MRMC Bolt Junior User manual

LEADERS IN CAMERA ROBOTICS
CRANES AND RIGS | BROADCAST | HEADS & DSLR | PRODUCT PHOTOGRAPHY | RENTALS
Bolt Junior
COMPACT LIGHTWEIGHT HIGH SPEED ROBOT
Quick Start Guide
Product Code: MRMC-1558-00
Part number: MRMC-1567-00

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Bolt Junior Quick Start Guide
Product Code: MRMC-1558-00
Part number: MRMC-1567-00
© 2018 Mark Roberts Motion Control Ltd. All rights reserved.
No part of this publication may be reproduced, transmitted, or translated
by any means — graphical, electronic, or mechanical — including
photocopying, recording, taping, or storage in an information retrieval
system, without the express written permission of Mark Roberts Motion
Control.
Although every care has been taken to ensure that the information in this
document is accurate and up to date, Mark Roberts Motion Control
continuously strives to improve their products and may make changes to
the hardware, firmware, and software described in this document. Mark
Roberts Motion Control therefore cannot be held responsible for any
error or omission in this document.
All product names mentioned herein are the trademarks or registered
trademarks of their respective owners.
Contact information
Mark Roberts Motion Control Ltd.
Unit 3, South East Studios
Blindley Heath
Surrey
RH7 6JP
United Kingdom
Telephone: [phone]
E-mail: [e-mail] (sales and general enquiries)
[e-mail] (customer support)
Web: www.mrmoco.com
www.mrmocorentals.com

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Contents
Chapter 1 Quick Start..................................................................... 1
Overview .................................................................................1
Safety procedures for using industrial robots,
including high speed track....................................................2
Assessing a site ..............................................................3
Installation safety..........................................................3
Software setup ...............................................................6
Operational safety.........................................................6
Connecting the cables ...........................................................8
Bolt Junior arm connectors for Ulti-box and camera .....11
Starting up the Bolt Junior system.....................................12
Bolt Junior start-up summary...................................16
Shutting down the Bolt Junior system...............................17
Bolt Junior shut-down summary..............................18
Moving the Bolt Junior arm by hand.................................18
Appendix 1 Troubleshooting........................................................... 22
Typical symptoms, causes, and actions .............................22
Appendix 2 Bolt Junior panels ........................................................ 24
Bolt Junior Base panel connector summary.....................24
Bolt Junior arm panels connector summary ....................26
Ulti-box connector summary.............................................28
Ulti-box connector pin-out information ..........................30
Servo motor connector ..............................................30
Program serial connector ..........................................30
Power connector .........................................................31
Camera Accessory connector....................................31
Data In connector.......................................................32
Appendix 3 Specifications............................................................... 34
Rig Weights ........................................................34
Rig Performance ................................................34
Operating Envelope ..........................................34

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Bolt Junior Quick Start Guide
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Bolt Junior Quick Start GuideBolt JuniorQuick Start Guide
Chapter 1 Quick Start
Overview
Thank you for using the Bolt Junior Cinebot from Mark Roberts Motion
Control (MRMC). Bolt Junior is designed for reliable day-in, day-out use
in professional studio and Outside Broadcast environments. It has a
small, lightweight robotic arm which can be used either as camera rig or
model mover. It has a base designed for moving along Precision Track,
which can be bolted to the ground and can also be held down with
weights at temporary locations. It has removable trolley wheels for
moving between sets.

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Safety procedures for using industrial robots,
including high speed track
Note that the words Robot and Rig are completely interchangeable and
identical in meaning, for the purposes of this document.
Motion Control rigs are potentially dangerous. It is important that you
and everyone else on the set understand the safety notes on the following
pages in order to stay safe.
You should use this document in addition to the normal Safety Manual
instructions that are applicable to all motion control rigs, such as Milos.
This section emphasises the safety concerns that are especially important
around high-speed, high-acceleration, industrial-grade robots which can
cause severe injuries, such as Bolt Junior.
Unlike traditional motion control equipment, Bolt Junior can
get to maximum speed in the blink of an eye - too fast for
someone to be able to quickly move out of the way.
You need to take extra steps during installation and use due to
the additional risks involved in using track. See the separate
Precision Track Quick Start Guide for information on laying the
track, securing it to the floor, and mounting Bolt Junior onto it.
The notes given below for track users are marked with this
symbol: .
It is ultimately the operator of the rig who is responsible for
the safe use of the equipment so never bypass any of the safety
points listed here.
No one other than a highly trained operator should use the
robot, no matter how simple it looks or is.
This document is for the use of robots for carrying cameras or
props, not people. Additional safety steps should be taken prior
to using a rig to carry people.

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Assessing a site
Before setting up Bolt Junior you need to assess the site, paying particular
attention to the following points:
Is the ground or floor firm enough and level enough? You
might have to use boards or bricks to create a level surface. The
surface needs to be strong enough to take the weight of Bolt
Junior itself (294 kg) plus the weight of the track (95 kg per
section).
Does the site have access? You need to make sure you can
either push Bolt Junior into position on its wheels or carry it
there using a pallet truck or forklift.
Does the site have a power source with sufficient capacity for
the robot and the correct mains voltage?
– Bolt Junior requires a 400 Volt, three-phase power
supply (five-wire including Neutral and Ground), and
can not be configured to run on less.
– The computer stack that controls Bolt Junior (that is, the
desktop computer and the power supply brick for the
RT-14 interface box) are auto-switching and can run on
120-240 Volts AC.
Does the site have unusual environmental attributes that
require specialised protection from extreme temperatures,
humidity, rain, or dust?
Installation safety
Due to the large mass of the rigs and the accelerations they
achieve it is important that they are securely mounted, with the
recommended plates and bolts to a secure and concrete floor.
When using track, ensure that it is properly bolted to the floor.
If bolting the track is not possible, use 100kg of counter
weights on each corner of the track.
Make sure there is plenty of clearance around the length of the
track for the trailing cables of the rig to slide along the floor.
Ensure that they are not mounted in such a way so that they
can catch on the track or robot as it moves along the full
length.

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Ensure the floor can support the load and the stresses (see
above).
Ensure the power supply is properly earthed (grounded) and of
the correct voltage (see above).
If the rig is mounted to something other than the floor then
the mount should be heavy and strong enough to take the
forces and not move or fall over during sudden starts and
stops. Use the recommended minimum thickness steel plates.
Check with MRMC if you are unsure of the exact requirements
for your robot.
Check that all cables are securely fixed and are not going to
catch during motion.
Ensure the camera, lens, focus motor, accessories, power
supplies/batteries, etc. are all very securely mounted and will
not come off during sudden motions, to become lethal
missiles.
Ensure all safety accessories are securely attached and in
working order, including emergency stops, safety sensors, etc.
Clearly mark the area around the robot in which no persons
are allowed to enter. As a bare minimum, use brightly marked
tape on the floor, outside the reach of the robot, to indicate the
“No Go Zone”. Ideally, use physical safety barriers, and light
guards/curtains.
Keep stands, lights and accessories out of the No Go Zone, if
possible. If not possible then try to take as much care with their
positioning and the motion of the rig, as if they were a person.
Remember a light, accidentally hit at high speed by the robot,
can be just as dangerous to someone standing outside the No
Go Zone as the robot is to someone standing in the zone.
Where physical safety barriers are impractical, light guards
should be used or similar alternatives such as laser scanners, to
stop anyone entering the No Go Zone during motion.
Ideally have the robot surrounded on all four sides by a safety
barrier, but where that is not practical, ensure that the
maximum number of sides feasible are closed off, and that any
person having to stand within reach of the robot is located as
far away as possible for the shot.

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Never let anyone cross the robot’s track when the track motor
is powered up. In fact, it is a good idea to get into the routine of
walking around the track instead of over it so that you don’t
cross the track out of habit when the track motor is powered
up.

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Software setup
Always ensure you have the right configuration for the robot
you are using, such as maximum axis speeds and accelerations.
Prior to running moves, enter in and keep to a minimum all
software axis and Cartesian limits. For example if the main axis
only needs to travel +/-40 degrees then reduce the limit to +/
-40 degrees even though it could do +/-180 degrees. This keeps
the likelihood of operator or software errors to a minimum.
Also check the Cartesian speed and acceleration limits are set
to reasonable values.
Operational safety
Do not use around flammable gas. All electrical equipment can
generate sparks that can ignite flammable gas.
Keep the equipment dry. The system has not been made
weatherproof. Do not use with wet hands.
Always run moves only when standing within easy reach of the
emergency stop.
Always tell the production
company and the crew to keep
away from the robot and not
approach it when any of its red
lights are on which indicates it is
powered up. Have them sign the
appropriate safety documents
and disclaimers to ensure they
understand this and are
indemnifying MRMC if
anything happens.
Always loudly and clearly indicate to others when the rig is
about to move. Shout “Rig Moving!” if no other means exists.
When using track motion always have someone keep an eye on
the trailing rig cables to ensure they don’t get caught on
anything or anyone.
Always ensure the rig is disabled when someone has to enter
the No Go Zone.

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Always run any move or adjusted move slowly at first to check
the motion. Even if you have checked the move previously, if
you make a minor change to it then you need to recheck it.
Keep the software in “slow mode” unless the move has been
tested and is now specifically doing a high speed pass.
In the event that a person or Actor has to be within the no-go
zone during a move (hand model etc.) ensure that they fully
briefed on the safety requirements and that they know not to
change their position or do anything other than the rehearsed
moves without fully warning the operator. Any such person is
to have a clear escape route to allow them to move safely away
from the robot.
During use, repeatedly check the rig mounting points, cables,
camera mount, accessories etc. to ensure nothing has, or is,
working its way loose.
Never bypass any safety hardware or software.

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Connecting the cables
Cable
wrap
VIDEO 1
J1201
48V OUT
E-STOP
ETHERNET
VIDEO 2
ETH*
415 Volt
*These Ethernet (ETH)
ports are for network
connection to the track
motor controller and to the
Ulti-box for LCMs via the
Staubli arm. ETHERCAT
goes to the Stäubli CS8 in
the base only, which
controls the arm.
TEACH
PENDANT
for Camera
POWER
ETHERCAT
J1202
ETHERNET 10GB
ETH*

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ETHERCAT
E-STOP
Ethernet
Power Supply:
415 Volt, 3-phase,
5-wire including
Neutral and Ground
VIDEO SIGNALS
Power Supply:
120-240 Volts
hub
5V
INtime
dongle cable
in USB port
RT-14 Hand Held Box
Ethernet for Camera
ETHERNET
E-STOP
POWER
ETHERNET
24V IN
EX-011 cable

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Picture of Bolt Junior connections:

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Bolt Junior arm connectors for Ulti-box and
camera
The connections that go through the Bolt Junior arm are shown below.
These are for the Ulti-box mounted on the arm, and for the camera that
you mount in the cage at the end of the arm.
POWER output:
24-48 Volts DC
POWER input: 24-48 Volts DC
Video 2
Video 1
ETHERNET
POWER input for camera:
24-48 Volts DC
J1202: Power input
and Ethernet for the
Ulti-box
Additional connectors
for the camera (exact
positions may vary)
ETHERNET
Video 1
Video 2
Power and Ethernet
for the Ulti-box
Ulti-box, which provides various
connectors for camera and lens
controls. For details see Ulti-box
connector summary on page 28.
ETHERNET for the Ulti-box
for camera
for camera
10GB

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Starting up the Bolt Junior system
Once you have attached all the cables, you power up the rig by switching
on the components in the order described below.
1. Make sure you have secured the area around Bolt
Junior. Put up guard rails around Bolt Junior (and the
track) as necessary, and tell others on the set that you
are now powering up the rig.
2. Release the E-stop on the Bolt Junior Base by turning
the red button clockwise until the button pops up. Also
make sure the key is in the clockwise position. Do not
release the other E-stop by the computer stack yet.
3. Power up Bolt Junior itself as follows:
The Bolt Junior power-up sequence takes about three minutes.
Turn on the power switch on
the side of the Bolt Junior
Base.

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4. Power up the Flair computer system and all of its components,
including the RT-14 interface box. You can do this while the robot is
powering up (step 3). Do not start the Flair application yet.
5. After the robot has finished powering up (step 3), the cifX board in
the Flair PC display two steady lights and one blinking light (see
previous diagram).
If the cifX board lights do not show as above after about three
minutes, then close Flair and restart INtime as follows:
Hint
The Stäubli CS8 is
housed inside the
Bolt Junior Base,
which you will not
need to access under
normal
circumstances.
However, in case of
a fault, you can
access CS8 by unscrewing the bolts on the plate covering the
CS8 in Bolt Junior Base.
When the power-up sequence has completed, the Stäubli CS8
shows an “A” on its display.
BoltJunior
Base plate
covering
CS8
“A”
3
5
Steady
Blinking
cifX board

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5.1 In the Windows Taskbar, right-click the INtime icon.
5.2 Select Restart NodeA.
6. On the Flair PC, start the Flair application by double-clicking on the
Flair icon on the Desktop.
Flair automatically loads the relevant firmware into all attached axis
boards, including:
The quad board that runs the track motor The Ulti-box that is
mounted on the Bolt Junior arm
Any additional interface boxes that are attached to the
computer stack
7. Release the E-stop that is plugged into
the computer stack, by turning the
button clockwise until the red button
pops up and then pressing the Reset
button. Also make sure the key is in
the vertical position. The horizontal
position of the key bypasses E-stop
from Hand Held box and Flair.
Therefore, the key should not be kept
in horizontal position when using Bolt
Junior except for testing purposes.
Once all E-stop buttons on the system are up, the Stäubli CS8 display
shows “U”.
Reset button Key

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8. Zero the axes as required in Flair. The Bolt arm itself does not
require zeroing but you need to zero other axes such as:
The track: To do this you use the Zero >Home Axis > Track
menu option.
Any external Lens Control Motors (LCMs) that you are using.
To zero these you first set the focus to infinity (), zoom to
wide-angle (zoomed out all the way), iris/aperture to wide
open and then use the relevant Zero >Direct Zero Axis menu
option to set those lens positions as the zero points in Flair.
9. In Flair, click on the Engage Robot button.
10. In Flair, move the Bolt Junior arm to its home position (rotated
straight forward and tucked under).
11. Set the soft limits for the rig axes in Flair as required:
Arm position limits
Track limits
Hint
You use the Track button in Flair to toggle the track on and off,
independently of the Engage Robot/Disengage Robot button
that you use to toggle the Bolt Junior arm on and off.
Hint
If the Bolt Junior arm is in a backward or reversed
starting position, the arm might swing overhead or
around the side to reach the home position,
possibly striking the walls, ceiling, or other rigging!
If the rig is in an enclosed space or near other equipment, it is
recommended that you do the following:
•Manually move the arm close to its home position before
Homing it.
•When you home the rig, have one hand ready on the
E-stop in case you need to stop the rig quickly.

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Lens Control Motor limits (if using external LCMs)
Bolt Junior start-up summary
1. Secure the area
2. Release the E-stop on the rig
3. Switch on Bolt Junior
4. Switch on the Flair PC
5. Check networking lights after three minutes; Start Robot if needed
6. Start Flair
7. Release the E-stop on the computer stack
In Flair:
8. Zero the track and Lens Control Motor axes
9. Engage Robot
10. Home the arm, carefully
11. Set the soft limits
The rig is now ready to use.