Otto 750 User manual

OPERATION AND
MAINTENANCE MANUAL
OTTO 750
SDV
Document ID
OMM-000083
Revision
A
Release Date
19 Sep 2019

OTTO 750 Operation and Maintenance Manual • Rev. A
DISCLAIMER
© 2019 Clearpath Robotics, Inc. OTTO and CLEARPATH are trademarks of Clearpath Robotics Inc.
The information found within this document 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.
SAFETY
OTTO Motors considers the safety of its users very important. OTTO Motors produces high
power and fast-moving pieces of machinery that could lead to death or serious injury if they are
improperly used or maintained. In order to inform our users of some of these risks, throughout
this document you will see safety messages corresponding to either a DANGER, WARNING, or
CAUTION.
Failure to follow instructions will result in DEATH or SERIOUS INJURY.
Failure to follow instructions may result in DEATH or SERIOUS INJURY.
Failure to follow instructions may result in INJURY or DAMAGE to the
system and or property.
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. Individuals must exercise their own good
judgement when operating or performing maintenance. If at any time you have any questions
or concerns regarding the safe operation of your robotic vehicle, please contact us.

OTTO 750 Operation and Maintenance Manual • Rev. A
© 2019 Clearpath Robotics. All Rights Reserved.
3
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.
Clearpath Robotics Inc.
2A-1425 Strasburg Road
Kitchener, ON N2R 1H2
General Inquiries: 1-844-733-6886
24/7 Support: 1-226-336-8046
https://ottomotors.com/support
https://help.ottomotors.com
REVISION TABLE
Table 1: Revision Table
Rev
Date
Author
Changes Made
A
19 Sep 2019
A. Gerlach
Initial Release

OTTO 750 Operation and Maintenance Manual • Rev. A
CONTENTS
Disclaimer ...................................................................................................................................2
Safety..........................................................................................................................................2
Contact Information ....................................................................................................................3
Revision Table .............................................................................................................................3
Contents .....................................................................................................................................4
List of Figures..............................................................................................................................6
List of Tables ...............................................................................................................................7
1 Introduction..............................................................................................................................8
1.1 Included Items ...................................................................................................... 8
1.2 Applicable Documents.......................................................................................... 8
1.3 Abbreviations and Acronyms ................................................................................ 9
2 Getting Started.......................................................................................................................10
2.1 Manual Pendant Control ......................................................................................10
2.2 First Robot Bring-up.............................................................................................11
3 Overview................................................................................................................................13
3.1 Components ........................................................................................................14
3.2 Sensors ................................................................................................................18
System Architecture ...................................................................................................19
3.3 Status Indicators...................................................................................................20
3.4 Specifications.......................................................................................................23
4 Safety .....................................................................................................................................25
4.1 Working with OTTO.............................................................................................25
4.2 Lock-Out Tag-Out................................................................................................31
4.3 Risk Reduction......................................................................................................31
4.4 Reporting.............................................................................................................31
4.5 Safety Features ....................................................................................................32
4.6 Transport .............................................................................................................36
5 System Operation...................................................................................................................37
5.1 System Start Up ...................................................................................................37
5.2 System Shut Down ...............................................................................................37

OTTO 750 Operation and Maintenance Manual • Rev. A
© 2019 Clearpath Robotics. All Rights Reserved.
5
5.3 Charging OTTO ...................................................................................................38
5.4 Pendant Controller...............................................................................................39
6 Attachment.............................................................................................................................41
6.1 Mechanical Interface Specifications .....................................................................41
6.2 General Attachment Interface Signals..................................................................42
6.3 24 volts vs. 48 volts Power Outputs .....................................................................43
6.4 Attachment Safety................................................................................................43
6.5 Footprint Safety ...................................................................................................44
7 Maintenance Schedule ...........................................................................................................45
7.1 Cleaning...............................................................................................................45
7.2 Manual Bypass of the Drive Wheels .....................................................................45
7.3 Storage ................................................................................................................46
7.4 Battery Pack .........................................................................................................46
8 Maintenance Schedule ...........................................................................................................47
Appendix A Glossary............................................................................................................48
Appendix B LIDAR Field Sets ...............................................................................................49

OTTO 750 Operation and Maintenance Manual • Rev. A
LIST OF FIGURES
Figure 1: Pendant Controller.....................................................................................................10
Figure 2: Manual Charge and Pendant Bay...............................................................................11
Figure 3: OTTO 750 Port and Front..........................................................................................13
Figure 4: OTTO 750 Starboard and Rear ..................................................................................13
Figure 5: Wireless Antennas Clearance.....................................................................................15
Figure 6: Manual Disconnect Switch .........................................................................................16
Figure 7: Live Voltage Locations ...............................................................................................17
Figure 8: OTTO 750 Drive System ............................................................................................18
Figure 9: Minimum Safety Distance...........................................................................................30
Figure 10: OTTO-Charge 1500 .................................................................................................38
Figure 11: Pendant Controller...................................................................................................40
Figure 12: OTTO 750 showing mechanical and electrical interface locations............................41
Figure 13: Attachment Interface Port .......................................................................................42

OTTO 750 Operation and Maintenance Manual • Rev. A
© 2019 Clearpath Robotics. All Rights Reserved.
7
LIST OF TABLES
Table 1: Revision Table.............................................................................................................. 3
Table 2: Reference Documentation............................................................................................ 8
Table 3: Abbreviations and Acronyms ....................................................................................... 9
Table 4: Emergency Stop Conditions........................................................................................19
Table 5 OTTO 750 Status Indication.........................................................................................21
Table 6: OTTO 750 System Specifications ................................................................................23
Table 7: Hazard Levels..............................................................................................................25
Table 8: Specific Hazards ..........................................................................................................26
Table 9: Safety Working Distance .............................................................................................31
Table 10: Emergency Stop Conditions......................................................................................34
Table 11: LiFePO4Battery Technical Specifications...................................................................46
Table 12: LIDAR Mode..............................................................................................................49

OTTO 750 Operation and Maintenance Manual • Rev. A
1INTRODUCTION
Welcome to the OTTO 750 heavy duty self-driving vehicle. Before putting OTTO 750 into use,
carefully review the instructions and safety precautions found within this document to ensure the
safety of all users who interact or share a working space with OTTO 750. This document provides
important information pertaining to the operation and use of an OTTO 750 and is organized into
sections pertaining to system components and overview, robot safety, system operation,
attachment interfacing and details on maintenance.
1.1 Included Items
The following items are included with OTTO 750:
1x Clearpath Robotics OTTO 750
OTTO 750 Operational and Maintenance Manual
1.2 Applicable Documents
Table 2: Reference Documentation
No.
Reference
Number
Rev
1
Operations and Maintenance Manual, OTTO 750
OMM-000083
A
2
Stability and Center of Gravity, OTTO 750
ICD-000081
A
3
Modes of Motion, OTTO 750
SYS-000037
A
4
Mechanical Interfaces and Layout, OTTO 750
ICD-000082
A
5
Attachment Interface, OTTO 750
ICD-000083
A
6
Spare Parts List, OTTO 750
SPL-000013
A

OTTO 750 Operation and Maintenance Manual • Rev. A
© 2019 Clearpath Robotics. All Rights Reserved.
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1.3 Abbreviations and Acronyms
The following table lists abbreviations and acronyms used throughout this document.
Table 3: Abbreviations and Acronyms
Abbreviation/Acronym
Phrase
E-Stop
Emergency Stop
LIDAR
Combination of "light" and "radar"
BMS
Battery Monitoring System
LVC
Large Vehicle Controller
HMI
Human-Machine Interface
CAN-bus
Controller Area Network-bus
EFI
Enhance Function Interface
KPI
Key Performance Indicator

OTTO 750 Operation and Maintenance Manual • Rev. A
2GETTING STARTED
This section will outline the basic manual pendant control and first time bring-up instructions
for OTTO 750 to get the system up and running upon arrival at the facility. Please continue
review the entire manual for the correct safety procedures and precautions as well as operating
conditions for the OTTO 750 system.
2.1 Manual Pendant Control
Using the pendant attachment, OTTO 750 can be controlled with directional buttons, drive
forward, reverse, turn left, and turn right. The pendant also contains an E-stop, enabling, and
emergency stop reset button. The pendant directional buttons are dual acting (they have two
depressed states). The first level of depression allows the system to move 117mm/s and the
second level allows OTTO 750 to move 235mm/s. These two levels of control help to accurately
manually maneuver OTTO 750 around a warehouse. The enabling switch is a double pole design
allowing for three (3) unique positions. When depressing the button from the not pressed state,
it will transition to the ON state. If the button is not pressed or full depressed it will operate in
the OFF position. The button will not enter an ON state when releasing from a full depressed
position.
Figure 1: Pendant Controller
When the pendant is being used, the LIDAR fields will be
ignored and so there will not be any obstacle avoidance. Pay
close attention to where OTTO 750 is and avoid obstacles as
you use the pendant.

OTTO 750 Operation and Maintenance Manual • Rev. A
© 2019 Clearpath Robotics. All Rights Reserved.
11
2.1.1 Pendant Connection
The pendant connection port is found behind the hinged plate found on the starboard side of
OTTO 750. To access the port, remove the one screw and open the plate door. Remove the
pendant port terminator plug to use the port. Ensure to return the plug prior to changing the
system into autonomous mode. Otherwise the system will remain in an emergency stop state.
Figure 2: Manual Charge and Pendant Bay
2.2 First Robot Bring-up
Prior to operating OTTO 750 for the first time, it is important to perform a hardware operational
check. These tests will determine if there are any hardware damages or defects that may be
caused during shipping. Before performing these tests, ensure that the test area is safe to
operate within and has been cleared of obstacles.
1. Manually bypass the drive wheels of OTTO 750 such that they are not in contact
with the ground. This is done such that the system safety and operations can be
verified before allowing OTTO 750 to maneuver. Rotate the manual bypass screws
clockwise until there is a gap of at least 10mm between the drive wheels and the
floor.
When the drive wheels are not engaged with the floor, there is
no active braking system on OTTO 750.
2. Visually inspect the outside of OTTO 750 for any visible damage.

OTTO 750 Operation and Maintenance Manual • Rev. A
3. Inspect both front and rear LIDARs to ensure that the optical elements are not dirty
nor obstructed by foreign material. For detailed instructions regarding this procedure,
refer to the S3000 Operating Instructions Manual.
4. Trip OTTO 750 into an emergency stop state by fully depressing one of the four E-
stop buttons on the port or starboard sides of the vehicle.
5. After performing the above instructions, the system is ready to be powered on.
6. Lower the system drive wheels until they are in full contact with the floor. This is
done by rotating the manual bypass screws counter-clockwise. Once the drive
wheels come in contact with the floor, remove the manual bypass screws from
OTTO 750 .
The manual bypass screws must be removed from OTTO 750
to prevent contact with the drive wheel suspension. Failure to
do this may result in damage to the vehicle suspension.
7. Connect the pendant to the manual control port on the side of the vehicle.
8. On the port side of the vehicle turn the selector switch to the “ENABLE” position.
9. Check to ensure that all E-stop switches as well as any on the Attachment are released.
10. On the pendant controller, press and hold the enable button in the middle “On”
position.
11. Press the reset button found on the port side. You will hear an audible click from the
system.
12. The LED light indicators will change to indicate that OTTO 750 is now in manual drive
mode.
13. While holding the enable button, test the “Forward”, “Reverse”, “Left”, and “Right”
button functions.
14. After testing the drive system, you may disconnect the pendant and allow OTTO 750
to begin driving autonomously.
If OTTO 750 fails to perform as expecting during the above procedure, there may be a
mechanical or electrical issue with the system. Contact Clearpath support for assistance.

OTTO 750 Operation and Maintenance Manual • Rev. A
© 2019 Clearpath Robotics. All Rights Reserved.
13
3OVERVIEW
This section provides the user with a functional and mechanical overview of the entire OTTO
750 system. Figure 4 and Figure 3 give a tour of the key components of OTTO 750.
Figure 3: OTTO 750 Port and Front
Figure 4: OTTO 750 Starboard and Rear

OTTO 750 Operation and Maintenance Manual • Rev. A
3.1 Components
The following section outlines the various components which together make OTTO 750.
3.1.1 Attachment Connector Bay
The Attachment Connector Bay houses all the connector terminals for the attachment to
interface with OTTO 750. This Bay contains the following connections:
General Connector
Power Connector
Ethernet Connector
USB Connector
For specific details regarding the Attachment Bay connections and general Attachment
specifications, see Section Error! Reference source not found..
3.1.2 Power Switch
The Power switch on OTTO 750 is a simple two-state switch that allows the user to turn OTTO
750 on and off.
3.1.3 Manual Charge and Pendant Connector Bay
The Manual Charge and Pendant Connector Bay is a dual-purpose bay that allows the user to
connect the Manual charger to OTTO 750 when not using the OTTO-Charge and also allows
the connection of the Manual Control Pendant.
This Bay is secured with screws and also has a spring-loaded hatch to keep is the bay closed
when it is not in use.
3.1.4 Pendant
The pendant is an optional input device which, when connected, allows for the manual control
of OTTO 750. Refer to Section 5.4 for specific detail on using the Pendant controller.

OTTO 750 Operation and Maintenance Manual • Rev. A
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15
3.1.5 Manual Bypass Screws
The manual bypass screws are two screws which allow the user to disengage the drive wheels
from the floor and manually move OTTO 750 using the 4 swivel castor wheels. The user must
pay very close attention to OTTO 750 when using the manual bypass screws because there will
be no active braking when the drive wheels are disengaged from the floor. Payload weight and
uneven floors can cause OTTO 750 to move unexpectedly which poses a danger to users
around the platform. Refer to section 7.2 for more information on proper procedure for using
the manual bypass screws.
When the manual bypass screws are not needed to raise the drive wheels, the screws should
be removed from OTTO 750 to protect the user from unpredictable movement (caused by
uneven floors) and also to protect the OTTO 750’s suspension.
If the unit has been moved or shipped with the drive wheels
manually bypassed, it may be prone to shift its position because
there is no active braking. The four load bearing wheels are
swivel casters and are not equipped with brakes.
3.1.6 WiFi Radio Antennas
There are two wireless antennas location on OTTO 750, and the front and rear. The space
above these antennas should remain clear of obstructions for optimal signal strength and
network connection. See Figure 5 below for an example of the clearance that should be
maintained about the antennas.
Any modifications or Attachments which obstruct or impair the WiFi Radio Antennas need to
be validated before use with the system.
Figure 5: Wireless Antennas Clearance

OTTO 750 Operation and Maintenance Manual • Rev. A
3.1.7 E-Stop Buttons
There are four emergency stop buttons (E-stops) located on the platform (and a fifth on the
pendant) which will trip the system into the emergency stop state. There may also be additional
emergency stops present when Attachments are connected to OTTO 750. Users should
familiarize themselves with all E-stops present on both the Attachment and the OTTO 750.
3.1.8 Light and Sound System
This system consists of four corner light panels, each with two LED Light Stacks. There is also
one LED Light Pipe which wraps around the entire body of OTTO 750. These LEDs indicate the
behaviour or intended behaviour of OTTO 750 for users to understand and predict how OTTO
750 will move around the workspace. These light signals are also coupled with unique sounds
to add another layer of indication for the OTTO 750 behaviour and improve safety.
For a full layout of the various light and sound signals refer to Table 5 in Section 3.3
3.1.9 Lock-Out Tag-Out Manual Disconnect
OTTO 750 is equipped with a Manual Disconnect which allows the user to remove energy from
the system by disconnecting the battery pack. This disconnect is equipped with a lock location
so that a lock or multi-lock hasp may be used on the disconnect switch so user can work safely
around OTTO 750.
Figure 6: Manual Disconnect Switch
Not properly following the Lock-Out Tag-Out procedure can
result in live voltage locations on the OTTO 750 system. Always
be sure to Lock-Out the vehicle before proceeding with
inspections and maintenance.

OTTO 750 Operation and Maintenance Manual • Rev. A
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17
3.1.10 Power System
OTTO 750 is powered by a 51.2V (nominal) 100Ah battery pack. This battery pack is connected
in series though a Battery Monitoring System (BMS). In addition, a 12V lead-acid battery is
connected to the BMS to provide state-of-charge and error code data when the system is
powered off. This 12VDC backup power supply also provides a redundant power supply to
control the safety contacts for the main battery cells. The power supplied to the motor controllers
is routed through a main contactor relay. When an emergency stop state is triggered, the main
contactor relays release, disconnecting the power supply from the motor controllers.
Whenever removing the top plate of OTTO 750 to perform maintenance, be sure to follow the
Lock-Out Tag-Out procedure outlined on the OTTO 750 product page. Also be aware that the
locations highlighted in Figure 7 can be live voltage.
Figure 7: Live Voltage Locations

OTTO 750 Operation and Maintenance Manual • Rev. A
3.1.11 Swivel Casters and Drive Wheels
OTTO 750 is equipped with four swivel casters, one on each corner of OTTO 750. These wheels
are used for load bearing purposes only and do not drive, steer, or brake the vehicle. The caster
wheels sit atop a thrust bearing connected to a rocker arm.
There are two drive wheels on the vehicle, located at the center of each side. The drive wheels
are connected with the drive motors through a planetary gearing system. The motor drive shaft
is directly connected to the electromechanical brake.
Figure 8: OTTO 750 Drive System
3.1.12 Hoist Locations
The four hoist points, with or without the load cell option are used to hoist OTTO 750 for
transporting to another location. Refer to document: Attachment Interface, OTTO 750 for the
exact specifications of these four hoist points.
3.2 Sensors
OTTO 750 is equipped with multiple types of sensors, each providing vital information for the
operation of the system. The LIDARs and Relative Encoders provide feedback information that
is critical to performing autonomous navigation.
3.2.1 LIDAR (Front / Rear)
There are two internally mounted and safety rated LIDARs mounted in the front and rear of OTTO
750. These are optical object detection and ranging sensors used for the safe and accurate
navigation of the platform during autonomous behaviour. These two components are S3000
Safety Laser Scanners manufactured by SICK AG. The front LIDAR is a S3000 Professional and
the rear LIDAR is a S3000 Remote.

OTTO 750 Operation and Maintenance Manual • Rev. A
© 2019 Clearpath Robotics. All Rights Reserved.
19
3.2.2 Relative Encoders
Relative encoders are used to measure the rotational position of the platform drive wheels and
aid in tracking its odometry. Additionally, the relative encoders can be used to determine if a
mechanical failure has occurred in the drive train.
3.2.3 Load Sensors - Optional
Optional Load sensor integration on each of the four attachment mounting points. These allow
for the measurement of the payload at each mounting point and combined measurement of the
entire payload on OTTO 750.
System Architecture
3.2.4 Large Vehicle Controller (LVC)
The LVC is the central nervous system of OTTO 750. It provides the central interface point
between the computer, sensors, and actuators. The LVC system also provides the low level
control and is an integral part of the safety control of the system. The motor controllers,
electromechanical brakes, HMI lights and system power are all controlled by or connected to the
LVC.
3.2.5 Emergency Stop System
There are two (2) forms of Emergency Stops on OTTO 750 which are defined in Table 4. When
the emergency stop state is triggered, the system will immediately apply the brakes and cut all
power to the drive motors. If an attachment is connected, a stop signal will be relayed to the
attachment. Likewise, an Attachment can send an emergency stop state to the base platform.
Table 4: Emergency Stop Conditions
Emergency Stop
Condition
Description
Physical
A user pressing one of the various E-stop buttons on
either OTTO 750, the Pendant Controller, or the
Attachment.
Software
A software triggered E-stop due to a system fault or self-
diagnostic tool

OTTO 750 Operation and Maintenance Manual • Rev. A
3.2.6 Protective Stop System
Protective Stops are similar to Emergency Stops however they are triggered by an object being
detected in either (front or rear) LIDAR’s protective field. This stop condition will attempt to
reset itself every 2 seconds if the object has been cleared from the field. These stops do not
remove energy from the system like an Emergency Stop would.
Unlike the Emergency Stop system, a Protective Stop does not
remove energy from the system. OTTO 750 will also attempt to
reset the Protective Stop condition every 2 seconds.
The LIDAR Protective Field extends out from the LIDAR in a rectangular pattern, refer to
Appendix B and the S3000 LIDAR Operating Instructions document for more details. The active
velocity of OTTO 750 will determine the size of the protective field to provide adequate
emergency stopping distance automatically. To remove the system from the Protective Stop
state, first all conditions that caused the state transition must be cleared. Then OTTO 750 will
attempt to reset the protective stop. Likewise, during an emergency stop state, pressing the
emergency stop reset button located on the starboard side of OTTO 750 will return the system
to normal operation.
3.2.7 Onboard Computer
OTTO 750 has an onboard computer which performs all of the autonomous navigation and
control of the vehicle. OTTO 750’s environmental perception, navigation, and goal planner are
the core autonomy functions that run on this computer.
3.2.8 Communication Network
The majority of the OTTO 750’s components communicate directly through the LVC node. The
LIDARs communicate directly with the onboard computer via USB. Two CAN Bus networks
operate on the platform to provide communication between the safety critical components. One
CAN bus provides communication between the LVC, computer, BMS, and interface; while the
second between the LVC, computer, and left and right motor controllers. An 802.11 WiFi bridge
is also present onboard the vehicle to allow for wireless communication between the platform
and the external control systems (and attachment accessories if connected).
3.3 Status Indicators
OTTO 750 is equipped with four sets of light stack panels (one on each corner) and one light
pipe which encircles the entire robot. The colour of the lights illuminated and the frequency of
the flashing are used to indicate the state of OTTO 750. Additionally, different combinations of
lights on OTTO 750 will illuminate to indicate either status conditions or motion. Table 5
indicates the status corresponding to each light pattern.