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MRMC Bolt X Quick Start Manual

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

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Summary of Contents for MRMC Bolt X

  • Page 1 Bolt X Quick Start Guide QSG Product Code: MRMC-2253-00 Products Covered: MRMC-2023-00, MRMC-2080-00...
  • Page 2 Bolt X Quick Start Guide QSG Product Code: MRMC-2253-00 Products Covered: MRMC-2023-00, MRMC-2080-00 Document version: BOLTX-QSG-20012022 © 2022 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...

  • Page 3: Table Of Contents

    Starting up the Bolt X system ..........24 Bolt X start-up summary ............26 Shutting down the Bolt X system........27 Appendix 1 Using Weight Plates with Bolt X on Track ....29 Number of plates............29 Using Bolt X without Track (with Weight Plates)....31 Appendix 2 Troubleshooting............
  • Page 4 Flair ..................54 Resolving Position Error on Track ......54 Pinchwheel Setting...............55 Appendix 3 Bolt X panels..............60 Bolt X On Track base panel connector summary....60 Bolt X arm panels connector summary ......62 12VDC connector............64 48VDC connector............64 Ulti-box connector summary..........65 Ulti-box connector pin-out information ......68 Servo motor connector ..........68...

  • Page 5: Quick Start

    Bolt X Quick Start Guide 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:...

  • Page 6: Safety Procedures For Using Industrial Robots, Including High Speed Track

     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.

  • Page 7: Assessing A Site

    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).

  • Page 8: Installation Safety

    Use the recommended minimum thickness steel plates. Check with MRMC if you are unsure of the exact requirements for your robot. ...
  • Page 9 WARNING when using generators! Bolt on Track versions MRMC-2080-00 to -02, the Regen Protection box must be used for regenerative current protection damage along with a generator of 20kW.

  • Page 10: Software Setup

    Bolt X Quick Start Guide 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.
  • Page 11 Bolt X Quick Start Guide  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...

  • Page 12: Mounting The Yaskawa Arm

    Bolt X Quick Start Guide Mounting the Yaskawa arm 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.

  • Page 13: Mounting The Weight Wings

    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.

  • Page 14: Anchoring Bolt X On Pedestal To The Floor

    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. 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.
  • Page 15 × 4 corners × 4 corners Temporarily put the Bolt X On Pedestal into place where you want. 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.
  • Page 16 11. Repeat steps 7 to 10 for the other Drop-in three corners. anchor insert 12. Put Bolt X On Pedestal in place over the holes. 13. Insert the four retaining bolts (M16) × 4 corners through the corners of the base and into the drop-in anchor inserts, and tighten.
  • Page 17 Bolt X Quick Start Guide Notes...

  • Page 18: Attaching The Track Motor Pinch Wheel To Bolt (Family Of Robots) On Track

    Bolt X Quick Start Guide Attaching the track motor pinch wheel to Bolt (Family of Robots) On Track Mounting bar Socket On the separately supplied pinch wheel assembly, remove the brass retaining pin by pulling on the ring. 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.
  • Page 19 Bolt X Quick Start Guide 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. Plug the pinch wheel cable to the socket on the rig underside, and...

  • Page 20: Connecting The Cables - Bolt X On Pedestal

    Bolt X Quick Start Guide Connecting the cables — Bolt X On Pedestal Bolt X Arm Power for Camera Power for Ulti box VIDEO 1 VIDEO 2 Yaskawa Robot cable E-Stop (Safety PLC) Power Supply: ideally 415 Volt, YRC1000 3-phase, 5 pin including Ground...
  • Page 21 Bolt X Quick Start Guide Power Supply: 120-240 Volts INtime dongle cable in USB port VIDEO Ethernet Hub ROBOT ONLY ETHERNET for Camera ETHERNET for Ulti Jumper [14823] Bypass jumper [19788] Hand Held XLR Cable RT-14 [18826] Bypass jumper [15843]...

  • Page 22: Connecting The Cables - Bolt X On Track

    Bolt X Quick Start Guide Connecting the cables — Bolt X On Track Power for Camera Power for Ulti box 48V OUT VIDEO 2 VIDEO 1 Cable wrap ETHERNET for camera YRC1000 Robot Controller VIDEO 1 VIDEO 2 ULTI ETH...
  • Page 23 Bolt X Quick Start Guide E-stop Bypass jumper [19788] RT-14 XLR Cable [18826] Jumper [14823] Bypass jumper [15843] 24V IN ETHERNET Power Supply: 120-240 Volts Ethernet Wifi ROBOT ONLY Dongle ETHERNET INtime dongle cable in USB port VIDEO SIGNALS Power Supply:...
  • Page 24 Bolt X Quick Start Guide Important The Jumper* in the Safety PLC applies when using this robot as a single robot operation. For more information on using the Universal Robot system with multiple robots, refer to the Universal E-stop System Quick Start Guide.

  • Page 25: Bolt X Arm Connectors For Ulti-Box And Camera

    Bolt X Quick Start Guide Bolt X arm connectors for Ulti-box and camera The connections that go through the Bolt X 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.

  • Page 26: Regenerative Current Protection

    Bolt X Quick Start Guide Regenerative current protection Bolt X is now equipped with Regen Protection Box within the Bolt X base, which is designed to detect and discharge power surges caused by regeneration with Bolt X on Track when voltage reaches a certain level and poor regulation from the generator occurs..
  • Page 27 435VAC 3 phase, under a regenerative event. DO NOT press the buttons on the display. In case of a fault contact MRMC at support@mrmoco.com. It is important that the Bolt X is connected to a supply strictly 400/415VAC. A voltage applied greater than 435VAC will result in the regenerative resistors being switched on and cause an over temperature condition.

  • Page 28: Starting Up The Bolt X System

    Bolt X Quick Start Guide Starting up the Bolt X system Once you have attached all the cables, you power up the Bolt X rig by switching on the components in the order described below. Make sure you have secured the area around Bolt X.
  • Page 29 Bolt X Quick Start Guide For Bolt X on Pedestal, For Bolt X On Track, turn power on the YRC1000 on the power switch on the controller unit side of the Bolt X Base. The pendant shows the boot up sequence which normally takes about 1 minute.

  • Page 30: Bolt X Start-Up Summary

    Bolt X Quick Start Guide Bolt X start-up summary Secure the area Release the E-stop on the rig Switch on all the equipment on the system Switch on the Flair PC Start Flair Release the E-stop on the computer stack...

  • Page 31: Shutting Down The Bolt X System

    Bolt X On Track). or... If you are going to transport Bolt X to a new location, put the Bolt X arm into its transport position. You can do this either by using Flair (although you might have to reset the soft limits to reach the transport position).
  • Page 32 Bolt X Quick Start Guide Notes...

  • Page 33: Appendix 1 Using Weight Plates With Bolt

    Quick Start Guide X on Track If you are using a fast robot with a long arm, such as Bolt X on Track, it is recommended that you hold the track down by bolting it to the ground as above. If that is not feasible, use the weight plates to lay under and then bolt the track on to the weight plates.
  • Page 34 Bolt X Quick Start Guide Rail Sections Plates Required 3 to 6 More than 6 One plate per rail section, spaced evenly 1 section = 6 plates or equivalent 3 sections = 6 plates 5 sections = 6 plates 8 sections = 8 plates...

  • Page 35: Using Bolt X Without Track (With Weight Plates)

    Bolt X Quick Start Guide Using Bolt X without Track (with Weight Plates) Ensure that the Bolt X is not on track and can be wheeled on its jacking castors. Lay the first weight plate on the floor, in a position that will be the rear of the Bolt X turret, across the “facing front”...
  • Page 36 Bolt X Quick Start Guide While carefully aligning and keeping the wheels straight, wheel the Bolt X over the first plate. Once the first pair of wheels has wheeled over the first weight plate, remove the 2 x ramps from the inner edge of the weight plate and...
  • Page 37 Bolt X Quick Start Guide Still keeping the wheels straight, wheel the Bolt X so it climbs the second weight plate using the ramps. Drop the screws in the Bolt X base screw cavities along with the supplied nuts and, if required, adjust the weight plates below so that the screws line up.
  • Page 38 Bolt X Quick Start Guide 10. Stack 2 x weight plates perpendicular to the weight plates that are secured under the robot.
  • Page 39 Bolt X Quick Start Guide Notes...

  • Page 40: Appendix 2 Troubleshooting

    The YRC1000 teach pendant should only be used for troubleshooting purposes and should not be used for normal operation of the rig. The teach pendant is not related to Flair/RTL in any way and is not an interlace to MRMC Bolt system. Symptoms Cause and/or action Flair fails to establish a Try a different cable.
  • Page 41 Bolt X Quick Start Guide Symptoms Cause and/or action Bolt X axes won’t move Make sure you have enabled Bolt in Flair/RTL (click on the Engage Robot button). Cabled properly but there seems no power Ensure that the Orange LED on YRC1000 is in the robot.

  • Page 42: Checking When Yrc1000 Is Ready

    Bolt X Quick Start Guide Checking when YRC1000 is ready After powering, the YRC1000 controller should successfully boot within 2 minutes, then start Flair. If Flair doesn’t connect, undo the screws on the pendant hatch plate at the lower right corner in the base.

  • Page 43: Switching Bolt X To Manual Mode

    MRMC. Switching Bolt X to Manual Mode You can run the Bolt X in manual mode without using Flair. Ensure that YRC1000 is powered up and booted. Switch the key on the pendant to ‘Teach’ position.

  • Page 44: Moving The Robot In Manual Mode

    If you release the deadman’s handle, the robot will power off. Press the Servo On Ready button on the pendant and the deadman's handle half way again to power up the robot. Use the axes buttons X to Z, shown, to move the joints on Bolt X. Rotate/ Track...

  • Page 45: Setting Bolt X Back To Remote Mode

    Bolt X Quick Start Guide Setting Bolt X Back to Remote Mode Switch the key in Safety PLC back to vertical position. Switch the key in the teach pendant back to “Network” position. If you are using the Bypass Estop box [20529] instead of Safety PLC, replace it with Safety PLC.
  • Page 46 Bolt X Quick Start Guide  If any of the encoder cables is unplugged then the encoder position will be lost.  If you try to change the encoder batteries when the power to the robot is off then also the encoder position will be lost.
  • Page 47 Bolt X Quick Start Guide appear instead of absolute encoder position indicating that there is a problem with the calibration. (In this example, we are using Pan.) A message appears when you press Select. Select Yes. The values in the ABSOLUTE DATA column will not change as they...

  • Page 48: Changing User Profile

    Bolt X Quick Start Guide Select MAIN MENU → ROBOT → CURRENT POSITION. The axis is changed to 0. Changing User Profile Select MAIN MENU → SYSTEM INFO → SECURITY.

  • Page 49: Second Home Position Check And Reset

    Bolt X Quick Start Guide You will be presented with a list of user profiles. Select the desired user profile. Enter the password for the user:  Management Mode Password: 9999999999999999 (all 9s' - 16 digits)  Safety Mode Password: 5555555555555555 (all 5s' - 16 digits)
  • Page 50 Bolt X Quick Start Guide For example, when Flair is started and the robot is engaged, the robot will engage successfully but all axes would become ‘grey’ in Flair again and you might not be able to move them. To resolve this issue: Switch to Manual (Teach) Mode.
  • Page 51 Bolt X Quick Start Guide Move all axes to the SPECIFIED POSITION so that the values in the DIFFERENCE column are zero or close to zero. To do this enable the robot and press and hold FWD. Use the Fast/Slow buttons to alter the robot speed during this movement.

  • Page 52: Setting Joint Limits

    Bolt X Quick Start Guide Setting Joint Limits Switch user profile to Safety Mode. Select MAIN MENU → ROBOT → SOFT LIMIT SETTING. Select the limit setting and enter a new setting. (Values are in pulses) Joint T (Roll) is 100000, which is approximately 180...

  • Page 53: Moving The Bolt X Arm By Hand (Using Brake Release Function)

    Bolt X Quick Start Guide Moving the Bolt X Arm by Hand (Using Brake Release Function) In certain situations, it might be pertinent to move the robot arm by hand. This can be in a situation, for example, when momentum or a...
  • Page 54 Bolt X Quick Start Guide Select MAIN MENU → SYSTEM INFO → SECURITY. You will be presented with a list of user profiles. Scroll to Safety Mode and press Enter. Enter the password for the Safety Mode user: 5555555555555555 (all 5s' - 16 digits) 10.
  • Page 55 Bolt X Quick Start Guide 11. Navigate to Robot  Manual Brake Release. Scroll to find the option, if required. Select Yes for confirmation. 12. Scroll down to the axis for which the brake needs to be released. WARNING! It is important that the desired axis is highlighted and people are prohibited in the isolation area around the robot.
  • Page 56 Bolt X Quick Start Guide...
  • Page 57 Bolt X Quick Start Guide 13. Simultaneously press deadman’s handle to half position and Interlock + Select buttons. The brake releases on the highlighted axis and is ready to be moved by hand. WARNING! Exercise extreme caution when using Brake Release function as unexpected movement of the robot can cause damage to both personnel and equipment.

  • Page 58: Checking If Yaskawa Yrc1000 Output File Is Set To Flair

    To do so: Ensure that the tack pinion is not in mesh. Access the coupling by opening the hatch in the Bolt X base and removing the screw, as shown.

  • Page 59: Pinchwheel Setting

    Bolt X Quick Start Guide You might need to flash a torch in the cavity for a clear view. Once in the clamp is in view, move the track motor slowly from Flair until the screw is clearly in view.
  • Page 60 Bolt X Quick Start Guide 1.2 Once these bolts are slackened, loosen the 4 nuts on the extruding bolts. We advise that when loosening these nuts, that an allen key is held in the bolt, as this bolt should not move, it is designed to stay tight: 1.3 Wind the locking nut out to the head of the bolt, so the...
  • Page 61 Bolt X Quick Start Guide This can be done on the robot, with the pinch wheel assy. attached, locking pin in, close the engagement bar, check tightness of mesh (Too loose - the pinch wheel should not be able to be turned by hand. Too tight –...
  • Page 62 Bolt X Quick Start Guide 2.2 Loosen the end nuts. 2.3 With the engagement bar closed, squeeze the cam to the engagement block. This will push the threaded bar out to the necessary adjustment point: 2.4 While squeezing the cam to the block, wind the adjustment nut down loosely finger tight, then lock the locking nut in place.
  • Page 63 Bolt X Quick Start Guide This adjusts the compression of the cam bar spring. A suitable compression, unengaged, the spring should be approx. 60mm. It is adjusted and locked by the two nuts shown:...

  • Page 64: Appendix 3 Bolt X Panels

    Bolt X Quick Start Guide Bolt X Quick Start Guide Bolt X On Track base panel connector summary 240V AC output, for general use by additional devices that you want to mount on the base. VIDEO 1 IN input connector for the video 1 signal from the camera.
  • Page 65 Bolt X Quick Start Guide ROBOT connector. You use this to connect the robot Controller YRC1000 inside the Bolt X base, via the umbilical cable, to the hub in where the Flair PC is connected 10. E-STOP connector. You connect this to the PLC via the umbilical...

  • Page 66: Bolt X Arm Panels Connector Summary

    VID 1 output connector for the video 1 signal from the camera. This can be connected to the VIDEO 1 IN connector on the Bolt X base. VID 2 output connector for the video 1 signal from the camera. This can be connected to the VIDEO 2 IN connector on the Bolt X base.
  • Page 67 Bolt X Quick Start Guide YRC1000 power and controller connector. This is for the encoder and power cable that runs between the Bolt X arm and the YRC1000 controller unit, which supplies control to the arm.

  • Page 68: 12Vdc Connector

    Bolt X Quick Start Guide Bolt X arm connector pinout information 12VDC connector This type of connector is used to power the camera through the robot arm. +12-24V Not used 48VDC connector This type of connector is used to power the camera through the robot arm.

  • Page 69: Ulti-Box Connector Summary

    Bolt X Quick Start Guide Ulti-box connector summary The Ulti-box that is mounted on the Bolt X arm is a multi-purpose interface box that is used to control servo motors on many MRMC heads and Lens Control Motor (LCM) units. The Ulti-box offers versatile...
  • Page 70 Bolt X Quick Start Guide PAN connector for the Pan servo motor on a head. For pin-out information see Servo motor connector on page 68. PROG serial connector for connection to a controller using a Serial RS232 connection (as an alternative to an Ethernet or DataLink connection), and for updating the firmware in the Ulti-box.
  • Page 71 Bolt X Quick Start Guide connected to the external E-Stop box, but if no external E-Stop is needed, a bypass jumper may be used. CAN connector is used to communicate with external CAN capable motor drives. 10,11. ZOOM, FOCUS connectors for external servo Lens Control Motors (LCMs) mounted on the camera platform.

  • Page 72: Ulti-Box Connector Pin-Out Information

    Bolt X Quick Start Guide Ulti-box connector pin-out information Servo motor connector This type of connector is used for six servo motor connectors on the Ulti-box: Pan, Zoom, Focus, Tilt, Aux-1, Aux-2. DATUM Brake/Enable output MOTOR_B MOTOR_A LIMIT 10. GND...

  • Page 73: Power Connector

    Bolt X Quick Start Guide Power connector The power input connector for the Ulti-box. For usage see page 66. +35V +35V Camera Accessory connector This is a multi-purpose camera accessory connector with connections for three stepper motors, two serial lens controls, two trigger in controls, and two trigger out controls.

  • Page 74: Data In Connector

    Bolt X Quick Start Guide Data In connector This is a DataLink In connector for connection to a controller using a DataLink connection. DataLink In (Up Link) connector for connection to a DataLink device higher up in the DataLink daisy-chain. For usage see.

  • Page 75: Brake 24V Connector

    Bolt X Quick Start Guide Brake 24V connector This is a Lemo Size 1 2-way connector; external circuitry should keep the pins closed. E-STOP- E-STOP+ CAN connector This is a Lemo Size 0 3-way connector; is used to communicate with external CAN capable motor drives.

  • Page 76: Appendix 4 Specifications

    Bolt X Quick Start Guide Appendix 4 Specifications Bolt X Quick Start Guide Bolt X Quick Start Guide Physical Specification Dimensions Bolt X On Bolt X On Track Pedestal Weight - Arm [kg] Weight - Base [kg] Weight - YRC1000 controller unit...

  • Page 77: Range Of Travel

    Tilt: +/- 150˚ range of travel @ 430˚/s Roll: +/- 455˚ range of travel @ 630˚/s Power requirements Bolt X on Track requires three-phase power line with Neutral in Wye connection plus Earth (Ground), 50-60 Hz. Phase 1 (Brown) 240volts...

  • Page 78: Cable Colours

    50/60Hz and consumes no more than 500 Watts. All PSUs adjust automatically to the supply voltage. WARNING when using generators! Bolt on Track versions MRMC-2080-00 to -02, the Regen Protection box must be used for regenerative current protection damage along with a generator of 20kW.

  • Page 79: Power Data By Country - Usa

    Notes Bolt X on Pedestal does not need a neutral. If needed the Bolt X on Pedestal requires a transformer to bring the voltage into the operating range 380-480V 3-Phase. Bolt X on Track will require a transformer to bring the voltage into the operating range of 400/415V for correct operation of the Regen Protection Unit and to provide a balanced neutral.
  • Page 80 Bolt X Quick Start Guide Notes...

  • Page 81: Appendix 5 Cleaning And Maintenance

    Do not spry cleaning fluids into these plugs and sockets. Cleaning The Bolt X on tracks should be turned off and unplugged for cleaning. Main Body and Arm The Bolt X on Track requires little maintenance, but should be cleaned frequently depending upon where it is used.

  • Page 82: Track Gearbox

    Bolt X Quick Start Guide Track Gearbox After approximately five years of use the track gearbox oil will need changing, this is just a gear oil available from motor factors, grade EP90. Track and Track Bearings The Track Bearings should be frequently greased using a good quality grease gun, again from a motor factor;...

  • Page 83: Replacing The Pinch Wheel

    Bolt X Quick Start Guide Replacing the Pinch Wheel The worn out pinch wheel can be replaced in the pinch wheel assembly using the following procedure: Unscrew the small screw on the pinch wheel on the underside of the pinch wheel assembly. The pinch wheel is not completely detached yet.
  • Page 84 Bolt X Quick Start Guide Notice a washer above the pinch wheel; keep it aside. Discard the worn out pinch wheel. Underside of the Pinchwheel centre shaft Replace the washer on the new pinch wheel carefully and inserting it lined with the screw cavities in the centre shaft of the pinch wheel assembly.

  • Page 85: Replacing The Track Pinion

    Bolt X Quick Start Guide Replacing the Track Pinion This procedure can be performed either while the robot is on track or while the robot is on jacking wheels. If the robot is mounted on the track, remove the pinchwheel assembly from the track motor and move the track motor away from the rail racking.
  • Page 86 Bolt X Quick Start Guide Once the pinion is sufficiently expanded, using heat-proof gloves, try removing the pinion; again without using much pressure. Replace the new track pinion by inserting and pushing it onto the shaft. Using the reflection of the pinion on a mirror or mobile phone, align the pinion on the shaft.
  • Page 87 Bolt X Quick Start Guide Notes...
  • Page 88 Mark Roberts Motion Control Ltd. Unit 3, South East Studios, Blindley Heath, Surrey RH7 6JP United Kingdom Telephone: +44 (0) 1342 838000 info@mrmoco.com www.mrmoco.com...

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