MIR 500 User manual

User guide (en)
Date: 06/2020
Revision: v.1.4

MiR500 User guide (en) 06/2020 - v.1.4 ©Copyright 2018-2020: Mobile Industrial Robots A/S. 2
Copyright and disclaimer
All rights reserved. No parts of this manual may be reproduced in any form without the
express written permission of Mobile Industrial Robots A/S (MiR). MiR makes no warranties,
express or implied, in respect of this document or its contents. In addition, the contents of
the document are subject to change without prior notice. Every precaution has been taken in
the preparation of this manual. Nevertheless, MiR assumes no responsibility for errors or
omissions or any damages resulting from the use of the information contained.
Copyright © 2018-2020 by Mobile Industrial Robots A/S.
Contact the manufacturer:
Mobile Industrial Robots A/S
Emil Neckelmanns Vej 15F
DK-5220 Odense SØ
www.mobile-industrial-robots.com
Phone: [phone]
Email: [e-mail]
CVR: 35251235

MiR500 User guide (en) 06/2020 - v.1.4 ©Copyright 2018-2020: Mobile Industrial Robots A/S. 3
Table of contents
1. About this document 6
1.1 Where to find more information 6
1.2 Version history 7
2. Safety 8
2.1 Safety message types 8
2.2 General safety precautions 9
2.3 Intended use 10
2.4 Users 11
2.5 Foreseeable misuse 12
2.6 Risk assessment 12
2.7 Residual risks 13
2.8 Safety-related functions and interfaces 13
2.9 Limiting safety-related functions 14
2.10 Safety-related electrical interfaces 15
2.11 Lithium battery 17
3. Getting started 18
3.1 In the box 18
3.2 Unpacking MiR500 19
3. IT security 23
3.3 Managing users and passwords 23
3.4 Software security patches 23
4. Commissioning 25
4.1 Powering up 25

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4.2 Connecting to the robot interface 27
4.3 Driving the robot in Manual mode 28
4.4 Checking the hardware status 30
4.5 Charging the robot 31
4.6 Shutting down the robot 33
4.7 Creating and configuring a map 33
5. Planning 34
5.1 Analysis of the work environment 34
5.2 MiR500 user roles 36
5.3 Creating an efficient map 39
5.4 Creating efficient missions 44
5.5 Create mission 45
5.6 Mission editor 48
5.7 Error handling 50
5.8 Handover testing 51
6. Product presentation 54
6.1 Main features of MiR500 54
6.2 Identification label 56
6.3 MiR500 control panel 56
6.4 MiR500 operating modes 58
6.5 MiR500 external parts 59
6.6 MiR500 internal parts 62
6.7 Sensor system 69
6.8 Light indicators 75

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7. Applications 77
7.1 Mounting a top module 77
7.2 Lift modifications 80
8. Maintenance 83
8.1 Regular weekly checks and maintenance tasks 83
8.2 Regular checks and replacements 84
8.3 Packing for transportation 87
9. Payload specifications 90
10. Interface specifications 92
10.1 General purpose interfaces 92
10.2 Safety interfaces 100
10.3 Connector list 103

1. About this document
MiR500 User guide (en) 06/2020 - v.1.4 ©Copyright 2018-2020: Mobile Industrial Robots A/S. 6
1. About this document
This user guide explains how to set up and start operating your MiR500 and provides
examples of simple missions you can expand to your purposes. This guide also contains
information regarding the external and internal components of MiR500 along with a guide
for proper maintenance of the robot. You will also find information regarding safety and
specifications needed to commission a safe MiR500 robot application.
This guide explains how to set up and start operating your MiR500. You will also find
information regarding safety precautions that must be considered when operating MiR500.
NOTICE
Save this manual. It contains important safety and operating instructions.
1.1 Where to find more information
At www.mobile-industrial-robots.com, several additional resources are available. To access
more information, sign in to the Distributor site with your distributor account at
http://www.mobile-industrial-robots.com/en/account/. The following resources are
available:
•Quick starts describe how you start operating MiR robots quickly. This document is in
print in the box with the robots. Quick starts are available in multiple languages.
•User guides provide all the information you need to operate and maintain MiR robots.
User guides are available in multiple languages.
•Risk Analysis Guides include guidelines on how to create a risk assessment of your robot
solution.
•Commissioning guides describe how to commission your robot safely and prepare it to
operate in the workplace.
•Operating guides describe how to set up and use top modules and accessories, such as
charging stations, hooks, shelf lifts, and pallet lifts.
•Getting started guides describe how to set up products that are mainly software-based,
such as MiR Fleet.
•Reference guides contain descriptions of all the elements of the robot interface and MiR
Fleet interface. Reference guides are available in multiple languages.
•REST API references for MiR robots, MiR hooks, and MiR Fleet.

1. About this document
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•The MiR network and WiFi guide specifies the performance requirements of your
network and how you must configure it for MiR robots and MiR Fleet to operate
successfully.
1.2 Version history
This table shows current and previous versions of this document and their interrelations with
hardware releases.
Revision Release
date Description HW
1.0 2018-10-
29
First edition. 1.0
1.1 2019-01-
31
New section: Maintenance.
Updated styles.
1.0
1.2 2019-07-
11
New sections: Create mission, Mission editor, Lift
modifications
Updated status lights
Added notice regarding using smart phones in flight
mode for manual driving
1.0
1.3 2019-10-
08
New section: Updating MiR500 software 1.1
1.4 2020-06-
11
New section: IT security.
Added new information about payload.
1.1

2. Safety
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2. Safety
Read the information in this section before powering up and operating MiR500.
Pay particular attention to the safety instructions and warnings.
NOTICE
Mobile Industrial Robots disclaims any and all liability if MiR500 or its
accessories are damaged, changed, or modified in any way. Mobile Industrial
Robots cannot be held responsible for any damages caused to MiR500,
accessories, or any other equipment due to programming errors or
malfunctioning of MiR500.
2.1 Safety message types
This document uses the following safety message types.
WARNING
Indicates a potentially hazardous situation that could result in death or serious
injury. Carefully read the message that follows to prevent serious injury or
death.
CAUTION
Indicates a potentially hazardous situation that could result in minor or
moderate injury. Alerts against unsafe practices. Carefully read the message
that follows to prevent minor or moderate injury.
NOTICE
Indicates important information, including situations that can result in damage
to equipment or property.

2. Safety
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2.2 General safety precautions
This section contains general safety precautions.
WARNING
Using a charger different from the one supplied by the manufacturer can
cause a fire.
•Use only the original charger.
WARNING
Lithium battery packs may get hot, explode or ignite and cause serious injury if
they are abused electrically or mechanically.
Observe the following precautions when handling and using lithium batteries:
•Do not short-circuit, recharge or connect with false polarity.
•Do not expose to temperature beyond the specified temperature range or
incinerate the battery.
•Do not crush, puncture or disassemble the battery. The battery contains
safety and protection devices, which, if damaged, may cause the battery to
generate heat, explode or ignite.
•Do not allow the battery to get wet.
•In the event the battery leaks and the fluid gets into one’s eye, do not rub
the eye. Rinse well with water and immediately seek medical care. If left
untreated, the battery fluid could cause damage to the eye.
•Use only the original charger (cable charger or charging station) and
always follow the instructions from the battery manufacturer.
WARNING
Attempting to charge batteries outside the robot can lead to electrical shock
or burns.
•Never charge the batteries outside the robot.

2. Safety
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CAUTION
The robot cannot see staircases going downwards and holes in the floor.
•Mark staircases or holes on maps with Forbidden zones.
•Keep the maps up to date.
CAUTION
Use Flight Mode with smartphone control of the robot. Risk of personal injury
and/or damage to the robot.
•If you use Manual control with a smartphone to drive the robot, make sure
that the phone is set to Flight Mode. An incoming call on the smartphone
will interrupt control of the robot.
2.3 Intended use
MiR500 is intended to be commissioned and used in indoor industrial environments where
access for the public is restricted. For details about the environmental conditions in which
the MiR500 robot should operate, see Technical specifications on our website.
MiR500 is intended to be commissioned according to Commissioning on page25 and
prepared to the environment according to the guidelines. This is a prerequisite for safe
usage of MiR500.
MiR500 is designed and all risks are considered when used with one of the following types of
top applications:
•MiR500Pallet Lift used with MiR Lift Pallet Rack.
•MiR500EUPalletLift used with MiR EU Pallet Rack.
•A custom designed top application (including total payload) designed to fulfill the
following requirements:
•Must not increase the footprint of MiR500 and be within the requirements in Payload
specifications on page90
•Must not have any moving parts

2. Safety
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MiR500 can be used as a partly complete machine as defined in the EU machinery directive,
with top applications that do not meet above limitations. Those who design, manufacture or
commission a system that does not meet the limitations of use of MiR500, carry the
obligations of a manufacturer and shall ensure a safe design according to EN ISO 12100.
Guidelines outlined in this manual are not sufficient. Examples of top applications, which are
not intended use of MiR500, but not limited to, are:
•Shelf on supporting legs (with or without wheels)
•Top applications (including total payload) which increase the footprint of MiR500
•Conveyers (power and non-powered)
•Industrial robot arm
•Towing of trailers
•Customized load transfer station
2.4 Users
MiR500 is only intended to be used by personnel that have received training in their
required tasks.
There are three types of intended users for MiR500: commissioners, operators, and direct
users.
Commissioners
Commissioners have received extensive training in the full use of MiR500 and have the
following main tasks:
•Commissioning the product. This includes creating maps and restricting the user interface
for other users.
•Making the risk assessment.
•Determining the payload limit, weight distribution, and safe fastening methods of loads
on MiR500.
•Ensuring the safety of nearby personnel when the robot is accelerating, braking, and
maneuvering.
Operators
Operators have thorough knowledge of MiR500 and of the safety precautions presented in
the user guide of MiR Fleet PCMiR500 and operating guide of MiR500. Operators have the
following main tasks:

2. Safety
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•Servicing and maintaining MiR500.
•Creating and changing missions and map positions in the robot interface.
Direct users
Direct users are familiar with the safety precautions in the user guide and have the following
main tasks:
•Assigning missions to MiR500.
•Fastening loads to MiR500 properly.
All other persons in vicinity of MiR500 are considered indirect users and must know how to
act when close to the robot. For example, they must be aware that visibly marked operating
hazard zones must be respected.
2.5 Foreseeable misuse
Any use of MiR500 deviating from the intended use is deemed as misuse. This includes, but
is not limited to:
•Using MiR500 to transport people
•Using MiR500 on steep surface grades, such as ramps
•Exceeding the total payload of 500 kg
•Positioning or fastening load incorrectly according to the specifications
See the Payload specifications on page90
•Failing to make a risk assessment of the full installation
Refer to Risk assessment below.
•Failing to follow the guidelines for commissioning
Refer to Commissioning on page25.
•Use in medical and life critical applications
•Operating outside the permissible operating parameters and environmental
specifications
•Use in potentially explosive environments
•Use outdoors
•Use in hygiene zones
2.6 Risk assessment
You must make a risk assessment to achieve a safe installation. The risk assessment is the
responsibility of the commissioner who must ensure that MiR500 is commissioned safely in
the environment it will be used in.

2. Safety
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The risk assessment must cover not only MiR500 itself, but also take into account potential
load transfer stations, work cells, and the work environment. MiR does not take any
responsibility for the creation of the risk assessment, but we provide information and
guidelines that may be used in the MiR 500 and MiR1000 Risk Analysis Guide found on the
Distributor Site under Manuals.
It is recommended that the commissioner follows the guidelines in ISO 12100, EN 1525, ANSI
B56.5, or other relevant standards to conduct the risk assessment.
In EN 1525, clause 4, there is a list of significant hazards, hazardous situations, and events
that can be used for inspiration.
2.7 Residual risks
Mobile Industrial Robots has identified the following potential hazards that commissioners
must inform personnel about and take all precautions to avoid:
•Risk of being run over, drawn in, trapped, or impacted when a person stands in the path
of MiR500 or walks towards MiR500 while it is driving in reverse. MiR500 will only drive
in reverse when parking or picking up a cart or undocking from a marker such as MiR
Charge48V.
•Risk of being run over, drawn in, trapped, or impacted when a person stands in the path
of MiR500 or walks towards MiR500 while it is in motion.
•Risk of being crushed or trapped when user touches MiR500.
•Risk of being crushed, drawn in, or trapped at pallet racks or other load transfer stations,
work cells, or charging stations.
NOTICE
Other significant hazards may be present in a specific robot installation and
must be identified during commissioning.
2.8 Safety-related functions and interfaces
MiR500 is equipped with a range of built-in safety-related functions as well as safety-related
electrical interfaces designed for integration with a top module and/or top manipulator.
Each safety function and interface is designed according to the standard ISO 13849-1.
The safety-related functions and interfaces are selected to support compliance with EN
1525.

2. Safety
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2.9 Limiting safety-related functions
MiR500 has several built-in safety-related functions that are used to ensure safe operation in
the environment it is designed to be used in.
Advanced control software ensures that locomotion and the drive pattern are within safety
related limits and thereby avoid triggering a safety function. Violations of limits will hence
only occur in exceptional cases. Nevertheless, if a limit is violated, the safety system issues a
category 0 stop (stopping by “immediate removal of power to the machine actuators
according to IEC 60204-1”) followed by a controlled brake which brings MiR500 to a stop.
See Technical specifications on our website for more details.
Collision avoidance
The collision avoidance safety function ensures that the robot will come to a stop before it
collides with a human or object.
The function measures the speed on the two driving wheels and switches between the
predefined protective fields accordingly. The faster the speed, the larger the protective
fields will be.
This ensures that the robot will be brought to a stop in case a human or object is detected
within the active protective field.
Collision avoidance is automatically deactivated two seconds after the protective field is
free.
Safe load position
The safe load position safety function ensures that the robot will not drive, while
MiR500Pallet Lift or MiR500EUPalletLift is not in the lowest position and hence there is a
risk of compromising stability.
The safe load position safety system consists of interlock switches that detect if the lift
modules are in the lowest position or not.
The input can be used for a customized top module/manipulator when a MiR500Pallet Lift
or MiR500EUPalletLift is not installed.
The safe load position safety function must be manually deactivated by activation of the
restart button.

2. Safety
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Overspeed avoidance
The safety system monitors if the speed of each motor is above limits for maximum rated
speed and hence an indication of speed control is lost for any reason.
The overspeed avoidance safety function must be manually deactivated by activation of the
restart button.
Stability
The safety system monitors if the speed difference between the two motors are above
predefined limits and hence an indication of speed control is lost for any reason.
The stability safety function must be manually deactivated by activation of the restart
button.
Emergency stop
MiR500 has four emergency stop buttons and an option to connect additional emergency
stop buttons through the electrical interface.
The emergency stop is only intended to be used in case of an emergency and shall not be
used for operational stop.
Emergency stop must be manually deactivated by activation of the restart button.
2.10 Safety-related electrical interfaces
The robot is equipped with several safety-related electrical inputs and outputs. All safety-
related electrical inputs and outputs are dual channel. They are safe when low, e.g. the
emergency stop is not active when the signal is high (+24V).
Safety-related electrical inputs
This section contains the safety-related electrical inputs of the robot.
External emergency stop button input
This input is for connection of an optional emergency stop button. If activated, the safety
system issues a category 0 stop followed by a controlled brake which brings MiR500 to a
stop.
Must be manually deactivated by activation of the restart button.

2. Safety
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System emergency stop input
This input should be used in case a top manipulator has its own emergency stop circuit. The
input must be used in combination with a system emergency stop output. With this, it is
possible to ensure that activation of any emergency stop button will cause an emergency
stop of both MiR500 and top manipulator. If activated, the safety system issues a category 0
stop followed by a controlled brake which brings the robot to a stop.
Must be manually deactivated by activation of the restart button.
Safeguard stop input
This input can be used to issue a category 0 stop followed by a controlled brake which brings
MiR500 to a stop.
Will be automatically deactivated when signal is driven high again.
Load handling position (position control of load)
This input can be used to apply the safe load position (position control of load) safety
function on a system with customized top modules or manipulators. A variety of sensors or
interlock switches that detect load handling position or position of load can be connected
and thereby enable the safe load position safety function.
Safety-related electrical outputs
This section contains the safety-related electrical outputs of the robot.
Locomotion
This safety related output is activated if the robot is in locomotion or intend to locomote
within two seconds.
The safety function is limited if locomotion is detected while the output is
deactivated.
Shared emergency stop output
This output should be used in case a top manipulator has its own emergency stop circuit. The
output should be used in combination with a system emergency stop input. With this, it is
possible to ensure that activation of any emergency stop button will cause an emergency
stop of both the robot and top manipulator.
Activated by an emergency stop button or emergency stop input.

2. Safety
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2.11 Lithium battery
This section contains safety precautions related to lithium batteries in MiR robots.
NOTICE
MiR does not support any additional batteries applied to the MiR500 by the
customer.
WARNING
Lithium battery packs may get hot, explode or ignite and cause serious injury if
they are abused electrically or mechanically.
Observe the following precautions when handling and using lithium batteries:
•Do not short-circuit, recharge or connect with false polarity.
•Do not expose to temperature beyond the specified temperature range or
incinerate the battery.
•Do not crush, puncture or disassemble the battery. The battery contains
safety and protection devices, which, if damaged, may cause the battery to
generate heat, explode or ignite.
•Do not allow the battery to get wet.
•In the event the battery leaks and the fluid gets into one’s eye, do not rub
the eye. Rinse well with water and immediately seek medical care. If left
untreated, the battery fluid could cause damage to the eye.
•Use only the original charger (cable charger or charging station) and
always follow the instructions from the battery manufacturer.

3. Getting started
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3. Getting started
This section describes how to get started with MiR500.
NOTICE
Read Safety on page8 before powering up the robot.
3.1 In the box
This section describes the content of the MiR500 box.
The box contains:
1. The MiR500 robot
2. MiR500 document folder containing the printed documents and the USB flash drive.
3. Printed documents:
•MiR500 Quick Start
•MiR username and passwords
•CE declaration of conformity

3. Getting started
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4. USB flash drive with the following content:
•MiR500 User Guide
•MiR Robot Interface 2.0 Reference guide
•MiR robot REST API reference
•MiR Charge48V Operating Guide
•MiR500Pallet Lift Operating Guide
•MiR500EUPalletLift Operating Guide
•MiR username and passwords
•CE declaration of conformity
3.2 Unpacking MiR500
This section describes how to unpack MiR500.
Keep the original packaging for the future transportation of the robot.
The robot is shown with a EU pallet lift.
1. Place the box with the robot so that there is 3m of free space at the front or the back of
the box. This is necessary since the robot drives out of the box on the ramp.
2. Remove the screws that attach the walls of the box to the box lid and the base of the box.