OTTO MOTORS 1500 Fast Charger V1.2 User manual

OTTO 750/1500 Fast Charger V1.2
Document ID: OMM-000001
Revision: D
Original instructions provided in English
APR-21
T02REL EASE DAT E
OPERATION AND MAINTENANCE
MANUAL
OTTO 750/1500 Fast Charger V1.2

OTTO 750/1500 Fast C harge r V1.2 • OMM- 000001 • REV. D
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© Clearpath Robotics Inc. 2021. 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. The information contained in these documents is the Confidential and/or Proprietary property of Clearpath Robotics Inc. and may not
be duplicated, reproduced or further disclosed without the express written approval of Clearpath Robotics Inc.
CONTACT INFORMATION
OTTO Motors is committed to your success and satisfaction. We are located in Kitchener, Ontario. If you
have any questions or concerns, visit our support knowledge base for more information, or get in touch with
our support team.
CLE ARPATH ROBOTI CS INC.
2A-1425 Strasburg Road
Kitchener, ON N2R 1H2
24/7 Support: 1-844-733-6886
https://ottomotors.com/support
https://help.ottomotors.com

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© Clearpath Robotics Inc. 2021. 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. The information contained in these documents is the Confidential and/or Proprietary property of Clearpath Robotics Inc. and may
not be duplicated, reproduced or further disclosed without the express written approval of Clearpath Robotics Inc.
CONTENTS
Contact Information 2
Contents 3
List of Figures 4
List of Tables 5
1 Revision History 6
2 Important Safety Information 7
2.1 Safety Examples 7
2.2 General Hazards 7
2.3 Hazard labels 11
2.4 Safety Awareness 13
2.5 Facility Conditions 15
2.6 Payload Maximums 16
2.7 Battery Handling 17
2.8 Overhang and Underhang Detection 17
2.9 Disclaimer 18
3 Intended Use 20
4 Introduction 21
4.1 Included Items 21
5 Applicable Documents 22
6 System Overview 23
7 Components Overview 24
7.1 Charge Controller 24
7.2 Intelligent Charger 25
7.3 Extension Cable 25
7.4 Targeting Fixture 25
7.5 Charge Dock 26
8 Unboxing 27
9 Installation 28
9.1 Intelligent charger installation 28
9.2 Charge dock installation 28
9.3 Dock target installation 32
10 Basic Usage 33
10.1 Starting Up 33
10.2 Shutting Down 33
11 Maintenance 34
11.1 Bi-Monthly Preventative Maintenance 35
11.2 Charge Contact Cleaning 37
12 Disposal 38
13 Troubleshooting 39

OTTO 750/1500 Fast C harge r V1.2 • OMM- 000001 • REV. D
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© Clearpath Robotics Inc. 2021. 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. The information contained in these documents is the Confidential and/or Proprietary property of Clearpath Robotics Inc. and may not
be duplicated, reproduced or further disclosed without the express written approval of Clearpath Robotics Inc.
LIST OF FIGURES
Figure 1 Perception-Assist Flap Installation 18
Figure 2 OTTO 750/1500 Fast Charger V1.2
components 24
Figure 3 Charge dock pinch/crush points 25
Figure 4 Charge dock components 26
Figure 5 Charger Contacts Cover Removal 29
Figure 6 Sensor Array Removal 30
Figure 7 Charger Contacts Anchor Holes 30
Figure 8 Concrete Anchor Dimensions 31
Figure 9 Charge Contact Gauge Use Example 31
Figure 10 Correct and Incorrect Charge Contact
Height Examples 32
Figure 11 Shimming Anchors 32
Figure 12 Service Procedure Components 34
Figure 13 Pivoting Arm Play 35
Figure 14 Charge Contact Gauge Use Example 36
Figure 15 Correct and Incorrect Charge Contact
Height Examples 36

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© Clearpath Robotics Inc. 2021. 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. The information contained in these documents is the Confidential and/or Proprietary property of Clearpath Robotics Inc. and may not
be duplicated, reproduced or further disclosed without the express written approval of Clearpath Robotics Inc.
LIST OF TABLES
Table 1 Revision History 6
Table 2 Applicable Documents 22
Table 3 Charger System Specifications 23
Table 4 Maintenance and Inspection Schedule 34

OTTO 750/1500 Fast C harge r V1.2 • OMM- 000001 • REV. D
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© Clearpath Robotics Inc. 2021. 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. The information contained in these documents is the Confidential and/or Proprietary property of Clearpath Robotics Inc. and may not
be duplicated, reproduced or further disclosed without the express written approval of Clearpath Robotics Inc.
1REVISION HISTORY
Table 1 Revision History
REVISION
DATE
CHANGES
A
March 2016
Initial release
B
May 2016
Updated with field services feedback, general edits, and Lock-
Out/Tag-Out procedure
C
November
2016
Torque updated in Installation section changed to 4 Nm
D
April 2021
Template update, additional installation details

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© Clearpath Robotics Inc. 2021. 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. The information contained in these documents is the Confidential and/or Proprietary property of Clearpath Robotics Inc. and may not
be duplicated, reproduced or further disclosed without the express written approval of Clearpath Robotics Inc.
2IMPORTANT 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.
2.1 Safety Examples
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.
2.2 General Hazards
WARNING!
Failure to follow these instructions may result in SERIOUS INJURY, INCLUDING DEATH.
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.
FIRE OR SHOCK HAZARD! Never use a power cord or cable that appears damaged.

OTTO 750/1500 Fast C harge r V1.2 • OM M- 000001 • REV. D
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© Clearpath Robotics Inc. 2021. 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. The information contained in these documents is the Confidential and/or Proprietary property of Clearpath Robotics Inc. and may not
be duplicated, reproduced or further disclosed without the express written approval of Clearpath Robotics Inc.
CAUTION!
Failure to follow these instructions may result in MINOR or MODERATE INJURY or DAMAGE
to the system and/or property.
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 for 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.
2.2.1 Robot hazards
WARNING!
Failure to follow these instructions may result in SERIOUS INJURY, INCLUDING DEATH.
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.
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.

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© Clearpath Robotics Inc. 2021. 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. The information contained in these documents is the Confidential and/or Proprietary property of Clearpath Robotics Inc. and may not
be duplicated, reproduced or further disclosed without the express written approval of Clearpath Robotics Inc.
CAUTION!
Failure to follow these instructions may result in MINOR or MODERATE INJURY or DAMAGE
to the system and/or property.
IMPACT HAZARD! Always maintain a safe distance from a robot in operation. Be aware of the
Emergency Stop button locations.
CRUSH or IMPACT HAZARD! Robots must be prevented from traveling in areas that do not
follow Facility Conditions specifications, such as ramps and stairwells.
IMPACT HAZARD! While driving the robot manually, the safety fieldsets monitored by the
LiDAR scanners are 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.
Do not expose the product for a prolonged period to temperatures outside the range
specified in the product documentation.
IMPACT HAZARD! Never leave the manual bypass screws installed in the robot. This can
prevent the braking system from functioning properly and can cause unpredictable driving
patterns.
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 outside of the robot's path.
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.
Never lift the robot by the attachment or while the attachment is installed on the robot.

OTTO 750/1500 Fast C harge r V1.2 • OM M- 000001 • REV. D
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© Clearpath Robotics Inc. 2021. 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. The information contained in these documents is the Confidential and/or Proprietary property of Clearpath Robotics Inc. and may not
be duplicated, reproduced or further disclosed without the express written approval of Clearpath Robotics Inc.
2.2.2 Charger hazards
WARNING!
Failure to follow these instructions may result in SERIOUS INJURY, INCLUDING DEATH.
FIRE OR SHOCK HAZARD! Never use a power cord or cable that appears damaged.
SHOCK HAZARD! Automatic chargers use high voltage power. 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!
Failure to follow these instructions may result in MINOR or MODERATE INJURY or DAMAGE
to the system and/or property.
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.
Always remove the eye nuts from the lifting points before operating the charger to avoid
damage to the charger or robots.