MRMC Bolt X User manual

Bolt X
Quick Start Guide
QSG Product Code: MRMC-2253-00
Products Covered: MRMC-2023-00, MRMC-2080-00

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Bolt X Quick Start Guide
QSG Product Code: MRMC-2253-00
Products Covered: MRMC-2023-00, MRMC-2080-00
Document version: BOLTX-QSG-20012021
© 2021 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: [email protected]m (sales and general enquiries)
[email protected]m (customer support)
Web: www.mrmoco.com
www.mrmocorentals.com

Bolt X Quick Start Guide
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Bolt X Quick Start GuideBolt XQuick Start Guide
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..........................................................4
Software setup ...............................................................6
Operational safety.........................................................6
Mounting the Yaskawa arm ..................................................8
Mounting the weight wings ..................................................9
Anchoring Bolt X On Pedestal to the floor ......................10
Attaching the track motor pinch wheel to Bolt
(Family of Robots) On Track ....................................14
Connecting the cables — Bolt X On Pedestal ..................16
Connecting the cables — Bolt X On Track.......................18
Bolt X arm connectors for Ulti-box and camera .............21
Starting up the Bolt X system .............................................22
Bolt X start-up summary ....................................................24
Shutting down the Bolt X system.......................................25
Appendix 1 Troubleshooting........................................................... 26
Typical symptoms, causes, and actions ............................26
Checking when YRC1000 is ready.....................................27
Switching Bolt X to Manual Mode.....................................28
Moving the Robot in Manual Mode..................................29
Setting Bolt X Back to Remote Mode................................29
Bolt X Recalibration.............................................................30
Changing User Profile .........................................................33
Second Home Position Check and Reset..........................34
Setting Joint Limits ..............................................................37
Checking if Yaskawa YRC1000 Output File is set to
Flair ........................................................................................38
Appendix 2 Bolt X panels................................................................ 40
Bolt X On Track base panel connector summary............40
Bolt X arm panels connector summary ............................42
12VDC connector.......................................................44
48VDC connector.......................................................44
Ulti-box connector summary.............................................45

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Ulti-box connector pin-out information ..........................48
Servo motor connector ..............................................48
Program serial connector ..........................................48
Power connector .........................................................49
Camera Accessory connector....................................49
Data In connector.......................................................50
Brake 24V connector..................................................50
Brake 24V connector..................................................51
CAN connector...........................................................51
Appendix 3 Specifications............................................................... 53
Physical Specification.................................................53
Range of Travel............................................................54
Power requirements..................................................... 54
Cable Colours ....................................................55
General Electric Data.................................................55
Earth....................................................................55
Earth Leakage Protection .................................55
Power for Flair and PC (500W) ................................55
Power Data by Country - United States of
America........................................................................56
Appendix 4 Cleaning and Maintenance.......................................... 59
General Care.........................................................................59
Cleaning ................................................................................59
Main Body and Arm ..................................................59
Cables ...........................................................................59
Pinchwheel...................................................................59
Track Gearbox.............................................................60
Track and Track Bearings ..........................................60

Bolt X Quick Start Guide
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Bolt X Quick Start GuideBolt XQuick Start Guide
Chapter 1 Quick Start
Overview
Thank you for using the Bolt X High-speed Cine-bot from Mark Roberts
Motion Control (MRMC). Bolt X is designed for reliable day-in, day-out
use in professional studio and Outside Broadcast environments. There are
two versions of Bolt X:
Bolt X On Pedestal has a
stationary base which you
either hold down with
weights or, for more
permanent installations,
attach to the floor.
Bolt X On Track has a base
designed for moving along
Precision Track. It has
removable trolley wheels for
moving between sets, and can
also be held down with weights
at temporary locations.

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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 X.
Unlike traditional motion control equipment, Bolt X 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.
If you are using Bolt X On Track then 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 X 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 X 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 X
itself (630 kg for Bolt X On Pedestal, 830 for Bolt X On Track)
plus the weight of the track (95 kg per section). The track must
either be secured to the ground or to the weight plates supplied
(2 plates per section=2x80 kg). If you are using Bolt X On
Pedestal for high-speed moves then 400 kg of anchor weights
on each corner are recommended.
Does the site have access? You need to make sure you can
either push Bolt X 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 X On Pedestal gets its power from the YRC1000
robot controller unit which runs 415 Volt, 32A, 50/60Hz,
three-phase power supply (five-wire including Neutral
and Ground).
– Bolt X On Track requires one 415 Volt, three-phase
power supply (five-wire including Neutral and
Ground) connections. It cannot be configured to run on
less without significant loss of track speed performance.
– The RTL/Flair computer that controls Bolt X (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?

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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.
No amount of counterweight will stop the track from moving
and twisting if the track isn’t secured, especially with short
lengths of 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.
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.

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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.
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.
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.
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.

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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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Mounting the Yaskawa arm
1. Remove all packaging from the Bolt X arm and the pedestal. If not
already added, attach the two mounting plates on the arm using 4 x
M12 screws on each side. Ensure that each plate is mounted on the
correct side.
2. Securely attach shackles on each of the four corners of the lifting
plates.
3. Use the shackles to tie a lifting sling around the arm and insert the
hook from the gantry hoist on to it.
4. Wheel the Bolt X base under the gantry hoist.

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5. Use the gantry hoist to gently lift the arm and lower it in position on
the Bolt X base aligning the screw slots.
6. Tighten the 8xM20 screws to secure the arm on the Bolt X base.
7. Remove the gantry hook and the straps from the arm. Also, remove
the yellow lifting plates from the arm.
Mounting the weight wings
If you want to use Bolt X in a stationary position that is temporary (or if
you don’t want to damage the floor by installing anchors in it), you must
weigh down the Bolt X base to keep it stable during high-speed moves. To
do this you install wings on the base, which lie flat on the floor, and then
put weights on the wings to securely hold down the rig.
1. Use a pallet truck for Bolt X On Pedestal to lift Bolt high enough to
go over the wings (about 10 cm).
2. Lay one of the wings beside the Bolt X base and push the edge of the
wing over the edge of Bolt X, lining up the four holes.

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3. Lower the base close to the wing but not quite resting on it, close
enough for the five retaining bolts to reach the wings through the
base.
4. Insert the four retaining bolts (two on each corner of the base) and
tighten. Note that some versions have locknuts.
5. Repeat steps 1 to 4 to mount the other wing.
6. Lower the base completely so it is resting on both wings.
7. Put the weights onto the wings. Bolt requires 800kg of weights on
both sides.
Anchoring Bolt X On Pedestal to the floor
If you are setting up Bolt X On Pedestal in a permanent (or
semi-permanent) location, it is recommended that you anchor the
pedestal to the floor. If this is not possible, as an alternative you can hold
Hint
You can move Bolt X using a pallet jack without removing the wings
if you want, as long as you take the weight plates off first.
Bolt X On
Pedestal with
wings and
weights

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it down with weights. The following procedure tells you how to anchor
the pedestal to a concrete floor.
1. Temporarily put the Bolt X On Pedestal into place where you want.
2. At one corner of the pedestal, use one of the two holes to draw a
circle on the concrete with a pencil, to mark the position of the hole.
You can use either hole.
Repeat for the other three corners of the pedestal.
3. Temporarily remove Bolt X On Pedestal and at one of the four
circles that you have drawn, draw a cross centred on the circle, to
help you precisely locate the drill bit.
Repeat for the other three corners.
4. On the 20mm diameter drill bit, put tape around the bit 5 cm from
the tip. This will help you gauge the depth of the hole in the next
step.
5. At one of the corner circles, drill a hole 5 cm deep into the concrete,
centred on the cross. When the tape on the drill bit reaches the floor,
drilling is complete.
Repeat for the other three corners.
6. Clean the four holes.
× 4 corners
2
1
2
× 4 corners
3
× 4 corners
5 cm
5 cm
Tape
5
4

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7. At one of the holes insert the drop-in
anchor insert, threads upward, all
the way to the bottom.
8. Insert the anchor spreader tool into
the drop-in anchor insert.
9. Hit the top of the anchor spreader
tool with a hammer until the anchor
is fully spread in the concrete.
10. Remove the anchor spreader tool.
11. Repeat steps 7 to 10 for the other
three corners.
12. Put Bolt X On Pedestal in place over
the holes.
13. Insert the four retaining bolts (M16)
through the corners of the base and
into the drop-in anchor inserts, and
tighten.
7
Anchor
spreader
tool
8
9
Drop-in
anchor
insert
× 4 corners
13

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Notes

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Attaching the track motor pinch wheel to Bolt (Family of
Robots) On Track
1. On the separately supplied pinch wheel assembly, remove the brass
retaining pin by pulling on the ring.
2. Mount the pinch wheel assembly onto the track motor on the rig
underside, by sliding the track motor gear against the rack and
putting the pinch wheel Socket onto the track motor Mounting bar.
3. Replace the retaining pin in the pinch wheel assembly by pushing on
the ring (not the sleeve), to hold the assembly in place on the track
motor.
4. Ensure that the track motor gear is held firmly against toothed side
of the rack. If it is not, then push the pinch wheel assembly slightly
towards the rack so that the rubber wheel presses firmly against the
smooth side of the rack. Check that the space between the black
plastic block behind the rubber wheel and racking after mounting
the pinch wheel assembly is less than 1mm.
Mounting bar
12
Socket
2
3

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5. Insert the small side of an allen key in the cavity on the block of the
pinch wheel assembly and using the allen key pull the block towards
the racking.
6. Plug the pinch wheel cable to the socket on the rig underside, and
use cable ties to hold it securely up away from the track, if required.
4
5
6

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Connecting the cables — Bolt X On Pedestal
Power Supply: ideally 415 Volt,
3-phase, 5 pin including Ground
(For different voltage, check
Yaskawa manual)
ETHERNET for Camera
E-Stop
(Safety PLC)
ROBOTONLY
Power for Ulti box
VIDEO 1
VIDEO 2
ETHERNET (for Ulti box)
YRC1000
Teach Pendant
Power for Camera
Bolt X Arm
Yaskawa Robot
cable