Overview
This article explains how the AT500 laser tracker is powered, how long its batteries last, and how to hot-swap a battery so the tracker keeps running. It applies to the Leica Absolute Tracker AT500 used with Dusty Robotics systems.
How the AT500 is Powered
The AT500 has an all-in-one integrated design with a built-in controller and built-in battery power — no external controller box and no power cables required for normal operation. It runs on two batteries housed in the tracker.
| Spec | Detail |
|---|---|
| Battery count | 2 (both installed during operation) |
| Battery type | IATA-compliant rechargeable batteries (Leica/Hexagon) |
| Hot-swappable? | Yes — designed for it |
| Runtime | Up to 6 hours per pair |
| External power option | Can run on external power via the tracker's AC power adapter instead of using the batteries (batteries must still be installed — see below) |
Can I Hot-Swap the Batteries While the Tracker Is On?
Yes — and you replace them one at a time. The AT500's two-battery design lets you swap a depleted battery for a charged one while the tracker stays powered on the remaining battery. This is the intended way to extend runtime through a full shift without shutting down, re-leveling, or re-stationing.
⚠️ Swap one battery at a time. Removing both batteries at once cuts power and shuts the tracker down — which interrupts your print and forces a re-station. Always keep at least one battery seated.
How to Hot-Swap an AT500 Battery
Prerequisites
- A charged spare AT500 battery on hand
- The tracker powered on and not mid-measurement, if avoidable (swap during a natural pause)
Steps
- Confirm at least one battery remains seated and powering the tracker throughout the swap.
- Open the battery compartment for the depleted battery (release the compartment lock/latch).
- Remove the depleted battery.
- Insert the fully charged battery and confirm it seats and locks fully.
- Verify the tracker shows a healthy power status for the new battery.
- Repeat for the second battery only after the first swap is confirmed — never remove both at the same time.
Verify It Worked
The tracker remains powered throughout, the new battery registers, and no power-loss or re-station prompt appears in the Dusty App.
Runtime and Field Readiness
A charged pair gives roughly 6 hours of operation. To run all day without interruption:
- Keep spare batteries charged and on hand before arriving onsite.
- Swap one battery at a time as each depletes, so the tracker never loses power.
- Plan swaps during natural breaks in printing to minimize disruption.
Running on External Power
Instead of running on battery charge, you can power the AT500 from an external power source using the tracker's AC power adapter. This is useful when a power source is available onsite and you want to preserve battery life or run continuously.
Important: The batteries must remain installed in the tracker to operate — even if they hold no charge. The AT500 will not run on the AC adapter alone with the battery bays empty.
Common Issues
- Tracker shut off during a swap: Both batteries were likely out at the same time, or the new battery didn't seat. Reinsert a charged battery, power on, and re-station before resuming.
- Damaged battery or power cord: Don't attempt repairs in the field. Contact Dusty Support for a replacement.
Frequently Asked Questions
Can I hot-swap both AT500 batteries at the same time? No. Swap one at a time. Pulling both cuts power and shuts the tracker down.
Will a hot-swap make me re-station? No. A re-station is only needed when the tracker physically moves from its position. A clean one-at-a-time swap keeps the tracker in place and won't disturb stationing. Even if the tracker fully loses power, the station information is saved in the robot — when the tracker reconnects to the system, it syncs back to the robot's saved station information.
Are the AT500 batteries the same as the FieldPrinter's Milwaukee M18 batteries? No. They are different systems with different batteries and different procedures.
Can I run the AT500 on external power instead of batteries? Yes. You can power the AT500 from an external power source using the tracker's AC power adapter instead of running on battery charge. Note: the batteries must still be installed in the tracker — even if they have no charge — for the AT500 to operate.