KUKA Robotics Auto-Axcess DI Connection Guide

KUKA Robotics Auto-Axcess Connection Specification
Auto-Axcess Connection to Devicenet
Revision History
Date Version Description Author PM Approval
1-Jan-08 V01.D01 Document Created Jeff Funke
22-Jan-08 V01.D02 Document Released Jeff Funke
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CONFIDENTIAL DO NOT COPY
APN-0512002V01D02 V01.D02 Page 2 of 34

Table of Contents
Table of Contents 3
1 Overview 3
2 Material Requirements and Cable Construction –
Auto-Axcess DI 3
2.1 Solution A – D-net cable to D-net Interface at bottom of KR C2 3
2.1.1 Materials Required 3
2.1.2 Hardware Installation 3
2.2 Solution B – D-net cable through cord grip to LPDN 3
2.2.1 KUKA Supplied Materials 3
2.2.2 3rd Party Vendor Materials 3
2.2.3 Tools Required 3
2.2.4 Hardware Installation 3
3 Modifying the Registry 3
3.1 Open the Registry 3
4 ArcTech System and I-O Configuration 3
4.1 DNSC2.SL 3
4.2 DNSC2.CO 3
4.3 IOSYS.INI 3
4.3.1 Drivers 3
4.3.2 [DNSC2] 3
4.4 Config.dat 3
4.4.1 ArcTech Outputs 3
4.4.2 ArcTech Inputs 3
4.4.3 Definition of Controller lines MODE 1 3
4.4.4 Definition of Controller lines MODE 2 3
4.4.5 USER GLOBALS 3
4.5 SPS – Submit Interpreter Modification 3
4.5.1 Submit USER INIT Modification/Addition 3
4.5.2 Submit Loop USER PLC Modification/Addition 3
4.6 A10.SRC – Modification from MPM to IPM 3
4.7 A10.DAT 3
4.8 ArcTech_A10.TXT 3
4.9 Import Arc Text to Database 3
4.10 BOF Reinitialization 3
4.11 Variable Overview Screen Modification 3
4.11.1 Edit the ConfigMon.INI file 3
4.11.2 Variable Overview Monitor Display Screen 3
5 I-O Structure 3
5.1 Auto-Axcess DI 3
6 Hardware Ordering 3
6.1 KUKA Hardware 3
6.2 Wire Feed Mounting Bracket Error! Bookmark not defined.
6.3 Miller Electric Hardware 3
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6.4 Third Party Hardware 3

7 Programming Example 3
7.1 Programming Pulsed 3
7.2 Programming MIG 3
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1 Overview
The intent of this document is to specify proper implementation
of devicenet communication between the KUKA KR C2 robot
controller and Miller Electric Auto-Axcess weld power supplies
equipped with the direct devicenet connector or 72 pin Harting
connector.
KUKA Robotics has released this application release note to help integrators and
customers more easily integrate KUKA robots into welding systems utilizing Miller
Electric weld power supplies.
Benefits:
• Standard interface familiar to hotline staff at KUKA and Miller Electric
• Provides full functionality of equipment
• Design is properly documented for duplication and replacement parts
• No time wasted redesigning cables and connections
KUKA Robotics is an authorized OEM distributor for the Miller Auto-Axcess DI weld
power supply using straight devicenet communication via the KUKA LPDN card across
a standard 5 wire devicenet cable. This method eliminates the need for a devicenet
module with bus-coupler, discrete signal and analog modules.
As an OEM, KUKA Robotics is able to provide support in several ways:
• Offering welding systems completely integrated with the KUKA Robot mechanical arm and
controller.
• Provide the software configuration information required to get an integrator or system partners
installation operational.
• Train customers, integrators and system partners to configure, operate and maintain the Miller
Electric Auto-Axcess DI weld power supply.
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2 Material Requirements and Cable Construction –

Auto-Axcess DI
2.1 Solution A – D-net cable to D-net Interface at bottom of KR C2
This solution makes the assumption the devicenet cable is to be removed from the weld power supply
and KR C2 controller and requires no tools to replace a cable by the operator/technician. The higher cost
of this solution ensures cable replacement / installation is mistake free and fast reducing the cost
associated with time required during installation, maintenance and troubleshooting to identify loose wires
or frayed connections when problems occur. There is also no engineering time required to design, order
and procure the necessary parts.
2.1.1 Materials Required
2.1.1.1 KUKA Supplied
1. Devicenet Scanner LPDN (2 Channel) 00-104-
196
2. Multi-Power-Tap (MPT) 00-129-606
2.1.1.1.1 3rd Party Vendor
3. Turck Cable – RSF 5711-2M/NPT
4. Turck Cable – RKF 5711-2M/NPT
5. Turck Cable – RSF 46-2M/NPT
6. Turck Cable – RSM WSM 575-15M (15 meter
Devicenet Thick, length dependent on distance
from KR C2 to Weld Power Supply)
2.1.1.2 Tools Required
7. Phyllips Tip Screw Driver
8. Straight blade terminal screw driver
9. Wire Cutter and Stripper
10. Ty-Raps
Figure 1 Cable Connection KR C2 Base
Figure 2 Cable Connection Auto-Axcess Rear
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2.1.2 Hardware Installation

11. Install LPDN in PC Rack. Reference Chapter 3 of the LPDN Software Configuration KR C2
Manual.
12. Install the Multi-Power Tap in the base of the KR C2 controller according to the
documentation.
13. Remove one of the cabinet entry blanks and modify
per Figure 1 below.
14. Install the 3 Turck bulkhead connectors as shown
in Figure 2.
15. Terminate SD2 on LPDN channel 2 with 121 ohm
terminating resistor between pins 2 and 4.
16. Terminate SD1 on the Multi-Power Tap.
17. Terminate P1 on an Auxilliary Devicenet power
supply if needed.
18. Install the devicenet cable from the base of the
robot controller (straight connector) to the back of
the Miller Electric Auto-Axcess DI weld power
supply (90 Degree connector).
19. Mount the wire feed motor onto axis 3 of the KUKA
Robot using bracket XX-XXX-XXX.
20. Install the Dress package following the procedure
in section 7.
21. Attach the wire feed interface cable to the back of
the Miller Electric Auto-Axcess DI weld power
supply.
Figure 3 Cover Blank Modification
Figure 4 – Devicenet Bulkhead Installation
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2.2 Solution B – D-net cable through cord grip to LPDN

This solution makes the assumption a non-flexing cable would not wear out easily and should therefore
not need to be replaced quickly. Sacraficing the ease of replacement with significantly lower
manufacturing cost is the advantage of this solution. Another advantage is the limited number of
terminations for individual conductors in this solution reducing possible errors in assembly.
2.2.1 KUKA Supplied Materials
22. Devicenet Scanner LPDN (2 Channel) 00-104-196
23. Wieland cable inlet, part number 69-000-490
2.2.2 3rd Party Vendor Materials
24. Turck Devicenet Cable – Turck # WSM 575-10M (length dependent on distance KR C2 to
Weld power supply)
25. 5 Pin Phoenix Connector for LPDN card
26. 121Ω resistor
27. Wieland cable inlet, part number 69-000-490
28. DeviceNet Scanner LPDN (2Channels), 00-104-196
29. Crimp style wire ferruls
30. IGUS CF300-950-1 3/0 Stranded Single Conductor Cable
2.2.3 Tools Required
31. Wire stripper
32. Wire ferrul crimper
33. Small terminal screw driver
34. Wire cutters
35. Phyllips Tip Screw Driver
36. Measuring Scale
2.2.4 Hardware Installation
37. Install LPDN in PC Rack. Reference Chapter 3 of the LPDN Software Configuration KR C2
Manual.
38. Install the Weiland Housing in an empty slot on the bottom of the KR C2 controller.
39. Install the Devicenet cable through one of the rubber grommets in the Weiland shell and
ensure the end without the connector is toward the inside of the cabinet. Route the cable
neatly along the inside to the top of the PC Rack, secure with Ty-Rap’s.
40. Attach the 5 Pin Pheonix connector with the 121 Ohm resistor as illustrated below.
2.2.4.1 Pinout Solution B – Devicenet Cable to CombiCon on LPDN Channel 2
The cable must meet the cableing requirements specified in the Manual
DevicNet (CAN Bus) Release 2.2 or later.
Figure 5 Combicon Connector Pinout
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NOTE – Be sure proper terminating resistor is installed between pin 2 and

4. Reference section 2.1 of the Devicenet manual for more information on
installing the fieldbus cables.
41. Place the 5 pin Pheonix connector onto Channel 2 of the LPDN card mounted in the PC
Rack.
42. Attach the other end of the cable to the Miller Electric Auto-Axcess DI weld power supply.
43. Mount the wire feed motor onto axis 3 of the KUKA Robot using bracket XX-XXX-XXX.
44. Install the Dress package following the procedure in section 7.
45. Attach the wire feed interface cable to the back of the Miller Electric Auto-Axcess DI weld
power supply.
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3 Modifying the Registry

Windows Registry Modifications Required to Allow Inches Per
Minute up to 100.
3.1 Open the Registry

1. While an expert or administrator, bring up the START menu (from the KCP with NUMLOCK off,
the 2 key is CTRL), CTRL-ESC.
2. Select RUN or arrow up 3 times to the RUN command, press enter to open.
3. Type “regedit” and press ENTER
4. Navigate through the tree to HKEY_CURRENT_USER Software VB and VBA Program
Settings KUKATPARCCP_VEL
5. Press Tab to move the cursor to the right window.
6. Move the cursor to the MAX registry, press ENTER
7. If using KCP keyboard, Set NUM-LOCK ON
8. Change the value from “2” to “100”. (100 will now be the maximum cartesian feedrate allowed in
ArcTech, this is acceptable since most GMAW welding cannot exceed 100 unless using
TANDEM TWINWIRE process)
9. Press Enter to close the registry entry
10. If using KCP keyboard, Set NUM-LOCK OFF
11. Hold the SHIFT key and press TAB to move back to the registry tree.
12. Move down the tree to the VEL Registry. (Full location HKEY_CURRENT_USER Software
VB and VBA Program Settings KUKATPARCVEL)
13. Press Tab to move the cursor to the right window.
14. Move the cursor to the MAX registry, press ENTER
15. If using KCP keyboard, Set NUM-LOCK ON
16. Change the value from “2” to “100”. (100 will now be the maximum cartesian feedrate allowed in
ArcTech, this is acceptable since most GMAW welding cannot exceed 100 unless using
TANDEM TWINWIRE process)
17. If using KCP keyboard, Set NUM-LOCK OFF
18. Press Enter to close the registry entry
19. Press ALT-F and then arrow down to exit the registry.
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4 ArcTech System and I-O Configuration

1. Install the ArcTech Analog v1.0.3 or later software. Select the proper type of application (Thin, Thick,
Thick with Sensor).
4.1 DNSC2.SL
[MODULE_STARTUP]
INACTIV=; Example: 1,5,6
CONTINUE_WITH_WARNING=; Example: 8,25
[SCANNERCFG]
NET_EPR=75
NET_ISD=2
NET_BACKGROUND_POLL_RATE=1
NET_TX_RETRY_COUNT=1
; ------- End entry -------
[1] ; Slave number

MAC_ID=27 ; 0-63
VENDOR_ID=486 ; device keying info
PRODUCT_TYP=12 ; device keying info
PRODUCT_CODE=1 ; device keying info
POLL_RESPL=8 ; total # of bytes expected in poll resp
POLL_CMDL=8 ; total # of bytes expected sent in poll
; ------- End entry -------
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4.2 DNSC2.CO
;-----------------------------------------------------------------------------------------------------------
; Configuration for LPDN-Scanner(Channel 2)
;-----------------------------------------------------------------------------------------------------------
;
;Section [CONFIG]
;
;MAC_IDValues:0..63
;Default:-- (required parameter)
;Description:MacID of the robot DeviceNet channel
;
;BAUDRATEValues:125, 250, 500
;Default:-- (required parameter)
;Description:Baudrate of the CAN network in KBaud
;
;DEBUGValues:0, 1 corresponding (off / on)
;Default:0
;Description:Enhanced diagnostic information
;
;USE_ERROR_DBValues:0, 1 corresponding (use not / use)
;Default:0
;Description:Usage of the language database
;
;SCANLIST_COMMENTValues:0, 1 corresponding (off / on)
;Default:0
;Description:Baudrate of the CAN network
;
;OPTIONSValues:0, 1179992907
;Default:0
;Description:user option
;
;-----------------------------------------------------------------------------------------------------------
;
;Section [FAST_OUT]
;
;MAC_IDValues:0..63
;Default:Deaktivated (required parameter if used)
;Description:Fastwrite MacID. To deactivate, use a not valid value or remove the whole entry.
;
;-----------------------------------------------------------------------------------------------------------
[CONFIG]
MAC_ID=27 ;; Required Mac ID for robot to be Miller Communication Node
BAUDRATE=125 ;; Miller recommended baud rate
DEBUG=1
; USE_ERROR_DB=; use default value
; SCANLIST_COMMENT=; use default value
; OPTIONS=; use default value
[FAST_OUT]
; MAC_ID=20; not activated
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4.3 IOSYS.INI
4.3.1 Drivers
[DRIVERS]
DNSC2=13,dnsc2Init,dnsc2drv.o
4.3.2 [DNSC2]
[DNSC2]
;;The Configuration below is intended for use with
;; Miller Electric Auto-Axcess weld power supplies.
;; The configuration is for the LPDN channel 2 as slave
;; to the Miller Electric Master Devicenet Scanner.
;; The LPDN channel 2 node ID for the robot is 27
;; Miller Auto-Axcess Digital Inputs

inb32=27,0,x2 ;; Digital Inputs [257 - 272]
inb34=27,2,x2 ;; Digital Inputs [273 - 288] Analog 1
inb36=27,4,x2 ;; Digital Inputs [289 - 304] Analog 2
inb38=27,6,x2 ;; Digital Inputs [305 - 320]
;; Miller Auto-Axcess Digital Outputs

outb32=27,0,x2 ;; Digital Outputs [257 - 272]
outb34=27,2,x2 ;; Digital Outputs [273 - 288] Analog 1
outb36=27,4,x2 ;; Digital Outputs [289 - 304] Analog 2
outb38=27,6,x2 ;; Digital Outputs [305 - 320]
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4.4 Config.dat
INT A_ACT_AN_MAX=3 ;Maximum of analog channels to see parameterlists
4.4.1 ArcTech Outputs

;FOLD ArcTech Outputs
DECL CTRL_OUT_T A_WLD_OUT[16]
A_WLD_OUT[1]={OUT_NR 266,INI FALSE,NAME_NAT[] "WELD_START "}
A_WLD_OUT[2]={OUT_NR 260,INI FALSE,NAME_NAT[] "GAS PREFLOW "}
A_WLD_OUT[3]={OUT_NR 313,INI FALSE,NAME_NAT[] "WELD_MODE PS/MM"}
A_WLD_OUT[4]={OUT_NR 0,INI FALSE,NAME_NAT[] "CLEANER "}
A_WLD_OUT[5]={OUT_NR 0,INI FALSE,NAME_NAT[] "RECEIPT ERRORS "}
A_WLD_OUT[6]={OUT_NR 0,INI FALSE,NAME_NAT[] "ERR MESSG_SIGNAL"}
A_WLD_OUT[7]={OUT_NR 0,INI FALSE,NAME_NAT[] "START ERROR "}
A_WLD_OUT[8]={OUT_NR 0,INI FALSE,NAME_NAT[] "APPL_ERROR "}
A_WLD_OUT[9]={OUT_NR 0,INI FALSE,NAME_NAT[] "INTERPRETER-STOP"}
A_WLD_OUT[10]={OUT_NR 0,INI FALSE,NAME_NAT[] " "}
A_WLD_OUT[15]={OUT_NR 259,INI FALSE,NAME_NAT[] "WFD + "}
A_WLD_OUT[16]={OUT_NR 258,INI FALSE,NAME_NAT[] "WFD - "}
;ENDFOLD (ArcTech Outputs)
4.4.2 ArcTech Inputs
;FOLD ArcTech Inputs
DECL CTRL_IN_T A_WLD_IN[16]
A_WLD_IN[1]={IN_NR 0,NAME_NAT[] "WELDER READY "}
A_WLD_IN[2]={IN_NR 257,NAME_NAT[] "ARC ESTABLISHED "}
A_WLD_IN[3]={IN_NR 0,NAME_NAT[] "SEAM_ERROR "}
A_WLD_IN[4]={IN_NR 0,NAME_NAT[] "CURRENT OVER "}
A_WLD_IN[5]={IN_NR 0,NAME_NAT[] "KEY SWITCH HOT/COLD "}
A_WLD_IN[6]={IN_NR 0,NAME_NAT[] " "}
A_WLD_IN[7]={IN_NR 0,NAME_NAT[] "BURN FREE INP_SIGNAL"}
A_WLD_IN[10]={IN_NR 0,NAME_NAT[] "WATER AVAILABLE "}
A_WLD_IN[11]={IN_NR 0,NAME_NAT[] "GAS AVAILABLE "}
A_WLD_IN[12]={IN_NR 0,NAME_NAT[] "WIRE AVAILABLE "}
A_WLD_IN[13]={IN_NR 0,NAME_NAT[] "COLLECTION FAILURE "}
;ENDFOLD (ArcTech Inputs)
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4.4.3 Definition of Controller lines MODE 1

;FOLD Definitions of Controllerlines
;FOLD Mode1 (Pulse Mode)
DECL A_ANA_DEF_T A_ANA_DEF[2,8,5] ;WELD_Mode,Channel,Points of controler line
1:pulse/2:MigMag
;Mode1 Channel1 command value
A_ANA_DEF[1,1,1]={PARA 0.0,VAL 0.0}
A_ANA_DEF[1,1,2]={PARA 100.0,VAL 100.0}
A_ANA_DEF[1,1,3]={PARA 101.0,VAL 0.0}
A_ANA_DEF[1,1,4]={PARA 102.0,VAL 0.0}
A_ANA_DEF[1,1,5]={PARA 103.0,VAL 0.0}
;Mode1 Channel2 wire feed [IPM]
A_ANA_DEF[1,2,1]={PARA 80.0,VAL 80.0}
A_ANA_DEF[1,2,2]={PARA 1000.0,VAL 1000.0}
A_ANA_DEF[1,2,3]={PARA 1001.0,VAL 0.0}
A_ANA_DEF[1,2,4]={PARA 1002.0,VAL 0.0}
A_ANA_DEF[1,2,5]={PARA 1003.0,VAL 0.0}
;Mode1 Channel3
A_ANA_DEF[1,3,4]={PARA 10.0,VAL 0.0}
A_ANA_DEF[1,3,5]={PARA 11.0,VAL 0.0}
4.4.4 Definition of Controller lines MODE 2
;FOLD Mode2 (Mig/Mag Mode)
;Mode2 Channel1 command value
A_ANA_DEF[2,1,1]={PARA 10.0,VAL 100.0}
A_ANA_DEF[2,1,2]={PARA 44.0,VAL 440.0}
A_ANA_DEF[2,1,3]={PARA 45.0,VAL 0.0}
A_ANA_DEF[2,1,4]={PARA 46.0,VAL 0.0}
A_ANA_DEF[2,1,5]={PARA 47.0,VAL 0.0}
;Mode2 Channel2 wire feed [IPM]
A_ANA_DEF[2,2,1]={PARA 80.0,VAL 80.0}
A_ANA_DEF[2,2,2]={PARA 1000.0,VAL 1000.0}
A_ANA_DEF[2,2,3]={PARA 1001.0,VAL 0.0}
A_ANA_DEF[2,2,4]={PARA 1002.0,VAL 0.0}
A_ANA_DEF[2,2,5]={PARA 1003.0,VAL 0.0}
;Mode2 Channel3
A_ANA_DEF[2,3,1]= {PARA 1.0,VAL 0.0}
A_ANA_DEF[2,3,4]={PARA 10.0,VAL 0.0}
A_ANA_DEF[2,3,5]={PARA 11.0,VAL 0.0}
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4.4.5 USER GLOBALS

;FOLD USER GLOBALS
;==================================
; Userdefined Types
;==================================
;==================================
; Userdefined Externals
;==================================
;==================================
; Userdefined Variables
;==================================
;FOLD Miller GLOBALS
SIGNAL Miller_AO1 $OUT[273] TO $OUT[288] ;; Voltage Correction
SIGNAL Miller_AO2 $OUT[289] TO $OUT[304] ;; Wirefeed Speed
SIGNAL Miller_AO3 $OUT[269] TO $OUT[271] ;; Program Number
SIGNAL Miller_AI1 $IN[273] TO $IN[288] ;; Voltage Correction Feedback

SIGNAL Miller_AI2 $IN[289] TO $IN[304] ;; Current Feedback
SIGNAL s_I_RI_1 $IN[305] TO $IN[308]

SIGNAL s_I_RI_2 $IN[309] TO $IN[312]
SIGNAL s_I_SI_1 $IN[313] TO $IN[316]
SIGNAL s_I_SI_2 $IN[317] TO $IN[320]
SIGNAL s_O_RI_1 $OUT[305] TO $OUT[308]

SIGNAL s_O_RI_2 $OUT[309] TO $OUT[312]
SIGNAL s_O_SI_1 $OUT[313] TO $OUT[316]
SIGNAL s_O_SI_2 $OUT[317] TO $OUT[320]
;ENDFOLD (Miller GLOBALS)
;ENDFOLD (USER GLOBALS)
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4.5 SPS – Submit Interpreter Modification

4.5.1 Submit USER INIT Modification/Addition
;FOLD USER INIT
s_O_RI_1 = 4
s_O_RI_2 = 5
s_O_SI_1 = 4
s_O_SI_2 = 5
;ENDFOLD (USER INIT)
;ENDFOLD (INI)
4.5.2 Submit Loop USER PLC Modification/Addition

;;FOLD USER PLC
;FOLD Miller PLC
IF ($OUT[313]==TRUE) THEN
s_o_SI_1=3
ELSE
s_o_SI_1=4
ENDIF
Miller_AO1 = A_O_ANA1; Voltage Command
Miller_AO2 = A_O_ANA2; Wirefeed Command
Miller_AO3 = A_O_ANA3; Program Number
;ENDFOLD (Miller PLC)
;;ENDFOLD (USER PLC)
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4.6 A10.SRC – Modification from MPM to IPM

Approximately Line 472
IF $EDIT_MODE==2 THEN
$VEL.CP=((W.VEL/30.0)*0.0254); During online optimization, the OV_PRO is 50% and the weld
velocity must be doubled.
FIF_VELCTRL[A_FIFO_WRITE]=TRUE
ELSE
FIF_VELCTRL[A_FIFO_WRITE]=FALSE
IF A_SAVE_OVR>0 THEN
$VEL.CP= (W.VEL*0.00000423418*A_SAVE_OVR) ; take care of override <> 100
ELSE
$VEL.CP=((W.VEL/60)* 0.000423418) ; 100 per cent mps=ipm/60*0.000423418
ENDIF
ENDIF
4.7 A10.DAT
;FOLD Main Adjustments
BOOL RE_INITIALIZE=TRUE ; TRUE: TPARC.DLL forced to new initialization MIN/MAX and controller
line parameters
BOOL HIDE_BB_TIME=TRUE ; FALSE: Burnbacktime element visible / TRUE:Hidden
DECL CHAN_INFO CHANNEL_INFO[8] ; Unit and steps
CHANNEL_INFO[1]={UNIT[] "V/Arc L",STEP[] "1.0"}
CHANNEL_INFO[2]={UNIT[] "in/min",STEP[] "1.0"}
CHANNEL_INFO[3]={UNIT[] "Program",STEP[] "1.0"}
CHANNEL_INFO[4]={UNIT[] "s",STEP[] "0.01"}
CHANNEL_INFO[5]={UNIT[] "Hz",STEP[] "1.0"}
CHANNEL_INFO[6]={UNIT[] "ms",STEP[] "0.1"}
CHANNEL_INFO[7]={UNIT[] "ms",STEP[] "0.1"}
CHANNEL_INFO[8]={UNIT[] "s",STEP[] "0.1"}
DECL CHAN_INFO VEL_INFO[1]

VEL_INFO[1]={UNIT[] "in/min",STEP[] "1.0"} ; Convert MPM to Inches per Minute
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4.8 ArcTech_A10.TXT
The file “C:\KRC\UTIL\DBTEXTCONVERT\ArcTech_A10.txt” must be modified to
match the following text.
Start11 V 10-44/TRIM 0-100

Start12 Wire Feed IPM
Start13 Program Number 0-7
Start14 Reserve Start14
Weld11 V 10-44/TRIM 0-100
Weld12 Wire Feed IPM
Weld13 Program Number 0-7
Weld14 Reserve Weld14
CraterChannel11 V 10-44/TRIM 0-100
CraterChannel12 Wire Feed IPM
CraterChannel13 Program-Number 0-7
CraterChannel14 Reserve CraterChannel14
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4.9 Import Arc Text to Database

1. Press SETUP | SERVICE | LONGTEXT
2. Press left button for LONGTEXT -> DATABASE
3. With NUMLOCK off, press Tab twice to change focus to the bottom pane in middle.
4. Arrow up to KRC, press ENTER or yellow button
5. Arrow down to UTIL and press ENTER
6. Arrow down to DBTEXTCONVERT and press enter
7. Press TAB once to change focus to right pane and then arrow down once.
8. Press button below checkmark at bottom.
9. Press button below door on bottom to exit.
4.10 BOF Reinitialization
1. Press CONFIGURE | MISELLANEOUS | REINITIALIZATION | BOF REINITIALIZATION
2. Wait for the Reinitialization to complete.
3. Verify the CP_VEL MAX in the registry is still 100. See section 3.1 for procedure to check the
value. Set back to 100 if it was reset to 2.
4. Cold Start the controller
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4.11 Variable Overview Screen Modification

4.11.1 Edit the ConfigMon.INI file
Open the file KRC\Roboter\INI\ConfigMon.ini.
Edit Group 2 (or Group 1) with the following text.
[Group2]
GroupTitle=Auto Axcess DI
Editable=Expert
Visible=User
ColWidthState=35
ColWidthName=100
ColWidthVariable=100
ColWidthValue=97
ConfigWindowWidth=250
ShowWindowWidth=246
Item1=Miller_AO1;Volt/Trim Out;1;3;20
Item2=Miller_AO2;WFS;1;3;20
Item3=Miller_AO3;Program#;1;3;20
Item4=Miller_AI1;Volt/Trim In;1;3;20
Item5=Miller_AI2;Amps;1;3;20
4.11.2 Variable Overview Monitor Display Screen
Figure 6 Variable Overview Monitor Screen
APN-0512002V01D02 V01.D02 Page 23 of 34

5 I-O Structure
5.1 Auto-Axcess DI
This table is intended as a reference for configuring the Miller Weld Power Supply interface with the
KUKA robot. The actual location of the signal within the I-O table may be modified to suit the actual
customer’s installation.
The default weld interface installation for the Miller Electric weld power supply starts at input and output
257 allowing cell control I-O to be at the top of the list since this is likely to be referenced the most from
the I-O Monitor screen.
Table 1 – Robot I-O Table
Robot Input Description Robot Output Description

$IN[257] Arc Detected $OUT[257] Arc Detect (N/A)
$IN[258] Motor Feeding Retract $OUT[258] Motor Retract ON/OFF
$IN[259] Motor Feeding Forward $OUT[259] Motor Forward ON/OFF
$IN[260] Gas is ON $OUT[260] Turn Gas ON
$IN[261] Touch Sensed $OUT[261] Reserved
$IN[262] Coolant Flow Detect $OUT[262] Coolant Flow Detect (N/A)
$IN[263] N/A - Dual Schedule on/off $OUT[263] Dual Schedule ON/OFF (N/A)
$IN[264] N/A – Trigger Held on/off $OUT[264] Trigger Hold ON/OFF (N/A)
$IN[265] Error Detected $OUT[265] Error Detect from Robot
$IN[266] Contactor is ON $OUT[266] Contactor ON Command
$IN[267] Weld State Status $OUT[267] Reserved – write as OFF
$IN[268] Touch Sense Command $OUT[268] Touch Sense Command
$IN[269] Program Bit 0 Feedback $OUT[269] Program Bit 0 Command
$IN[272] Reserved – do not write $OUT[272] Reserved – do not write
Analog Input Description Analog Output Description
$IN[273] to $IN[288] Voltage\Trim Feedback $OUT[273] to $OUT[288] Analog 1 Voltage \ Trim Command
$IN[289] to $IN[294] Current\ Feedback $OUT[289] to $OUT[294] Analog 2 WFS Command in IPM
$OUT[269] to $OUT[271] Program Number 0-7
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6 Hardware Ordering
6.1 KUKA Hardware
Stock Number Description
Mechanical Unit Hardware
00-124-080 Energy Supply A1-A3 Empty NW 42
Z-99-999-990 Wire Feed Mounting Bracket KR 5, 6, 16 A3 Qty 1
Controller Hardware
00-104-196 DeviceNet Scanner LPDN (2 Channel)
00-129-606 Multi-Power-Tap
6.2 Third Party Hardware

Communication Cable – Option A (Pick only one cable)
RSM WSM 575-10M Turck 10M Devicenet Cable Male straight to Male 90 degree – Heavy Duty
RSM WSM 579-10M Turck 10M Devicenet Cable Male straight to Male 90 degree – Normal Duty
Communication Cable – Option B (Pick only one cable)
RSM 575-10M Turck 10M Devicenet Cable Male straight – Heavy Duty
RSM 579-10M Turck 10M Devicenet Cable Male straight – Normal Duty
WSM 579-10M Turck 10M Devicenet Cable Male 90 degree – Normal Duty
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6.3 Miller Electric Hardware

Auto-Axcess DI Welding Power Source - Select Only One
907-151-012 Auto Axcess 300 Digital (Power Source only)
907-151-021 Auto Axcess 300 Digital/ RMD (Power Source only)
907-153-014 Auto Axcess 450 Digital (Power Source only)
907-153-021 Auto Axcess 450 Digital/ RMD (Power Source only)
Wire Feed Motor - Select Only One

195-426 Wire Drive Motor Assembly, AA-40GB W/ OCP (left)
195-515 Wire Drive Motor Assembly, AA-40GB W/ OCP (right)
Wire Feed Motor Cable - Select Only One (12’ required from Wirefeed Motor to
base of robot)
300-097 Motor Control Cable, 40 Volt DC,20 FT
Wire Feed Motor Mounting Plate – Required

300-### Motor Mounting Plate for KUKA Robot
Palm Convenience Pack – Optional

Palm Convenience Pack With Service pack (One required
195-517 per installation site)
Drive Rolls- Select Only One

151-026 .035" Drive Rolls Kit V- Grove
151-029 1/16" Drive Rolls Kit V- Grove
151-036 .035" Drive Rolls Kit U- Grove
151-039 1/16" Drive Rolls Kit U- Grove
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7 Programming Example
For the purposes of understanding and clarity:
• PS refers to PULSED welding. Pulsed in this document refers to a weld program stored on the
Auto Axcess DI (range 1-8) with a process defined as PULSE, ACCU-PULSE, or ACCU-SPEED.
Pulsed uses trim and wire feed speed to define the weld.
• MM refers to MIG/MAG welding. MIG in this document refers to weld program stored on the Auto
Axcess DI (range 1-8) with a process defined as MIG. Mig welding uses volts and wirefeed
speed to define the weld.
• PS and MM are not dependant on Filler Metal (Steel, Stainless Steel, Metal Cored, or Aluminum),
Shielding Gas, or wire diameter (0.030, 0.035, 0.045, 0.052, 1/16)
• Voltage is commanded in volts in a range of 10-44.
• Trim is commanded in % in a range of 0-100 with 50 being the theoretical ideal value.
• Wire Feed Speed (WFS) is commanded in inches per minute (IPM) in the range of 80-1000.
• Program Number is an integer value in the range of 1-8 and corresponds with the weld programs
currently stored in the Auto-Axcess Memory at the time of welding. The programmer is
responsible to ensure the welding programs stored on the weld power supply hold the correct
values.
For more in-depth information specific to the Auto-Axcess DI weld power supply, please consolut your
Owners Manual or you local Miller Technical Support Personnel.
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7.1 Programming Pulsed

When programming pulsed welds, be sure the PS is selected in the ILF and you use the proper value
range for programming pulsed welds.
Figure 7 Pulsed Arc Start Page 1 and 2
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Figure 9 Pulsed Weld Instrucstion
Figure 8 Pulsed Crater
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7.2 Programming MIG
Figure 10 MIG Arc Start Instruction
Figure 11 MIG Arc Switch Instruction
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KUKA Robotics Auto-Axcess DI Connection Guide

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KUKA Robotics Auto-Axcess Connection Specification

Auto-Axcess Connection to Devicenet

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6.4 Third Party Hardware 3

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2 Material Requirements and Cable Construction –

Figure 1 Cable Connection KR C2 Base

Figure 2 Cable Connection Auto-Axcess Rear

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2.1.2 Hardware Installation

Figure 3 Cover Blank Modification

Figure 4 – Devicenet Bulkhead Installation

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2.2 Solution B – D-net cable through cord grip to LPDN

Figure 5 Combicon Connector Pinout

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NOTE – Be sure proper terminating resistor is installed between pin 2 and

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3 Modifying the Registry

3.1 Open the Registry

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4 ArcTech System and I-O Configuration

[1] ; Slave number

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;; Miller Auto-Axcess Digital Inputs

;; Miller Auto-Axcess Digital Outputs

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4.4.1 ArcTech Outputs

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4.4.3 Definition of Controller lines MODE 1

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4.4.5 USER GLOBALS

SIGNAL Miller_AI1 $IN[273] TO $IN[288] ;; Voltage Correction Feedback

SIGNAL s_I_RI_1 $IN[305] TO $IN[308]

SIGNAL s_O_RI_1 $OUT[305] TO $OUT[308]

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4.5 SPS – Submit Interpreter Modification

4.5.2 Submit Loop USER PLC Modification/Addition

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4.6 A10.SRC – Modification from MPM to IPM

DECL CHAN_INFO VEL_INFO[1]

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Start11 V 10-44/TRIM 0-100

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4.9 Import Arc Text to Database

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4.11 Variable Overview Screen Modification

Edit Group 2 (or Group 1) with the following text.

4.11.2 Variable Overview Monitor Display Screen

Figure 6 Variable Overview Monitor Screen

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Robot Input Description Robot Output Description

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6.2 Third Party Hardware

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6.3 Miller Electric Hardware

Wire Feed Motor - Select Only One

Wire Feed Motor Mounting Plate – Required

Palm Convenience Pack – Optional