OTTO MOTORS Lifter V1 User manual

OTTO Lifter V1 - OMM-000111
Operation and maintenance manual
OMM-000111
Publication date Jan-23
English

Copyright © 2023 CLEARPATH and OTTO Motors are trademarks of Clearpath Robotics Inc. All other
product and company names listed are trademarks or trade names of their respective companies. The
information provided herein is for general guidance only and is subject to change. For support, please
contact your sales or customer success representative.

TABLE OF CONTENTS
1. IMPORTANT SAFETY INFORMATION ..................................................................................... 6
1.1. Hazards ....................................................................................................................... 6
General hazards ......................................................................................................... 7
Robot hazards ............................................................................................................ 8
Charger hazards ......................................................................................................... 9
1.2. Hazard labels .............................................................................................................. 10
1.3. Safety awareness ........................................................................................................ 12
Facility conditions ...................................................................................................... 13
Payload maximums and stability ................................................................................. 14
Battery handling ........................................................................................................ 15
Overhang and underhang detection ............................................................................ 15
Safety system functionality ......................................................................................... 16
Perception sensor layout ............................................................................................ 16
Emergency stop system ............................................................................................. 17
Safety stop system .................................................................................................... 17
Zone-specific behavior ............................................................................................... 17
Robot modes ............................................................................................................. 17
Footprint safety .......................................................................................................... 18
1.4. Disclaimer ................................................................................................................... 19
2. Intended use .......................................................................................................................... 19
3. Introduction ........................................................................................................................... 19
3.1. Included items ............................................................................................................. 20
4. Applicable documents ............................................................................................................ 21
5. In case of a collision ............................................................................................................... 22
6. OTTO Lifter specifications ...................................................................................................... 23
6.1. Size and weight ........................................................................................................... 23
6.2. Speed and performance .............................................................................................. 24
6.3. Battery and power system ............................................................................................ 25
6.4. Control system ............................................................................................................ 25
6.5. Interfacing and communication ..................................................................................... 25
6.6. Operating environment ................................................................................................ 26
6.7. Safety system ............................................................................................................. 27
7. Components overview ............................................................................................................ 27
7.1. Components ............................................................................................................... 27
7.2. Emergency Stop buttons .............................................................................................. 28
7.3. Safety Reset button ..................................................................................................... 29
7.4. Auto button ................................................................................................................. 29
7.5. Digital interface ........................................................................................................... 30
7.6. Robot off checks ......................................................................................................... 30
7.7. Tiller ........................................................................................................................... 31
7.8. Forks .......................................................................................................................... 32
7.9. Robot battery state indicator ........................................................................................ 33
7.10. Light pipe and visual indications ................................................................................. 33
7.11. Safety Reset button states ......................................................................................... 36
7.12. Speakers .................................................................................................................. 36
7.13. Dome light ................................................................................................................ 36
7.14. Direction lights .......................................................................................................... 37
OTTO Lifter V1 - OMM-000111
© Clearpath Robotics Inc. 2023. All rights reserved. CLEARPATH and OTTO are trademarks of Clearpath Robotics Inc.
All other product and company names listed are trademarks or trade names of their respective companies. 3

7.15. Lift points .................................................................................................................. 38
7.16. Top door ................................................................................................................... 38
7.17. Top rear door ............................................................................................................ 38
7.18. Left side door ............................................................................................................ 39
7.19. Right side door .......................................................................................................... 39
7.20. Rear door ................................................................................................................. 39
7.21. Safety LiDAR ............................................................................................................ 40
7.22. 3D perception cameras .............................................................................................. 41
7.23. Fork impact sensors .................................................................................................. 41
7.24. Dock assist sensors ................................................................................................... 41
7.25. Incremental encoders ................................................................................................ 41
7.26. Thermal detectors ..................................................................................................... 42
8. Basic usage ........................................................................................................................... 42
8.1. Locking-out/tagging-out the OTTO Lifter ....................................................................... 42
8.2. First time OTTO Lifter digital interface setup ................................................................. 43
8.3. Starting up the OTTO Lifter .......................................................................................... 44
8.4. Shutting down the OTTO Lifter ..................................................................................... 45
8.5. Replacing the OTTO Lifter battery ................................................................................ 45
8.6. Manually charging the OTTO Lifter ............................................................................... 49
8.7. Moving the OTTO Lifter V1 .......................................................................................... 50
8.8. Storing the OTTO Lifter ................................................................................................ 53
8.9. Connecting to a robot using an Ethernet cable .............................................................. 53
8.10. Connecting a robot to a network ................................................................................. 54
8.11. Adding a robot to a fleet ............................................................................................. 54
8.12. Autonomous operation ............................................................................................... 55
Enabling autonomous mode ....................................................................................... 55
Dispatching jobs ........................................................................................................ 56
Troubleshooting autonomous mode ............................................................................ 56
8.13. Manual mode operation ............................................................................................. 57
Enabling manual mode .............................................................................................. 57
Raising and lowering forks ......................................................................................... 58
Moving forward and backward .................................................................................... 58
Using the horn ........................................................................................................... 59
8.14. Robot dashboards ..................................................................................................... 59
Accessing robot dashboards ....................................................................................... 60
Interacting with jobs in a robot dashboard .................................................................... 60
Monitoring robot sensors in robot dashboard ............................................................... 61
8.15. Exceptions ................................................................................................................ 62
Accessing exceptions in OTTO Fleet Manager ............................................................ 62
Accessing exceptions in OTTO App ............................................................................ 63
Accessing exceptions in robot dashboard .................................................................... 63
Navigating exceptions ................................................................................................ 63
Filtering exceptions .................................................................................................... 64
9. Preventative maintenance ...................................................................................................... 64
9.1. Maintenance schedule ................................................................................................. 64
9.2. Circle check ................................................................................................................ 65
Robot off checks ........................................................................................................ 65
Robot on checks ........................................................................................................ 66
Checking the battery water level ................................................................................. 67
9.3. Monthly preventative maintenance ............................................................................... 67
Inspecting and replacing OTTO Lifter guarding ............................................................ 68
OTTO Lifter V1 - OMM-000111
© Clearpath Robotics Inc. 2023. All rights reserved. CLEARPATH and OTTO are trademarks of Clearpath Robotics Inc.
All other product and company names listed are trademarks or trade names of their respective companies. 4

Inspecting string pots ................................................................................................. 68
9.4. 3-month preventative maintenance ............................................................................... 68
Lubricating the OTTO Lifter periodically ....................................................................... 68
9.5. 6-month preventative maintenance ............................................................................... 68
Brake inspection ........................................................................................................ 69
9.6. Annual preventative maintenance ................................................................................. 69
Inspecting and refilling hydraulic fluid .......................................................................... 69
10. Disposal .............................................................................................................................. 69
11. Troubleshooting ................................................................................................................... 69
12. Robot forklift pre-op checklist - OMM-000105 ......................................................................... 72
12.1. Robot forklift safety and operational checks ................................................................ 72
Robot off checks ........................................................................................................ 72
Robot on checks ........................................................................................................ 73
OTTO Lifter V1 - OMM-000111
© Clearpath Robotics Inc. 2023. All rights reserved. CLEARPATH and OTTO are trademarks of Clearpath Robotics Inc.
All other product and company names listed are trademarks or trade names of their respective companies. 5

1. IMPORTANT SAFETY INFORMATION
The top priority of OTTO Motors is the safety of its users. OTTO Motors produces high power and
fast-moving pieces of machinery that could cause serious injury, including death, if improperly used or
maintained. Additional hazards may be identified and need to be addressed during the site-specific risk
assessment.
Review the safety messages and all instructions before using the product. Save this document for
reference.
WARNING
Failure to follow operating instructions may result in death or serious injury.
• Read and understand the operation and maintenance manual before using the robot,
charger, or attachment.
• For the physical location of elements on the product, refer to the Component Overview
section of the operation and maintenance manual.
1.1. Hazards
The following are examples of hazard notices:
DANGER
Failure to follow these instructions will result in SERIOUS INJURY, INCLUDING DEATH.
WARNING
Failure to follow these instructions may result in SERIOUS INJURY, INCLUDING DEATH.
CAUTION
Failure to follow these instructions may result in MINOR or MODERATE INJURY or
DAMAGE to the system and/or property.
OTTO Lifter V1 - OMM-000111
© Clearpath Robotics Inc. 2023. All rights reserved. CLEARPATH and OTTO are trademarks of Clearpath Robotics Inc.
All other product and company names listed are trademarks or trade names of their respective companies. 6

General hazards
WARNING
• BURN or SHOCK HAZARD! Never use this product if the enclosure or any of the
connectors are broken, cracked, open, or show any other indication of damage.
• SHOCK HAZARD! Always perform the lock-out/tag-out procedure at the facility or on
the product before inspecting, servicing, cleaning, removing components, or opening
any enclosure.
• FIRE HAZARD! Observe all safety precautions when using flammable fluids.
• CRUSH HAZARD! Keep a safe distance from suspended loads.
• Always be aware of operation limitations such as floor grades, negative and
overhanging obstacles, and the LiDAR obstacle detection plane.
• FIRE OR SHOCK HAZARD! Never use a power cord or cable that appears damaged.
CAUTION
• Never operate the product after faulty parts are identified.
• Never expose OTTO Motors products to rain, condensation, or standing water. Store
products in a clean and dry location.
• Use appropriately rated lift equipment and follow safe lifting procedures as defined by
the facility when lifting the product.
• Wear appropriate safety equipment when operating or working around the product.
• TRIP HAZARD! Take care when walking around the product.
• Only qualified personnel should perform installations, maintenance, and inspections.
• Only use the attachments, accessories, tools, replacement parts, and cleaning
products approved by OTTO Motors.
• Installation must be performed by an electrically qualified person to ensure compliance
with local electrical codes.
• PINCH HAZARD! Keep objects and body parts away from pinch points.
• FIRE HAZARD! Observe all safety precautions when using flammable fluids.
OTTO Lifter V1 - OMM-000111
© Clearpath Robotics Inc. 2023. All rights reserved. CLEARPATH and OTTO are trademarks of Clearpath Robotics Inc.
All other product and company names listed are trademarks or trade names of their respective companies. 7

Robot hazards
WARNING
• Always use level rigging when lifting or lowering the product.
• IMPACT HAZARD! Never bypass the drive wheels of the robot while on a sloped
surface.
• Never use OTTO Motors products to transport people or live animals.
• CRUSH or IMPACT HAZARD! Robots must be prevented from traveling in areas that
do not follow Facility Conditions specifications, such as ramps and stairwells.
• FIRE HAZARD! If the battery is damaged or a battery fire occurs, contact local
emergency services and vacate the area. Do not use water to douse the fire.
• FIRE OR SHOCK HAZARD! Never use a power cord or cable that appears damaged.
• SHOCK HAZARD! Never attempt operation if the power supply is not within the
specified voltage and current, as identified in the product documentation.
• FIRE HAZARD! Observe all safety precautions when using flammable fluids.
• CRUSH HAZARD! Pedestrians should be aware of hazard mode or docking mode
audio-visual indications. When robots are in docking mode, the front of the robot is
no longer safeguarded—personnel must be restricted from areas where robots will be
docking. When robots are in hazard mode, the region safeguarded by LiDAR safety
scanners is reduced in size. Under rare circumstances, robots can get mislocalized
and enter docking hazard mode in an unintended location. For audio-visual indicator
identification, refer to the Component Overview section of the robot operation and
maintenance manual.
• CRUSH HAZARD! Payloads, attachments, or a combination thereof, should always
remain within the stability envelope relevant to the specific robot model. For payload
constraints, refer to the System Specifications for the product.
• CRUSH/PINCH HAZARD! Manual or automatic load transfer may introduce a crush or
pinch hazard. Take care when performing a manual load transfer. A risk assessment
should be conducted to mitigate hazard risk when designing load transfer systems.
• CRUSH or IMPACT HAZARD! All stairwells or similarly open holes must be marked
and surrounded by obstacles exceeding 20 cm in height with spacing no greater than
30 cm. These obstacles must be able to withstand 2000 N of force without failing or be
at least 70 mm wide from all directions and visible to the LiDAR.
OTTO Lifter V1 - OMM-000111
© Clearpath Robotics Inc. 2023. All rights reserved. CLEARPATH and OTTO are trademarks of Clearpath Robotics Inc.
All other product and company names listed are trademarks or trade names of their respective companies. 8

CAUTION
• IMPACT HAZARD! Always maintain a safe distance from a robot in operation. A
robot being operated in manual mode should only be operated by personnel who
have been trained and authorized according to the standards of the facility in which
the robot is in use. Be aware of the Emergency Stop button locations. For button
location information, refer to the Component Overview section of the robot operation
and maintenance manual.
• IMPACT HAZARD! While driving the robot in manual mode, the safety field sets
monitored by the LiDAR scanners can be disabled. To avoid impact, be aware of the
robot's surroundings.
• Avoid making contact with the LiDAR safety sensors as they are fragile and easily
damaged. For sensor locations, refer to the Component Overview section of the robot
operation and maintenance manual.
• Do not expose the product for a prolonged period to temperatures outside the ranges
specified in the product documentation.
• IMPACT HAZARD! Do not place anything on the robot that extends beyond
its footprint. Refer to the robot Safety Configuration document for the footprint
dimensions.
• CRUSH or IMPACT HAZARD! Keep low profile objects that the LiDAR cannot detect,
such as forklift tines and pallets, outside of the robot's path. For sensor layouts, refer
to the Component Overview section of the robot operation and maintenance manual.
• BURN HAZARD! Allow the product to cool before performing maintenance.
• Do not connect the robot to a manual charger and an automatic charger at the same
time as this can result in damage to either charger.
• SHOCK HAZARD! Improper use or maintenance of robot batteries may result in a high
energy discharge.
• Never exceed the maximum total payload constraints of the product. For payload
constraints, refer to the System Specifications for the product.
• CRUSH HAZARD! Objects can fall from the product. Where possible, secure loads to
the product to avoid falling, tipping, shifting, or sliding.
Charger hazards
For instructions on connecting the robot to a charger, refer to the charging information in the Basic Usage
section of the product operation and maintenance manual.
OTTO Lifter V1 - OMM-000111
© Clearpath Robotics Inc. 2023. All rights reserved. CLEARPATH and OTTO are trademarks of Clearpath Robotics Inc.
All other product and company names listed are trademarks or trade names of their respective companies. 9

WARNING
• FIRE OR SHOCK HAZARD! Never use a power cord or cable that appears damaged.
• SHOCK HAZARD! Automatic chargers are powered by hazardous voltage levels. Do
not touch the charge contacts when the product is in operation.
• Chargers must be installed with a disconnect that electrically isolates the charger and
functions as an emergency switch.
• FIRE HAZARD! If the battery is damaged or a battery fire occurs, contact local
emergency services and vacate the area. Do not use water to douse the fire.
• SHOCK HAZARD! Never attempt operation if the power supply is not within the
specified voltage and current, as identified in the product documentation.
CAUTION
• CRUSH HAZARD! Always maintain a safe distance from a charger in operation.
• SHOCK HAZARD! Improper use or maintenance of robot batteries may result in a high
energy discharge.
• Installation must be performed by an electrically qualified person to ensure compliance
with local electrical codes.
• Do not connect the robot to a manual charger and an automatic charger at the same
time as this can result in damage to either charger.
• BURN HAZARD! Allow the product to cool before performing maintenance.
• TRIP OR FIRE HAZARD! Position all cables where they cannot contact hot surfaces,
be pulled, tripped over, or damaged.
• Never disconnect the system while it is under electrical load.
• GROUNDING ELECTRICAL HAZARD! The power supply for the charger must be
grounded.
• FIRE HAZARD! Chargers and batteries must only be used in a well-ventilated area
and must be easily accessible.
• FIRE HAZARD! Never smoke, use power tools, or perform any activity that can create
sparks around a battery or charger.
1.2. Hazard labels
Review the following to learn more about the labels that may be used on OTTO Motors products. Hazards
can also apply to attachments and accessories used in conjunction with an OTTO Motors product.
OTTO Lifter V1 - OMM-000111
© Clearpath Robotics Inc. 2023. All rights reserved. CLEARPATH and OTTO are trademarks of Clearpath Robotics Inc.
All other product and company names listed are trademarks or trade names of their respective companies. 10

Label Title Description Label Title Description
Grounding
electrical
hazard
Improper grounding
of OTTO Motors
chargers can result in
a potential shock risk.
Pinching risk Keep hands and other
objects clear of pinch
points at all times.
Keep clear of all
docking robots.
Harmful
battery
substance
Robot batteries
contain harmful
material. Always
use proper handling
procedures when
handling robot
batteries.
Crushing risk Objects or personnel
can be crushed
between robots and
another object.
Keep hands and other
objects clear of crush
points at all times.
Keep clear of all
docking robots.
Burn hazard Robot PC heat sinks
and robot motors can
become extremely hot
during operation.
Impact hazard OTTO Motors robots
travelling through a
facility can potentially
impact objects and
personnel.
Keep clear of all
docking robots.
Manual load
handling
Always use ergonomic
technique when
manually lifting loads.
Robot
movement
Robots may suddenly
begin moving
autonomously or
when being driven
manually.
Always be aware
of OTTO Motors
products and
their potential for
movement.
Tripping
hazard
OTTO Motors
products may pose a
tripping hazard.
Shock hazard Improper use/
disconnection of a
component with this
label can result in a
potential shock risk.
Hydraulic
pressure
Components under
hydraulic pressure
and loss of pressure
could result in injury.
Impact from
above risk
Robots equipped with
a lift can potentially
impact objects and
personnel from above.
Keep clear of all
docking robots.
Automated
mobile robot
traffic
Be aware that robots
can be anywhere in
the operating area of
the facility at any time.
OTTO Lifter V1 - OMM-000111
© Clearpath Robotics Inc. 2023. All rights reserved. CLEARPATH and OTTO are trademarks of Clearpath Robotics Inc.
All other product and company names listed are trademarks or trade names of their respective companies. 11

Label Title Description Label Title Description
Personal
Protective
Equipment
(PPE)
requirement
Proper PPE must be
worn, including safety
footwear (ie. steel toe)
around OTTO Motors
products.
Insulated gloves
and/or tools are
recommended when
performing any
maintenance on
OTTO Motors
products.
Lock- out/tag-
out
When performing
maintenance on an
electrically powered
OTTO Motors product,
always follow the
applicable lock-out/
tag-out procedure.
Do not ride Robots are not
designed for carrying
personnel and should
not be ridden at any
time.
Do not step The labeled
component must not
be used as a step.
1.3. Safety awareness
WARNING
• IMPACT HAZARD! Always maintain a safe distance from a robot in operation. A
robot being operated in manual mode should only be operated by personnel who
have been trained and authorized according to the standards of the facility in which
the robot is in use. Be aware of the Emergency Stop button locations. For button
location information, refer to the Component Overview section of the robot operation
and maintenance manual.
Personnel present in a facility with OTTO Motors products need to be made aware or be accompanied by
personnel who are familiar with the specific risks and hazards associated with automated mobile robots.
The following checklist identifies basic topics that should be addressed by site-specific worker and visitor
safety orientation training.
• Proper PPE must be worn, including safety footwear (ie. steel toe) around OTTO Motors products.
• Crossing into the path of a moving robot should be avoided, as well as placing or throwing obstacles
into the path of a moving robot.
• Be aware that a robot can be anywhere in the operating area of the facility at any time, and may pose a
tripping hazard even when not in motion.
• Personnel need to be aware of operation limitations, such as floor grades, underhanging and
overhanging obstacles, and the LiDAR obstacle detection plane.
• The floor of the operating area should be kept free of dirt and debris.
• Personnel need to be aware of robot docking and charging areas, where detection fields are reduced.
• Personnel should be aware of facility areas where robots travel through narrow aisles/corridors
resulting in reduced clearance between robots and personnel and aisles/corridors shared between
robots, other robots, and personnel.
OTTO Lifter V1 - OMM-000111
© Clearpath Robotics Inc. 2023. All rights reserved. CLEARPATH and OTTO are trademarks of Clearpath Robotics Inc.
All other product and company names listed are trademarks or trade names of their respective companies. 12

• Personnel should be aware that OTTO Motors LiDAR safety scanners are laser products rated class
1/1M. Personnel must not look directly at the laser beam source.
• Personnel should keep all loose clothing and body parts away from robots, accessories, attachments,
and payloads, while they are in autonomous operation.
In addition to the preceding basic items for all workers and visitors, the following should be considered for
facility personnel, including drivers of other robots:
• High traffic areas, tight clearance areas, emergency exits, areas around electrical panels or in front of
shelves and racking, and obstacles that are outside the field of view of safety sensors (i.e. overhanging
obstacles) should have bollards placed around them so that robots do not drive or stop in those areas
• Operators of other industrial robots must not leave skids or other loads overhanging or unstable near
the edges of racking as they may not be detected by a robot.
• Alert personnel that while operating a robot outside of the autonomy state, they are solely responsible
for obstacle and collision avoidance.
• Maintenance not outlined in the operations and maintenance manual can only be performed by OTTO
Motors-authorized personnel.
Facility conditions
WARNING
• IMPACT HAZARD! Never bypass the drive wheels of the robot while on a sloped
surface.
• CRUSH or IMPACT HAZARD! Keep low profile objects that the LiDAR cannot detect,
such as forklift tines and pallets, outside of the robot's path. For sensor layouts, refer
to the Component Overview section of the robot operation and maintenance manual.
• CRUSH or IMPACT HAZARD! Robots must be prevented from traveling in areas that
do not follow Facility Conditions specifications, such as ramps and stairwells.
• CRUSH or IMPACT HAZARD! All stairwells or similarly open holes must be marked
and surrounded by obstacles exceeding 20 cm in height with spacing no greater than
30 cm. These obstacles must be able to withstand 2000 N of force without failing or be
at least 70 mm wide from all directions and visible to the LiDAR.
Robots, attachments, and accessories are designed to work on flat, clean surfaces. Facility conditions
greatly affect their ability to operate safely and navigate properly.
• Robots should never be operated in spaces insufficient to their physical dimensions and safety
configuration specifications.
• Areas in front of or behind chargers or other docking area, for example P&D stands, must be marked
for personnel to avoid the space.
Driving surface
• To better assist robots in achieving safe stopping distances, facility floors must be dry and clean with
a coefficient of friction greater than 0.8. Debris on the floors may become caught in the wheels and
lead to premature failure of wheels, casters, or drive components. Areas with floors that can't meet
these requirements should be isolated by bollards or physical LiDAR-height barriers. Exclusion zones in
OTTO Lifter V1 - OMM-000111
© Clearpath Robotics Inc. 2023. All rights reserved. CLEARPATH and OTTO are trademarks of Clearpath Robotics Inc.
All other product and company names listed are trademarks or trade names of their respective companies. 13

OTTO Fleet Manager cannot be solely relied upon to prevent entry to areas with floors that don't meet
the robot requirements.
• Robots should never be driven onto curbs or across gaps in the floor that may result in damage to the
robot drive systems, attachments, or accessories - for example, at the top of stairs, the top of dock
doors, or mezzanines without a protective ledge.
• Robot drive wheels and cart brakes should never be manually bypassed on a ramp condition as this
may lead to robots or carts navigating erratically and losing control. If stopped on a slope greater than
that specified in system specifications, robots and carts may begin to roll and present a hazard.
Environment
For additional information on the operating environment conditions, refer to the System Specifications in the
product operation and maintenance manual.
• OTTO Motors robots use LiDAR with a wavelength of 905 nanometers, and are designed to operate
indoors free of direct sunlight. Infrared light sources (including sunlight, light curtains, welding) may
interfere with the operation of robots when shone directly into the robot's optical sensors.
• Robots rely on LiDAR to protect personnel from crushing or collision hazards. Although rare, very
reflective or very light absorbent (eg. black) material can impede the LiDAR safety systems. Avoid the
use of such materials in clothing or obstacles to assist their detection by OTTO Motors LiDAR safety
systems.
• Robots have no minimum ambient brightness requirements, as they are designed to operate in the
dark.
• When the robot detects a significant reduction in air quality, it enters a safety stop.
Payload maximums and stability
OTTO Motors products support a specific maximum payload and payload dimensions. OTTO Motors
robot maximum payloads and their dimensions change when an attachment or accessory is connected
because of the weight of the attachment/accessory itself. In the case of an attachment/accessory-equipped
robot, payloads must not exceed the maximum payload documented on the attachment nameplate and
dimensions specified in safety configuration documentation.
For the robot to remain stable, the combined center of gravity must remain within the stability triangle of the
robot. The following items can affect the combined center of gravity:
• Payload center of gravity
• Movement of the robot (acceleration, deceleration, turning, and sudden braking)
• Height of the load to be lifted
For robot, attachment, or accessory payload specifications, refer to the Stability and Center of Gravity,
payload interface documentation, or nameplate for the applicable product.
Robots require a custom robot configuration and hardware configuration changes in order to accommodate
payloads that project beyond the dimensions of the base robot platform, equipped accessory, or
attachment. Contact OTTO Motors if a custom robot configuration is required.
OTTO Lifter
For the default configuration for the OTTO Lifter robot, payload dimensions must stay within the projected
view of the OTTO Lifter robot body and not project over the front or sides of the robot's forks. The OTTO
Lifter platform is rated to work with a specific maximum payload—failure to load the OTTO Lifter robot
within the payload specifications will affect its safe operation.
OTTO Lifter V1 - OMM-000111
© Clearpath Robotics Inc. 2023. All rights reserved. CLEARPATH and OTTO are trademarks of Clearpath Robotics Inc.
All other product and company names listed are trademarks or trade names of their respective companies. 14

Battery handling
WARNING
• FIRE HAZARD! If the battery is damaged or a battery fire occurs, contact local
emergency services and vacate the area. Do not use water to douse the fire.
• SHOCK HAZARD! Improper use or maintenance of robot batteries may result in a high
energy discharge.
Like most applications using batteries, special precautions should be taken to handle this type of material.
Battery packs should only be handled by trained personnel to ensure proper handling. Be aware of the
operating environments for robots and more specifically, the battery pack.
Overhang and underhang detection
WARNING
• CRUSH or IMPACT HAZARD! Keep low profile objects that the LiDAR cannot detect,
such as forklift tines and pallets, outside of the robot's path. For sensor layouts, refer
to the Component Overview section of the robot operation and maintenance manual.
• IMPACT HAZARD! Do not place anything on the robot that extends beyond
its footprint. Refer to the robot Safety Configuration document for the footprint
dimensions.
OTTO Motors autonomous mobile robots (AMR) use LiDAR to detect potential obstacles and obstacles
located above a robot's LiDAR detection plane may not be perceived by a robot. Existing equipment in the
facility could be rendered invisible to a robot due to an "overhang", for example a robot with wheels offset
from the body of the robot itself. In the example, the robot would detect the existing equipment's wheels but
not its body panels, increasing the possibility of a collision.
To assist robots without 3D perception capabilities in detecting obstacles, perception-assist flaps should be
installed (see following), especially in cases of potential mobile obstacles.
OTTO Lifter V1 - OMM-000111
© Clearpath Robotics Inc. 2023. All rights reserved. CLEARPATH and OTTO are trademarks of Clearpath Robotics Inc.
All other product and company names listed are trademarks or trade names of their respective companies. 15

Robots capable of 3D perception, either integrated or through use of an equipped 3D Perception
Attachment, are better able to detect overhanging obstacles without the presence of perception-assist flaps.
• Ideally, installed flaps should touch the floor; however, in instances where the flap can't be installed that
close to the floor, the distance between the flap's bottom edge and the floor should not exceed 75 mm.
• Glass and mirror-like surfaces should be avoided as reflective materials can scatter LiDAR pulses.
Rubber works especially well due to its flexibility, color, and durability.
• Flaps can be bolted directly to exterior body panels or secured using high-strength magnets.
Safety system functionality
Autonomous mobile robots (AMR) move and travel differently depending on several factors including any
detected obstacles, the robot's speed, the currently occupied zone, and the robot's current step, task, or
job.
The robot is equipped with LiDAR safety scanners. These safety scanners have a Safety Detection Range
that initiates response of the safety system. Safety scanner input is read directly by the perception system
that relates the robot to its surroundings when localizing to a map, planning paths, and interacting with local
infrastructure.
There is a protective field around the robot during normal operation. The size of this field is dynamic and
grows larger as the speed of the robot increases, allowing the robot to stop safely between obstacles and
itself at all speeds. Although the robot braking system may be performing correctly and as designed, it
cannot be expected to function as designed and specified should an object suddenly appear in the path of
the robot and within the designed safe stopping distance. Examples include but are not limited to objects
falling from overhead or a pedestrian stepping into the path of robot at the last instant.
Perception sensor layout
The LiDAR perception sensors present on the robot perform the following functions:
• Scan the surroundings of the robot to determine its location or observe features used during navigation.
• Provide safety functionality by applying 'stop zones' around the robot while it is in motion. LiDAR
scanners are wired into the drive wheels directly and are able to size the required stop range based on
the robot's ground speed and payload, dictating a safe stopping distance if autonomous control does
not direct the robot to avoid an obstacle or stop before impacting an encountered obstacle.
• Detect obstacles and either stop the robot or re-plan a path around the obstacle, if possible.
The LiDAR scanners have restrictions based on robot speed, allowed turning distances, differential wheel
speeds, and direction, depending on the LiDAR field set (LFS) they are commanded to apply.
The robot control system can request and confine itself to operate within one of these safety supervisor
modes as dictated by the factory configuration of the LiDAR units. Under most circumstances, the system
can automatically determine, control, and confine itself within LiDAR usage cases.
The robot's Open Detection Range is much larger than the fields used for the Safety Detection Range.
The safety scanners are tilted up from the horizontal plane to avoid ground hits and to meet the testing
requirements for ANSI/ITSDF B56.5, Safety Standard for Driverless, Automatic Guided Industrial robots
and Automated Functions of Manned Industrial robots. This also allows for shorter objects to be detected
closer to the robot.
Safety scanners use IR light to detect objects -highly reflective objects or highly matte objects can create
issues with the light being able to detect the object. Standard industrial paints, finishes, and clothing should
not present an issue.
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Emergency stop system
There are two types of emergency stops on a robot. When the emergency stop state is triggered, the
system will immediately apply the brakes and cut all power to the drive motors.
Emergency stop condition Description
Physical A user pressing one of the Emergency Stop buttons on the robot
Software A software-triggered emergency stop caused by a system fault or self-diagnostic tool
Safety stop system
Safety stops are similar to emergency stops; however, they are triggered by an object being detected inside
of the pre-defined LiDAR safety field. This stop condition will attempt to reset itself every 2 seconds once
the object has been cleared from the field.
The LiDAR safety fields extend out from each LiDAR safety scanner. The active velocity of the robot will
determine the size of the safety field to provide adequate stopping distance automatically. To remove the
system from the safety stop state, all conditions that caused the state transition must be cleared.
See the applicable safety configuration for the robot and the MicroScan3 LIDAR Operating Instructions
document for more details.
Credentialed OTTO Motors platform users can learn more on the OTTO Motors Support Center (login
required). If access is required, contact OTTO Motors Support and they will be happy to answer any
questions or provide access.
Zone-specific behavior
Zones are areas in a map that change the behavior of a robot while it occupies the zone. Certain modes
are only available in certain spaces due to a change of the safety requirements present in each zone.
Robot modes
Robots can select from several modes in which the safety system can operate, determined by the robot
occupying a particular zone type on a map, or by a condition on the map requiring a particular mode
function.
Autonomous mode
Autonomous mode is applied during typical operation in regular transit zones under standard traffic rules.
The applied LiDAR safety field set is dynamically adjusted based on the speed of the robot as reported
through its sensors.
IMPORTANT
Autonomous mode behavior also applies to the robot forks.
Depending on the speed that the robot is travelling, the safety scanners will select the matching safety field
based upon the encoder input. Each field range has a maximum allowed turning rate.
Only one safety field set at a time will be selected based on robot speed.
Manual mode
While controlling the OTTO Lifter autonomous mobile robot (AMR) using its tiller, there are no speed
restrictions and the safety field sets monitored by the LiDAR are disabled. Height restrictions for the forks
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are also disabled while in manual mode. There is a collision risk with objects while driving the OTTO Lifter
in manual mode.
While controlling the autonomous mobile robot (AMR) using its pendant, there are no speed restrictions and
the safety field sets monitored by the LiDAR are disabled. There is a collision risk with objects while driving
the in manual mode.
CAUTION
IMPACT HAZARD! Always maintain a safe distance from a robot in operation. A robot
being operated in manual mode should only be operated by personnel who have been
trained and authorized according to the standards of the facility in which the robot is in
use. Be aware of the Emergency Stop button locations. For button location information,
refer to the Component Overview section of the robot operation and maintenance manual.
Hazard mode
Hazard mode is used when robots must navigate down a narrow pathway, the dimensions of which are
determined by a robot's safety configuration. Robot speed in this mode is limited to 0.3 m/s for safety
considerations.
Although hazard mode is designed to allow the robot to travel through narrow corridors, the robot can still
turn freely. Turning is not affected by a safety field when in hazard mode and follows the 0.3 m/s speed
constraint.
In hazard mode, robots will allow for the drive trains to move in opposite directions, allowing the robot to
perform zero point turns or any directional motion that does not violate the 0.3 m/s speed constraint on
either drive train.
Warnings and signage must be respected in these areas.
Docking mode
Docking mode is used when robots dock when transferring payloads or charging. Robot speed in this mode
is limited to 0.3 m/s for safety considerations.
The use of human exclusion zones is recommended where robots will be docking as both personnel and
other objects will not be detected within the same safety field range as in other operation LiDAR modes.
Warnings and signage must be respected in these areas.
Footprint safety
It should be noted that the overall profile including any attachment, payload, or combination thereof of the
robot must remain within its safety configuration—this is measured by the projection of any part that has
been extended outside the robot projected to the floor.
Depending on the attachment or payload to be mounted on the robot, the safety configuration may have
to be adjusted to suit the attachment or payload to allow the robot to navigate autonomously with all of its
safety features in place. Should the attachment configuration change or be removed, LiDAR safety field
sets will need to be reset to match the current footprint for each robot. Safety configurations are based on
the largest possible combination of attachment and payload at all times.
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Extension of payload height will not be detected by the robot. Payload height needs to be qualified in the
facility of installation and inspected in all spaces in which the robot will operate to reduce the risk of a
collision.
1.4. Disclaimer
The information found within this documentation is subject to change without notice. This document may
be periodically reviewed and revised in the future. OTTO Motors assumes no responsibility for any errors
or omissions that may appear in this document. In no event shall OTTO Motors be liable for any costs
or damages arising from the use of this document or the hardware and software described within. The
reference documents listed in this manual shall be applicable at the latest revision in effect.
While OTTO Motors does its best to inform its users of potential risks, it is impossible to provide an
exhaustive list of all possible hazards in your environment.
It is the responsibility of the user to be familiar with all applicable safety standards and ensure that the
hardware, software, and/or services delivered by OTTO Motors (collectively referred to as the “Product”)
are maintained and operated in a safe manner, in a suitable environment, and in accordance with the
recommended maintenance requirements prescribed by OTTO Motors .
Without limiting the foregoing, it is the user’s responsibility to ensure that personnel operating the
Product are adequately trained and comply with all laws, regulations, codes, and safe practices, including
health and safety and workers' compensation laws, applicable to the user's activities and its ownership,
possession, and use of the Product. Modification, removal or addition of components, or changes to the
functionality or operation of the Product in any way, except as expressly authorized by OTTO Motors , may
jeopardize the safety of the Product. If at any time you have any questions or concerns regarding the safe
operation of your OTTO Motors product, contact OTTO Motors Support.
2. Intended use
OTTO Motors robots are Autonomous Mobile Robots (AMR) intended for use in industrial facilities. OTTO
Motors robots are intended to transport materials indoors in industrial buildings, utilizing SLAM mapping,
and intelligent navigation and localization to plan their motion. They can perform autonomous navigation
and route planning to achieve their planned jobs and will operate without direct user intervention. Operators
are intended to have suitable training or familiarization as needed for their interactions with the robots and
systems. This intended use extends to the infrastructure including—but not limited to—chargers, docks,
carts, attachments, custom components, and software.
3. Introduction
This document provides important information pertaining to the safe operation and use of the OTTO Lifter
autonomous mobile robot (AMR). The OTTO Lifter robot is a heavy duty AMR designed to move pallets
through dynamic production environments.
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IMPORTANT
Information in this document related to software functionality is up-to-date as of OTTO
Motors software version 2.26. Hardware functionality outlined in this document pertains
both to the base platform and the functionality of any of its versions.
Functionality described herein assumes access to a full deployment of OTTO Fleet
Manager.
A robot being operated in manual or remote mode should only be operated by personnel who have been
trained and authorized according to the standards of the facility in which the robot is in use.
CAUTION
IMPACT HAZARD! Always maintain a safe distance from a robot in operation. A robot
being operated in manual mode should only be operated by personnel who have been
trained and authorized according to the standards of the facility in which the robot is in
use. Be aware of the Emergency Stop button locations. For button location information,
refer to the Component Overview section of the robot operation and maintenance manual.
3.1. Included items
The following items are included:
• OTTO Motors robot
• Lock-out/tag-out cover bag (026239)
• OTTO Motors safety guide
IMPORTANT
No field modifications of the robot that influence the performance or safety of the robot
are permitted. This includes, but is not exclusive to, modifications that affect the physical
size, mass, or floor traction of the robot. No modifications may be carried out that affect
the integrated sensors or internal electronics.
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All other product and company names listed are trademarks or trade names of their respective companies. 20