MIR 500 User manual

User Guide
10/2018 v 1.0
en

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 ApS (MiR). MiR makes no warranties, express or implied, in respect
of this document or its contents. In addition, the contents of the document is 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 by Mobile Industrial Robots
For more material
,
go to our website
Contact the manufacturer:
Mobile Industrial Robots
Emil Neckelmanns Vej 15F
DK-5220 Odense SØ
www.mir-robots.com
Phone: [phone]
Email: [e-mail]
CVR: 35251235

Table of contents
1 About this manual ............................................................................................................ 1
1.1 Overview..................................................................................................................... 1
1.2 Document history ....................................................................................................... 1
1.3 Where to find more information ................................................................................ 1
2 Safety................................................................................................................................ 3
2.1 Introduction................................................................................................................ 3
2.2 Safety concept ............................................................................................................ 3
2.3 General safety instructions......................................................................................... 4
2.3 1 Warning notes ................................................................................................. 4
2.3 2 Caution notes................................................................................................... 4
2.4 Intended use............................................................................................................... 4
2.5 Foreseeable misuse .................................................................................................... 5
2.6 Risk assessment .......................................................................................................... 5
2.7 Residual risks .............................................................................................................. 6
2.8 Safety-related functions and interfaces ..................................................................... 6
2.9 Limiting safety-related functions................................................................................ 6
2.10 Safety-related electrical interfaces........................................................................... 7
2.10 1 Safety-related electrical inputs...................................................................... 7
2.10 2 Safety-related electrical outputs ................................................................... 8
2.11 Lithium battery ......................................................................................................... 8
3 Getting started.................................................................................................................. 9
3.1 In the box.................................................................................................................... 9
3.2 Unpacking MiR500.................................................................................................... 10
3.3 Commissioning ......................................................................................................... 13
3.3 1 Powering up................................................................................................... 13
3.3 2 Connecting to the robot interface ................................................................. 16
3.3 3 Driving the robot in Manual mode ................................................................ 17
3.3 4 Checking the hardware status ....................................................................... 18
3.3 5 Charging the robot......................................................................................... 19
3.3 6 Shutting down the robot ............................................................................... 20
3.4 MiR500 control panel ............................................................................................... 21
3.4 1 The Operating mode key ............................................................................... 21
3.4 2 The control panel buttons ............................................................................. 22
3.4 3 MiR500 operating modes .............................................................................. 23
3.4 4 Muting of the personnel detection means.................................................... 23
3.5 Packing for transportation........................................................................................ 24
3.5 1 Preparations .................................................................................................. 24
3.5 2 Battery ........................................................................................................... 24
3.5 3 Packing the robot for transportation............................................................. 24
4 Planning .......................................................................................................................... 26
4.1 Introduction.............................................................................................................. 26
4.2 Analysis of the work environment............................................................................ 26

4.2 1 What does the robot see? ............................................................................. 26
4.2 2 Possible hazards in the environment............................................................. 28
4.3 Analysis of the users ................................................................................................. 29
4.3 1 Types of users ................................................................................................ 29
4.3 2 Interface and dashboards.............................................................................. 30
4.3 3 Training of the users ...................................................................................... 30
4.4 Creating a safe map .................................................................................................. 31
4.4 1 Optimizing the map ....................................................................................... 31
4.5 Creating simple and safe missions............................................................................ 36
4.6 Error handling ........................................................................................................... 36
4.7 Handover testing ...................................................................................................... 37
5 Product presentation...................................................................................................... 39
5.1 About MiR500........................................................................................................... 39
5.2 Main features of MiR500.......................................................................................... 40
5.3 Identification label.................................................................................................... 41
5.4 MiR500 external parts .............................................................................................. 42
5.5 MiR500 internal parts............................................................................................... 44
5.5 1 Front compartment ....................................................................................... 44
5.5 2 Rear compartment......................................................................................... 45
5.5 3 Side compartments........................................................................................ 47
5.5 4 Top compartments ........................................................................................ 48
5.6 Sensor system........................................................................................................... 49
5.6 1 Safety laser scanners ..................................................................................... 49
5.6 2 3D cameras .................................................................................................... 52
5.6 3 Proximity sensors........................................................................................... 54
5.6 4 Light indicators .............................................................................................. 54
5.7 Internal sensors ........................................................................................................ 56
6 Applications .................................................................................................................... 57
6.1 Overview................................................................................................................... 57
6.2 Mounting a top module............................................................................................ 57
Appendices
A Payload specifications ......................................................................................................60
B Interface specifications .................................................................................................... 62
C Declaration of conformity ................................................................................................ 69

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MiR500 User Guide 10/2018 v.1.0 1
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1 About this manual
1.1 Overview
This document contains the following information:
• How to start up and operate a MiR500 robot.
• Product presentation.
• Typical applications.
• Guidelines for proper maintenance of the robot.
The document is intended for Mobile Industrial Robots’ distributors as well as end users responsible
for the daily operation of the robot.
1.2 Document history
The table in this section shows the version history of this document. Each document version is valid
for a particular software and hardware release. SW and HW stand for the software and hardware
versions of the robot.
1.3 Where to find more information
At mobile-industrial-robots.com, the following extra resources on MiR500 robots are available. To
access the pages in the Distributor site, sign in with your distributor account at http://www.mobile-
industrial-robots.com/en/account.
• Distributor site > Downloads
http://www.mobile-industrial-robots.com/en/account/download/
The section contains the following resources:
• MiR500 Quick Start
The short guide that lets you start operating the robot quickly. This document is in the box
with the robot in the printed format. Available in multiple languages.
• MiR500 Lift Operating guide
The operating guide that describes how to set up and use MiR500 with MiR500 Lift.
• MiR500 EU Pallet Lift Operating guide
The operating guide that describes how to set up and use MiR500 with MiR500 EU Pallet Lift.
• MiRCharge 500 Operating guide
The operating guide that describes how to set up MiRCharge 500 and configure the MiR500
robot for automatic battery charging at the charging station.
• MiR Robot Interface 2.0 Reference Guide
The reference that describes the elements of the MiR robot interface. Available in multiple
languages.
• MiR500 REST API reference.
The REST API reference for the robot.
• CAD drawings.
Click Show CAD-files to see the list of available CAD drawings.
Doc version Release date Description SW HW
1.0 2018-10-29 First edition 2.4.0 1.0

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MiR500 User Guide 10/2018 v.1.0 2
• Certificates.
Click Show Certificates to see the list of certificates for the robot.
• Distributor site > How to
http://www.mobile-industrial-robots.com/en/account/how-to/
This page contains how-to articles that describe how to perform specific tasks with the robot.
• MiR500 product page
http://www.mobile-industrial-robots.com/en/products
This page contains specifications, pictures, and brochures for the robot.

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MiR500 User Guide, 10/2018 v.1.0 3
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2 Safety
2.1 Introduction
This information must be read and understood before MiR500 is powered up for the first time. It is
important to read the following safety information in order to operate MiR500 safely.
This manual contains notices you have to observe to ensure your personal safety, as well as to
prevent damage to property. The notices referring to your personal safety are highlighted in the
manual by a safety alert symbol. The notices shown below are graded by signal words to indicate
degree of danger.
2.2 Safety concept
Mobile Industrial Robots ApS disclaims any and all liability if MiR500 or its accessories are damaged, changed
or modified in any way. Mobile Industrial Robots ApS can not be held responsible for any damages caused to
MiR500, accessories or any other equipment due to programming errors or malfunctioning of MiR500.
Indicates an immanently hazardous situation that will result in death or severe personal injury if proper
precautions are not taken.
Indicates a potentially hazardous situation that could result in death or severe personal injury if proper
precautions are not taken.
Indicates a situation that could result in minor personal injury or damage to the equipment if proper
precautions are not taken.
Indicates a situation that could result in property damage if proper precautions are not taken.

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MiR500 User Guide, 10/2018 v.1.0 4
2.3 General safety instructions
This section contains general safety notes. Some safety notes are repeated or further specified in
other sections of the manual and further safety notes are present throughout the manual.
2.3.1 Warning notes
2.3.2 Caution notes
2.4 Intended use
MiR500 is intended to be commissioned and used in an indoors industrial environment where access
for the public is restricted. For details about the environmental conditions under which the robot
should operate, see Technical specifications on our website.
MiR500 is equipped with special safety-related features, which are purposely designed for
collaborative operation, where the robot operates without fences and/or together with humans.
• Ensure proper mounting of loads during transport
Danger of personal injury from overturning robot or falling load.
All accessories and loads mounted on top of the robot should be fastened correctly and meet specifications.
See Payload specifications on page 60.
• Use only the original charger
Danger of personal injury and/or damage to the robot.
Use of other charger than the one supplied by the manufacturer can ruin the battery and may cause fire.
• Update maps to avoid hazards on the route
Danger of personal injury and/or damage to the robot.
Make sure to update maps with areas without drive surfaces such as stairways.
• Do not drive the robot irresponsibly
Danger of personal injury and/or damage to the robot.
The robot should not be driven over edges or in other ways operated irresponsibly.
• Turn off main power immediately after removal of top cover
Risk of personal injury and/or damage to the robot. Turn off main power relay to avoid short circuit. See
Product presentation on page 39.
• Leave robot in enabled state
Be aware that the robot can unexpectedly receive a mission or control signal from the control device and start
moving.
• Use Flight Mode with smartphone control of robot
Risk of personal injury and/or damage to the robot.
If you control the robot with a smartphone, make sure that the phone is set to Flight Mode. An incoming call
on the smartphone will interrupt control of the robot.

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MiR500 User Guide, 10/2018 v.1.0 5
MiR500 can be used with the lift modules MiR500 Lift, MiR500 EU Pallet Lift and pallet racks MiR500
Lift Pallet Rack and MiR500 EU Pallet Rack, or it can be used with a customized top module or top
manipulator. See details for add-ons on our website or in the operating guides.
2.5 Foreseeable misuse
Any use or application deviating from the intended use is deemed to be impermissible misuse. This
includes, but is not limited to:
•Use of the robot to transport people.
Risk of personal injury and/or damage to the robot.
•Gradients above 5% on the route.
Risk of personal injury and/or damage to the robot. The surface grade (ramps etc.) cannot
exceed 5% as this may cause the robot to skid.
• Use outdoor.
Risk of personal injury and/or damage to the robot. MiR500 is designed and intended to use
indoors only.
•Overloading of the robot.
Risk of personal injury and/or damage to the robot. The maximum payload for the load on top
of the robot is 500 kg / 1100 lbs. If exceeded, it may cause overturning, falling load and damage
to the robot.
•Failure to follow the guidelines for commissioning.
See Getting started on page 9 and Planning on page 26.
•Failure to make a risk assessment of the full installation.
See Risk assessment on page 5. This may cause the risks not being fully uncovered. This also
applies to MiR500 with a Lift or EU Pallet Lift installed on top.
•Failure to configure audible and light warning signal(s) according to environment.
The risk reduction is not sufficient.
•Operation outside the permissible operating rating parameters and environmental
specifications.
Risk of instability, impact or tipping over.
•Transportation of liquids or food.
Risk of instability.
• Use in potentially explosive environments.
• Use in medical and life critical applications.
• Use for towing.
•Use on board ships.
Risk of personal injury and/or damage to the robot. Unstable surface caused by moving vessel
may cause the robot to skid.
2.6 Risk assessment
One of the most important steps in achieving a safe installation is to make a risk assessment. The
risk assessment is the responsibility of the individuals who are commissioning MiR500 in the
environment it will be used in. Most often it will be an integrator who also designs and/or builds
work cells or other required infrastructure related to MiR500.
The risk assessment must cover not only MiR500 itself, but also take into account potential top
module/manipulator, load transfer, work cells and the environment it will be used in.
It is recommended that the integrator uses guidelines in ISO 12100, EN 1525, ANSI B56.5 or other
relevant standards to conduct the risk assessment.
The risk assessment should consider two scenarios:

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• Teaching (setup where maps are made and the missions are defined and verified) the robot
while developing the robot installation.
• Normal operation of the robot installation.
In EN 1525, clause 4 there is a list of significant hazards, hazardous situations and events which can
be used for inspiration.
2.7 Residual risks
Mobile Industrial Robots ApS has identified the potential significant hazards listed below as hazards
that must be considered by the integrator. Note that other significant hazards might be present in a
specific robot installation.
• Being run over, drawing-in, trapping or impact if a person steps into the route or walk towards
MiR500 while in motion.
• Crushing, drawing-in or trapping at load transfer stations, work cells or charging stations.
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.
2.9 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 MiR500 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 MiR500 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 MiR500 will not locomote, while MiR500 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.

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MiR500 User Guide, 10/2018 v.1.0 7
The input can be used for a customized top module/manipulator when a MiR500 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.
Overspeed
avoidance
The safety system monitors if the speed of each motor is above limits for maximum 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 should only be activated in case of an emergency.
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).
2.10.1 Safety-related electrical inputs
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.
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 MiR500 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.

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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 module/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.
2.10.2 Safety-related electrical outputs
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 to trig 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 MiR500
and top manipulator.
Activated by a MiR500 emergency stop button or emergency stop input.
2.11 Lithium battery
Lithium batteries are primary power sources with high energy content designed to represent the
highest possible degree of safety.
Potential hazard
Lithium battery packs may get hot, explode or ignite and cause serious injury if they are abused
electrically or mechanically.
Observe the following precautions 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 and always follow the instructions from the battery manufacturer.

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MiR500 User Guide, 10/2018 v.1.0 9
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3 Getting started
3.1 In the box
This section describes the content of the MiR500 box.
Figure 3.1. The MiR500 box.
1.The MiR500 robot.
2 MiR500
document folder containing:
• Printed documents:
– MiR500 Quick Start.
– MiR username and passwords.
– CE declaration of conformity.
• USB flash drive with the following content:
– MiR500 User Guide.
– MiR Robot Interface 2.0 Reference guide.
– MiR robot REST API reference.
– MiRCharge 500 Operating Guide.
– MiR500 Lift Operating Guide.
– MiR username and passwords.
– CE declaration of conformity.

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MiR500 User Guide, 10/2018 v.1.0 10
3.2 Unpacking MiR500
Keep the original packaging for the future transportation of the robot.
Step Action
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.
3 Remove the lid from the box.
4 Take the folder with MiR printed documents and the USB drive out of the box.

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MiR500 User Guide, 10/2018 v.1.0 11
5
Remove the walls of the box and the protective foam blocks.
6 Cut the protective straps.
Step Action

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MiR500 User Guide, 10/2018 v.1.0 12
7 Place the lid of the box so that you can use it as a ramp. Align the lid so that it is flush with the
base of the box.
8 Remove the wheel stop board from the pallet to let the robot drive on the ramp.
Step Action

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MiR500 User Guide, 10/2018 v.1.0 13
3.3 Commissioning
Read the Safety chapter before powering up the robot.
Commissioning consists of the following parts:
1. Powering up.
2. Connecting to the robot interface.
3. Checking the hardware status.
4. Charging the robot.
5. Shutting down the robot.
For further steps, refer to the MiR500 User Guide.
3.3.1 Powering up
Follow these steps to power up MiR500 .
Step Action
1 Open the rear maintenance hatch. To open the hatch, push two buttons on the hatch and pull the
hatch.

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MiR500 User Guide, 10/2018 v.1.0 14
2
Turn the battery disconnect switch to position ON.
The Power button turns blue.
3 Close the maintenance hatch.
Step Action

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4
Ensure that all 4 emergency stop buttons are in the released state. Turn an emergency stop button
clockwise to release it.
5 Press the Power button for five seconds.
The robot turns on the yellow indicator lights and starts the software initialization process. When
the initialization process ends, the robot goes into the emergency stop mode.
Step Action

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3.3.2 Connecting to the robot interface
When the robot is on, it enables the connection to its WiFi access point. The name of the access point
appears in the list of available connections on your laptop, tablet, or a phone.
The username and password for the robot’s WiFi access point and for accessing the
web interface are in the MiR username and passwords document. The document is
in the box with the robot.
Follow these steps to connect to the robot interface:
6
Press the Restart button to clear the emergency stop. The robot is ready for operation, the status
lights turn constant yellow.
Step Action
Step Action
1 Using your laptop, tablet, or a phone, connect the WiFi access point of the robot. The access point name has
the following format: MiR_UXXXX.