications and conditionsThe system solution may only be operated in systems equipped with the requiredmonitoring and protection devices.

2.3 Target group

Operation The product must only be operated by qualified personnel. Qualified personnel in thiscontext are persons who have the following qualifications:• Appropriate instruction• Knowledge of this documentation and all other referenced documentation• Participation in a product training for the system solution

Specialist formechanical work

Any mechanical work may only be performed by adequately qualified specialists. Spe-cialists in the context of this documentation are persons familiar with the design,mechanical installation, troubleshooting, and maintenance of the product who possessthe following qualifications:• Qualification in the mechanical area in accordance with the national regulations• Familiarity with this documentation

Specialist for elec-trotechnical work

Any electrotechnical work may only be performed by electrically skilled persons with asuitable education. Electrically skilled persons in the context of this documentation arepersons familiar with electrical installation, startup, troubleshooting, and maintenanceof the product who possess the following qualifications:• Qualification in the electrotechnical area in accordance with the national regula-

tions• Familiarity with this documentation

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2Safety notesDesignated use


Software specialist Any work with the software may only be performed by adequately qualified personnel.Qualified personnel in this context are persons who have the following qualifications:• Appropriate instruction• Knowledge of this documentation and other applicable documentation• Participation in a product training for the software and the products operated with

it.Additional qualifi-cation

In addition to that, these persons must be familiar with the valid safety regulations andlaws, as well as with the requirements of the standards, directives, and laws specifiedin this documentation. The persons must have the express authorization of the com-pany to operate, program, parameterize, label, and ground units, systems, and circuitsin accordance with the standards of safety technology.

Instructed persons All work in the areas of transportation, storage, operation and waste disposal must becarried out by persons who are trained appropriately. The purpose of the instruction isthat the persons are capable of performing the required tasks and work steps in a safeand correct manner.

2.4 Designated useThe system solution consists of one or several vehicles. The vehicle is designed formaterial transport within industrial and commercial systems using an active or passiveload handling device.The system solution is intended for integration in electrical systems and machines incovered industrial use.In case of installation in electrical systems or machines, startup of the system solutionis prohibited until it is determined that the system or machine meets the requirementsstipulated in the valid laws and directives.The standards included in the declaration of conformity are applied for the systemsolution.

Persons in the sys-tem

Observe the following notes regarding the protection of persons:• Instruct employees and visitors on how to act when accessing the system.• The vehicle always takes priority to forklifts or other industrial trucks.• Entering the hazardous areas is not permitted.• Access to the closed off areas is only permitted to trained personnel.

Restrictions Adhere to the following restrictions:• The system solution must only be used indoors and outside of potentially explosive

areas.• Do not operate the system solution in environments containing harmful substances

(e.g. oils, acids, gases, vapors, dusts, radiation).• Operate the system solution in a dry environment. Remove liquids from the floor.• Do not operate the system solution in environments with conductive dirt.• The vehicles are only suitable for transporting materials using the designated carri-

ers.• Transporting persons or animals is not permitted.• Make sure that there are no obstacles on the track and that no objects protrude in

the track.• Obstacles on the floor must have a minimum height of 200 mm to be detected by

the safety laser scanner (risk of collision).

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2 Safety notesFunctional safety


• Moving obstacles are detected. However, it is possible that the vehicle may notcome to a stop in due time. The braking distance is dimensioned for standingobstacles.

• Do not step into the travel range of the vehicle.• Keep a distance to the vehicle during load transfer (risk of crushing).• Do not reach or walk into the pivoting/curved area of the vehicle.• Adhere to the technical data, e.g. the maximum permitted total weight.• Make sure no undetectable staircases, loading bays, or gaps in the floor are within

the range of the vehicle. Fence off areas that cannot be detected.• Make sure the specified functional and safely test is completed before you start the

vehicle.• Observe the travel range of adjacent systems.• Operation is only permitted when the notes on safe operation are adhered to.

2.5 Functional safety2.5.1 Safety-relevant conditions

To ensure that the emergency stop buttons can be used in case of danger, observethe following notes:• Do not block or cover the emergency stop buttons.• Use the emergency stop buttons only in case of danger.• Replace defective emergency stop buttons immediately.

2.5.2 ValidationThe purpose of the validation is to confirm the specification and conformity of the drivesolution described in this document within the overall specification for the safety re-quirements of the machine/plant.The validation must confirm that every safety-related component of the different safetyfunctions fulfills the required safety guidelines.The validation process comprises the analysis and tests in accordance with a valida-tion plan. Consult the various standards (e.g. ISO 13849-1) and corresponding re-sources.If safety-relevant components and/or software is modified, the system/machine mustbe validated again.

2.6 Bus systemsA bus system makes it possible to adapt electronic drive components to the particularsof the machinery within wide limits. There is a risk that a change of parameters thatcannot be detected externally may result in unexpected (but not uncontrolled) systembehavior and may have a negative impact on operational safety, system availability, ordata security.Especially in Ethernet-based networked systems and with engineering interfaces,make sure that unauthorized access is prevented.Use IT‑specific safety standards to increase access protection to the ports. For a portoverview, refer to the respective technical data of the device in use.

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2Safety notesTransport


2.7 TransportObserve the following information to avoid damage to the product:

Before transport • Before you lift the product, read the safety notes on transport.• Always use suitable, sufficiently rated handling equipment.• Observe the ambient conditions of the components included in the product in the

SEW‑EURODRIVE documentation or in the documentation of the respectivemanufacturer for third-party components.

During transport • Ensure that the product is not subject to mechanical impact during transportation.After transport • Inspect the shipment for eventual damage as soon as you receive the delivery. In-

form the shipping company immediately about any damage. Do not startup anydevice if it has been damaged during transport.

• Remove transport protection prior to startup.

2.8 Electrical installation

Ensure that all of the required covers are correctly attached after carrying out the elec-trical installation.Make sure that preventive measures and protection devices comply with the applic-able regulations (e.g. EN 60204-1 or EN 61800-5-1).

2.9 Startup and operation

Do not deactivate monitoring and protection devices even for a test run. When indoubt, switch off the unit whenever changes occur in relation to normal mode (e.g. in-creased temperatures, noise, oscillation). Determine the cause. It may be necessaryto contact SEW‑EURODRIVE.Where required, systems with these devices integrated must be equipped with addi-tional monitoring and protection devices in accordance with the applicable safety regu-lations, e.g. the legislation governing technical equipment, accident prevention regula-tions, etc.Additional preventive measures may be required for applications with increased haz-ard potential. You must check the functionality of protection devices each time youchange the configuration.Do not touch live components or power connections immediately after disconnectingthe device from the voltage supply because some capacitors may still be charged. Ob-serve the corresponding minimum switch-off time on the device labels and in the com-ponent documentation.For further information on separating the power supply, refer to chapter Disconnectingthe power supply.When the unit is switched on, dangerous voltages are present at all power connec-tions as well as at any connected cables and motor terminals. This also applies evenwhen the unit is inhibited and the motor is at standstill.The fact that the operation LED and other display elements are no longer illuminateddoes not indicate that the device has been disconnected from the supply system andno longer carries any voltage.

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2 Safety notesInspection and maintenance


Mechanical blocking or internal safety functions of the unit can cause a motor stand-still. Eliminating the cause of the problem or performing a reset may result in the drivere-starting automatically. If, for safety reasons, this is not permitted for the drive-con-trolled machine, first disconnect the device from the supply system and discharge itcompletely. Only then, start troubleshooting.Electric arcs may damage electrical components. Do not disconnect power connec-tions during operation. Do not connect power connections during operation.

2.10 Inspection and maintenanceCarry out maintenance and repair work only on a secured and de-energized machine/system. Ensure a de-energized state of the machine/system before you start workingon it. Ensure a de-energized state for the entire time you work on the system.

2.11 StorageObserve the following instructions when shutting down or storing the product:• Make sure that the product is not subject to mechanical impact during storage.• In case of extended storage, connect the product to the relevant supply voltage for

at least 8 hours every 2 years.• Observe the note of the manufacturer regarding the shelf life of the energy storage

device in the vehicle.• To avoid damage to the wheels, move the vehicles at least 2 times a year or store

the vehicle without load being applied to the wheels.Adhere to the notes on storage temperature:• In chapter "Technical Data".• In the manufacturer documentation if third-party components are installed.

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3VehicleType designation


3 Vehicle3.1 Type designation

The type designation of the vehicle contains the following data:

MAXO MAXOLUTION® system solution

-MTS Mobile transport system

-T 3-wheel drive

005 Load capacity 500 kg

-P Standardized platform

-00 No load handling device

-B04 Lead crystal battery bundle 48 V

-04 DC link voltage DC 48 V

-C Energy supply with contact

-V Optical navigation

R Navigation via RFID transponder

-A Vehicle software AGVbasic

-00 Version

3.2 Short designationsThe following short designations are used in this documentation:

Component Short designationMAXO-MTS-T005-P-00-B04-04-C-VR0-A-00 Vehicle

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3 VehicleNameplates


3.3 Nameplates3.3.1 Main nameplate

The main nameplate lists information about the product. The following figure shows anexample of a main nameplate:

D-76646 Bruchsal

Made in Germany

Ernst-Blickle-Str. 42

Typ:

S#:

Leergewicht: Max. Zuladung:

Max. Geschw.:

MAXOLUTION®-Projekt-Nr.:

Versorgungsspg.:

[1] [3] [4][2]

[5]

[6]

9007219191538955

[1] Type designation[2] Serial number[3] Data matrix code[4] CE marking[5] Technical data, such as no-load weight, max. velocity, max. payload, and sup-

ply voltage[6] MAXOLUTION® project no.

3.3.2 Battery nameplateThe nameplate contains information on the battery. The following figure shows an ex-ample of a nameplate:

D-76646 Bruchsal

Made in Germany

Ernst-Blickle-Str. 42

Typ:

S#:

Batterien Anzahl / Gewicht:

Spannung Batteriesatz:

Batterie Typ:

Fahrerloses Transportfahrzeug

Kapazität Batteriesatz:

[1] [2]

[3]

[4]

20099741835

[1] Type designation[2] Serial number[3] Technical data, such as number and weight of the batteries, battery type,

voltage of the battery set, and capacitance of the battery set.[4] Designation of the system solution

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3VehicleStructure


3.4 Structure3.4.1 Vehicle structure

[2]

[1]

[3]

9007220061939595

[1] Load handling device module (project-specific)[2] Energy module[3] Technology module

3.4.2 Front of the vehicle

[2]

[3]

[4]

[3]

[5][1]

[1]

18014418711452299

No. Component Function[1] Caution signs Warning about hazards.

[2] WLAN antenna Communication with the higher-level controller.

[3] Emergency stop button Stopping the vehicle in case of emergency.

[4] Safety laser scanner Detecting persons and objects.

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3 VehicleStructure


No. Component Function[5] Attachment point for the

vehicleTransporting the vehicle.

3.4.3 Bottom of the vehicle

[9]

[2]

[3]

[1]

[5]

[4]

[6]

[3]

[2][1] [4]

[8]

[3]

[3]

[7]

[10]

18014418711455755

No. Component Function[1] Travel drive Driving the drive wheel

[2] Drive wheel Moving the vehicle

[3] LED lights Optical display of the vehicle status

[4] Auxiliary wheel Vehicle stability

[5] Safety laser scanner Recognition of persons in the direction of travel

[6] Read head Optical track guidance

[7] Read/write head Reading and writing the RFID transponder.Distance read/write head (center) to the central axis of the vehicle: 175 mmDistance read/write head (center) to the front edge of the vehicle: 735 mm

[8] Positive terminal char-ging contact

Charging the battery. The positive terminal is on the left in the direction oftravel.

[9] Read head (optional) Optical track guidanceOnly required for vehicles with reverse motion.

[10] Negative terminal char-ging contact

Charging the battery. The negative terminal is on the right in the direction oftravel.

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3VehicleStructure


3.4.4 Back of the vehicle[1] [2] [4][3]

[7]

[5] [6][6]

[8]

9007219456717067

No. Component Function[1] Multi-function button Flashing green lighted pushbutton

[2] Acknowledgment button Flashing blue lighted pushbutton

[3] Emergency stop button Stopping the vehicle in case of emergency

[4] Key switch Keyswitch mode

DANGER! Danger due to safety functions that can be bypassed viakeyswitch. Serious injuries. Do not bypass safety functions in normal operation!

[5] WLAN antenna Communication with the higher-level controller

[6] Attachment point for thevehicle

Transporting the vehicle

[7] DOP operator terminal Operating and display element for manual mode and diagnostics

[8] Safety switching strip(optional)

Safety measure to avoid crushing.Only required for vehicles with reverse motion.

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3 VehicleStructure


3.4.5 Vehicle backside – drawer

[1]

[3]

[4]

[5]

[2]

20811159691

No. Component Function[1] I/O module I/O system of the MOVI‑PLC®

[2] Safety relays Safe brake control

[3] MOVISAFE® UCSsafety controller

Processing the signals of all safety components on the vehicle.

[4] MOVI‑PLC® Vehicle controller

[5] WLAN client Communication of the vehicle with the logistics controller

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3VehicleDetailed drawings


3.5 Detailed drawings3.5.1 Technology module

X32X42

X11X21

X12X22

X13

X31

UCS12B

X6

DI 01 02 03 04

DO K1 K2 02 03 DI 05 06 07 08

DI 09 10 11 12

ENTER

STATUS

DI 13 14 P1 P2

X7

X8

16

5

16

59

XCSXCD

/PS

RUN

SYSFault

X41

UCS23B

DI 01 02 03 04

DIO 03 04 05 06 DI 05 06 07 08

DI 09 10 11 12

STATUS

DIO 13 14 P1 P2

DIO 07 08 09 10

X35X45

X36X46

X15X25

X16X26

UCS23B

DI 01 02 03 04

DIO 03 04 05 06 DI 05 06 07 08

DI 09 10 11 12

STATUS

DIO 13 14 P1 P2

DIO 07 08 09 10

X35X45

X36X46

X15X25

X16X26

DHP11B

X30

2

2

2

2

0

1

2

3

2

2

2

4

5

6

[1]

[2]

[1]

[3]

[3]

[1]

[7]

[1]

[15][14]

[26]

[25]

[5]

[6]

[10][5] [9]

[24]

[9]

[5]

[23]

[22]

[11][6]

[18][19][20][21]

[13]

[4]

[17]

[8]

[12]

[16]

21477269771

[1] LED strip [10] Read/write head for RFIDtransponder

[19] LED switch

[2] Safety switching strip [11] MOVI‑PLC® [20] Fuse[3] Motor CMP ELVCD [12] Safety relays [21] OCC11C bus coupler[4] Energy module interface [13] Relay [22] Access Point[5] Emergency off button [14] MOVISAFE® UCS23B [23] DOP operator terminal[6] WLAN antenna [15] MOVISAFE® UCS12B/PS [24] Multi-function button[7] Safety laser scanner [16] Relay [25] Key switch[8] Charging contacts [17] Horn [26] Acknowledgment button[9] Optical track guidance with

PGV data matrix positioningsystem

[18] MOVI‑PLC® I/O system

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3 VehicleFunctional principle


3.5.2 Energy module

A

[2]

[3]

[4]

[6]

[1]

[5]

21483207051

[1] Measuring transducer [4] Technology module interface[2] Batteries [5] DC/DC converter[3] Load handling device module inter-

face[6] Relay

3.6 Functional principle3.6.1 Information

The following pages illustrate all options. Observe the information applicable to yourvehicle according to the type code.

3.6.2 Control and communicationThe vehicle communicates with the higher-level controller (logistics controller) usingthe WLAN infrastructure. The software transferring the travel order to the vehicle is in-stalled on the logistics controller.After having received a travel task, the vehicle warns persons close to it before itstarts its travel by means of warning and safety measures.The vehicle transmits operating data of the vehicle to the logistics controller.

3.6.3 Energy supplyThe vehicle is supplied with energy by batteries. The batteries are charged via char-ging contacts.

3.6.4 Navigation

OpticalThe track guidance is realized optically via a read head and via track marks glued tothe floor.

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3VehicleCaution signs on the vehicle


3.6.5 Referencing

RFIDThe positioning is realized using RFID transponders and a read/write head. The read/write head detects the RFID transponders embedded in the floor and uses them to de-termine the position.

Data matrix codeThe positioning is realized using a data matrix positioning system. The read head foroptical track guidance detects the data matrix code and thus determines the absolutevehicle position in the system.

3.6.6 Service and diagnosticsStatus and commands of the vehicle can be read using the DOP operator panel. Fur-thermore, the DOP operator panel shows further information regarding faults.You can control the vehicle manually in the operating mode "manual mode". Use theDOP operator panel to switch to the operating mode "manual operation". For furtherinformation on the operating modes, refer to chapter "Operation".

3.7 Caution signs on the vehicleCaution signs waring about potential hazards must be attached to multiple areas onthe vehicle. Ensure that the following hazard symbol for identifying hazardous areasare complete and legible:

Hazard symbol MeaningWarning of injury to the hand

Do not ride on vehicle

3.8 Load handling device interfacesThe following interfaces can be routed from the energy module to the outside to theload handling device:

Voltage

Terminal Function3X9.1 DC 48 V

3X3.10 2 A, DC 24 V, 48 W

Housing DC 0 V (DC 24 V + DC 48 V)

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3 VehicleLoad handling device interfaces


CANBus

Terminal Function3X3.1 CAN ground

3X3.2 CAN high

3X3.3 CAN low

Safe inputs/outputs

Terminal Function3X0.1 – 3X0.8 DI 1 – 8 (8 inputs)

3X0.9 – 3X0.12 DIO 1 – 4 (4 inputs/outputs)

3X0.13 – 3X0.14 DO 2 (2 outputs)

Emergency stop button

Terminal Function3X3.4 P1 (pulse 1)

3X3.5 P2 (pulse 2)

3X3.6 P1 output

3X3.7 P1 input

3X3.8 P2 output

3X3.9 P2 input

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4Warning and safety devicesSafety concept


4 Warning and safety devices4.1 Safety concept

INFORMATIONDo not perform any changes to the safety concept. Changes require a new validationand a new conformity procedure.

The safety concept of the system solution is based on the principle of functional safetyand is realized using the following safety technology:• Safety laser scanner• Emergency stop button• Optical and acoustic warning signalsThe machine/system manufacture is responsible for performing a risk assessment andthe resulting construction measures, such as for example:• Putting up safety fences at the travel section• Attaching warning signs to hazardous areas

4.2 Safety functions

Application Safety function DescriptionMonitoring the maximum ve-locity

SLS (Safely LimitedSpeed)

The speed of the vehicle is monitored. If the definedmaximum travel speed is exceeded, the enable of thedrive is revoked.

Speed-dependent safetyzone switchover

SCA (Safe Cam) The safety zones of the safety laser scanner areswitched depending on the actual vehicle speed of thevehicle.

Safety zone switchover bythe vehicle controller

SCA (Safe Cam) The controller can perform safety zone switchovers.This is necessary to travel underneath trestles, for ex-ample. For this reason, it cannot be ensured that thesafety zones are activated for speeds below 0.3 m/s.

Monitoring the direction ofmovement

SDI – Safe Direction In order to switch the safety zones in the direction ofmovement, the direction of movement I monitored (for-ward and backward).If no protection device for backward motion is installed(safety switching strip), backward motion is safely pre-vented.

Indicating the direction oftravelRestart after emergencystop

– When the vehicle moves, the direction of travel is in-dicated by optical displays in the direction of travel.An acoustic signal indicates if the vehicle is startedagain after an STO.

Safe standstillSafe brake control

SS2c (Safe Stop 2),SOS (Safe Operat-ing Stop)SBC (Safe BrakeControl), STO (SafeTorque Off)

If the systems for person detection trip, the SS2csafety function is activated and the safe operationalstop (SOS) is monitored. If the safety functions SS2cor SOS are violated, an STO is trigged and safe brakecontrol is activated.

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4 Warning and safety devicesSafety laser scanner


Application Safety function DescriptionEmergency stop SS2c (Safe Stop 2)

SBC (Safe BrakeControl), STO (SafeTorque Off)

Several emergency stop buttons allow for switching offall travel, conveying, and hoist movements.

Safety switching strip evalu-ationEmergency stop

SBC (Safe BrakeControl), STO (SafeTorque Off)

The safety switching strip is used for switching offmovements.

4.3 Safety laser scannerBasic functionalprinciple

The safety laser scanner is a device for protecting persons and systems. The safetylaser scanner monitors the route of the vehicle and detects obstacles in areas that aredefined as hazardous.The scan field of the safety laser scanner is a two-dimensional layer. The scan field isgenerated in the vehicle environment through an opening in the vehicle cover and ispositioned in a specific height. Objects above or below this scan field cannot be detec-ted.The monitored area is defined in so-called zone sets. A zone set consists of one orseveral warning and safety zones.Depending on the travel speed, the applicable zone set is activated automatically.The following specifications depend on the safety requirements of the application:• Number and position of used safety laser scanners at the vehicle.• Number, shape, and dimensions of the warning and safety zones.• Reaction in case of violations to warning or safety zones.The width of the scan field is always 250 mm from the edge of the vehicle. The lengthof the scan field is variable.

INFORMATIONThe specifications are defined at the project start and must not be changed after-wards.

The following figure depicts the example of assembly variants for a vehicle, as well asthe resulting warning and safety zones.

[1][2][3]

20740427531

[1] Warning zone[2] Safety zone[3] Travel direction 23

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4Warning and safety devicesEmergency stop button


For further information, refer to the following documentation:• Operating instructions of the safety laser scanner

Warning zonebreach

If a safety laser scanner recognizes an obstacle in the warning zone, the vehiclespeed is reduced.

Safety zonebreach

If the safety zone of the safety laser scanner is breached, an emergency stop of thevehicle is triggered. The vehicle is decelerated with the rapid stop ramp until standstill.If the vehicle does not reach standstill within a defined time, the brake of the traveldrive is activated and the vehicle is brought to a complete stop.During standstill, the vehicle is monitored by the safety function "Safe OperationalStop (SOS)".As soon as the obstacle is removed from the safety zone of the safety laser scanner,the vehicle sends an optical signal and starts moving again after a waiting time of2 seconds.

4.4 Emergency stop buttonEmergency stop buttons are installed at the vehicle in positions that are easy to reach,so that the vehicle can be manually stopped in hazardous situations. If you push theemergency stop button, the vehicle will be brought to standstill in a controlled way.

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4 Warning and safety devicesOptical and acoustic warning signals


4.4.1 Starting the vehicle after an emergency stopTo restart the vehicle in automatic mode after an emergency stop, proceed as follows:ü The hazardous situation is eliminated.1. Unlock the activated emergency stop button.

ð The acknowledgment key (blue) is flashing.2. Press the acknowledgment key (blue) on the vehicle.

ð The emergency stop has been acknowledged.ð The vehicle is ready for operation again.ð The vehicle gives a warning signal and automatically restarts after a waiting time

of 2 seconds.ð The vehicle resumes the last pending travel command.

4.5 Optical and acoustic warning signals4.5.1 LED lights

The LED lights have the following meaning:

Lighting StateGreen/white

Green light The vehicle is supplied with energy by the energystorage unit.

White light The energy storage unit of the vehicle is charged.

One side illuminated in green or white. The vehicle travels in the direction of the LED light.

One side flashes green or white. Startup warning

The lights on the vehicle sides are flash-ing in green or white around the vehiclecircumference, in clockwise or counter-clockwise direction.

The vehicle rotates in the direction of the LED light.

The vehicle is illuminated in white at thefront and the back.

The vehicle stands still and the energy storage unitis charged.

Blue The right and left side are illuminated inblue.

The vehicle is in the station.

Yellow The right or left side is flashing yellow. The vehicle turns in the direction of the LED light.

The right and left side are flashing yellow.The vehicle is illuminated in green orwhite at the front and the back.

The vehicle is in manual mode and travels in thedirection of the green or white LED lights.

All sides illuminated yellow. The safety laser scanner or emergency stop hasbeen triggered.

All sides flashing yellow. The keyswitch has been activated.

Red All sides illuminated red. A fault at the vehicle occurred.

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4Warning and safety devicesKey switch


4.5.2 HornThe vehicle is equipped with a horn, to warn persons near the vehicle. After thevehicle has been reset in the event of emergency stop or actuation of the safetyswitching strip, the vehicle gives an acoustic warning signal and starts moving againafter a waiting time of 2 seconds.

4.6 Key switch4.6.1 Using keyswitches

Certain safety functions of the vehicle can be jumpered using the keyswitch.

1. DANGER! No monitoring due to jumpered safety functions. Severe or fatal in-juries. Use is only permitted for trained persons.Turn the keyswitch to position 1.ð The acknowledgment key (blue) is flashing.

2. Press the acknowledgment key (blue).ð The existing safety laser scanner is not active.ð The travel speed is safely limited (max. 0.1 m/s).ð The emergency stop safety function remains active.

4.6.2 Resetting time monitoringTo prevent unauthorized use, manual mode is limited to a maximum time of 120 s. Torestart the time monitoring of the safety controller, proceed as follows:1. Turn the keyswitch to position 0.2. Turn the keyswitch to position 1.

ð The acknowledgment key (blue) is flashing.3. Press the acknowledgment key (blue).ð The time monitoring has been restarted.

4.6.3 No longer use keyswitch

1. Turn the key to position 0.ð The safety laser scanners are active again.

2. Remove the key to prevent unauthorized use.3. Press the acknowledgment key (blue) on the vehicle.

ð The emergency stop has been acknowledged.ð The vehicle is ready for operation again.ð If automatic mode has been activated previously, the vehicle gives a warning sig-

nal and automatically restarts after a waiting time of 2 seconds.

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5 OperationNotes on safe operation


5 Operation5.1 Notes on safe operation

WARNINGRisk of crushing if persons are present in the assembly areas when the vehicleenters.Severe or fatal injuries.• Do not sit or stand in the vehicle entry area.

WARNINGAn insufficient stopping distance may lead to collision, e.g. due to entering the safetyzone from the side.Severe or fatal injuries.ü The vehicle takes the stopping distance to stop. The stopping distance depends

on the speed.• To ensure that the stopping distance is sufficient and to prevent a collision, do

not enter the safety zone of the safety laser scanner from the side.• Do not move toward the vehicle against the travel direction.

CAUTIONRisk due to tilting of the vehicle because the center of gravity is too high.Serious injuries.• Always adhere to the maximum permitted weight of the transported goods (see

chapter "Technical data").• Adhere to the maximum center of gravity of the loading (project-specific).• Make sure the weight is distributed evenly and centered.• Use the vehicle exclusively in accordance with the intended use.

CAUTIONRisk if the load falls down if it shifts.Serious injuries.• Make sure the weight is distributed evenly and centered.• Ensure that the load does not protrude on any side.• Secure the load.• Make sure the load carrier is in flawless condition.• Make sure no parts of the stationary system protrude via the outer edge of the

vehicle.

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5OperationOperating modes of the vehicle


CAUTIONDanger due to insufficient floor quality.Serious injuries.• Operate the vehicle only on floors that ensure sufficient traction of the vehicle.• Keep the travel section clean and dry.

NOTICERisk of collision with obstacles that the safety laser scanner does not detect.Damage to the vehicle and/or parts of the system.• Remove all obstacles from the travel section.• Especially flat objects that cannot be detected by the safety laser scanner.

5.2 Operating modes of the vehicle5.2.1 Automatic mode

After the system was started up the vehicle automatically is in the operating mode"Automatic mode".In "Automatic mode" the logistics controller coordinates travel orders during operation,and ensures the priority rules. In addition, travel orders can be transferred to thevehicle using the control elements.

5.2.2 Manual modeThe DOP operator panel can be used to interrupt the automatic mode and manuallyoperate the vehicle functions.

5.2.3 Keyswitch mode

CAUTIONRisk of crushing due to limited safety zone in keyswitch mode.Risk of injury.• Keyswitch mode must only be executed by especially trained personnel (e.g.

maintenance staff).

Use the keyswitch to start the keyswitch mode. Note that this jumpers some safetyfunctions (e.g. safety laser scanners).

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5 OperationControl elements on the vehicle


5.3 Control elements on the vehicleThe control elements may have various functions assigned, depending on the operat-ing mode and location of the vehicle within the track.

5.3.1 Multi-function buttonThe multi-function button (green) has the following functions:• Switching the vehicle on and off.• Starting the vehicle movement after an emergency stop has been acknowledged

(in automatic mode).• Sending the vehicle to the next station (in automatic mode).

5.3.2 Acknowledgment buttonIn automatic mode, the acknowledgment (blue) has the following functions:• Acknowledgment of pending vehicle faults at the safety module.

5.4 Switching on the vehicleü The vehicle is switched off or in "Standby".1. Press the multi-function button for 3 seconds, until the LED at the DOP operator

panel lights up.ð The vehicle is ready for operation.ð If the vehicle is in automatic mode and an order is pending, the vehicle will start

moving.

5.5 Switching off the vehicleü The vehicle is not in a charging station, or the charging station is switched off.1. Push an emergency stop button at the vehicle.2. Press the multi-function button for 5 seconds until it stops blinking.3. Release the multi-function button.

5.6 DOP operator panelThe DOP operator panel can be used to manually operate the vehicle functions andcomponents (e.g. hoist). Status and fault messages can be displayed for diagnosticpurposes.Note that some functions are initiated via the DOP interface and completed via themulti-function button.

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5OperationDOP operator panel


5.6.1 Initial screenIf the power supply of the vehicle is switched on, the DOP interface shows importantstatus information of the vehicle:

[5]

[4]

[1] [3][2]

[6]

21228349067

No. Meaning[1] Currently selected part data

[2] Current position• Address of the last successfully read transponder/data matrix code• Distance (mm) that the vehicle travelled after the last position was read.

[3] Current power rating of the vehicle

[4] Charging state of the battery

[5] Name of the vehicle

[6] Status and error messages

[7] Speed• Setpoint: Setpoint speed according to the settings in manual mode or auto-

matic mode• Actual: Current speed• Limit: Maximum speed according to the settings in the safety controller

Meaning of the background colorsThe background colors have the following meaning:

Color MeaningGray Software not ready.

No communication to the DOP operator panel.

Purple Timeout to higher-level controller

Green The vehicle is ready for operation.

Blue The vehicle has stopped at the target position in automatic mode.2350

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5 OperationDOP operator panel


Color MeaningYellow The safety controller has stopped the vehicle (e.g. caused by

safety zone breach or emergency stop).

Red The vehicle is not ready to move due to a fault.

5.6.2 Menu and navigation barTap onto the initial screen to switch to the menu level. A window opens with the menuand the navigation bar:

[1]

[2]

[3][4][5]

21283259915

No. Meaning[1] Buttons to selected operating modes/functions

[2] The control elements in the navigation bar vary depending on the operatinglevel:• On all levels:

Navigation buttons [3] and [5]• Menu level (top level):

Language selection [4]• Levels of the operating modes/functions (submenu):

Buttons for submenus (if available) and display of the current operatingmode/function

[3] Back to initial screen

[4] Select one of the following languages:• English• English• French

[5] Back to the last operating level

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5.6.3 Automatic modeIn the "automatic mode" menu item, the following elements are available:

[6]

[5]

[4]

[3]

[1]

[2]

21286286603

No. Meaning[1] Information on the used program.

[2] Part data

[3] Current velocity

[4] Resume automatic mode

[5] To identify the position, the following values are displayed:• Last transponder: Address of the last successfully read transponder/data

matrix code• Distance: Distance (mm) that the vehicle travelled after the last position

was read.

[6] To change parameters, deactivate automatic mode, see chapter "Changingparameters".

Changing parametersTo change parameters, switch off automatic mode. The following procedure requiresthe vehicle to remain at standstill after the automatic mode is switched off.If the vehicle moves, changing parameters requires a special authorization (expertmode) that is only granted to trained employees of SEW‑EURODRIVE and is there-fore not described in this documentation.1. Click the [Deactivate automatic mode] button.

ð The designation on the button changes to [Activate automatic mode]. Thevehicle stops.

2. Click on the edit box of a parameter (e.g. Cmd).ð A screen keyboard is displayed.

3. Enter a value. Apply the value using the enter key.ð After the value has been changed successfully, the value "0" will be displayed

for the parameter "Cmd".4. Reactivate the automatic mode.23

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5.6.4 Manual modeIn the "manual mode" menu item, the following elements are available:

[4]

[2]

[1]

[3]

[5]

9007219365621131

No. Meaning[1] Select the track direction:

• CCW• Straight forward• CWThe selection must correspond to the track guidance ([2] or [4]) for the vehicleto move in the desired direction of travel.

[2] Select the speed of the travel drive:• Slow• Fast

[3] Select the available track guidance (forwards):• No track guidance: Vehicle travels without track guidance.• Optical track guidance: Vehicle travels along an optical track.

[4] Specify the direction of travel of the travel drive:• Turning (CCW/CW)• Forward/reverse

[5] Select the available track guidance (backwards):• No track guidance: Vehicle travels without track guidance.• Optical track guidance: Vehicle travels along an optical track.

Executing travel commandsProceed as follows:1. Select the desired manual mode function.

ð Selected elements are highlighted in green on the software interface.ð The multi-function button at the back of the vehicle flashes if you execute the

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ð The multi-function button is lit if you execute the function by continuously push-ing the button.

2. Push the multi-function button (push and hold) to execute the travel command.

Measure when leaving track guidanceIf the vehicle leaves track guidance unintentionally, proceed as follows:ü Error number "110" displayed, background color is red.ü The vehicle is in automatic mode.1. Switch to manual mode.2. Execute travel commands in manual mode to return to the track.

3. DANGER! Switch to automatic mode.

ð The vehicle continues in automatic mode after a warning signal.

5.6.5 DiagnosticsIn the "diagnostics" menu item, the following elements are available:

[2]

[1]

9007219335920779

No. Meaning[1] Button for selecting a submenu.

[2] Button for performing the following functions:• Reset fault.• Restarting the vehicle controller.• Shut down the vehicle controller. DC 24 V supply is switched off.

Meaning of the status LEDsThe following table shows the meaning of the status LEDs if diagnostics information isdisplayed:

Color MeaningGray No communication to the component.23

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Color MeaningGreen Fault-free communication to component.

Red A fault occurred at the component.

StatusIn the "status" menu item, the following elements are available:

[4]

[2]

[1]

[5]

[3]

21284733963

No. Meaning[1] Displays the active settings for track guidance

[2] Status code/fault code of the vehicle. For further information about the codes,refer to the documentation of the devices.

[3] Displays the current status of the drives

[4] Displays the current status of the batteries

[5] Displays the current status for:• Availability of MOVITRANS® (optional)• Multi-function button• UCS safety module• Transponder read head• EKK energy interface

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PositionIn the "position" menu item, the following elements are available:

[3]

[2]

[1]

[4]

21284851083

No. Meaning[1] Displays the relative position:

• Last transponder: Address of the last successfully read transponder/datamatrix code

• Distance: Distance (mm) that the vehicle travelled after the last positionwas read.

[2] Displays the absolute position in directions X and Y, as well as the rotation ofthe vehicle.

[3] • Displays the single track ID• Virtual track ID: No. of the virtual track the vehicle travels on.

[4] Displays the area:• Area ID: Can be set to a defined position in automatic mode.• Position in track: traveled distance from Area ID in mm

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Version informationIn the "Version information" menu item, the following elements are available:

[1] [2]

21669909259

No. Meaning[1] Shows the used software products

[2] Software version

SafetyIn the "Safety" menu item, the following elements are available:

[1] [2] [3] [4]

[7]

[5]

[6][8]

9007219329108107

No. Meaning[1] Displays the current status of the safety functions.

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No. Meaning[2] Displays the current status of the safety functions for stopping the vehicle in

hazardous situations.

[3] Displays if brake diagnostics is required:• LED red: required.• LED gray: not required.Displays the current status of the brake diagnostics:• Not tested• OK• Warning• Failed

[4] Displays the current status of the safety laser scanner.

[5] Switch off scanner.

[6] Deactivate SS2 ramp.This function is safety-relevant and may only be performed by qualified per-sonnel (password-protected).

[7] Start static brake diagnostics.

[8] Test inputs/outputs.

Brake diagnostics

Brake diagnostics is started by the logic controller (project-specific deviations pos-sible). Brake diagnostics is performed after every start and is repeated every 24 hours.If the brake diagnostics could not be performed in the defined time period or the testwas not passed, the travel speed of the vehicle is limited.

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6 MaintenanceInspection and maintenance work


6 Maintenance6.1 Inspection and maintenance work6.1.1 Requirements

Qualification requirementsThe work steps at the system solution described in the following chapters may only beperformed by trained and authorized employees.For this reason, SEW‑EURODRIVE demands that the following minimum qualificationrequirements are met, according to the roles of the employees:

Role Qualification WorkingOperator Participation in the basic train-

ing (L1) for system operators, orin the training for advanced sys-tem operators (L2):• By specialist from

SEW‑EURODRIVE• Or by maintenance person-

nel of the operator trainedby SEW‑EURODRIVE

Simple inspection and mainten-ance work, that is usually per-formed daily.

Maintenance staff Participation at a training formaintenance personnel taughtby SEW‑EURODRIVE special-ist.

All inspection and maintenancework included in the training.

The system solution was installed and taken into operation by SEW‑EURODRIVE em-ployees. Companies wanting to re-install or expand the system solution must first con-sult SEW‑EURODRIVE.

Types of inspection and maintenance workThe product includes components that require inspection and maintenance. Thischapter provides an overview of the following inspection and maintenance work:• Inspection work

Work that may be performed by the operating personnel.• Inspection and maintenance work

Work that may only be performed by service engineers.If stationary components fail, they can be replaced independently by the relevant spe-cialists. The vehicle may only be completely replaced. If you are not sure which com-ponents you can install by yourself, the staff of SEW‑EURODRIVE will be glad to help.

Keeping purchased parts in stockThird-party components used in this project have deviating replacement and repairtimes than standard components by SEW‑EURODRIVE. The operator is responsibleof keeping sufficient numbers of spare parts in stock.

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6MaintenanceInspection and maintenance work


6.1.2 Inspection (operators)The operator is responsible for the following inspection work:

1 dayClean the vehicle cover.Use teflon spray for dirt-repellent surfaces.

Check the caution signs at the vehicle for damages and dirt.The safety notes attached to the vehicle must be complete and legible.

Check the operating and display elements for damages and dirt.The check includes the following components:• DOP operator terminal• Buttons at the vehicle and carrier

Check the warning and safety devices for damages and dirt.The check includes the following components:• Safety laser scanner• Safety switching strip (if installed)• Emergency stop button• LED lights

Check the wheels for damage and wear.The wheel lining is 22 mm thick. If the lining is down to 19 mm, replace the wheel.

Check the WLAN antenna for damages.Defective WLAN antennas may cause communication problems.

Check the markings of the hazardous areas along the tracks.Labels and markings on the floor must be complete, legible and visible.

Check the tracks for obstacles and remove them.It is possible that work equipment (e.g. boxes or lifting carriages) were put down afterthe operation has been interrupted.

Check if the tracks are clean.Dirt on the tracks influences the travel/braking behavior.

Check if the track markings are clean and visible.Dirty or damaged track markings influence the optical track guidance.

6.1.3 Inspection and maintenance (service engineers)The service engineer performs the following inspection and maintenance works:

1 weekCheck the warning and safety devices for damages and dirt.The check includes the following components:• Safety laser scanner• Safety switching strip (if installed)• Emergency stop button• LED lights

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6 MaintenanceInspection and maintenance work


1 weekCheck if the vehicle is clean/contaminated and clean it.

Check the optical track for damages and replace it if necessary.

6 monthsCheck the function of the safety devices and clean them.The check and cleaning work includes the following components:• Safety laser scanner• Safety switching strip (if installed)• Emergency stop button• LED lights

Check the function of the sensors and clean them.

Check the drive wheels and auxiliary wheels for damage, such as pitting, cracks, orwear. Check if the non-driven wheels run smoothly.

Visual inspection of motors and gear units.

6.1.4 Inspection and maintenance (SEW-EURODRIVE)SEW‑EURODRIVE performs the following inspection and maintenance works:

1 yearVisually check the cabling and power supply chains (in drawer).

Clean the inside of the vehicle using a vacuum cleaner, and clean the electroniccomponents (using compressed air).

Inspection of entire drive: Check for running noise. Visual check of oil level.

Inspection of entire motor: Brake function and wear check. Check for running noise.Clean the cooling air ducts.

Check the FS04 encoders for functional safety according to EN ISO 13849‑1.

Check the auxiliary wheels of the pivot bearings and lubricate them if necessary.

Check to see if the bearings and wheels run smoothly and for signs of wear. Replacethem if necessary.

Check the parameters/project data according to the project documentation.

Charge and discharge the batteries under supervision, then check the batteries.

Perform brake test on SS2 ramp.

3 yearsReplace auxiliary wheels (optional).

Replace drive wheels (optional).

Extensive maintenance of the travel drive: Replacing wear parts. Change the oil. Re-place oil seal. Check the bearings for clearance and replace them if necessary.

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6MaintenanceFailures


6.2 Failures

Fault Possible cause MeasureOil leaking from vehicle. Gear unit leaking. Contact

SEW‑EURODRIVE.

Touching the vehicle or theload carriers might result inelectrostatic discharge.

Static charge of the vehicledue to insufficient electricaldischarge capacity of thefloor.

• Improve the electricaldischarge capacity ofthe floor.

• Install ESD protection.• Contact

SEW‑EURODRIVE.

Unusual noises at thevehicle during travel.

Gear unit or travel drive de-fective.

ContactSEW‑EURODRIVE.

Vehicle stops on the travelsection.

Safety controller detects anerror.

• Eliminate cause of error(e.g. unlock emergencystop button).

• Acknowledge the errorusing the acknowledg-ment key.

Vehicle swings duringtravel.

Drive wheels are worn ordirty.

Check and clean the drivewheels.

• Insufficient traction ofthe drive wheels.

• Wheels aligned incor-rectly.


Vehicle does not move. Emergency stop not un-locked or reset.

Unlock the emergencystop. Reset the emergencystop.

• There is an obstacle inthe safety zone of thesafety laser scanner(safety zone violation).

• The protection devicesof the load handlingdevice has tripped.

• Remove the obstacle.• Check the protection

devices of the loadhandling device.

• Safety controller de-tects an error.

• Brake, swivel caster, ordrives defective.


6.2.1 Acknowledging faultsFaults that were triggered by an activated safety function can be acknowledged dir-ectly at the vehicle using the acknowledgment button (blue).

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6 MaintenanceStatus and error messages


The following table lists measures to acknowledge a failure at the vehicle:

State Control element MeasureFault present. Acknowledgment button (blue):

lights upEliminate fault.Unlock the emergency stopbutton if it has been pushedduring a failure.

Fault eliminated. Acknowledgment button (blue):flashing at 1 Hz

Press the acknowledgmentbutton to acknowledge themeasure.

INFORMATIONFaults that cannot be acknowledged.In case of faults on the vehicle that cannot be acknowledged, the acknowledgmentbutton is lit permanently, despite pressing it.• Contact SEW‑EURODRIVE.

Faults that were not triggered by an activated safety function can be acknowledged atthe vehicle using the operator panel DOP.

6.3 Status and error messagesThe system solution can display different error messages. This chapter offers help fortroubleshooting.Codes and meaning of the faults and status are displayed on the initial screen of theoperator panel.

6.3.1 Status reports

Code Meaning Description001 Vehicle travels. Vehicle executes travel command.

(If the vehicle does not move, check on the ini-tial screen if the speed setpoint and the speedlimit are set ≠ "0".)

002 Initialization Vehicle controller reboots.

003 Standby The vehicle is in energy-saving mode.The vehicle movement can be started usingthe multi-function button or by a travel com-mand of the higher-level controller.

004 Motion pending. The vehicle will start moving soon.

011 "Single track" occupied. The higher-level controller prevents a vehiclefrom entering a reserved area ("Single track").

012 In station The vehicle is at the target position.The number of the transfer station is displayedafter the "/" character.

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6MaintenanceStatus and error messages


Code Meaning Description013 Stop due to higher-level

controller.The vehicle is stopped by the higher-level con-troller.

014 Waiting for command. The vehicle is in automatic mode and waits fora command.

021 Manual mode The vehicle is in manual mode.

022 Target transponderreached.

The vehicle has reached the target position.

023 Waiting for travel com-mand.

The vehicle is in automatic mode and waits fora travel command.

6.3.2 Error messages

Code Meaning Possible cause Measure091 Safety function The internal monitoring function

of the safety controller (UCS) hastripped.

Contact SEW‑EURODRIVE.

092 Emergency stop The vehicle was stopped by thesafety controller due to an actu-ated emergency stop button.

• Eliminate the cause of theerror.

• Unlock the emergency stopbutton.

• Acknowledge the fault usingthe acknowledgment button.

093 Obstacle on the track Safety laser scanner detectedsafety zone violation because ofan obstacle.

• Remove the obstacle.• If the obstacle cannot be re-

moved, deactivate the safetylaser scanner using the key-switch.

099 Application error Error in program sequence.The special error code is dis-played after the "/" character.


100 Left drive The inverter of the left/right traveldrive signals an error.The special error code is dis-played after the "/" character.

• Eliminate the fault as de-scribed in the documentationof the drive.

• Reset the error by clicking the[Reset] button on the initialscreen.

101 Right drive

103 Optical sensor Device and communication error Contact SEW‑EURODRIVE.

106 Transponder reader Device and communication error Contact SEW‑EURODRIVE.

107 Safety controller Device and communication error • Eliminate the fault as de-scribed in the documentationof the safety controller.

• Acknowledge the fault in thesoftware.

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6 MaintenanceReplacing the battery


Code Meaning Possible cause Measure110 Track not detected The selected track sensor does

not detect a track.• Position the vehicle on the

track correctly.• Select the correct track

sensor.• Look for damages or dirt on

the optical track.

111 DC link too low • DC 48 V voltage supply inter-rupted.

• Energy storage unit dis-charged.


112 Transponder distance The read value of the transpon-der distance does no longermatch the configured value.


113 Position window The vehicle stops after a travelcommand but the position is out-side the position window.


114 Invalid track guidance The selected track sensor is nolonger available.


115 Battery service life The battery is at the end of itsservice life.


116 I/O module Device and communication error Contact SEW‑EURODRIVE.

117 Brake diagnostics re-quired

The internal brake diagnosticsfailed or is overdue.


6.4 Replacing the batteryProceed as follows:1. Move the vehicle to a suitable position away from the travel section, charging sta-

tion, and MOVITRANS® line cables if present.2. Switch off the vehicle.3. Remove the screws on the cover plate of the vehicle.

[1]

9007220210067083

[1] Cover

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6MaintenanceReplacing the battery


4. Remove the cover plate of the vehicle.

[1]

[2] [2][2] [2]

9007220212218507

[1] Fuse[2] Battery

5. Remove the fuses.

6. DANGER! Danger due to arcing. Severe injuries and damage to property. Dis-connect the batteries in the correct sequence. Do not disconnect the cables fromthe vehicle, but directly from the battery.

7. Disconnect the minus pole (blue) from the battery.8. Disconnect the plus pole (red) from the battery.9. Disconnect the wire jumpers between the batteries.10. Remove the batteries.11. Insert the new batteries.12. Connect the wire jumpers between the batteries.

13. DANGER! Danger due to arcing. Severe injuries and damage to property. Con-nect the batteries in the correct sequence. Do not connect the cables to thevehicle, but directly to the battery.

14. Connect the plus pole (red) to the battery.15. Connect the minus pole (blue) to the battery.16. Insert the fuses.17. Place the cover plate onto the vehicle.18. Screw the cover plate onto the vehicle.19. Switch on the vehicle.

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6 MaintenanceTransport


6.5 Transport

WARNINGHazard from suspended load.Severe or fatal injuries.• Do not stand under the load.• Secure the area where loads can fall down.• Use all lifting eyebolts.• Align the lifting eyebolts with the direction of tension.• Use adequately dimensioned lifting devices and lashing straps.

Proceed as follows:Lifting the vehicle ü The vehicle is switched off.

1. Install the lifting eyebolts at the attachment points [1] on the cover plate, as shownin the figure.

[1]

[1]

[1]

[1]

18014418711506187

2. Use the specified attachment points [1] to carry the load.3. Select suitable lifting devices.4. Lift the vehicle.

Wrapping thevehicle

NOTICEDamage to components at the vehicle frame (e.g. LED lights).Damage to property.• Place the vehicle on the wheels for transport.• Make sure that the wheels carry the vehicle load. Components that are damaged

by the load are attached to the vehicle frame.

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6MaintenanceSpare parts


5. Place the vehicle in the supplied transport box.

21457645067

6. Secure the vehicle against rolling away.

6.6 Spare parts

Component Part numberLabel "Do not ride on vehicle" 19112955

Label "CAUTION hand injuries" 19112998

Lifting eyebolt for attachment point 19085427

6.7 Electronics ServiceContact the SEW‑EURODRIVE Electronics Service in Bruchsal if a malfunction cannotbe rectified.If you send the vehicle in for repair, provide the following information:• Serial number (nameplate)• Type designation• Project number• Brief description of the application• Nature of the fault• Accompanying circumstances• Your own assumptions

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6 MaintenanceElectronics Service


• Any unusual events preceding the problem, etc.• Name of the affected vehicle

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7Technical dataAmbient conditions


7 Technical data7.1 Ambient conditions

Data ValueFloor quality According to DIN 18560 Floor screeds in

building construction – Part 7: Heavy dutyfloor screeds (industrial screeds)

Floor leakage resistance < 108 Ω

Ambient temperature during operation + 5 – + 40 °C

Ambient temperature during storage + 10 – + 40 °C

Climate class according to EN 60721‑3‑3 Class 3K3, no condensation

Vibration and shock load during operation According to EN 61800-5-1

7.2 Vehicle

Data ValueDimensions (L × W × H) 845 × 600 × 305 mm (without batteries)

Mass technology module without load 150 kg

System voltages DC 48 V

For further information, refer to the vehicle nameplate.

7.2.1 Vehicle with energy module (55 Ah)

Data ValueDimensions (L × W × H) 845 × 600 × 415 mm

Mass entire vehicle without load 225 kg

Maximum payload 520 kg

Electric charge 55 Ah

Travel time without charging ≈ 4 h







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7 Technical dataStartup parameters








7.3 Startup parametersThe following table lists the parameters for startup via the MOVITOOLS® MotionStudiosoftware:

Window Parameter ValueGeneral settings Device type ELVCD

Kinematic model Center drive

Vehicle type 0

Remote IP Customer-specific IP ad-dress of the logistics con-troller

Receiving port 51000

Timeout 1000 ms

Travel axis scaling para-meters

Gear ratio i 21.98

Drive wheel diameter 200 mm

Direction of rotation re-versal right wheel

Activated

Direction of rotation re-versal left wheel

Deactivated

Monitoring/system limits Position window 100 mm

Rapid stop deceleration 2000 mm/s2

Ramp set acceleration 250 mm/s2

Ramp set deceleration 700 mm/s2

Ramp set jerk 5000 mm/s3

Minimum radius 1000 mm

Maximum speed forward 1400 mm/s

Maximum speed reverse 180 mm/s

Maximum speed turning 200 mm/s

Maximum track gap 100 mm

Maximum angle of rotationfor track scanning

45°

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7Technical dataStartup parameters


Window Parameter ValueMaximum transponder spa-cing

0 mm (project-specific)

Geometry/sensors Center distance 530 mm

MOVITRANS® sensor front Deactivated

Distance from front sensorto axis

–

MOVITRANS® sensor back Deactivated

Distance from rear sensorto axis

–

Front optical sensor Activated

Reverse assembly Deactivated

Distance from sensor toaxis

500 mm

Track color (move down-wards)

Blue (RAL 5015)Optional: red (RAL 3001)

Rear optical sensor Activated

Reverse assembly Activated

RFID sensor Activated

Distance from sensor toaxis

0

Distance from sensor tocenter

0

Energy management Drive lock when not active 10000 ms

Number of energy inter-faces

None

Safety technology UCS activated Active

Keyswitch speed 80 mm/s

Warning zone speeds:

Field set 1 90 mm/s

Field set 2 90 mm/s

Field set 3 270 mm/s

Field set 4 540 mm/s

Ignore rear warning zone Deactivated

Brake diagnostics Brake diagnostics active Activated

Speed 300 mm/s

Ramp set 1

Standstill torque M0 of themotor

3.5 Nm

Current I0 at standstilltorque M0

32 A

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7 Technical dataStartup parameters


Window Parameter ValueDiagnostic mode Forwards/backwards

Test distance "Brakeopens"

50 mm

Test time 2000 ms

Test torque "Level 1" 2.4 Nm

Test torque "Level 2" 2.4 Nm

Maximum deviation 90°

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7Technical dataDimension sheets


7.4 Dimension sheetsThe following drawing shows the dimensions of the vehicle with 55 Ah battery capa-city. The height of vehicles with other battery capacities varies as specified in the tech-nical data.

846

609

415

9007219456721675

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8 MAXOLUTION® Competence Center


8 MAXOLUTION® Competence CenterGermanyBruchsal SEW-EURODRIVE GmbH & Co KG

Ernst-Blickle-Straße 4276646 Bruchsal

Tel. +49 7251 75-0Fax +49 7251 75-1970http://[email protected]

Kirchheim SEW-EURODRIVE GmbH & Co KGDomagkstraße 585551 Kirchheim (München)

Tel. +49 89 909552-10Fax +49 89 [email protected]

AustraliaMelbourne SEW-EURODRIVE PTY. LTD.

27 Beverage DriveTullamarine, Victoria 3043


BrazilSão Paulo SEW-EURODRIVE Brasil Ltda.

Estrada Municipal José Rubim, 205 – Rodovia San-tos Dumont Km 49Indaiatuba – 13347-510 – SP

Tel. +55 19 [email protected]

ChinaTianjin SEW-EURODRIVE (Tianjin) Co., Ltd.

No. 78, 13th Avenue, TEDATianjin 300457

Tel. +86 22 25322612Fax +86 22 25323273http://[email protected]

FranceHagenau SEW-USOCOME

48-54 route de SoufflenheimB. P. 2018567506 Haguenau Cedex

Tel. +33 3 88 73 67 00Fax +33 3 88 73 66 00http://[email protected]

IndiaChennai SEW-EURODRIVE India Private Limited

Plot No. K3/1, Sipcot Industrial Park Phase IIMambakkam VillageSriperumbudur - 602105Kancheepuram Dist, Tamil Nadu

Tel. +91 44 37188888Fax +91 44 [email protected]

ItalySolaro SEW-EURODRIVE di R. Blickle & Co.s.a.s.

Via Bernini,1420020 Solaro (Milano)

Tel. +39 02 96 9801Fax +39 02 96 79 97 81http://[email protected]

PolandTychy SEW-EURODRIVE Polska Sp.z.o.o.

ul. Strzelecka 6643-109 Tychy

Tel. +48 32 32 32 610Fax +48 32 32 32 648

South AfricaJohannesburg SEW-EURODRIVE (PROPRIETARY) LIMITED

Eurodrive HouseCnr. Adcock Ingram and Aerodrome RoadsAeroton Ext. 2Johannesburg 2013P.O.Box 90004Bertsham 2013


South KoreaAnsan SEW-EURODRIVE KOREA CO., LTD.

7, Dangjaengi-ro,Danwon-gu,Ansan-si, Gyeonggi-do, Zip 425-839


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8MAXOLUTION® Competence Center


SwedenJönköping SEW-EURODRIVE AB

Gnejsvägen 6-8553 03 JönköpingBox 3100 S-550 03 Jönköping

Tel. +46 36 34 42 00Fax +46 36 34 42 80http://[email protected]

USALyman SEW-EURODRIVE INC.

1295 Old Spartanburg HighwayP.O. Box 518Lyman, S.C. 29365


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SEW-EURODRIVE—Driving the world

SEW-EURODRIVE GmbH & Co KGErnst-Blickle-Str. 4276646 BRUCHSALGERMANYTel. +49 7251 75-0Fax +49 7251 [email protected]

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