Kuka KRC2 ed05, adding external axis

Edit: I updated machine.dat with another thread I found on this forum (posted the wrong link earlier), only non-default setting was in_pos_ma - set to 0.2 and it works just fine.

I have a KR20-2 Series 2000 robot with a KRC2 Ed05 running KSS 5.6.8.

Robot Type KR2210_2 S C2 FLOR ZH210

I'm trying to add 2 external axes, one is a rotary turntable and one is a linear track carrying the robot arm. For now I'd be happy with just the rotary, so I'll focus on that, and hopefully I'm skipping something simple.

My process:

0. With no ext axes, I can jog the robot, no errors.

1. Expert logon

2. Setup>Service>Axisconfigurator

3. Change EX_AX_NUM to 1

4. External Axis tab: Change AXIS_TYPE to 5, and MOTORTYPE to 69-225-463, B. (This automatically changed values accordingly, and used the KSD32 servofile)

5. Ext. Kinematics tab: Set transformation type to EASYS

6. Save and Exit

At this point, I get a popup saying "Submit interpreter cannot be started", continue on and I have two error messages: R1 data loader aborted, and Erroneous DSE assignment 1, and if I try to jog the robot I get "machine data error" and active commands prohibited.

The KSD-32 was installed and wired by the seller but not configured. I haven't found a problem with the wiring.

After talking with KUKA support I believe the machine.dat file has issues. Has anyone got a machine.dat with an enabled ext axis that I could reference? Mine are attached as they are after step 6.

Thanks!

I see I'm missing several lines in the machine.dat file (things like DSECHANNEL and most other things).

Should have just looked a little harder but I'll run through these and change to default values and update again.

Thanks Panic mode, I'll search through the D: drive when I install the 8th axis next. This has been a pretty pleasant project so far, overall. Really happy with Kuka support and this forum

I'm back on it with this project, the 7th axis rotary has been working just fine after going through machine.dat, searching for [7], and making sure an appropriate value is there.

Now that the covid panic has shut most of our customers down, it's a good time to get the track operating.

To simplify some things, I just moved the cables to the linear motor and changed the data to linear (ERSYS instead of EASYS, etc, using the axis configurator and the external axis manual).

Firstly, I also have this error that I don't know if it's affecting or not:

29: Drive bus DSE 1 participant no. 9 not configured

Here's the main problem:

When I try to jog, the axis will move maybe 5cm (more of a lurch than a steady move) and stop, brakes engage, errors pop up:

    1104 Ackn. regulator limit exceeded E1
    1161 Ackn. monitoring of the actual velocity E1

If I lower the $VEL_AXIS_MA to 100.0, it moves much slower, same behavior, but then the error code is:

3030: Ackn. target speed monitoring E1

Here's my data for the linear axis 7 (the only one currently connected), mostly taken straight from the example:

$AXIS_TYPE: 1
MOTORTYPE: NONE  <<If I enter the motor here, it autofills KT_MOT and others, then after cold boot, this field is back to "NONE" but the motor data stays.
$KT_MOT: 1315999997
$KTO_MOT: 1.33000004
$RAISE_T_MOT: 5
$RAT_MOT_ENC {N 1,D 3}
$BRK_ENERGY_MAX: 2600
$BRK_COOL_OFF_COEFF: 41.0
$BRK_TORQUE: 13.3
$SERVOFILE: "KSD_32_MC0_A_2"
$CURR_MAX: 32.0
$CURR_LIM: 100
$CURR_MON: 12.0000002
$CURR_CAL: 1.0
$CURR_COMM_EX: 100.0
$DSECHANNEL: 7
$PMCHANNEL: 21
$AXIS_RESO: 4096
$IN_POS_MA: 1.5
$RED_VEL_AXC: 5
$RED_ACC_AXC: 10
$RED_ACC_OV: 100
$VEL_AXIS_MA: 3000.0
$G_VEL_PTP: 75.0
$G_VEL_CP: 80.0
$I-VEL-PTP: 200.0
$LG_PTP: 0.5
$LG_CP: 0.600000024
$G_COE_CUR: 85
$APO_DIS_PTP: 500.0
$SOFTN_END: -500.0
$SOFTP_END: 4500.0
$RAT_MOT_AX: {N -360,D 33}
$AX_ENERGY_MAX: 2500
$MAMES: 0.0
$VEL_AX_JUS: 0.9648
$L_EMT_MAX: 9.60000038
$RAISE_TIME: 900.0
$RED_ACC_EMX: 150
$DECEL_MB: 600.0
$AXIS_DIR: -1
$AXYNC_T1_FAST: 0
$EX_AX_ASYNC: 0
$AXYNS_EX_AX_DECOUPLE: 0
$JERK_MA: 1000.0
$AXIS_JERK: 11.6400003

I've tried changing values for RAT_MOT_AX and RAT_MOT_ENC, the velocity max, assuming something with speed or reading that speed is going wrong.

Has anyone got any idea what I'm missing?

I'm going to run through the optimization process for $G_VEL_PTP, $G_VEL_CP etc using the ext axis manual. (Section 7.4.2 page 60)

I put the cart ahead of the horse there. I can release the brakes by moving A1-6, but get the velocity error as soon as I try to move E1. The other motor will work just fine with the same hardware, so it's got to be something with parameters.

Update:

I'm convinced the motor itself is the problem, and have a replacement on the way. The motor I was using had a damaged encoder plug that we repaired, but there must be some kind of broken connection we didn't see - we'll know in a few days if this solves it.

Solved by replacing the motor!