Page 1 HD-1500 Platform User's Manual I645-E-05...
Page 2 Every precaution has been taken in the preparation of this manual. Nevertheless, OMRON assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained in this publica- tion.
Page 3: Intended Audience
Thank you for purchasing the HD-1500 Autonomous Mobile Robot (referred to as AMR in this docu- ment). This manual is OMRON's original instructions describing the setup, operation, and user maintenance of the AMR. This document describes the AMR functionality provided with FLOW v3.3.5.
Page 4: Manual Information
Manual Information Manual Information Page Structure The following page structure is used in this manual. 5 Installation Unpack This section provides details on how to unpack the Industrial Panel PC. 5-1-1 Unpack Procedure Check the package for damage. If there is any visible damage: •...
Page 5 Manual Information Precautions for Safe Use Precautions on what to do and what not to do to ensure safe usage of the product. Precautions for Correct Use Precautions on what to do and what not to do to ensure proper operation and performance. Additional Information Additional information to read as required.
Page 6 Manual Information HD-1500 Platform User's Manual (I645)
Page 7: Sections In This Manual
Sections in this Manual Sections in this Manual Overview Specifications Installation Operation Troubleshooting Maintenance Appendices Index HD-1500 Platform User's Manual (I645)
Page 8: Table Of Contents
CONTENTS CONTENTS Introduction ......................1 Intended Audience............................1 Units.................................1 Manual Information....................2 Page Structure..............................2 Special Information ............................2 Sections in this Manual ................... 5 Terms and Conditions Agreement................ 12 Warranty and Limitations of Liability ......................12 Application Considerations ..........................13 Disclaimers ..............................13 Safety Precautions....................15 Definition of Precautionary Information......................15 Symbols .................................15 Dangers .................................16...
Page 9 CONTENTS 1-2-13 User Access Panel ........................1-14 1-2-14 Input and Output Control ......................1-15 1-2-15 Wireless Antennas ........................1-15 1-2-16 Localization Sensors .........................1-15 1-2-17 Interlock Switches ........................1-15 1-2-18 Electronics Bay .........................1-15 1-2-19 Payload Mounting Surface ......................1-16 Autonomous Navigation .....................1-17 Labels............................1-19 1-4-1 AMR Information Label ......................1-19 1-4-2 Docking Target Information Label .....................1-20 1-4-3...
Page 10 CONTENTS 2-4-4 Charging Station Specifications ....................2-12 2-4-5 Operator Panel Screen ......................2-13 2-4-6 Drive Train..........................2-13 2-4-7 Safety Function Performance Levels ..................2-13 2-4-8 Stopping Distance and Time .....................2-16 2-4-9 Wireless Specifications ......................2-17 2-4-10 USER PWR Connector ......................2-18 2-4-11 REG PWR Connector .......................2-18 2-4-12 SCPU Connector........................2-18 2-4-13...
Page 11 CONTENTS Section 4 Operation Payload Movement and Transfer..................4-3 AMR Start-up ..........................4-4 AMR Shut-down ........................4-5 AMR Controller LED Indicators ....................4-6 Workspace..........................4-7 4-5-1 Physical Barriers .........................4-9 4-5-2 Logical Barriers ...........................4-9 4-5-3 Obstacles ..........................4-10 4-5-4 Environmental Hazards ......................4-10 4-5-5 Restricted Zones ........................4-10 4-5-6 Operating Hazard Zones ......................
Page 12 CONTENTS 4-19-9 Booting ............................4-42 4-19-10 Operating inside a designated MutePersonnelDetectionSector Area ........4-42 4-20 Light Strips and Optional Beacon States ................4-43 4-20-1 Driving Straight..........................4-43 4-20-2 Turn Signal ..........................4-43 4-20-3 Emergency Stop........................4-43 4-20-4 Lost ............................4-44 4-20-5 Stopped .............................4-44 4-20-6 Stopped with Warning .......................4-44 4-20-7 Obstacle Detected / Protective Stop ..................4-44 4-20-8...
Page 13 CONTENTS Lifting the AMR ........................6-6 Maintenance Items.........................6-8 6-5-1 Mechanical Brake Inspection Procedure..................6-8 6-5-2 AMR Charging Contact Inspection ....................6-9 6-5-3 Docking Target Inspection ......................6-9 6-5-4 Safety and Warning Labels .......................6-10 6-5-5 Drive Power Indicator Check Procedure ...................6-10 6-5-6 Caster Lubrication Procedure ....................6-10 Storing Batteries ........................6-12 Cleaning..........................6-13 6-7-1...
Page 14: Terms And Conditions Agreement
Omron’s exclusive warranty is that the Products will be free from defects in materials and work- manship for a period of twelve months from the date of sale by Omron (or such other period ex- pressed in writing by Omron). Omron disclaims all other warranties, expressed or implied.
Page 15: Application Considerations
• Omron Companies shall not be responsible for the user’s programming of a programmable Product, or any consequence thereof. • Omron Companies shall not be responsible for the operation of the user accessible operating sys- tem (e.g. Windows, Linux), or any consequence thereof.
Page 16: Errors And Omissions
Terms and Conditions Agreement Errors and Omissions Information presented by Omron Companies has been checked and is believed to be accurate; how- ever, no responsibility is assumed for clerical, typographical or proofreading errors or omissions. HD-1500 Platform User's Manual (I645)
Page 17: Safety Precautions
Safety Precautions Safety Precautions Definition of Precautionary Information The following notation is used in this manual to provide precautions required to ensure safe usage of the AMR. The safety precautions that are provided are extremely important to safety. Always read and heed the information provided in all safety precautions. The following notation is used.
Page 18: Dangers
Safety Precautions Dangers DANGER The AMR can cause serious injury to personnel or damage to itself or other equipment if it drives off of a ledge, such as a loading dock, or down stairs. Improper operation of the AMR on inclined floors that do not comply with the applicable operating specifications can result in the AMR tipping over, and consequently a serious personal injury.
Page 19 The assembly instructions shall then form part of the technical file for the final machine. Use only the specified tools, equipment, and OMRON-supplied spare parts to service and maintain the AMR according to the specified service intervals. Failure to do so could result in an unsafe operating state that might result in personal injury or damage to prop- erty.
Page 20 The rear and top of the AMR also pose pinch hazards when the rear skin and the top plate are removed. OMRON is not responsible for any risks incurred by modifying safety zone sizes or other Safety Laser Scanner settings.
Page 21 The AMR battery and the Charging Station outputs have high current. You must take ap- propriate precautions to avoid potential short circuit. Replace the battery only with an OMRON factory-supplied battery intended for use in the AMR. Do not use batteries intended for use in other OMRON AMR models.
Page 22: Operating Environment
If a payload is beyond the footprint of the AMR, it can compromise the AMR's safety functions. Payloads beyond AMR footprint may require modifying safety zone size. The OMRON AMR Safety Zone Generator tool is available for safety zone resizing. Operating Environment Abrupt appearance of objects or persons in the path of the AMR could result in personal injury or property damage.
Page 23 Safety Precautions If the AMR is in an operational hazard or restricted zone, these areas must be properly marked or restricted according to applicable standards. The AMR can cause serious injury to personnel or damage to itself if a dangerous area is not properly configured in the map and blocked with a physical barrier.
Page 24: Cautions
Safety Precautions Cybersecurity To maintain the security and reliability of the system, a robust cybersecurity defense pro- gram should be implemented, which may include some or all of the following: Anti-virus protection • Install the latest commercial-quality anti-virus software on the computer connected to the control system and keep the software and virus definitions up-to-date.
Page 25 Safety Precautions Any electrical charge that accumulates on the AMR skins does not have a path to ground, and therefore cannot discharge. This can be hazardous to electrostatic sensitive devices. Always keep electrostatic sensitive devices at least 30 cm away from the AMR skins.
Page 26: Precautions For Safe Use
It should be shipped and stored in the supplied packaging, which is designed to prevent damage from normal shock and vibration. • OMRON recommends storing and securing the Pendant when not in use to prevent an unauthorized person from operating the AMR.
Page 27 • In case of fire, use a type ABC or type BC dry chemical fire extinguisher. • Although the lasers used are Class 1/1M (eye-safe), OMRON recommends that you not look into the laser light. The maximum permissible exposure cannot be exceeded when viewing lasers with the naked eye.
Page 28 • Never access the interior of the AMR while it is connected to the Docking Target. • Only use charging equipment and batteries supplied by OMRON. The charger shall only be used to charge an HD-1500 or MD-series AMR battery.
Page 29: Precautions For Correct Use
• Do not connect user-supplied equipment to the Ethernet switches located in the electronics bay. • Rough or uneven floors can degrade the drive wheels, and shorten their life span. • Replacement of the differential drive train, casters, and wheels require an OMRON service engineer. Contact your local OMRON representative for more information.
Page 30 • Do not exceed 10 kN per payload structure mounting point. • OMRON does not provide the protective coverings with the HAPS option. A protective covering needs to be installed when applying the magnetic tape to the floor to prevent damage from the AMR traffic.
Page 31 Precautions for Correct Use • OMRON recommends that you train personnel on the safe use of the brake release operations and procedures for safely pushing an AMR. • IATA regulations (UN 3480, PI 965) require that air freight shipped lithium ion batteries not installed in the AMR must be transported at a state of charge not exceeding 30%.
Page 32: Regulations And Standards
Regulations and Standards Regulations and Standards Conformance to EU Directives The AMR complies with the following EU Directives. Directives • 2006/42/EC Machinery Directive • 2014/30/EU EMC Directive EN / IEC Standards The AMR system conforms to the following EN standards. •...
Page 33: Conformance To Kc Certification
Regulations and Standards Battery Chargers (Charging Station). • ANSI/CAN/UL/ULC 2271 Standards for Safety Batteries for use in Light Electric Vehicle (LEV) Applications (Battery). • CAN/UL 3100 Automated Mobile Platforms (AMPs). Conformance to KC Certification When you use this product in South Korea, observe the following precautions. This product meets the electromagnetic compatibility requirements for business use.
Page 34: Related Manuals
Related Manuals Related Manuals Use the following related manuals for reference. Manual Title Description Fleet Operations Workspace Core User's Manual (Cat. Describes Fleet management, MobilePlanner soft- No. I635) ware, the SetNetGo OS, and most of the configuration procedures for an AMR. Enterprise Manager 2100 User's Guide (Cat.
Page 35: Glossary
Debug Info File A zip file downloaded from SetNetGo that contains detailed information about the status of the system used by OMRON engineers for trouble- shooting. Docking Target A fixed object that is connected to the Power Supply Box that the AMR docks to that is used for autonomous charging.
Page 36 Glossary Term / Abbreviation Description Ethernet A type of network used in local area networks that typically uses a twisted pair cable and supports data speeds up to 100 Mbps. Factory Automation Fleet Two or more AMRs operating in the same workspace controlled by a single Fleet Manager.
Page 37 Glossary Term / Abbreviation Description Operator Panel The primary interface on the AMR that provides user interaction functions. Path The line on an AMR's map between its current position and its destination that provides an indication of the AMR's intended motion. Payload Any item(s) that are placed on the AMR for the purposes of securing, trans- porting, and transferring some object.
Page 38: Revision History
Revision History Revision History A manual revision code appears as a suffix to the catalog number on the front and back covers of the manual. I645-E-05 Cat. No. Revision code Revision code Date Revised content September 2024 Corrections and updates. February 2024 Corrections and updates.
Page 39: Overview
Overview This section provides general information about the AMR. Intended Use....................1-3 Features and Components ................1-6 1-2-1 Lasers......................1-6 1-2-2 Drive Train and Suspension ................1-8 1-2-3 Skins........................ 1-8 1-2-4 AMR Controller....................1-9 1-2-5 Battery ......................1-9 1-2-6 E-STOP Buttons .................... 1-10 1-2-7 Operator Panel ....................
Page 40 1 Overview 1-6-7 High Accuracy Positioning System..............1-28 1-6-8 Cell Alignment Positioning System..............1-28 1-6-9 Top Plate ....................... 1-29 FLOW Core Software ................... 1-30 1-7-1 MobilePlanner Software ................1-30 1-7-2 Fleet Management Software ................. 1-31 1-7-3 SetNetGo Software ..................1-32 1-7-4 MobileFirmware.....................
Page 41: Intended Use
OMRON does not provide the method of loading the payload on or off the AMR. It is the end user's responsibility to perform a complete task-based risk assessment in accordance with EN ISO 12100, and ensure safe transfer of the payload.
Page 42 1 Overview WARNING Dust, dirt, grease, and water (or other liquids) can affect wheel traction, as well as op- eration of the drive wheels. If the drive wheels slip, it can potentially affect operating duration, stopping distance, and navigation accuracy. The following actions are strictly prohibited and could result in injury or damage to the equipment.
Page 43 1 Overview Precautions for Safe Use The following actions are required for safe use of the AMR. • Review and understand the safety protections associated with your specific application and environment. • Make sure that the environment is suitable for safe operation of the AMR. •...
Page 44: Features And Components
1 Overview Features and Components This section provides an overview of the basic features and components of the AMR. Item Description Item Description Safety Laser Scanner Light Strip Low Laser Light Disc Front / Rear Skin Charging Contacts Side Skin User Access Panel (Cover) Wireless Antennas E-STOP Button...
Page 45: Additional Information
Precautions for Safe Use • Although the lasers used are Class 1/1M (eye-safe), OMRON recommends that you not look into the laser light. The maximum permissible exposure cannot be exceeded when viewing lasers with the naked eye.
Page 46: Drive Train And Suspension
This arrangement allows the AMR to maintain contact with the floor over uneven areas or bumps. Precautions for Correct Use Replacement of the differential drive train, casters, and wheels require an OMRON service en- gineer. Contact your local OMRON representative for more information.
Page 47: Amr Controller
1 Overview • Electronics bay. • Drive wheels. 1-2-4 AMR Controller The AMR Controller is the AMR's main computing system that provides all navigational controls and application interfaces. The AMR Controller consists of two main components: the Base Layer contain- ing standard PC interfaces and the Mobile Robot Layer for the processing of the AMR control interfa- ces and network interface.
Page 48: E-Stop Buttons
1 Overview Additional Information The battery is shipped separately from the AMR to comply with dangerous goods shipping reg- ulations. 1-2-6 E-STOP Buttons There are five E-STOP buttons located on the AMR. One button is located on the Operator panel and there are two buttons located on each side of the AMR.
Page 49: Pendant
1 Overview Screen A high-resolution, high-brightness screen provides operational status, wireless signal strength, battery level, IP address, AMR identification, faults, and up to six lines of instructions. ON and OFF Buttons ON and OFF buttons are used to start-up and shut-down the AMR under normal operating conditions. Integrated LED ring lights are provided around the buttons for visual indication of the AMR operating states.
Page 50: Light Discs And Strips
1 Overview Additional Information A Pendant is required for initial map creation. 1-2-9 Light Discs and Strips Colored light discs and strips are provided at highly visible locations on the exterior of the AMR. These provide visual indication about the AMR's status and its pending movement. 1-2-10 Speakers Two speakers can be used as a means to audibly notify personnel of an approaching AMR.
Page 51: Charging Station
1 Overview 1-2-11 Charging Station The Charging Station enables the AMR to charge autonomously. The Charging Station consists of three main parts: • Power Supply Box - supplies power to the Docking Target or can be used to directly charge a bat- tery that has been removed from the AMR.
Page 52: Charging Contacts
1 Overview LED Indicators Main Disconnect Switch Electrical Access Power Supply Box Panel Service Button Docking Target Charging Paddle 1-2-12 Charging Contacts Charging contacts are used to mate with the Docking Target to transfer power to the battery during autonomous recharging. 1-2-13 User Access Panel Connections for power, communications, safety devices, inputs, outputs, and other optional items are...
Page 53: Input And Output Control
1 Overview 1-2-14 Input and Output Control The input and output terminals in the User Access Panel are directly connected to an internally mount- ed NX102 controller. This controller can be programmed to utilize these inputs and outputs for specific applications.
Page 54: Payload Mounting Surface
1 Overview 1-2-19 Payload Mounting Surface Payloads are mounted directly to the top of the AMR chassis. Several mounting points are available for various payload designs. Mounting points are aligned with internal cross-members for payload support purposes. 1-16 HD-1500 Platform User's Manual (I645)
Page 55: Autonomous Navigation
1 Overview Autonomous Navigation The AMR combines hardware and mobile-robotics software to provide an adaptive, mobile platform to transport a payload. It is equipped with a Natural Feature Navigation system which enables the AMR to navigate and perform its basic functions independently and without the need for facility modification. After it scans physical features in its environment, the AMR navigates safely and autonomously to any accessible destination.
Page 56 • Editing the AMR's configuration to affect its behavior in all locations, such as restricting its maximum speed. Additional Information The AMR is capable of navigating autonomously while traveling in reverse, but special applica- tion-specific considerations and adjustments must be made. Contact your local OMRON repre- sentative for more information. 1-18 HD-1500 Platform User's Manual (I645)
Page 57: Labels
1 Overview Labels Labels provide important information about the AMR and Charging Station components. Use the fol- lowing information to understand label details and placement locations. 1-4-1 AMR Information Label The AMR information label is described below. The following example may differ slightly from your pro- duct's label.
Page 58: Docking Target Information Label
1 Overview 1-4-2 Docking Target Information Label The Docking Target information label is described below. The following example may differ slightly from your product's label. Item Name Description Part Number The Docking Target part number is provided. Product Type The product type is provided. Docking Target Information General information about the Docking Target is provided.
Page 59: Amr Safety And Warning Label Locations
1 Overview Item Name Description Part Number The Power Supply Box part number is provided. Product Type The product type is provided. Power Supply Box General information about the Power Supply Box is provided. Production Information The following information is provided. •...
Page 60: Power Supply Box Safety And Warning Label Locations
1 Overview cont prote ction inue with fire, repla again spec fuse ified only risk curre volta ratin Magnetic Field! Can be harful to pacemaker wearers. Pacemaker wearers stay back 36 in. (90 cm.) CAUTION AVOID CONTACT For continued WITH ELECTRICAL protection against risk TERMINALS.
Page 61 1 Overview Symbol Meaning Do not step or stand on this surface Electric shock hazard Heat hazard 1-23 HD-1500 Platform User's Manual (I645)
Page 62: Model Numbers
1 Overview Model Numbers Model numbers are provided in the table below. Item Part Number HD-1500 AMR 68000-000 Battery 68330-000 Power Supply Box 73990-000 Docking Target 68910-000 1-24 HD-1500 Platform User's Manual (I645)
Page 63: Optional Items
1 Overview Optional Items Information about optional items is provided in this section. 1-6-1 Fleet Manager To manage and administer multiple AMRs in the same workspace, you must use a Fleet Manager run- ning the Fleet Operations Workspace (FLOW) software. The Fleet Manager is a computing device with a processor capable of running the Fleet Operations Workspace Core suite.
Page 64: Additional E-Stop Buttons
1 Overview Precautions for Correct Use • Using the Fleet Manager or map features is not a substitute for physical methods of prevent- ing collisions, such as interlocked gateways or barriers. It is the user's responsibility to pro- vide a physical method of preventing collisions where necessary. •...
Page 65: Additional Signal Beacons
Access Panel Connections on page 3-21 for more information. Additional Information You can optionally supply a signal tower which includes a built-in warning buzzer, or a dedicat- ed warning buzzer. Contact your OMRON representative for more information on the available options. 1-6-5...
Page 66: Mobile I/O Box
The Goal will have Tasks that direct the AMR to proceed to the tape, follow the tape, and stop at the marker. Additional Information Contact your OMRON representative for information about the HAPS sensor installation or re- placement. 1-6-8...
Page 67: Top Plate
1 Overview target shape and position itself in relation to the target with high repeatability. It does not require addi- tional sensors or magnetic tape to be applied to the floor. Flexible navigation allows the AMR to approach a station or cart from any angle so that docking can be achieved from any direction.
Page 68: Flow Core Software
1 Overview FLOW Core Software The FLOW (Fleet Operations Workspace) Core software package consists of different software com- ponents that provide specific functionality during AMR configuration and operation. The information in this section provides an overview of the different FLOW Core software components, their functions, and interactions within the AMR system.
Page 69: System Requirements
• Send AMRs to charging locations or other map objects. • View alerts from AMRs. 1-7-2 Fleet Management Software Fleet Management software runs on the Fleet Manager hardware. It provides the following general functionality for a fleet of OMRON AMRs. 1-31 HD-1500 Platform User's Manual (I645)
Page 70: Setnetgo Software
Refer to the Mobile I/O Box User's Manual (Cat. No. I677) for more information. Integration Toolkit (ITK) Package The Integration Toolkit is OMRON’s interface application that enables integration between the Fleet Manager and the end user’s client application, manufacturing execution system (MES), or warehouse management system (WMS).
Page 71: Mobilefirmware
1 Overview This integration layer facilitates autonomous control for a fleet of AMRs using standard communication methods including REST and SQL. The Integration Toolkit facilitates queuing and monitoring of all AMR Job types such as pickup, drop-off, and multi-segment. Additional Information Refer to the Fleet Operation Workspace Core Integration Toolkit User’s Manual (Cat.
Page 72: Fleet Simulator Software
Fleet Simulator Software Fleet Simulator software runs on the Fleet Manager hardware. It provides the following general func- tionality for a simulated Fleet of OMRON AMRs. • Assess impact of map changes, scaling, route changes, and new software features. • Simulate up to 10 AMRs in up to three separate Fleets.
Page 73: Payload Considerations
1 Overview Payload Considerations This section describes considerations and requirements for AMR payloads. A payload is considered as any item(s) that are placed on the AMR for the purposes of securing, transporting, and transferring some object. A payload structure is typically required to secure an object during transport.
Page 74: Payload Structures
If a payload is beyond the footprint of the AMR, it can compromise the AMR's safety functions. Payloads beyond AMR footprint may require modifying safety zone size. The OMRON AMR Safety Zone Generator tool is available for safety zone resizing.  E-STOP Buttons User-supplied E-STOP buttons can be added to the payload structure.
Page 75: Exceeding The Amr Footprint
If a payload is beyond the footprint of the AMR, it can compromise the AMR's safety functions. Payloads beyond AMR footprint may require modifying safety zone size. The OMRON AMR Safety Zone Generator tool is available for safety zone resizing. 1-37...
Page 76: Safety Laser Scanner Zone Obstruction
Some applications such as cart transportation may require modifying Safety Laser Scanner zones if a payload structure obstructs them. The OMRON AMR Safety Zone Generator tool is available for Safe- ty Laser Scanner zone modification. Any change to Safety Laser Scanner zones may require validation using operational testing in accordance to your applicable standards.
Page 77: Coordinate System
1 Overview Coordinate System AMRs use the X, Y, Z, and Theta coordinate system displayed in the figure below. This information is relevant for some of the procedures used in this manual, such as identifying which are the left or right sides of the AMR.
Page 78 1 Overview 1-40 HD-1500 Platform User's Manual (I645)
Page 79: Specifications
Specifications This section provides specifications of the AMR and other associated items. Performance Specifications ................2-2 Physical Specifications ................. 2-3 2-2-1 Dimensions...................... 2-3 2-2-2 Weights ......................2-7 2-2-3 Payload Center of Gravity ................2-7 Environmental Specifications ..............2-10 2-3-1 AMR Environmental Specifications ............... 2-10 2-3-2 Charging Station Environmental Specifications ..........
Page 80: Performance Specifications
These values apply to the production revision level V or higher. Refer to 1-4-1 AMR Information Label on page 1-19 for more information on checking the AMR production revision level. Contact your local OMRON representative for values associated with previous production levels.
Page 81: Physical Specifications
2 Specifications Physical Specifications Physical specification of the AMR and other items are provided below. 2-2-1 Dimensions Dimensional specifications are provided in the following sections. AMR Dimensions Physical dimensions of the AMR are provided below. 1696 (Rear) (Front) = Center of Gravity = Center of Rotation A = Rear caster pivot point to Center of Rotation B = Front caster pivot point to Center of Rotation...
Page 82 2 Specifications 260 mm 280 mm 960 mm (Handle Retracted) 1570 mm (Handle Extended) 307 mm Power Supply Box Dimensions Physical dimensions of the Power Supply Box are provided below. 876.3 1112 171.5 571.5 4X M10 X 1.5 19.1 200.2 100.1 279.3 58.9...
Page 83 2 Specifications 1315 255 100 1256 1306 325 297 User Access Panel Dimensions Physical dimensions for the User Access Panel are provided below. User-supplied DIN rail is shown in the following figure for reference. The distance from the base of the User Access Panel to the AMR mounting surface is 92 mm. M4 X 2 Operator Panel Dimensions Physical Dimensions of the Operator Panel are provided below.
Page 84 2 Specifications 114 109 4X Ø 4.8 THRU Supplementary Laser Scanner Dimensions Physical dimensions of the Supplementary Laser Scanner are provided below. 2X M5 Screws 37.5 91.5 2X M5 Screws AMR Charging Position Dimensions The AMR charging position dimensions are provided below. HD-1500 Platform User's Manual (I645)
Page 85: Weights
2 Specifications 1025 1180 2028 2-2-2 Weights Weights are provided in the table below. Item Weight AMR (no battery or accessories) 220 kg Battery 29 kg Power Supply Box 111 kg Docking Target 28 kg 2-2-3 Payload Center of Gravity The following figures show the calculated safe center of gravity placements for AMR's maximum al- lowed payload weight.
Page 86 2 Specifications HD-1500 Platform User's Manual (I645)
Page 87 2 Specifications HD-1500 Platform User's Manual (I645)
Page 88: Environmental Specifications
2 Specifications Environmental Specifications Environmental specifications are provided in the following sections. 2-3-1 AMR Environmental Specifications Environmental specifications for the AMR are provided below. Item Specification Ambient operating temperature 5 to 40°C Ambient light interference Wavelength: 845 nm Brightness: 3000 lx max. Storage temperature -20 to 60°C Humidity...
Page 89: Battery Environmental Specifications
2 Specifications Item Specification Humidity 5% to 95%, non-condensing Altitude 2000 m maximum Pollution degree Ingress protection class IP20 (IP10 for charging pads) Class of equipment Class 1 2-3-3 Battery Environmental Specifications Environmental specifications for the battery are provided below. Item Specification Ambient operating temperature...
Page 90: Other Specifications
2 Specifications Other Specifications Specifications for other items are provided below. 2-4-1 Laser Specifications Specifications for the lasers are provided below. Item Specification Safety Laser Scanner Sensing Horizontal plane 181 mm from floor surface to a range of 40 m. Plane Safety Laser Scanning Class Class 1M in accordance with the following standards:...
Page 91: Operator Panel Screen
2 Specifications Description Specification Maximum input current 25 A Maximum output current 120 A (nominal) Input voltage 3-phase 200 to 240 VAC, 50/60 Hz - Delta/Wye 380 to 415 VAC, 50/60 Hz - Wye Output voltage (Power Supply Box / Docking Target) 40 to 57 VDC Power consumption 7.75 kW...
Page 92 2 Specifications Safety Reset Safety Function Description Category PFHd Stop Type Type E-STOP buttons Emergency Manual Pressing the E-STOP but- 8.84 x 10 on sides of AMR Stop Reset ton results in an emergen- cy stop (controlled stop). In this case, the power to the AMR motors remains ON in order to achieve a controlled stop.
Page 93 2 Specifications Safety Reset Safety Function Description Category PFHd Stop Type Type Enabling device on Emergency Manual When the enabling device 6.62 x 10 Pendant Stop Reset is not depressed or com- pletely depressed, an emergency stop (control- led stop) will occur. In this case, the power to the AMR motors remains ON in order to achieve a con-...
Page 94: Stopping Distance And Time
2 Specifications Safety Reset Safety Function Description Category PFHd Stop Type Type Brake release Protective Manual This function monitors the 4.23 x 10 monitoring Stop Reset brake to avoid continuous braking when the AMR is traveling. The brake re- lease monitoring initiates a category 1 stop.
Page 95: Wireless Specifications
2 Specifications Stopping Distance 1600 1400 1200 1000 1100 1300 1500 1700 Velocity (mm/s) Stopping Time 1100 1300 1500 1700 Velocity (mm/s) 2-4-9 Wireless Specifications Wireless network specifications for the AMR are provided below. Item Description Signal Strength The minimum required signal strength is -60 dBm. Channel Interference No more than two detectable access points at a level of -85 dBm at any given location.
Page 96: User Pwr Connector
2 Specifications Item Description Latency Maximum recommended latency for round trip communication is 10 ms. Standard IEEE 802.11 a/b/g Security Authentication: WPA-PSK, WPA2-PSK, PEAP-MSCHAPv2, EAP-TLS Encryption: TKIP/RC4/CCMP/AES 2-4-10 USER PWR Connector Electrical and other specifications for the USER PWR connector are provided below. Item Specification AMR connector...
Page 97: Lights Connector
2 Specifications Item Specification User-supplied mating connector TE Connectivity Micro Mate N Lok receptacle (part number: 1-794617-2) User-supplied mating connector pins TE Connectivity AMP connectors, 20-24 AWG (part number 1-794610-2) Input type PNP / sourcing Rated input voltage 24 VDC (20.4 to 28.8 VDC) Safety input current 3.0 mA Safety output current...
Page 98: Io 2 Connector
2 Specifications 2-4-15 IO 2 Connector Electrical and other specifications for the IO 2 connector are provided below. Additional Information The IO 2 connector is connected to the NX-OD4256 and NX-DA3603 units in the AMR. Refer to the NX-series Digital I/O Unit User's Manual (Cat. No. W521) and the NX-series Analog I/O Units User's Manual for Analog Input Units and Analog Output Units (Cat.
Page 99 2 Specifications Item Specification Molex Mini-Fit Jr. 2 x 1 receptacle (part number 0039012020) User-supplied mating connector Mini-Fit Female Crimp Terminal, Tin over Copper Plated Brass, User-supplied connector pins 18-24 AWG (part number 39000041) Rated input voltage 24 VDC (20.4 VDC to 28.8 VDC) Safety input current 3.0 mA Recommended user-supplied Molex components are provided.
Page 100 2 Specifications 2-22 HD-1500 Platform User's Manual (I645)
Page 101 Installation This section describes how to install and configure the AMR for operation. Installation Introduction ................3-3 Charging Station Installation ................ 3-4 3-2-1 Repositioning the Docking Target Power Connector........3-5 3-2-2 Mechanical Connections ................. 3-5 3-2-3 Charging Paddle Alignment................3-6 3-2-4 Electrical Connections..................
Page 102: Installation
3 Installation 3-12-2 Supplementary Laser Scanner Connection Procedure ......... 3-47 3-12-3 Supplementary Laser Scanner Configuration ..........3-48 HD-1500 Platform User's Manual (I645)
Page 103: Installation Introduction
3 Installation Installation Introduction The general AMR installation steps are provided below. WARNING • Use safe lifting practices when moving the heavy objects such as the Power Supply Box, Battery, Docking Target, and AMR. • The Charging Station, battery, and AMR transfer high electric power and contain hazardous voltages.
Page 104: Charging Station Installation
3 Installation Charging Station Installation Make the following considerations before installing the Charging Station. • Install the Charging Station on a flat and level floor, in a location that is kept clear and is easily ac- cessible to AMRs. • Install the Docking Target away from forklift traffic or high traffic areas. This will prevent collisions between the docked AMRs and other operating vehicles in the area.
Page 105: Repositioning The Docking Target Power Connector
3 Installation Precautions for Correct Use • Vertical orientation of the Power Supply Box allows for heat dissipation, which prevents over- heating and possible fire danger. Horizontal installation of the Power Supply Box is not al- lowed. • The Power Supply Box has cooling vents at the top and bottom of the unit. Do not block these areas.
Page 106: Charging Paddle Alignment
3 Installation When fastening the Docking Target, screw the mounting brackets directly to the wall or to the floor and tighten to torque of 9 N⋅m. When fastening the Power Supply Box, screw the mounting brackets directly to the wall or the floor and tighten to a torque of 61 N⋅m.
Page 107 3 Installation Charging Paddle Wiper Ideal Contact Location Charging Paddle Charging Contacts The Charging Paddle must be level and horizontal, regardless of the floor levelness under the Docking Target. The tip of the Charging Paddle must be 175 mm from the floor. 175 mm 175 mm 175 mm...
Page 108 OMRON support may be necessary. This only applies to Docking Targets with revision N or lower. Check the Docking Target label M/N to determine the revision code.
Page 109: Electrical Connections
3 Installation If the docked position of the AMR results in improper alignment in the X axis, adjust the Final Offset X parameter with the following method: • Increase the value to shift the AMR’s final docking position closer to the Docking Target. •...
Page 110 3 Installation WARNING Improper installation or wiring misconfiguration of the Power Supply Box could result in electrical shock hazard. You must ensure the safe and proper installation of the Power Supply box in accordance with the applicable rules and regulations, and by qualified personnel.
Page 111 3 Installation Wye Configuration User-supplied Connections Jumper Arrangement To Door Ground Point (A) Disconnect Switch (B) Terminal Strip (C) Circuit Breakers (D) Ground Bar 3-11 HD-1500 Platform User's Manual (I645)
Page 112: Power Supply Box Commissioning Procedure
3 Installation Delta Configuration User-supplied Connections Delta Jumper Arrangement To Door Ground Point (A) Disconnect Switch (B) Terminal Strip (C) Circuit Breakers (D) Ground Bar 3-2-5 Power Supply Box Commissioning Procedure Use the following procedure to commission the Power Supply Box. Prepare the facility AC supply and its disconnect switch.
Page 113 3 Installation Turn the Power Supply Box Main Disconnect Switch located on the electrical access panel to ON position (vertical). This will allow the facility AC power to energize the Power Supply Box. Confirm that the blue LED on the Power Supply Box turns ON to complete this procedure. 3-13 HD-1500 Platform User's Manual (I645)
Page 114: Battery Removal And Installation
• At least 3 people are required to lift the battery. Precautions for Safe Use • Only use charging equipment and batteries supplied by OMRON. The charger shall only be used to charge an HD-1500 or MD-series AMR battery. • Operating the AMR at high ambient temperatures (particularly when carrying a full payload at high speeds) can cause the battery to exceed its operating temperature limits.
Page 115: Battery Removal Procedure
3 Installation 3-3-1 Battery Removal Procedure Use the following procedure to remove the battery from the AMR. Turn the AMR OFF. Place the Main Disconnect Switch in the OFF position. Remove the AMR front skin to access the battery compartment. Refer to 6-8-1 Removing and Replacing Skins on page 6-17 for more information.
Page 116: Battery Installation Procedure
3 Installation Use the extended handle to pull the battery the rest of the way out of the AMR. Once the battery has been completely extracted from the AMR, this procedure is complete. 3-3-2 Battery Installation Procedure Use the following procedure to install a battery into the AMR. Place the Main Disconnect Switch in the OFF position.
Page 117: Network Connections
3 Installation Network Connections Wireless and wired networks are available on the AMR. The wired network is typically used for initial configuration and troubleshooting. The wireless network is typically used during normal operation and can also be used for maintenance and troubleshooting. Use the information in this section to configure the network settings of the AMR.
Page 118: Wireless Connection
3 Installation DHCP is used by default. If a static IP is preferred, set the range between 172.16.0.100 to 172.16.0.149. Verify the settings by opening a browser window and accessing https://172.16.0.215. If the set- tings are correct, this will display the SetNetGo web interface and complete this procedure. 3-4-3 Wireless Connection A wireless connection is required when the AMR is operating in a workspace with other AMRs.
Page 119: Wireless Considerations
3 Installation Item Details Security Encryption Disabled TKIP/RC4 CCMP/AES TKIP/CCMP/AES Authentication OPEN (not recom- Method mended) WPA2-PSK Key is either: Passphrase (8-63 ASCII only) Raw Hex (64 Hex-on- WPA-PSK Key is either: Passphrase (8-63 ASCII only) Raw Hex (64 Hex-on- •...
Page 120: Port Forwarding
Port forwarding can be configured between the USER LAN network and the wireless network. This al- lows the onboard NX102 controller to send and receive messages via the wireless network. Contact your local OMRON representative for more information. 3-20 HD-1500 Platform User's Manual (I645)
Page 121: Electrical Connections
3 Installation Electrical Connections Use the following information to understand the AMR's electrical connections. 3-5-1 User Access Panel Connections Use the following information to make all necessary User Access Panel connections. Additional Information Refer to 2-4 Other Specifications on page 2-12 for more information on User Access Panel con- nector and electrical specifications.
Page 122 3 Installation 48 to 57 VDC 0 VDC REG PWR The REG PWR connector on the User Access Panel provides regulated 24 VDC power and is typically used for payload structure control devices. Use the information below to understand all REG PWR connections.
Page 123 3 Installation Precautions for Safe Use The emergency stop or protective stop devices you install on the AMR must have a dual chan- nel circuit to ensure the same performance level as the other safety devices of the AMR. Precautions for Correct Use You must attach either a jumper or some other safety-rated devices (typically E-STOP buttons) to the SCPU connector in order for the AMR to function.
Page 124 3 Installation Pin Number Item Description Safety output 2 Dual-channel safety output. Refer to 4-16 Emergency Stop on page 4-36 Protective stop channel 2 input Dual-channel protective stop circuit input. Monitored for simultaneous switch- ing within 500 ms. Refer to 4-17 Protective Stops on page 4-38 for more information.
Page 125 3 Installation LIGHTS The LIGHTS connector in the User Access Panel provides outputs for user-supplied signaling devices such as signal beacons or buzzers. Use the information below to understand all LIGHTS connections. The following figure shows the pin arrangements for the LIGHTS connector on the AMR. PIN 1 PIN 3 PIN 4...
Page 126 3 Installation The following figure shows the pin arrangements for the IO 1 connector on the AMR. PIN 1 PIN 10 PIN 11 PIN 20 The information in the table below describes the signal designations for the IO 1 connector. Additional Information Use REG PWR pins 2 and 4 (0 VDC) for IOG ground connections.
Page 127 3 Installation Input1+ to 4+ 1MΩ REG PWR 0 VDC Analog circuit internal GND IO 2 The IO 2 connector on the User Access Panel provides analog and digital outputs for user-supplied devices that are typically used for control of a payload structure system. Use the information below to understand all IO 2 connections.
Page 128 3 Installation REG PWR 24 VDC OUT0 to OUT7 REG PWR 0 VDC A circuit diagram is provided below for the analog outputs. Output V1+ to V4+ REG PWR 0 VDC Analog circuit internal GND COMMS The COMMS connector in the User Access Panel is reserved for future use. FTPRT SEL The FTPRT SEL connector on the User Access Panel provides connections for Alternate Safety Zones.
Page 129 Use this connector to transfer user-defined programs to the NX102 unit for application-specific functionality such as I/O control or ARCL command operations. This connector can also be used for periodic updates to the safety control system issued by OMRON. The default IP address of the NX102 controller is 172.16.0.220.
Page 130: Attaching The Payload
3 Installation Attaching the Payload Use the information in this section to understand design considerations and other factors for attaching a payload to the AMR. Precautions for Safe Use You must perform a complete risk assessment for your payload design and the intended use of the AMR prior to its operation.
Page 131 3 Installation 650.0 650.0 660.0 125.0 375.0 125.0 375.0 660.0 394.0 300.0 187.5 187.5 300.0 394.0 M16 X 2.0 (x 4) M12 X 1.75 (x 20) Rivet Nut Considerations There are 20 M12 X 1.75 rivet nuts that are provided for payload structure mounting points. Rivet nuts have internal threads used to attach the payload to the AMR mounting surface.
Page 132: Overhanging Payloads
Overhanging Payloads Increasing the AMR's physical length or width by adding an overhanging payload requires that you in- crease the dimension of the AMR's safety zones. Contact your OMRON representative for more infor- mation on modifying the safety zones. Refer to 4-24-2 Alternate Safety Laser Scanner Zones on page 4-83 for more information.
Page 133: Relocating The Operator Panel
3 Installation Relocating the Operator Panel Some applications may require relocating the Operator Panel if a payload structure obstructs it. The Operator Panel can be removed and relocated to a convenient location, typically on the payload struc- ture. Refer to 6-8-4 Operator Panel Replacement / Removal Procedure on page 6-24 and Operator Panel Dimensions on page 2-5 for more information.
Page 134: Haps Installation And Configuration
3 Installation HAPS Installation and Configuration The following sections provide details about HAPS installation and configuration. 3-8-1 Front HAPS Sensor Installation Use the following procedure to install a HAPS sensor on the front of the AMR. Make the following considerations before attempting this procedure. •...
Page 135: Rear Haps Sensor Installation
3 Installation Apply Loctite 222 and M4 flat washers to two M4 x 12 screws, then insert and tighten using a T10 star bit to a torque of 2.5 N-m. Connect the front HAPS cable plug into the HAPS sensor. This cable is pre-routed near the sensor and has an M12 connector that connects to the top of the sensor.
Page 136 3 Installation Make the following considerations before attempting this procedure. • The rear skin will need to be removed during this procedure. • The AMR must be turned OFF and the disconnect switch must be in the OFF position. • The AMR may need to be lifted to better access the HAPS sensor mounting location. Refer to 6-4 Lifting the AMR on page 6-6 for more information.
Page 137: Tape And Marker Application
Markers (short sections of the tape) are used to signal the AMR where to stop. Precautions for Correct Use • OMRON does not provide the protective coverings with the HAPS option. A protective cover- ing needs to be installed when applying the magnetic tape to the floor to prevent damage from the AMR traffic.
Page 138: Software Configuration
3 Installation Conveyor 1 Conveyor 2 Markers Main Track 20 to 30 30° 2000 min. min. Front HAPS Sensor Goal 1 Goal 2 Rear HAPS Sensor If you use the same magnetic tape for markers as for the main tape strip, apply the markers upside- down, relative to the tape.
Page 139: Goals And Tasks
3 Installation AMR Physical HAPS Configuration Adjust the following parameters in the Robot Physical section of MobilePlanner to configure the use of the HAPS sensor. GuideSensor_Front parameter settings: • Check the AutoConnect Check Box. • Set the Port parameter value to /dev/ttyUSB9. GuideSensor_Rear parameter settings: •...
Page 140 3 Installation Additional Information In this context, a Goal on the AMR’s map is used as a starting point for Tasks that will drive the AMR along the tape, stopping at markers along the tape. There will be no Goals on the tape itself.
Page 141 3 Installation Determines how close Goals need to be for them to be considered as the same location. A toler- ance larger than the distance between the Goals will indicate that the Goals are at the same loca- tion. After entering True for this value, you will be given a choice of distance. The defaults are generally suitable.
Page 142: Attaching Warning Labels
3 Installation Attaching Warning Labels Two warning labels are provided with the AMR. These must be placed in a prominent location on a flat, horizontal surface on the payload structure or AMR itself, where a person could sit or stand. The labels should be placed where the operators will see them and must be visible from at least two op- posing sides of the AMR.
Page 143: 3-10 Commissioning
3 Installation 3-10 Commissioning The commissioning procedure is executed within MobilePlanner. Refer to Fleet Operations Workspace Core User's Manual (Cat. No. I635) for more information. It is used to confirm the correct operation of the following equipment and functions: • Emergency stop buttons on the sides of the AMR •...
Page 144: 3-11 Map Creation Overview
3 Installation 3-11 Map Creation Overview A map is a scanned representation of the floor plan in the AMR's operating space. Maps contain the static features in the AMR's environment, such as walls, doors, permanent shelving, etc. They also contain user-definable sectors, lines, and areas that help the AMR perform its Job. Maps also contain a variety of Goals, Routes, and Tasks that comprise the destinations and activities of the AMR in the workspace.
Page 145: Basic Mapping Tasks
3 Installation Object • Minimal or no payload. • Drive at low rotational speed and acceleration. Use the MobilePlanner software to create and then edit your workspace map. You can add virtual ele- ments to the map that modify the behavior of an AMR. Examples of virtual elements include the follow- ing items.
Page 146: Supplementary Laser Scanner Installation
3 Installation 3-12 Supplementary Laser Scanner Instal- lation Optional Supplementary Laser Scanners can be installed on the payload structure. The following sec- tions describe the mounting, wiring, and configuration of the Supplementary Laser Scanners. The ba- sic steps are provided below. Make location considerations and mount the Supplementary Laser Scanners.
Page 147: Supplementary Laser Scanner Connection Procedure
3 Installation 3-12-2 Supplementary Laser Scanner Connection Procedure Use the following procedure to connect the Supplementary Laser Scanners to the AMR. This procedure details the connection procedure of one of the Supplementary Laser Scanners and should be repeated for the other Supplementary Laser Scanner. A Supplementary Laser Scanner Kit (part number 68945-030) is required for this procedure.
Page 148: Supplementary Laser Scanner Configuration
• Scanner_5 and Scanner_6 These settings configure the Supplementary Laser Scanners. If more than two Supplementary Laser Scanners are required, contact your local OMRON representative for support. • Enabled This should be enabled and indicates to the system that the laser exists and it should be connected at start-up.
Page 149 This indicates the method by which the range of Z values below IgnoreBelowHeight and a range of Z values above IgnoreAboveHeight can be ignored. The possible options are None, Normal and Custom. Contact your local OMRON representative for more information. 3-49...
Page 150 3 Installation 3-50 HD-1500 Platform User's Manual (I645)
Page 151: Operation
Operation This section provides information about the operation of the AMR. Payload Movement and Transfer ..............4-3 AMR Start-up ....................4-4 AMR Shut-down....................4-5 AMR Controller LED Indicators..............4-6 Workspace ...................... 4-7 4-5-1 Physical Barriers ..................... 4-9 4-5-2 Logical Barriers ....................4-9 4-5-3 Obstacles ......................
Page 152 4 Operation 4-13-5 Maintenance Ethernet Port................4-32 4-13-6 Main Disconnect Switch ................4-33 4-13-7 Pendant Port ....................4-33 4-14 Releasing the Brakes ................... 4-34 4-15 Manually Pushing the AMR ................. 4-35 4-16 Emergency Stop ................... 4-36 4-16-1 Emergency Stop Recovery Procedure ............4-36 4-17 Protective Stops ...................
Page 153: Payload Movement And Transfer
4 Operation Payload Movement and Transfer A typical AMR application uses a payload structure to transport objects within a facility. For example, the AMR might pick up and carry a crate of parts from one conveyor belt then deliver it to another con- veyor belt.
Page 154: Amr Start-Up
4 Operation AMR Start-up Ensure the following conditions are present before attempting to start-up the AMR. • The battery is sufficiently charged. • The Main Disconnect Switch is in the ON position. Press and hold the power ON button for half a second, then release. It takes about one minute for all the systems to start-up and make their various interconnections.
Page 155: Amr Shut-Down
4 Operation AMR Shut-down Pressing the OFF button will shut down the AMR in a controlled manner. The system will save the AMR's last known location so it can automatically localize when it is powered ON later. An LED ring around the button flashes red during the shut-down procedure. When the AMR is shut down using the OFF button, it enters a standby state.
Page 156: Amr Controller Led Indicators
4 Operation AMR Controller LED Indicators The AMR Controller has 12 indicator LEDs that give a visual overview about its status. The following figure displays the AMR Controller LED indicator lights. Refer to the AMR Controller User's Guide (Cat. No. I650) for more information. HD-1500 Platform User's Manual (I645)
Page 157: Workspace
4 Operation Workspace The workspace is considered to be any area where the AMR will travel. It must be carefully evaluated and prepared before the AMR is placed into operation. Use the information below to adapt your work- space for optimal AMR performance. The workspace must be flat, free of clutter and debris, and have adequately wide doorways and corri- dors to allow navigation by an AMR.
Page 158 4 Operation Precautions for Correct Use • Do not operate the AMR on soft surfaces such as carpet. • The AMR is designed and intended to operate on smooth floors. While it is capable of driving over a step or gap, frequent or high-speed driving over steps or gaps will shorten the lifespan of the drivetrain components.
Page 159: Physical Barriers
4 Operation • If you make a permanent change to the workspace, such as by installing a large fixed machine, con- sider re-mapping the impacted area to incorporate the change, particularly if the change blocks the AMR's ability to scan original workspace features. 4-5-1 Physical Barriers Use physical barriers together with logical barriers (map restrictions) to prevent the AMR from ap-...
Page 160: Obstacles
4 Operation hazard. Refer to Fleet Operations Workspace Core User's Manual (Cat. No. I635) for more informa- tion. 4-5-3 Obstacles If the AMR will be entering high-traffic areas, take appropriate precautions to alert people in those areas that an AMR might enter. If the traffic consists of other machines, adjust the AMR and the other machines’...
Page 161: Operating Hazard Zones
4 Operation WARNING If the AMR is in an operational hazard or restricted zone, these areas must be proper- ly marked or restricted according to applicable standards. Precautions for Correct Use A physical barrier must be easily detectable by the AMR and also strong enough to stop a fully- loaded AMR traveling at its maximum speed.
Page 162: Ramps
• Ramp operation is verified with the specified payload center of gravity profile. Refer to 2-2-3 Payload Center of Gravity on page 2-7 for more information. • Contact your local OMRON representative for advanced ramp traversal optimization techni- ques. General considerations: •...
Page 163 4 Operation Operational Considerations: • Avoid prolonged operation on ramps. Limit the AMR's operation on ramps to under 5 minutes. • Avoid powering OFF the AMR on a ramp. • Avoid stopping or turning on a ramp. • The AMR will automatically apply mechanical brakes when it stops on a ramp. •...
Page 164: Clearances
4 Operation Clearances The AMR must operate in an environment that is generally flat, with no doors or other restricted areas that are too narrow for the AMR to pass through. The AMR is designed to operate in environments that contain doors, passageways, or other constrained areas that are wide enough for it to traverse. You must ensure that adequate clearance is maintained on each side of the AMR, so that a person cannot get trapped between the AMR and a wall or other fixed object.
Page 165 4 Operation with the Docking Target during the docking operation. This distance is measured from the Docking Tar- get to the center of the AMR. 2500 Dock Goal Docking Target 2500 1300 When docked, the distance between the AMR and the Docking Target is less than 500 mm. Refer to Operate inside a designated MutePersonnelDetectionSector Area on page 4-81 for more in- formation.
Page 166 4 Operation Configuring MutePersonnelDetectionSector Zone The Docking Target and Goal must be enclosed within a MutePersonnelDetectionSector zone. To min- imize safety risks in the muted zone, the sector size should be as small as possible, but should be sufficiently large to execute docking correctly, as shown in the figure below. Acceptable Unstable Unacceptable...
Page 167: Narrow Passageway Behavior (Linear)
4 Operation Narrow Passageway Behavior (Line- The AMR can operate at its maximum speed through a 2200 mm passageway and will traverse at a slower speed when approaching a 2100 mm passageway. The practical minimum width for a passageway is 2000 mm. The most narrow passageway it can tra- verse is 1500 m.
Page 168: Narrow Passageway Behavior (Non-Linear)
4 Operation Narrow Passageway Behavior (Non- linear) This section provides information about AMR behavior and other considerations when it travels through narrow passageways and doorways during non-linear motions. For all the cases presented in this section, the passageway widths are practical for average AMR speeds of 300 to 500 mm/s.
Page 169 4 Operation End Goal 6000 3000 2000 9000 Start Goal 2000 Doorway 3000 U-Turn Clearance 4-19 HD-1500 Platform User's Manual (I645)
Page 170: 4-10 Minimum Lane Width
4 Operation 4-10 Minimum Lane Width When an HD-series AMR operates in a corridor with other moving objects, it must have a minimum lane width of 2500 mm in order to travel at its maximum speed. These limitations are different from those described for narrow passageway behavior because the AMR needs more clearance when detecting another moving object.
Page 171: 4-11 Immobilization
4 Operation 4-11 Immobilization In rare circumstances, it is possible for the AMR to become physically immobilized in a position from which it cannot move without operator assistance. Immobilization may also occur from a low battery or AMR error. Precautions for Safe Use Physical immobilization might cause motors in the AMR to overheat.
Page 172: 4-12 Battery And Charging
Safely dispose of the battery through a designated facility according to all local and national environmental regulations regarding lithium battery disposal. • Only use charging equipment and batteries supplied by OMRON. The charger shall only be used to charge an HD-1500 or MD-series AMR battery.
Page 173: Battery Indicators And Controls
4 Operation 4-12-1 Battery Indicators and Controls The battery includes 5 LED indicators and one button. Button Indicators Pushing the button has different functions based on the battery location and the state of the AMR. When the battery is not installed in the AMR, press and hold the button until the LED indicators illumi- nate purple to display the state of charge (refer to the table below).
Page 174: Power Supply Box
4 Operation WARNING • The AMR battery and the Charging Station outputs have high current. You must take appropriate precautions to avoid potential short circuit. • The Charging Station, battery, and AMR transfer high electric power and contain hazardous voltages. You must take necessary precautions to avoid electric shock. Follow appropriate Lock-Out, Tag-Out (LOTO) instructions prior to any installation and maintenance work performed on or near these items.
Page 175: Operation
• Do not press the Service button on the Power Supply Box if the yellow DC POWER LED indi- cator is flashing when there is no battery connected. Contact your OMRON representative if this condition is present.
Page 176: Charging The Battery
4 Operation Docking Target The Docking Target provides an easily identifiable target for the AMR to locate when aligning for charging. The AMR travels at a low speed when approaching the Docking Target in preparation for engaging with the charging paddle. When the AMR successfully engages the charging paddle and the Power Supply box determines charging is possible, charging will automatically begin.
Page 177 4 Operation Safety Laser Scanners as it approaches the charging paddle (per applicable standards). Refer to Con- figuring MutePersonnelDetectionSector Zone on page 4-16 for more information. When the AMR arrives near the Charging Station, it searches for a unique trapezoidal shape integrat- ed into the front of the Docking Target.
Page 178 4 Operation Additional Information The Charging Station supplies adequate power for all onboard systems while charging its bat- tery, so you can continue operating those systems while charging. Significant user loads may impact the time required to fully-charge the AMR's battery. The light discs display a green arc indicating the current state of charge while the battery is charging.
Page 179: Balancing The Battery
Simultaneous charging configurations are not possible. • Do not press the Service button on the Power Supply Box if the yellow DC POWER LED indi- cator is flashing when there is no battery connected. Contact your local OMRON representa- tive if this condition is present.
Page 180 4 Operation • Stored batteries should be fully balanced and charged every 6 months to prevent significant deterio- ration. Failure to re-charge a stored battery periodically can damage it. • Batteries stored at temperatures greater than 35°C or less than -20°C must stabilize for 4 to 8 hours until within the nominal operating temperature, with no condensation before use.
Page 181: 4-13 Operator Panel
4 Operation 4-13 Operator Panel The information below describes the operator panel components and functions. Precautions for Correct Use Do not tamper with any AMR control devices. 4-13-1 Main Screen Information displayed on the main screen during AMR operation is described below. Signal Strength Battery Charge State IP Address...
Page 182: Off Button
4 Operation Additional Information There is a 2.5 second delay between when the ON button is pressed and the AMR resumes its activity. During this time, the AMR scans its path for potential obstacles and will resume its com- manded motion if there is adequate space to maneuver. Refer to 4-2 AMR Start-up on page 4-4 for more information.
Page 183: Main Disconnect Switch
4 Operation 4-13-6 Main Disconnect Switch When the Main Disconnect Switch is in OFF (horizontal) position, power is completely disconnected from the internal battery. All systems in the AMR will not be energized in this position. Rotating the Main Disconnect Switch to the ON (vertical) position will establish a connection between the internal battery and all AMR systems.
Page 184: 4-14 Releasing The Brakes
4 Operation 4-14 Releasing the Brakes The brakes on the drive wheels can be released with the brake release button in case of an emergen- cy or abnormal situation. This may be required to manually move the AMR. Refer to 4-15 Manually Pushing the AMR on page 4-35 for more information.
Page 185: 4-15 Manually Pushing The Amr
(Autonomous Mobile Robot) HD-1500 Platform Safety and Unpacking Guide (Cat. No. I647) should manually move the AMR. • OMRON recommends that you train personnel on the safe use of the brake release opera- tions and procedures for safely pushing an AMR.
Page 186: 4-16 Emergency Stop
4 Operation 4-16 Emergency Stop When an emergency stop is triggered, the AMR decelerates to a controlled stop, de-energizes the safety outputs, and then disables its motors and engages the brakes. The emergency stop circuit is classified as a Category 1 stop according to IEC 60204-1 (NFPA79). Typical reasons to activate an emergency stop during normal operation are: •...
Page 187 4 Operation This could be an E-STOP button, the enabling device on the Pendant, or additional safety devi- ces that may be connected to the emergency stop circuit. Make sure that all surrounding areas are clear so the AMR has room to maneuver. Press the ON button on the Operator Panel.
Page 188: 4-17 Protective Stops
4 Operation 4-17 Protective Stops When a protective stop is triggered, the AMR decelerates to a stop at the maximum allowed rate. It then removes power to its motors and engages the brakes. After the AMR comes to a complete stop, it waits a minimum of 2.5 seconds before it can resume operation.
Page 189: 4-18 Overspeed Protection
If this fault occurs frequently, the operating conditions leading up to this event should be investigated. Contact your OMRON representative for support. If the problem is not resolved, the AMR may stop operating in order to prevent the use of the potentially degraded brakes. Generally, the degradation of the motor brakes requires hundreds of these occurrences.
Page 190: Light Discs And Optional Beacon States
4 Operation 4-19 Light Discs and Optional Beacon States Light Discs located on the sides of the AMR provide a visual indication of its operational state. Light Discs supplement the Light Strips on the front and rear of the AMR for high visibility on all sides during operation.
Page 191: Stopped
4 Operation 4-19-5 Stopped When the AMR is stopped, the entire light disc on each side pulses blue slowly (0.25 Hz). An optional beacon will illuminate green during this operation. 4-19-6 Stopped with Warning When the AMR is stopped with a warning, the light discs pulse orange instead. An optional beacon will illuminate green during this operation.
Page 192: Booting
4 Operation Left Right State of Charge Side Light Disc Side Light Disc 0 to 90 cw 0 to 270 ccw 0 to 180 cw 0 to 180 ccw 0 to 270 cw 0 to 90 ccw full circle full circle 100% Additional Information The state of charge displayed is continuous and not limited to 25% increments.
Page 193: Light Strips And Optional Beacon States
4 Operation 4-20 Light Strips and Optional Beacon States Light Strips located on the front and rear of the AMR provide a visual indication of its operational state. Light Strips supplement the Light Discs on the sides of the AMR for high visibility on all sides during operation.
Page 194: Lost
4 Operation 4-20-4 Lost When the AMR is lost, both front and rear light strips repeatedly display two orange segments travel- ing from one edge to the middle in opposite directions. 4-20-5 Stopped While the AMR is stopped, both front and rear light strips repeatedly display two blue segments travel- ing from one edge to the middle in opposite directions.It then pulses at a frequency of 0.25 Hz as it fades ON and OFF.
Page 195: Charging
4 Operation 4-20-8 Charging When the AMR is engaged with a Docking Target, the front and rear light strips indicate the current state of charge as described in the table below. An optional beacon will illuminate green during this operation. ≤...
Page 196 4 Operation Refer to Operate inside a designated MutePersonnelDetectionSector Area on page 4-81 for more in- formation. 4-46 HD-1500 Platform User's Manual (I645)
Page 197: 4-21 Pendant Operation
• It is the end user's responsibility to make sure that the speed is appropriate for the payload that the AMR carries, and that the speed does not cause the AMR to move uncontrollably. • OMRON recommends storing and securing the Pendant when not in use to prevent an unau- thorized person from operating the AMR.
Page 198: Driving With The Pendant
4 Operation LED State Description Solid Red AMR is in an emergency stop state. Solid Yellow AMR transitioning from an emergency stop state to a normal operational state. Solid Green The AMR motors are enabled. Flashing Green The AMR is in motion. 4-21-1 Driving with the Pendant Use the following procedure to drive the AMR with the Pendant.
Page 199: 4-22 Warning Buzzer
4 Operation 4-22 Warning Buzzer The AMR has a warning buzzer that provides an audible alert during certain operating conditions. CAUTION Changing warning buzzer parameter values might make the AMR unsafe and affect its compliance to safety standards. Refer to the applicable safety standards for your locale before you change any parameter values.
Page 200: 4-23 Back Up And Restore The Amr
Safety Laser Scanner configuration and safety parameters are not stored in the SetNetGo restore function and will not be modified by restoring a configuration. Contact your local OMRON representative for restoring laser default configuration. • Refer to the Fleet Operations Workspace Core User's Manual (Cat. No. I635) and MobilePlanner Integrated Help for more information about using SetNetGo.
Page 201: Configuration File Backup
4 Operation Additional Information Only one Restore-Point can exist on an AMR at a time. Creating a new Restore-Point will over- write the existing one. Configuration File Backup SetNetGo provides a restore option to revert the AMR to a backed up configuration file. This method restores only user-defined software settings on the Configuration Tab.
Page 202: Restoring The Amr
4 Operation Click Save to complete the procedure. Debug Info File Backup SetNetGo provides a restore option to revert an AMR to a backed up Debug Info .zip folder saved on a PC. This provides an alternate backup location compared to a Restore-Point. This method will revert the ARAM and AMR settings on the Configuration Tab and the last 10 saved maps to the saved De- bug Info parameters.
Page 203 4 Operation Revert to a Restore-Point SetNetGo provides a restore option to revert the AMR to a user-defined Restore-Point. You can revert to a Restore-Point from the System Tab's Backup & Restore Options in SetNetGo. Click the Restore Now Button to revert to a saved Restore-Point. Additional Information The MobilePlanner connection will be terminated when reverting to a Restore-Point.
Page 204 4 Operation  Revert to Previous Configuration SetNetGo provides a restore option to revert the AMR to its previous configuration settings by click- ing the Revert to Previous Configuration Button. This method reverts the ConfigurationTab to its previous settings before a change was made. Changes could include uploading a new Configu- ration file or reverting to default values.
Page 205 4 Operation Select the type of configuration file and what sections to import. Click OK to confirm the import. Save MobilePlanner using File > Save to upload the configuration to the AMRs. An asterisk will be present on the Configuration tab, which will clear when saving is complete. If no errors occur during importing or saving, the procedure is complete.
Page 206 4 Operation Click Choose File and select a saved DebugInfo zip folder from its saved location to upload. Click either the Restore all Settings or Restore only the settings that are common to all robots in the fleet button to select which settings to import. 4-56 HD-1500 Platform User's Manual (I645)
Page 207: Setnetgo Recovery Mode
4 Operation Hovering the mouse over each button will open a tooltip with more information. • Restore all Settings button: "Use this operation to restore all settings in the selected DebugInfo file to this robot core. This feature is useful if you replace the robot core hardware. Note: You must update the WiFi security credentials (such as PSK and certificates) after you restore the core."...
Page 208 4 Operation Recovery Option Details Reset Entire ARAM Config Resets the ARAM configuration settings to remove all defaults. Con- figuration settings will need to be restored after exiting Recovery Mode. MobilePlanner can then be used to set the appropriate Robot_Type. Low-Level Factory Reset Removes all SetNetGo and ARAM configuration settings.
Page 209 4 Operation Wait approximately 30 seconds and then refresh the page after entering Recovery Mode. The SetNetGo Recovery Mode URL changes from HTTPS:// to HTTP://. After refreshing, the following will be displayed on the top bar to confirm the AMR is in Recov- ery Mode.
Page 210 4 Operation Confirm on the dialog box that pops up that you wish to reboot and disconnect all connections. Wait for a message to appear stating that the change was made successfully. Power cycle the AMR (push the OFF button and then push the ON button) or reboot the AMR using the Reboot Button under the Upload new OS Menu.
Page 211: 4-24 Safety Laser Scanner Zones
The safety zones adjust their detection range and shape automatically as the AMR drives forward and reverse or turns in place. WARNING OMRON is not responsible for any risks incurred by modifying safety zone sizes or other Safety Laser Scanner settings. Additional Information •...
Page 212 4 Operation Active Speed Ranges Safety Zone Pair(s) Operational Conditions (linear and rotational) 1 to 6 Enabled when the AMR is driving straight with minimal 115 to 1800 mm/s turning. Refer to Driving Straight with Minimal Turning 0 to 15 degrees/s on page 4-62 for more information.
Page 213 4 Operation Safety Zone Pair 1 1500 Front Zone Rear Zone Safety Laser Scanners 1000 -500 -1000 -1500 -2000 -1500 -1000 -500 1000 1500 2000 2500 3000 AMR X-axis Safety Zone Pair 2 1500 Front Zone Rear Zone Safety Laser Scanners 1000 -500 -1000...
Page 214 4 Operation Safety Zone Pair 3 1500 Front Zone Rear Zone Safety Laser Scanners 1000 -500 -1000 -1500 -2000 -1500 -1000 -500 1000 1500 2000 2500 3000 AMR X-axis Safety Zone Pair 4 1500 Front Zone Rear Zone Safety Laser Scanners 1000 -500 -1000...
Page 215 4 Operation Safety Zone Pair 5 1500 Front Zone Rear Zone Safety Laser Scanners 1000 -500 -1000 -1500 -2000 -1500 -1000 -500 1000 1500 2000 2500 3000 AMR X-axis Safety Zone Pair 6 1500 Front Zone Rear Zone Safety Laser Scanners 1000 -500 -1000...
Page 216 4 Operation Applicable Speeds Safety Zone Pair Linear (mm/s) Rotational (degrees/s) 0 to 115 16 to 28 counterclockwise 16 to 28 clockwise 29 to 45 clockwise and counter- clockwise Safety Zone Pair 8 1500 Front Zone Rear Zone 1000 Safety Laser Scanners -500 -1000 -1500...
Page 217 4 Operation Safety Zone Pair 9 1500 Front Zone Rear Zone Safety Laser Scanners 1000 -500 -1000 -1500 -2000 -1500 -1000 -500 1000 1500 2000 2500 3000 AMR X-axis Safety Zone Pair 10 1500 Front Zone Rear Zone Safety Laser Scanners 1000 -500 -1000...
Page 218 4 Operation Safety zone pairs 21 and 32 are not used. Applicable Speeds Safety Zone Pair Linear (mm/s) Rotational (degrees/s) 115 to 270 16 to 28 counterclockwise 271 to 690 115 to 690 29 to 45 counterclockwise 691 to 880 16 to 24 counterclockwise 25 to 30 counterclockwise 31 to 45 counterclockwise...
Page 219 4 Operation Safety Zone Pair 12 1500 Front Zone Rear Zone Safety Laser Scanners 1000 -500 -1000 -1500 -2000 -1500 -1000 -500 1000 1500 2000 2500 3000 AMR X-axis Safety Zone Pair 13 1500 1000 -500 Front Zone -1000 Rear Zone Safety Laser Scanners -1500 -2000...
Page 220 4 Operation Safety Zone Pair 14 1500 1000 -500 Front Zone -1000 Rear Zone Safety Laser Scanners -1500 -2000 -1500 -1000 -500 1000 1500 2000 2500 3000 AMR X-axis Safety Zone Pair 15 1500 1000 -500 Front Zone -1000 Rear Zone Safety Laser Scanners -1500 -2000...
Page 221 4 Operation Safety Zone Pair 16 1500 1000 -500 Front Zone -1000 Rear Zone Safety Laser Scanners -1500 -2000 -1500 -1000 -500 1000 1500 2000 2500 3000 AMR X-axis Safety Zone Pair 17 1500 1000 -500 Front Zone -1000 Rear Zone Safety Laser Scanners -1500 -2000...
Page 222 4 Operation Safety Zone Pair 18 1500 1000 -500 Front Zone -1000 Rear Zone Safety Laser Scanners -1500 -2000 -1500 -1000 -500 1000 1500 2000 2500 3000 AMR X-axis Safety Zone Pair 19 1500 1000 -500 Front Zone -1000 Rear Zone Safety Laser Scanners -1500 -2000...
Page 223 4 Operation Safety Zone Pair 20 1500 1000 -500 Front Zone -1000 Rear Zone Safety Laser Scanners -1500 -2000 -1500 -1000 -500 1000 1500 2000 2500 3000 AMR X-axis Safety Zone Pair 22 1500 Front Zone Rear Zone Safety Laser Scanners 1000 -500 -1000...
Page 224 4 Operation Safety Zone Pair 23 1500 Front Zone Rear Zone 1000 Safety Laser Scanners -500 -1000 -1500 3000 2000 1000 -1000 -2000 Safety Zone Pair 24 1500 Front Zone Rear Zone Safety Laser Scanners 1000 -500 -1000 -1500 -2000 -1500 -1000 -500...
Page 225 4 Operation Safety Zone Pair 25 1500 Front Zone Rear Zone Safety Laser Scanners 1000 -500 -1000 -1500 -2000 -1500 -1000 -500 1000 1500 2000 2500 3000 AMR X-axis Safety Zone Pair 26 1500 Front Zone Rear Zone Safety Laser Scanners 1000 -500 -1000...
Page 226 4 Operation Safety Zone Pair 27 1500 Front Zone Rear Zone Safety Laser Scanners 1000 -500 -1000 -1500 -2000 -1500 -1000 -500 1000 1500 2000 2500 3000 AMR X-axis Safety Zone Pair 28 1500 Front Zone Rear Zone Safety Laser Scanners 1000 -500 -1000...
Page 227 4 Operation Safety Zone Pair 29 1500 Front Zone Rear Zone Safety Laser Scanners 1000 -500 -1000 -1500 -2000 -1500 -1000 -500 1000 1500 2000 2500 3000 AMR X-axis Safety Zone Pair 30 1500 Front Zone Rear Zone Safety Laser Scanners 1000 -500 -1000...
Page 228 4 Operation Safety Zone Pair 31 1500 Front Zone Rear Zone Safety Laser Scanners 1000 -500 -1000 -1500 -2000 -1500 -1000 -500 1000 1500 2000 2500 3000 AMR X-axis  Traveling at Slow Speeds Safety zone pair 33 is used when the AMR is traveling at slow speeds as described below. •...
Page 229 4 Operation Safety Zone Pair 33 1500 Front Zone Rear Zone Safety Laser Scanners 1000 -500 -1000 -1500 -2000 -1500 -1000 -500 1000 1500 2000 2500 3000 AMR X-axis  Moving at Very Slow Speeds with the Pendant Disconnected Safety zone pair 34 is used when the AMR is moving at the following speeds with the Pendant dis- connected.
Page 230 4 Operation Safety Zone Pair 34 1500 Front Zone Rear Zone Safety Laser Scanners 1000 -500 -1000 -1500 -2000 -1500 -1000 -500 1000 1500 2000 2500 3000 AMR X-axis  Moving at Very Slow Speeds with the Pendant Connected Safety zone pair 35 is a nulled zone pair. It is used when the AMR is moving at the following speeds with the Pendant connected.
Page 231 4 Operation Safety Zone Pair 35 1500 Front Zone Rear Zone Safety Laser Scanners 1000 -500 -1000 -1500 -2000 -1500 -1000 -500 1000 1500 2000 2500 3000 AMR X-axis  Operate inside a designated MutePersonnelDetectionSector Area Safety zone pair 36 is a nulled zone pair. It is used when the AMR must operate inside a designat- ed MutePersonnelDetectionSector Area.
Page 232 4 Operation Safety Zone Pair 36 1500 Front Zone Rear Zone Safety Laser Scanners 1000 -500 -1000 -1500 -2000 -1500 -1000 -500 1000 1500 2000 2500 3000 AMR X-axis WARNING If the AMR is in an operational hazard or restricted zone, these areas must be properly marked or restricted according to applicable standards.
Page 233: Alternate Safety Laser Scanner Zones
The alternate Safety Laser Scanner zones are identical to the default zones when the default configu- ration is present. Activating the alternate zones has no effect until new zones are created. Contact your local OMRON representative for the OMRON AMR Safety Laser Scanner zone generation tool. Precautions for Correct Use If alternate Safety Laser Scanner Zones are used for varying payload sizes, an alternate AMR footprint should also toggle for navigation purposes.
Page 234: 4-25 Motion Limits
Precautions for Safe Use For payload applications where you cannot easily reduce the size and weight of the payload, or if the AMR’s center of gravity is not within the recommended limits, contact your local OMRON representative for support. Additional Information Use the configuration area in MobilePlanner to make parameter changes.
Page 235: 4-26 Emergency Situations
4 Operation 4-26 Emergency Situations In case of an emergency such as a fire or collision, you should stop the AMR quickly and safely. If the emergency situation is near the Charging Station, you must turn OFF the Power Supply Box's power using the Main Disconnect Switch.
Page 236: 4-27 Tilt Detection
Additional Information If the AMR has toppled, inspect it thoroughly for damage. If damage has occurred to items that are not user-replaceable, contact your local OMRON representative for support. Move the AMR back to the level position. Acknowledge the error message in MobilePlanner.
Page 237: 4-28 Interlock Switches
4 Operation 4-28 Interlock Switches If the interlock switches detect that the battery door is open or that any of the side skins are removed, the AMR's motion is disabled and power is removed from the motors, USER PWR connector, and charging circuits.
Page 238 4 Operation 4-88 HD-1500 Platform User's Manual (I645)
Page 239 Troubleshooting This section provides troubleshooting information. Collecting Troubleshooting Information ............5-2 Restoring the AMR Configuration ..............5-3 Power Supply Box Problems ................ 5-4 Battery Problems ................... 5-6 5-4-1 Low Battery Recovery ..................5-6 5-4-2 Battery Charging Problems ................5-6 5-4-3 Leaking Batteries.....................
Page 240: Collecting Troubleshooting Information
5 Troubleshooting Collecting Troubleshooting Informa- tion Troubleshooting information can be collected from the AMR by downloading a Debug Info File using SetNetGo. This is a collection of configuration, log, and system status files that support personnel can use for debugging and troubleshooting. Use the following procedure to download a Debug Info File for troubleshooting or diagnostic purposes.
Page 241: Restoring The Amr Configuration
SetNetGo restore function and will not be modified by restoring a configuration. Contact your local OMRON representative for restoring laser default configuration. • Refer to the Fleet Operations Workspace Core User's Manual (Cat. No. I635) for more infor- mation about using SetNetGo.
Page 242: Power Supply Box Problems
AMR. Red ERROR LED Critical failure. Cycle AC supply power flashing while all with no battery connect- other LEDs OFF ed. Contact your local when connecting OMRON representative if or disconnecting a problem persists. battery. HD-1500 Platform User's Manual (I645)
Page 243 DC been detected. of an absolutely depleted and the red ERROR LED turns POWER LED battery. ON, a problem with the battery flashing. was detected. Contact your local OMRON representative for more information. HD-1500 Platform User's Manual (I645)
Page 244: Battery Problems
5 Troubleshooting Battery Problems If a problem is detected with the battery while it is in an operating AMR, a message will be displayed on the Operator Panel with information about the cause. Use the following sections to troubleshoot and resolve other battery problems. WARNING Risk of Fire - No User Serviceable Parts AVERTISSEMENT: Risque d’incendie - Aucune des pièces ne peut être.
Page 245 5 Troubleshooting Condition Assumed Cause Remedy Additional Information The battery is A minor problem Contact your local OM- Charging may still be possible, charging slower has been detect- RON representative. but the charging time may be im- than normal. pacted. Power Supply Box indicators: •...
Page 246: Leaking Batteries
5 Troubleshooting Condition Assumed Cause Remedy Additional Information The battery stop- The charging cycle The AMR must be re- The following actions will inter- ped charging un- was interrupted. moved from the Docking rupt a charging cycle: • expectedly. Target and then re-engag- The OFF button on the AMR ed with the Docking Tar- was pressed.
Page 247 5 Troubleshooting Precautions for Safe Use You can contribute to resource conservation and protecting the environment by the proper dis- posal of Waste Electronics and Electrical Equipment (WEEE). All electrical and electronic products should be disposed of separately from the municipal waste system according to local ordinances using designated collection facilities.
Page 248: Exposure To Liquids
If you suspect that liquid has penetrated the skins or contaminated the AMR's interior, do not attempt to power ON the system and contact your OMRON representative. Power OFF the AMR immediately and then turn the Main Disconnect Switch to the OFF posi- tion.
Page 249: Amr Start-Up Problems
• Check that the skins are in place and fastened correctly and that all interlock switches are satisfied. Refer to 4-28 Interlock Switches on page 4-87 for more information. If the AMR does not start-up after the actions above, contact your local OMRON representative. 5-11...
Page 250: Amr Shut-Down Problems
• Faulty connection at the rear of the Operator Panel Refer to 3-7 Relocating the Operator Panel on page 3-33 for more information. • Internal component or connection problem. Contact your local OMRON representative for more information. 5-12 HD-1500 Platform User's Manual (I645)
Page 251: Amr Controller Errors
The AMR Controller's internal bat- This battery is not user-replacea- tery is low. ble. The battery lifespan is 10 years. Contact your local OMRON repre- sentative for more information. Solid red A thermal shut-down has occurred Reduce the environment's ambient from excessive heat.
Page 252: Operator Panel Information
5 Troubleshooting Operator Panel Information Troubleshooting information about Operator Panel information is provided in the following sections. Refer to Main Screen for more information. 5-9-1 Stop Flags Use the following information to understand to cause and corrective actions for stop flags that may ap- pear on the Operator Panel.
Page 253: Text Messages
Several text messages may be displayed on the Operator Panel screen to indicate operational status, required actions, errors messages, or faults. To troubleshoot specific error messages or faults, record the error message or fault message with oth- er operating conditions when this occurred, and then contact your local OMRON representative for more information. 5-15...
Page 254 5 Troubleshooting 5-16 HD-1500 Platform User's Manual (I645)
Page 255 Maintenance This section covers periodic maintenance and user-serviceable parts replacement for the AMR and the Charging Station. Maintenance Introduction................6-2 Charging Station Lock-out Tag-out Procedure ........... 6-4 AMR Lock-out Tag-out Procedure ..............6-5 Lifting the AMR....................6-6 Maintenance Items ..................6-8 6-5-1 Mechanical Brake Inspection Procedure............
Page 256: Maintenance Introduction
Follow appropriate Lock-Out, Tag-Out (LOTO) instructions prior to any installation and maintenance work performed on or near these items. • Use only the specified tools, equipment, and OMRON-supplied spare parts to serv- ice and maintain the AMR according to the specified service intervals. Failure to do so could result in an unsafe operating state that might result in personal injury or damage to property.
Page 257 6 Maintenance Precautions for Correct Use Maintenance of the payload structure is not covered in this document and is the responsibility of the end-user. HD-1500 Platform User's Manual (I645)
Page 258: Charging Station Lock-Out Tag-Out Procedure
6 Maintenance Charging Station Lock-out Tag-out Procedure Use the following procedure to execute Lock-out Tag-out before performing any maintenance or instal- lation work on the Charging Station. Disconnect the Power Supply Box from the battery or Docking Target and then lock and tag the Power Supply Box output power cord connector.
Page 259: Amr Lock-Out Tag-Out Procedure
6 Maintenance AMR Lock-out Tag-out Procedure Use the following procedure to execute Lock-out Tag-out before performing any maintenance or instal- lation work on the AMR. Shut down the AMR by pressing the OFF button on the Operator Panel. Turn the AMR Main Disconnect Switch to the OFF position (horizontal). Lock and tag the Main Disconnect Switch according to your facility requirement and regula- tions.
Page 260: Lifting The Amr
• Forklift, hoist, or other lifting device rated for a minimum of 1100 kg. Perform the appropriate Lock-out Tag-out procedures. Attach the OMRON-supplied lifting rings using to the locations shown in the figure below. There are four bolt holes on the AMR for attaching the lifting rings. Once the lifting rings are attached, tie and secure the straps.
Page 261 6 Maintenance Using an overhead hoist or a forklift, lift the AMR. After the AMR is on the floor, remove the lifting rings and straps from the AMR to complete the lifting procedure. HD-1500 Platform User's Manual (I645)
Page 262: Maintenance Items
Check the casters and wheels for excessive wear, uneven wear, or de- Drive Wheels bris. Replacement of the casters and wheels require an OMRON service en- gineer. Contact your local OMRON representative for more information. Inspect Caster Swiv- 3 months Check the caster swivels and tighten if loose.
Page 263: Amr Charging Contact Inspection
AMR charging contacts. 7.0 min. If pitting or discoloration are found, gather the following information and contact your local OMRON representative. • AMR model number and serial number. Refer to 1-4 Labels on page 1-19 for more information.
Page 264: Safety And Warning Labels
6 Maintenance 6-5-4 Safety and Warning Labels Perform periodic checks to ensure safety and warning labels are not damaged or removed. Yellow backings for emergency stop buttons must also remain in place. Refer to 1-4 Labels on page 1-19 for more information about label locations.
Page 265 6 Maintenance Attach the grease dispenser to the fitting and pump grease into the caster assembly. Observe the swivel bearing area and pump grease until you see grease that is forced out. Remove any excess grease around the swivel area with a rag. After all casters are lubricated, place the front and rear skins on the AMR to complete this pro- cedure.
Page 266: Storing Batteries
6 Maintenance Storing Batteries Use the following information when storing batteries. The battery should start the storage period completely charged. The batteries must be stored in the upright position (as it is positioned when installed in the AMR). Do not place the batteries on their sides, top, front, or rear. When a battery is stored for a period of more than six months, perform the following tasks at six month intervals to properly maintain the battery.
Page 267: Cleaning
6 Maintenance Cleaning Use the following information to understand how to clean the AMR and its associated components. WARNING Do not use organic solvents to clean any part of the AMR unless directed in the clean- ing instructions. Organic solvents might damage electronics resulting in an unsafe op- erating state that could cause injury or damage to equipment.
Page 268: Cleaning The Power Supply Box Cooling Ducts
6 Maintenance WARNING The Power Supply Box, charging contacts on both the Docking Target and the AMR, and the drive wheel motors can get hot during operation. Allow these items to cool down prior to servicing. Precautions for Correct Use •...
Page 269: Cleaning Laser Lenses
6 Maintenance 6-7-4 Cleaning Laser Lenses Use the following procedure to clean the AMR laser lenses. Precautions for Correct Use • The operation of the lasers may be affected by substances in the AMR operating environ- ment, such as fog, smoke, steam, dust, and other small particulates. You must clean the lens- es of all lasers periodically as noted in this document to avoid operational failures.
Page 270: Cleaning Caster Treads
6 Maintenance Carefully inspect the cleaned surfaces for dust or debris. Continue cleaning until the lens is completely free of dust or debris to complete this procedure. 6-7-5 Cleaning Caster Treads Remove any accumulated dirt or debris on the treads to prevent AMR’s performance degradation. Clean the caster treads with a mild soapy solution.
Page 271: Replacing Items
AMRs. WARNING • Use only the specified tools, equipment, and OMRON-supplied spare parts to serv- ice and maintain the AMR according to the specified service intervals. Failure to do so could result in an unsafe operating state that might result in personal injury or damage to property.
Page 272 6 Maintenance Skins are secured to the chassis by two latches found on each side of the skin. The skins include alignment pins that fit into holes in the chassis. No tools are required for skin removal. The left side and right side E-STOP buttons are not attached to the skins and remain attached to brackets on the chassis after removal of the skins.
Page 273 6 Maintenance Slide the latches towards the center (inward) to unlatch them from the AMR chassis. Once unlatched, pull the skin away from the chassis enough so that you can access front light strip connector and then disconnect the cable. The front skin cannot be completely removed until the front light strip cable is disconnected.
Page 274 6 Maintenance Locate the rear skin latches found in the recessed groove as shown in the following figure. The latches also act as recessed handles for easy grip. Slide the latches towards the center (inward) to unlatch them from the AMR chassis. Once unlatched, pull the skin away from the chassis enough so that you can access rear light strip connector and then disconnect the cable.
Page 275: Light Disc Led Replacement Procedure
6 Maintenance No tools are needed for either the removal or installation of the rear skin. Locate the side skin latches as shown in the following figure. The latches also act as recessed handles for easy grip. Slide the latches towards the center (inward) to unlatch them from the AMR chassis. Once unlatched, pull the skin away from the chassis just enough so you can access the light disc connector.
Page 276 6 Maintenance • 2.5 mm hex key. Unlatch the skin and pull it away from the AMR so that you can disconnect the cable. Refer to 6-8-1 Removing and Replacing Skins on page 6-17 for more information. Move the skin to an adequate working area after detaching it from the AMR. After the cable is disconnected, remove the skin completely.
Page 277: Light Strip Led Replacement Procedure
6 Maintenance Take note of the LED light orientation before removing it. Installing the new LED light in the in- correct orientation will cause the lighting patterns to display in reverse. Position the replacement LED light so that it is located around the entire circumference of the LED mount plate and in the correct orientation.
Page 278: Operator Panel Replacement / Removal Procedure
6 Maintenance Adhere the replacement LED light to the mounting channel in the same location that was ob- served in step 6. Connect the LED light electrical connector to the PCA board and then secure the cable with a new cable tie using the same orientation that was observed in step 5. Reverse steps 1 to 3 to complete this procedure.
Page 279: Wireless Antenna Replacement Procedure
6 Maintenance Remove the Operator Panel from the mounting bracket. This step concludes the procedure for Operator Panel removal. Proceed to the next steps to replace the Operator Panel. Insert the replacement Operator Panel into the mount bracket. Reverse steps 1 to 4 to complete this procedure. 6-8-5 Wireless Antenna Replacement Procedure Use the following procedure to remove and replace the wireless antenna located on the AMR.
Page 280: Amr Charging Contact Replacement Procedure
6 Maintenance Gently pull the antenna connector off of the AMR adapter coupling. This is a friction fitting which requires very little force. Using a 2.5 mm hex key, remove the two retaining screws that fasten the antenna backing plate to the compartment and then remove the assembly from the AMR. Remove the adapter coupling from the antenna connector on the AMR using a 8 wrench or socket driver.
Page 281 6 Maintenance Remove the front skin. Refer to Front Skin Removal and Replacement Procedure on page 6-18 for more information. Remove the four M5 screws with a 4 mm hex key that attach the contact housings to the base plate. Locate the bus bars inside the corner assembly and remove two M5 screws with a 4 mm hex key that attach the two charging connector leads.
Page 282 6 Maintenance Insert the new charging contact assemblies and route the cables to the corresponding bus bar. Insert two M5 screws through the charging contact lead terminals and attach them to the corre- sponding bus bar using a 4 mm hex key. Tighten to a torque of 4.5 N⋅m. Attach the contact housing to the base plate.
Page 283 Appendices Unpacking ...................... A-2 A-1-1 Power Supply Box Shipping Crate Information ..........A-3 A-1-2 Battery Shipping Crate Information ..............A-4 A-1-3 Docking Target Shipping Crate Information............. A-5 A-1-4 AMR Shipping Crate Information..............A-6 Parts List ...................... A-10 Network Port Allocation................A-12 Input and Output Control................
Page 284: A-1 Unpacking
If the items received do not match the packing slip or have been damaged, do not accept the deliv- ery. If the items received do not match your order, contact your local OMRON representative. • Retain the containers and packaging materials. These items may be necessary to settle claims or to relocate the equipment at a later date.
Page 285: Power Supply Box Shipping Crate Information
Appendices • Before driving the AMR down the ramp, ensure the Pendant speed knob is set at the lowest speed and remains at that setting during the driving process. • If the AMR is stopped on the ramp, do not release the brakes. •...
Page 286: A-1-2 Battery Shipping Crate Information
Appendices Remove the metal clips attaching the front panel to the housing crate using a pry bar. Place the pry bar between the crate and the metal clips and apply enough force to remove the clips. Pull the front panel and remove it completely. Remove the screws attaching the base pallet to the housing crate using a 13 mm socket and impact driver.
Page 287: A-1-3 Docking Target Shipping Crate Information
Appendices Loosen the two locking collars and then extend the battery handle out. After the handle is ex- tended, tighten the locking collars. Pull the battery out of the crate using the extended handle and drag it down the ramp to the floor.
Page 288: A-1-4 Amr Shipping Crate Information
Appendices Docking Target Unpacking Procedure Use the following procedure to unpack the Docking Target from its shipping crate. The following tools and equipment are required for this procedure. • Personal Protective Equipment including eye protection, toe protection, and gloves. • 13 mm socket. •...
Page 289 Appendices Driving the AMR Unpacking Procedure The AMR is secured to a base pallet with straps. Ramps are included so that the AMR can be driven from the base pallet to the floor. Ramp Storage Housing First Ramp Base Pallet Second Ramp Retaining Board Support Bars...
Page 290 Appendices Remove any weatherproof film or plastic sheet material wrapped around the shipping crate us- ing a safety box cutter. Remove the four screws along the bottom of the sides of the crate, near the bottom edge, us- ing a 13 mm socket and impact driver. These screws attach the housing to the base pallet.
Page 291 Appendices Two wood shipping bars are fastened to the top of the AMR and straps secure them to the base pallet. Loosen the straps and move them away from the AMR. Remove the two bolts that secure each wood shipping bar to the AMR using a 19 mm socket and impact driver and then set the shipping bars aside.
Page 292: A-2 Parts List
Includes mounting hardware. Docking Target Mounting Brack- 68910-105 Single bracket for fastening Docking Target to a wall or the floor. Charging power cord 68915-225L 4 m in length. Contact your local OMRON representative for replacement details. A-10 HD-1500 Platform User's Manual (I645)
Page 293 Appendices Item Sub-assembly Part Number Details Included AMR charging contact replace- 68129-120F One set of replacement charging contacts ment kit for the AMR. Set includes springs, contacts, charging leads, and housings. Two sets are required when replacing upper and lower charging contacts.
Page 294: A-3 Network Port Allocation
Appendices A-3 Network Port Allocation Network ports are assigned as described in the table below. Initiator to Re- Port Protocol Category Details cipient Intra-fleet Communica- AMR to Fleet Maintenance, Management, and Fleet tions Ports. Manager ports use this. Used to broadcast con- 5000 TCP/UDP Fleet port uses this.
Page 295 Appendices Initiator to Re- Port Protocol Category Details cipient 7171 Job Monitoring and WMS/MES to If ARCL Server is enabled in the config- Submission (ARCL In- Fleet Manager. uration (Robot Interface and then ARCL terface). Server Setup), then this port is open on Used for managing the Fleet Manager and accepts unlimit- Jobs on the Fleet Man-...
Page 296: A-4 Input And Output Control
Appendices A-4 Input and Output Control The AMR has built-in digital and analog I/O that is typically used for autonomous control of user-sup- plied objects on the payload structure. Customized user programs can be created for the onboard NX102 controller that utilize these inputs and outputs for specific applications. An interface exists be- tween the AMR Controller and the NX102 controller for event-based control functions.
Page 297 Index HD-1500 Platform User's Manual (I645)
Page 298 Index Index Digital Outputs..............3-27 Dimensions AMR Charging Position..........2-6 AMR Controller............1-9, 4-6 AMR Driving..............4-47 Battery................2-3 Analog Inputs..............3-25 Docking Target............... 2-4 Analog Outputs..............3-27 Operator Panel...............2-5 ARCL................1-33 Power Supply Box............2-4 Autonomous Charging.............4-26 Supplementary Laser Scanner........2-6 Autonomous Navigation..........1-17 User Access Panel............2-5 AMR................
Page 299 Index Lock-out Tag-out (Charging Station)........6-4 Logical Barriers..............4-9 Low Laser..............1-6, 1-7 Safety Devices..............3-22 Safety Laser Scanner..........1-6, 1-7 Safety Laser Scanner Zones........... 4-61 Safety Outputs............3-22, 4-36 Main Disconnect Switch (AMR)......1-11, 4-33 Safety Zone Pairs............4-61 Main Disconnect Switch (Charging Station)... 1-13, 4-24 Screen................1-11 Maintenance...............6-1, 6-8 Service button............
Page 300 Index Connection..............3-18 Considerations............. 3-19 Signal Availability............3-19 Workspace.................4-7 HD-1500 Platform User's Manual (I645)
Page 302 Fax: (31) 2356-81-388 Tel: (1) 847-843-7900 Fax: (1) 847-843-7787 OMRON ASIA PACIFIC PTE. LTD. OMRON ROBOTICS AND SAFETY TECHNOLOGIES, INC. 438B Alexandra Road, #08-01/02 Alexandra 4225 Hacienda Drive, Pleasanton, CA 94588 U.S.A. ©OMRON Corporation 2023 All Rights Reserved. Technopark, Singapore 119968...

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