Migatronic RCI2 User Manual Download Page 2

Page: 2 / 80

Specifications .............................................................................................. 3 - 4

How it works .................................................................................................... 5

Connection to a robot and welding machine ................................................ 6

How to connect the installation ................................................................ 7 - 8

How to do the first configuration and setup ................................................ 9

Jumper settings ............................................................................................. 10

Fieldbus serial communication setup .......................................................... 11

Status menu ............................................................................................ 12 - 14

Setup menu ............................................................................................. 15 - 31

Robot / PLC setup ........................................................................................... 32

Analog Configuration file - PI ................................................................ 33 - 38

Fieldbus Configuration file - PI and PI PLASMA ................................... 39 - 46

Fieldbus Configuration file - PI and PI PLASMA - Std. Motoman ....... 47 - 49

Analog Configuration file - Sigma Galaxy ............................................ 50 - 57

Fieldbus Configuration file - Sigma Galaxy - Standard ....................... 58 - 60

Fieldbus Configuration file - Sigma Galaxy - Standard Motoman ...... 61 - 64

Detailed Interface layout .............................................................................. 65

Software upgrade .......................................................................................... 66

Troubleshooting ............................................................................................. 67

Error List .................................................................................................. 68 - 70

ANYBUS - Error List ................................................................................. 71 - 75

Electric Diagram ............................................................................................. 76

SIGMA Robot interface basic setup .............................................................. 77

Spare parts list ............................................................................................... 78

Table of contents

Summary of Contents for RCI2

Page 1: ...USER GUIDE ROBOT CONTROL INTERFACE RCI2 50115001 C1 Valid from 2019 week 24...

Page 2: ...ile PI 33 38 Fieldbus Configuration file PI and PI PLASMA 39 46 Fieldbus Configuration file PI and PI PLASMA Std Motoman 47 49 Analog Configuration file Sigma Galaxy 50 57 Fieldbus Configuration file...

Page 3: ...ANALOG OUTPUTS Galvanic isolated differential outputs 2 Maximum load 2K Ohm Output voltage 0 10 V Digital resolution 12 Bit Sampling frequency 97 Hz Error 2 of reading 5 digits 50mV Remarks cannot be...

Page 4: ...Vendor ID Name 90 005Ah HMS Industrial Networks Product Name Anybus CC EtherNet IP ProdTypStr Generic Device Device Type 0 0000h Generic Device Product Code 99 0063h Anybus CompactCom EtherNet IP Asse...

Page 5: ...YBUS communication modules Referred to as Fieldbus in the rest of this manual 2 Analog communication A set of analog inputs and outputs can control the welding machine Configuration RCI2 has to be set...

Page 6: ...the following Anybus modules is installed when RCI2 is intended for serial communication ETHERNET IP DEVICENET PROFINET PROFIBUS EtherCAT Analog communication The analog communication is accessible th...

Page 7: ...elding inverter c Interconnection water hose gas and 2xwelding cable and CAN d Highly flexible interconnection for robot e Earth connection f Welding torch g Welding return cable h Interconnection wat...

Page 8: ...Read the Touch sensing status output bit When the welding wire or optional the gas nozzle has contact to work piece while not welding E x For Sigma Galaxy output Bit 147 is ON when there is contact a...

Page 9: ...ired file 4 Load from SD 10010xxx TXT RIGHT DOWN ENTER LEFT UP Select with ENTER 5 During loading process the display will indicate that a backup file is being saved on the SD card Indication of succe...

Page 10: ...ect to welding machine Can bus GND 35 GND 36 5V can bus GND 35 GND 36 Function defined by the configurations file Function defined by the configurations file Function defined by the configurations fil...

Page 11: ...RIGHT until the display shows the name of your Anybus module Continue on page 20 Continue on page 21 Continue on page 22 Continue on page 23 Continue on page 24 RIGHT DOWN ENTER LEFT UP DeviceNet Eth...

Page 12: ...Anybus module is installed and the correct configuration file is loaded this menu is indicating the status of the serial communication and Anybus module status Anybus Status Description Setup Anybus S...

Page 13: ..._13 14 DIN_2 15 DIN_1 13 DIN_3 11 DIN_5 12 DIN_4 9 DIN_7 2 DIN_14 16 DIN_0 0 1 2 3 4 5 6 7 8 9 A B C D E F Displayed numbers Connector numbers Digital input numbers Digital Outputs 0__3_ Indication of...

Page 14: ...alog voltage 29 28 27 26 25 AIN0 25 26 RE2 RE3 RE4 RE5 30 AN_IN_2 AN_IN_2 AN_IN_1 AN_IN_1 AN_IN_0 AN_IN_0 L C D C H A R A AIN1 27 28 AIN2 29 30 RIGHT DOWN ENTER LEFT UP The 2 analog outputs AN_OUT_1 a...

Page 15: ...u 5 IOs Options Analog Sens 3 Config file Save to SD Depending on installed module See description Diagnostic Dump LOG Display RTC clock IOs Options Digital Sens Config file Total backup Diagnostic Te...

Page 16: ...t and output setting must be loaded into RCI2 Take care that the inserted SD card holds the configuration files in a file structure as shown to the right List of available configuration files see page...

Page 17: ...ad from SD Error at NN Load from SD No files or SD Config file Save to SD This function is used when you want to copy the installed configuration file to another SD card Configuration file only is cop...

Page 18: ...p all Upload of backup file with all configuration setups and Anybus network setups stored on the SD card This function is useful when replacing the RCI2 after a breakdown or when cloning the RCI2 is...

Page 19: ...ens Analog Sens High RIGHT DOWN ENTER LEFT UP Analog Sens Low RIGHT DOWN ENTER LEFT UP RIGHT DOWN ENTER LEFT UP This filter allows change of sensitivity to background noise on all inputs LOW is defaul...

Page 20: ...he interface automatically detects and identifies the installed Anybus module and consequently displays different scenarios depending on the information needed by the Anybus module DeviceNet baud rate...

Page 21: ...nd consequently displays different scenarios depending on the information needed by the Anybus module Ethernet IP DHCP Setup menu DHCP Disabled IP address manual setup Press Enter Press Enter Set the...

Page 22: ...FT UP RIGHT DOWN ENTER LEFT UP RIGHT DOWN ENTER LEFT UP RIGHT DOWN ENTER LEFT UP EtherCAT Device ID Device ID setup Press Enter Set the Device ID as specified by the robot or network controller N is i...

Page 23: ...ller N is in the range 0 to 125 and SSA Set Slave Address Master is setting the address Press Enter RIGHT DOWN ENTER LEFT UP RIGHT DOWN ENTER LEFT UP Node address N PROFIBUS RIGHT DOWN ENTER LEFT UP T...

Page 24: ...oller E x 255 255 255 000 Press Enter to leave RIGHT DOWN ENTER LEFT UP RIGHT DOWN ENTER LEFT UP IP Address 000 000 000 000 PROFINET IO RIGHT DOWN ENTER LEFT UP RIGHT DOWN ENTER LEFT UP Profinet Subne...

Page 25: ...et locking code Press Enter Set the locking code Move the cursor to the _ lock icon RIGHT DOWN ENTER LEFT UP Lock menu Code 0000 St Lock menu RIGHT DOWN ENTER LEFT UP Lock menu Code 0000 St _ RIGHT DO...

Page 26: ...00 00 Wed 2014 04 01 RIGHT DOWN ENTER LEFT UP RIGHT DOWN ENTER LEFT UP Display Scr saver Screen saver Set screen saver time Press Enter UP increase DOWN decrease Press Enter to leave RIGHT DOWN ENTER...

Page 27: ...T DOWN ENTER LEFT UP RIGHT DOWN ENTER LEFT UP Backlight 60 Display Contrast Contrast RIGHT DOWN ENTER LEFT UP Set the intensity of backlight Press Enter UP increase DOWN decrease Press Enter to leave...

Page 28: ...chine are ignored Diagnostic Show LOG Set the intensity of backlight Press Enter r Scroll through the list Ex 005 008 First number is the current error displayed Second number is the total amount of s...

Page 29: ...Press Enter Press Enter Log file is saved on root of the inserted SD card Saved file name is RI_LOG00 TXT RI_LOG01 TXT etc etc Press Enter to leave Dump LOG to SD OK to confirm RIGHT DOWN ENTER LEFT...

Page 30: ...1 GND GND 31 M27 GND Test of Digital Outputs Diagnostic Test Dig OUT 21 20 19 18 17 DIG_OUT_0 19 DOUT_2 20 DOUT_3 18 DOUT_1 21 DOUT_4 0 1 2 3 4 DIG_OUT_1 DIG_OUT_2 DIG_OUT_4 DIG_OUT_3 RE1 RE2 RE3 RE4...

Page 31: ...that can be activated from robot In MIG it is also possible to active the functions wire inching and wire inch speed touch sensing gas test and panel lock Weld settings Controlled by Select control m...

Page 32: ...with the RCI2 holds also setup and configuration files that are needed by some robot and PLCs Take out the SD card and read the MIGA_CFG DOCUMENTS folder on your PC Each folder contains EDS or GSD fi...

Page 33: ...nation Bit3 LLLL Bit0 Selected from machine Bit3 LLLH Bit0 Select program 1 Bit3 LLHL Bit0 Select program 2 Bit3 LLHH Bit0 Select program 3 Bit3 HHHH Bit0 Select program 15 xxxx 8 D DIN8 Program Bit2...

Page 34: ...s L when some errors are active interface machine or feeder L 21 e DOUT4 ANALOG INPUTS Pin Military Plug Symbol Name Description Range 25 E AIN0 Wire Speed Set CWF Wire Speed Control CWF wire speed in...

Page 35: ...welding H 7 C DIN9 Program Bit3 Welding Program Selection Select program number based on inputs combination Bit3 LLLL Bit0 Selected from machine Bit3 LLLH Bit0 Select program 1 Bit3 LLHL Bit0 Select...

Page 36: ...when status is OK Output is L when some errors are active interface machine or feeder L 21 e DOUT4 Pilot Arc Detect Pilot Arc Detect Status Output is H when pilot arc is present H ANALOG INPUTS Pin Mi...

Page 37: ...arc can be operated also during welding H 7 C DIN9 Program Bit3 Welding Program Selection Select program number based on inputs combination Bit3 LLLL Bit0 Selected from machine Bit3 LLLH Bit0 Select p...

Page 38: ...tput is L when some errors are active interface machine or feeder L 21 e DOUT4 Pilot Arc Detect Pilot Arc Detect Status Output is H when pilot arc is present H ANALOG INPUTS Pin Military Plug Symbol N...

Page 39: ...t Level of Base current as Percent of Set current in slow pulse mode 1 unit 1 Example 35 35 12 89 96 Fast Pulsation Base Current Level of Base current as Percent of Set current in fast pulse mode 1 un...

Page 40: ...ast Pulse enabled 1 most common Fast pulse mode used is 1 31 241 248 Process selection 0 Tig DC 1 Tig AC 2 MMA DC 3 MMA AC 4 Plasma DC Example Welding Process Plasma DC 4 32 33 249 264 Control Bits Bi...

Page 41: ...tres min 11 12 81 96 Actual Wire speed Returns the speed of wire for the CWF in use on Pi mm min Example 2500 2 5m min 13 14 97 112 Error Code Low Byte Error Module High Byte Error Code Example 14 01...

Page 42: ...s On 4 Fast pulse Mode is On Synergic Pulse frequency depends from the level of current Example Fast Pulse enabled 1 most common Fast pulse mode used is 1 3 17 24 Process selection 0 Tig DC 1 Tig AC 2...

Page 43: ...Example 450 4 5 Litres min 11 12 81 96 Actual Wire speed Returns the speed of wire for the CWF in use on Pi mm min Example 2500 2 5m min 13 14 97 112 Error Code Low Byte Error Module High Byte Error C...

Page 44: ...lue Maximum number depends from the machine in use By setting 0 the program can be selected directly on the Panel of machine or remote Example Program no 21 21 8 57 64 Fast pulsation mode Possibility...

Page 45: ...2 of 3 INPUT Bytes to RCI2 Byte Bit Name Description Example 12 89 96 Control Bits Control of CWF Bit 89 Wire Hold Pause Bit 90 Wire Inch Bit 91 Wire Inch Bit 92 Disable Pulse Wire Bit 93 not used Bi...

Page 46: ...le 2500 2 5m min 13 14 97 112 Error Code Low Byte Error Module High Byte Error Code Example 14 01 and 13 03 E 03 01 Error codes can be found in the manual for the machine 15 113 120 Actual program num...

Page 47: ...ed of wire for the CWF specified on selected welding program of PI mm min Example 1 5 m min 1500 5 6 33 48 Plasma Gas Flow Rate Set the PLASMA gas flow rate Litres min 100 Example 4 5 Litres min 450 7...

Page 48: ...ually prior to starting Pilot arc Set Plasma gas value in byte 5 6 and purge Plasma gas Bit 80 Bit 101 not used Bit 102 not used Bit 103 Shield Gas Purge Bit 104 Plasma Gas Purge Interlock Gas Bit 105...

Page 49: ...es min 100 Example 450 4 5 Litres min 9 10 65 80 Actual Wire speed Returns the speed of wire for the CWF in use on Pi mm min Example 2500 2 5m min 11 81 88 Reserved for system 12 89 96 Actual program...

Page 50: ...rface if the machine is in job mode xxxxx xx 5 P DIN11 Program Bit5 2 n DIN14 Program Bit4 7 C DIN9 Program Bit3 8 D DIN8 Program Bit2 9 G DIN7 Program Bit1 10 H DIN6 Program Bit0 6 T DIN10 Tack Tack...

Page 51: ...Inch Speed Control welding current in real time Welding current cannot be controlled from interface if machine is in job mode This input is scaled with the maximum power module size For 500A power sou...

Page 52: ...nterface and cannot be controlled from the welding machine xxxx 5 P DIN11 2 n DIN14 7 C DIN9 Sequence Bit3 8 D DIN8 Sequence Bit2 9 G DIN7 Sequence Bit1 10 H DIN6 Sequence Bit0 6 T DIN10 Tack Tack Mod...

Page 53: ...Control welding current in real time Welding current cannot be controlled from interface if machine is in job mode This input is scaled with the maximum power module size For 500A power source this m...

Page 54: ...set from interface if the machine is in job mode xxxxx xx 5 P DIN11 Program Bit5 2 n DIN14 Program Bit4 7 C DIN9 Program Bit3 8 D DIN8 Program Bit2 9 G DIN7 Program Bit1 10 H DIN6 Program Bit0 6 T DIN...

Page 55: ...is activated H 19 k DOUT2 Duo Plus Duo Plus Status Output is H when duo plus is activated H 20 h DOUT3 Error Global Error Status Output is H when status is OK Output is L when some errors are active...

Page 56: ...trolled from the interface and cannot be controlled from the welding machine xxxx 5 P DIN11 2 n DIN14 7 C DIN9 Sequence Bit3 8 D DIN8 Sequence Bit2 9 G DIN7 Sequence Bit1 10 H DIN6 Sequence Bit0 6 T D...

Page 57: ...tivated H 19 k DOUT2 Duo Plus Duo Plus Status Output is H when duo plus is activated H 20 h DOUT3 Error Global Error Status Output is H when status is OK Output is L when some errors are active interf...

Page 58: ...job index 3 If an index with no associated job is chosen the welding machine will show an error E29 05 Selecting a valid index will clear this error Range 1 to 255 9 10 65 80 Welding Program Set the w...

Page 59: ...e mode cannot be set from interface if machine is in job mode Bit 122 Duo Plus Enable Set this input ON to enable duo plus Duo plus mode cannot be set from interface if machine is in job mode Bit 123...

Page 60: ...gram P113 is selected 15 16 113 128 Actual Sequence Number Returns the sequence number in use on machine Example1 0 Machine is not running in sequence mode Example2 5 Sequence 5 is selected 17 18 129...

Page 61: ...eed cm min 10 Example 5 0 5cm min 125 12 5cm min Minimum inch speed is 0 5cm min Range 0 to 30m Min 7 8 49 64 Job Number Index Set the job number index 0 Normal mode not job mode 1 255 Selecting job w...

Page 62: ...e set if the active welding program supports pulse mode Pulse mode cannot be set from interface if machine is in job mode Bit 106 Duo Plus Enable Set this input ON to enable duo plus Duo plus mode can...

Page 63: ...t wire feeder 0 Internal wire feeder xx External wire feeder xx At the moment only 1 and 2 are valid feeders If a second feeder is present it must be set as No 2 with a jumper inside the feeder Exampl...

Page 64: ...in use on machine Example1 0 Machine is not running in sequence mode Example2 5 Sequence 5 is selected 13 97 104 Status bits Bit 97 Arc Detect Bit 98 not used Bit 99 Touch Sense If touch sense is acti...

Page 65: ...35 34 33 32 36 DIG_OUT_0 DIG_OUT_1 DIG_OUT_2 DIG_OUT_4 DIG_OUT_3 VIRTUAL GND 10V 2mA AN_IN_2 AN_IN_2 AN_IN_1 AN_IN_1 AN_IN_0 AN_IN_0 AN_OUT_0 GND AN_OUT_1 GND GND GND 19 DOUT_2 20 DOUT_3 18 DOUT_1 21...

Page 66: ...reader Turn on the welding machine Wait until the display writes REMOVE SD CARD Turn off the machine and remove the SD card The machine is now ready for use Insert the Configuration SD cards again Not...

Page 67: ...ns High HIGH IMMUNITY filter enabled slower response but higher immunity Digital Sens Low No functionality Check all supply and status LEDs 5V_CAN ON OK OFF 11V CAN supply coming from the power source...

Page 68: ...connection Check all CAN connections 11V CAN supply is missing E 02 13 CAN gone to BUS WARNING state because of missing CAN connection Check all CAN connections E 02 19 CAN interrupt error Check the...

Page 69: ...mounted Anybus module E 33 42 Fieldbus Anybus Driver information Anybus module is defective See also next pages Anybus Error list E 33 43 Fieldbus Anybus Driver warning Anybus module is defective See...

Page 70: ...90 00 User has cleared logs Information only E 90 01 Invalid logs header Clear the log If error continues then exchange the RCI2 PCB 71617074 E 90 02 Undefined error Check the setup of RCI2 E 90 04 To...

Page 71: ...tions timed out Alternating Red Green Self test Module Status State Indication Off No power Green Operating in normal condition Flashing Green 1 Hz Missing or incomplete configuration device needs com...

Page 72: ...Duplicate IP address FATAL error Red flashing One or more connections timed out CIP Class 1 or 3 Module Status LED Note A test sequence is performed on this LED during startup LED State Description O...

Page 73: ...xchange Flashing Green Clear Flashing Red 1 flash Parametrization error Flashing Red 2 flashes PROFIBUS Configuration error Status State Indication Comments Off Not initialized Anybus state SETUP or N...

Page 74: ...peration Module has shifted from the NW_INIT state Green 1 flash Diagnostic Event s Diagnostic event s present Green 2 flashes Blink Used by engineering tools to identify the node on the network Red E...

Page 75: ...t HMS technical support ERR LED This LED indicates EtherCAT communication errors etc LED State Indication Description Off No error No error or no power Red blinking Invalid configuration State change...

Page 76: ...DIGITAL IN3 DIGITAL IN2 DIGITAL IN1 GROUND 37 s DIGITAL IN0 DIGITAL OUT0 DIGITAL OUT1 DIGITAL OUT2 2 1 5 4 3 7 6 10 9 8 DIGITAL OUT3 13 12 11 55V 15 14 18 17 16 21 20 19 23 22 26 25 24 29 28 27 31 30...

Page 77: ...on defined by the configurations file Function defined by the configurations file Function defined by the configurations file Function defined by the configurations file Function defined by the config...

Page 78: ...Anybus Modul PROFIBUS Anybus module de PROFIBUS 9b 17200070 Anybus modul DEVICENET Anybus module DEVICENET Anybus Modul DEVICENET Anybus module de DEVICENET 9c 17200071 Anybus modul ETHERNET IP Anybus...

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Page 80: ...20 411 135 600 www migatronic cz Hungary MIGATRONIC KERESKEDELMI KFT Szent Mikl s u 17 a H 6000 Kecskem t Hungary Tel 36 76 505 969 www migatronic hu MIGATRONIC ASIA China SUZHOU MIGATRONIC WELDING TE...

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