FSB_808000r3_Sercos

SERCOS® III
for Hypertherm® CNCs
Field Service Bulletin

808000 – Revision 3 – May 2015
Hypertherm Inc. Hypertherm Europe B.V.
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Hanover, NH 03755 USA 4704 SE
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[email protected] (Customer Service Email)
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[email protected] (RMA email) 2-1-1 Edobori, Nishi-ku
Osaka 550-0002 Japan
Hypertherm Plasmatechnik GmbH 81 6 6225 1183 Tel
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© 2015 Hypertherm, Inc. All rights reserved.

Hypertherm is a trademark of Hypertherm Inc. and may be registered in the United States and/or other countries. SERCOS is a trademark of Sercos
International. All other trademarks are the property of their respective holders.
Contents
1 SERCOS III Overview ................................................................................................................... 5

Introduction ....................................................................................................................................................................................... 5
SERCOS III equipment supported by Hypertherm CNCs .................................................................................................... 6
Drives .......................................................................................................................................................................................... 6
Bus couplers ............................................................................................................................................................................. 6
Beckhoff EK9700 bus coupler and I/O modules ..................................................................................................... 6
Bosch Rexroth fieldbus coupler and I/O modules ................................................................................................... 7
WAGO® bus coupler and I/O modules ...................................................................................................................... 7
Cables ........................................................................................................................................................................................ 8
SERCOS III system overview ....................................................................................................................................................... 9
General requirements for SERCOS III ....................................................................................................................................... 9
About drive addresses and axis assignments ........................................................................................................................ 11
Address the SERCOS III drives ........................................................................................................................................ 13
Drive I/O .......................................................................................................................................................................................... 14
Analog inputs ......................................................................................................................................................................... 15
I/O bus coupler ..................................................................................................................................................................... 15
About machine enable/disable inputs ...................................................................................................................................... 16
Enable the cutting machine after a power cycle or stop ............................................................................................. 16
Drive parameters used by the CNC ......................................................................................................................................... 17
IDN data structure ................................................................................................................................................................ 17
About absolute encoders ............................................................................................................................................................ 17
Absolute encoder setup ...................................................................................................................................................... 18
Parameters for absolute encoders .................................................................................................................................... 18
SERCOS Sensor THC setup for plasma cutting machines ............................................................................................... 18
Sensor THC voltage divider card ...................................................................................................................................... 18
SERCOS setup screen ....................................................................................................................................................... 19
Troubleshooting tips .................................................................................................................................................................... 20
To check the drive address ................................................................................................................................................ 20
SERCOS III Field Service Bulletin 808000 3

Contents
For Bosch Rexroth drives (IndraWorks Ds software) ........................................................................................... 20

For Kollmorgen AKD drives (WorkBench software) ............................................................................................. 20
SERCOS error codes ......................................................................................................................................................... 21
2 SERCOS III for Bosch Rexroth Drives .................................................................................. 23

Launch the IndraWorks Ds software ....................................................................................................................................... 24
SERCOS III drive and CNC setup ........................................................................................................................................... 24
Drive settings ......................................................................................................................................................................... 24
CNC settings ......................................................................................................................................................................... 25
Internet Protocol (IP) addresses ............................................................................................................................................... 25
Drive I/O ......................................................................................................................................................................................... 26
SERCOS axis setup screen ....................................................................................................................................................... 27
Scaling and units settings .......................................................................................................................................................... 28
Linear axis ............................................................................................................................................................................... 28
Rotary axis .............................................................................................................................................................................. 31
Pipe axis .................................................................................................................................................................................. 34
Sensor THC axis ................................................................................................................................................................... 38
Sensor THC connections to the Bosch Rexroth IndraDrive drives .................................................................................. 41
3 SERCOS III for Kollmorgen AKD Drives .............................................................................. 45

Launch the WorkBench software ............................................................................................................................................. 45
SERCOS III CNC and drive setup ........................................................................................................................................... 45
CNC settings ......................................................................................................................................................................... 46
Drive settings ......................................................................................................................................................................... 46
Internet Protocol (IP) addresses ............................................................................................................................................... 47
Drive I/O ......................................................................................................................................................................................... 47
Set drive units ................................................................................................................................................................................ 48
Set units for a linear axis ..................................................................................................................................................... 48
Set units for a rotary axis ..................................................................................................................................................... 51
Set units for a pipe axis ....................................................................................................................................................... 54
Set units for a Sensor THC axis ........................................................................................................................................ 57
Sensor THC connections to the Kollmorgen AKD drives ................................................................................................... 60
4 SERCOS III Field Service Bulletin 808000

Section 1
SERCOS III Overview
Introduction
SERCOS III is a real-time communication bus for digital servo drives designed for high-speed communications over
industrial Ethernet cable. This Field Service Bulletin describes SERCOS III setup for Hypertherm CNCs. In it you will
find:
 A SERCOS III overview that applies to all SERCOS III rings supported by Hypertherm CNCs. This section
describes general SERCOS III concepts and setup information for all SERCOS III system that are compatible with
Hypertherm CNCs, regardless of drive type.
 Concepts and setup information specific to Bosch Rexroth drives. If you have Bosch Rexroth drives, start with
Section 1, and then refer to Section 2 to complete your setup.
 Concepts and setup information specific to Kollmorgen AKD® drives. If you have Kollmorgen AKD drives, start with
Section 1, and then refer to Section 3 to complete your setup.
Hypertherm CNCs support both SERCOS II (fiber optics) and SERCOS III (Ethernet) communication protocols. See
the Phoenix V9 Series Installation and Setup Manual (806410) for information on SERCOS II. For more information
about the SERCOS standard, see www.sercos.com.
Work in partnership with your drive manufacturer when you size the drives and motors for your cutting machine. Refer to
your partner and the drive documentation for technical information about the drives that you need when you set up the
Hypertherm CNC to work with the SERCOS ring. Cutting machine specifications and mechanics are beyond the scope
of this document.
 Setting up the CNC requires that you have access to the password-protected Machine Setup screen. Contact your
table manufacturer or system integrator for assistance with password-protected screens on the CNC.

1 – SERCOS III Overview
SERCOS III equipment supported by Hypertherm CNCs

Hypertherm CNCs support the following SERCOS III equipment.
Drives
 All drives in the SERCOS III ring must use the same firmware version.
 Bosch Rexroth IndraDrive Cs Basic or Economy: Bosch Rexroth IndraDrive Cs Basic (CSB02.1A) or
IndraDrive Cs Economy (CSE) with multi-Ethernet support, drive firmware type MPB, and firmware version 16V24,
17V14 or later, or 18V06 or later. Requires Phoenix 9.73.0 or later.
 We recommend that you don’t mix Basic and Economy drives. Phoenix uses a cyclic rate
of 1 ms with the Basic drives and a cyclic rate of 2 ms with the Economy drives. But the
SERCOS master can only operate with one cyclic rate. So if you mix the Basic and the
Economy drives within the ring, then the cyclic rate can only operate at 2 ms, which
reduces the performance of the Cs Basic drives.
 Bosch Rexroth IndraDrive C: Bosch Rexroth IndraDrive C with drive firmware type MPB and firmware version
18V06 or later. Requires Phoenix 9.73.0 or later.
 Kollmorgen AKD: Kollmorgen AKD drives with the part number format AKD-PXXXXX-NBS3-XXXX and firmware
version 01-13-05 or later. Requires Phoenix version 9.76.1 or later.
Bus couplers
 The CNC supports one I/O bus coupler on the SERCOS ring. Make sure you connect the I/O bus coupler as
the last device on the ring.
Beckhoff EK9700 bus coupler and I/O modules
 This equipment requires Phoenix 9.76.0 or later.

Part Number Description
EK9700 Beckhoff bus coupler
EL1008 8-channel digital input terminal, 24 VDC, 3 ms
EL2008 8-channel digital output terminal 24 VDC, 0.5 A
EL3064 4-channel analog input terminal 0–10 V,

single-ended, 12-bit
EL4004 4-channel analog output terminal 0–10 V, 12-bit

Bosch Rexroth fieldbus coupler and I/O modules

Part Type Description
R-IL S3 BK DI8 DO4-PAC SERCOS III fieldbus coupler, 8 digital inputs,

4 digital outputs, 500 mA, Bosch Rexroth part
number R91170875
R-IB IL AO 2/U/BP-PAC Analog output module, 2 analog outputs,

±10 V/0-10 V, 2-wire connection
R-IB IL AI 2/SF-PAC Analog input module, 2 analog inputs: 0 to 20 mA/4

to 20 mA/±20 mA, ±10 V/0-10 V, 2-wire
connection
WAGO® bus coupler and I/O modules

Part Number Description
750-351 SERCOS III bus coupler, 2-port, 100 Mbit/s, digital

and analog signals
750-459 4-channel analog input module, ±10 V/0-10 V

(single-ended)
750-530 8-channel digital output module, 24 VDC
750-430 8-channel digital input module, 24 VDC
750-559 4-channel analog output module, ±10 V/0-10 VDC
750-627 Internal data bus extension end module (for

connecting remote I/O modules)
750-628 Internal data bus extension coupler module
750-1500 16-channel digital output module, ribbon cable,

high-side switching, 24 VDC
750-1400 16-channel digital input module, ribbon cable,

high-side switching, 24 VDC
750-600 End module, no function (physical end cap)

Cables
The SERCOS III ring requires Ethernet Cat5e or Cat6e STP (shielded twisted pair) cables. While the ring can function
through a single SERCOS port on the CNC, connecting a second cable to the second SERCOS port provides
redundancy.
The following Ethernet Cat5e shielded cables are available from Hypertherm.
Part number Length
223102 61.0 m (200 feet)
223101 45.5 m (150 feet)
223100 30.5 m (100 feet)
223099 23.0 m (75 feet)
223008 15.0 m (50 feet)
223223 10.5 m (35 feet)
223119 7.5 m (25 feet)
223222 6.0 m (20 feet)
223212 3.0 m (10 feet)
223380 1.5 m (5 feet)
223382 0.6 m (2 feet)
223381 0.3 m (1 feet)

SERCOS III system overview

Figure 1 shows two examples of SERCOS rings. The double ring provides redundancy through two counter-rotating
rings so that the system continues to operate if a single cable breaks. Hypertherm CNCs equipped with the SERCOS III
master card have two RJ-45 ports, P1 and P2, that allow you to set up the ring topology. The single ring topology, using
only P1, is also supported by the CNC but does not provide communication redundancy.
 In this document, the term “SERCOS ring” applies to either a single or double ring.
Figure 1 - Two examples of SERCOS III rings
SERCOS III master card
SERCOS III To laptop or CNC

P1 P2 drives (slaves) P1 P2 LAN connection
for drive
manufacturer
software
1 2 n 1 2 n
Double ring Single ring
 The communications between master and slaves, shown with the

blue and black lines, take place over a single physical cable.
General requirements for SERCOS III

Follow these requirements for ease of setup and best performance:
 Do the installation steps in this order:
1. Set up the SERCOS ring.
2. Set up the CNC to communicate with the ring.
3. Phase up the ring.
 The number of drives in the ring must match the number of axes actively assigned in the Machine Setups screen.
 Do not mix brands or types of drives in the same ring.
 Do not use drives that have different servo loop update rates in the same ring. For example, if one drive uses a 1 ms
servo loop update rate, and another drive uses a 2 ms servo loop update rate, the CNC uses the 2 ms servo loop
update rate for all the drives, which reduces system performance.
 Connect the axis limit switches (also called overtravel switches) to the drive I/O, not to an I/O module.

 Assign overtravel switches in both the CNC and the drive. This makes sure that the CNC is notified of the overtravel
condition while allowing the drive to provide the best deceleration of the cutting machine. An exception to this rule is
if you are homing to an overtravel switch, in which case the overtravel switch should only be assigned in the CNC.
 Connect the divided arc voltage signal (output) from the VDC3 to the THC drive analog input.
Figure 2 - Example of a SERCOS ring with the drives and axes
Drives Motors Axes
1 1 Transverse
2 2 Rail
3 3 Dual gantry
4 4 Sensor THC
5 5 Rotate
6 6 Tilt
I/O bus coupler
 The CNC supports one I/O bus coupler on the SERCOS ring. Connect the I/O bus coupler as the last
device on the ring as shown above.

About drive addresses and axis assignments

Hypertherm CNCs are hard-coded with the axis assignments and require that the axis assignment and drive address
match. The table below shows the drive addresses that the CNC uses for the 12 axes, and common letter identifiers for
the axes.
Drive address Axis assignment
1 Transverse or Rail (X)
2 Rail or Transverse (Y)
3 Dual Gantry (W)
4 Sensor THC 1 (Z)
5 Rotate 1 (B or C)
6 Tilt 1 (A)
7 Transverse 2
8 Rotate 2
9 Tilt 2
10 Sensor THC 2
11 Sensor THC 3
12 Sensor THC 4
 All cutting machines require both Transverse and Rail axes, but you can assign either to X or Y.
 Aposition
Dual Gantry axis is parallel to the Rail axis (think of it as a “Rail 2” axis). The Dual Gantry axis receives the same
command from the CNC as the Rail axis.
 Rotate and Tilt rotary axes are used for bevel cutting.
Special passwords NRT and 1RT (No Rotate Tilt and 1 Rotate Tilt respectively) redirect certain axis assignments to
different drive addresses. For example, a 2-station cutting machine on a 6-axis CNC requires the NRT password so that
the Transverse 2 and Sensor THC 2 digital signals are output to drive addresses 5 and 6 instead of 7 and 10.
The following tables identify the application, password, and drive addresses for common, supported cutting machine axis
configurations. Use these tables to identify the drive address where the CNC will output the axis signals.

5-axis I-cutting on pipe or tube, with Dual Gantry, NRT password
1 Transverse or Rail
2 Rail or Transverse
3 Dual Gantry
4 Sensor THC
5 Transverse 2
6-axis, 2-station, I-cutting on flat plate, with Dual Gantry, NRT password
3 Dual Gantry
4 Sensor THC
5 Transverse 2
6 Sensor THC 2

6-axis bevel cutting on pipe or tube, no Dual Gantry, 1RT password
3 Sensor THC
4 Transverse 2
5 Rotate
6 Tilt
7-axis bevel cutting on pipe or tube, with Dual Gantry, 1RT password
3 Dual Gantry
4 Sensor THC
5 Rotate
6 Tilt
7 Transverse 2
Address the SERCOS III drives
If the drives are in the physical order of the addresses 1 through n, you can set each drive to address 1 and the CNC will
address the drives during the first phase-up of the SERCOS ring. Again, this method works only when the drives are
in physical order in the ring. If the drives are not physically in order equal to the axis assignment, you need to manually
address each drive according to the tables on the preceding pages.
 When using the NRT or 1RT password, the CNC redirects the axis signals for Sensor THC, Transverse 2, and Sensor
THC 2 to lower-numbered drive addresses. These addresses are not shown on the CNC in the axis setup screens
(Machine Setups > Axes). See To check the drive address on page 20 for information on viewing the drive address
using IndraWorks (Bosch Rexroth drives) and WorkBench (Kollmorgen AKD drives).
 SERCOS drive addresses are different from IP addresses. Refer to the section of this document that applies to your
drive type for more information about IP addresses. For Bosch Rexroth drives, see Internet Protocol (IP) addresses
on page 25. For Kollmorgen AKD drives, see Internet Protocol (IP) addresses on page 47.

Drive I/O
The All I/O option for the Drive I/O parameter on the SERCOS screen (Setups > Password > Machine Setups >
SERCOS) controls the use of the drive I/O. Setting the Drive I/O parameter to All I/O is the recommended setting. The
CNC addresses the I/O starting with the first drive in the ring and continuing to the last drive.
Some I/O assignments may have already been made in the drives. The CNC does not reset these assignments. However,
if a drive uses an I/O point, set the same I/O point in the CNC to Spare. Likewise, when the CNC uses an I/O point, set
the same I/O point in the drive to Not Assigned or Off.
In most cases, you can assign the I/O points in the CNC, not in the drive. An exception to this rule is the assignment of X
and Y hardware limit (or overtravel) switches. The drive provides the best deceleration of the cutting machine if an
overtravel switch is activated, so assigning the overtravel switches in both the CNC and the drive is recommended.
 If you are homing to an overtravel switch, the overtravel switch should only be assigned in the CNC.
The table below shows an example of how the CNC would address the I/O in a SERCOS III ring with 6 drives (each
drive with 7 digital inputs, 1 digital output, 1 analog input, 1 analog output) and an I/O module.
 Refer to the section of this document that applies to your drive type for your drive I/O assignments. For Bosch Rexroth
drives, see Drive I/O on page 26. For Kollmorgen AKD drives, see Drive I/O on page 47.
Drive address Digital inputs Digital output Analog input Analog output
1 1–7 1 5 1
2 8 – 14 2 6 2
3 15 – 21 3 7 3
4 22 – 28 4 8 4
5 29 – 35 5 9 5
6 36 – 42 6 10 6
I/O module at address 50: 43 and above 7 and above 11 and above 7 and above
first input or output

Analog inputs
The CNC supports 16 analog inputs in the SERCOS ring. Analog inputs 1 through 4 are reserved by the utility board in
the CNC for system temperature and program speed and jog speed controls on the operator console. The analog inputs
on the SERCOS drives start with analog input 5.
Drive address Analog input
1 5
2 6
3 7
4 8
5 9
6 10
I/O bus coupler
A compatible I/O bus coupler can be used to handle miscellaneous I/O on the cutting machine. Use the following
settings to set up the CNC to use the I/O bus coupler in addition to the drive I/O.
 See SERCOS III equipment supported by Hypertherm CNCs on page 6 for part numbers of compatible equipment.
1. Choose Setups > Machine Setups > SERCOS.
2. For Drive I/O choose All I/O.
3. For Inline I/O Modules at Address 50 choose Yes.

About machine enable/disable inputs

Hypertherm CNCs provide three different inputs to disable the drives in an emergency or urgent stop condition, and to
disable and enable the drives before and after a power cycle:
 Drive Disabled
When this input activates, the CNC turns off the individual drive enable signals and the Drive Enable output after the
next update cycle (1 ms). The CNC also clears its internal home reference position; the cutting machine needs to be
re-homed before cutting can resume. The CNC displays the status message Drive Disabled when this input
activates. The Drive Disabled input should be wired into the cutting machine’s safety circuit so that it can be
deactivated by way of a reset mechanism.
 Front Panel E-stop
When this input activates, the CNC turns off the individual drive enable signals and the Drive Enable output after the
next update cycle (1 ms). The CNC also clears its internal home reference position; the cutting machine needs to be
re-homed before cutting can resume. The CNC displays the status message Emergency Stop Active when this
input activates. The Front Panel E-stop input should be wired into the cutting machine’s safety circuit.
 Fast Stop
Use the Fast Stop input when you want an urgent stop. When this input activates, the CNC decelerates motion using
the Fast Deceleration Rate on the Speeds screen, and turns off the individual drive enable signals. One second after
Fast Stop activates, the CNC turns off the Drive Enable output, which disables the drives. The CNC retains position
information so that you can restart the cutting job after you clear the condition that caused you to stop the system.
Fast Stop is often wired to a separate switch on the operator console.
 Momentarily pulsing Fast Stop for less than 1 second causes the cutting machine to do
a fast deceleration and stop motion but keeps the drives enabled. This allows you to stop
the machine without disabling the drives. Check with local safety authorities before using
the Fast Stop input in a cutting machine safety circuit.
Enable the cutting machine after a power cycle or stop
After you power up the cutting machine and after an emergency or urgent stop, you need to re-enable the drives. The
following is an example sequence of re-enabling the drives. How you re-enable the cutting machine depends on the
wiring of the drives, the machine’s safety circuit, the machine’s reset mechanisms, the disable input assigned in the CNC,
and the timing of the CNC's enable logic.
1. Turn on the CNC and wait for the SERCOS ring to phase up. (The state of the machine is: E-stop depressed, no
AC power to drives, and disable input active to the CNC.)
2. Deactivate the disable input to the CNC (Drive Disabled, Front Panel E-stop, or Fast Stop). Often this is
accomplished by way of a reset mechanism or push-button, depending on the operator console and drive box safety
circuit.
3. After the input is deactivated, the CNC attempts to re-enable the drives for up to 2 seconds. After 2 seconds, the
CNC stops trying. The drives must be in stand-by mode or the attempt fails after 2 seconds. If the CNC doesn’t
succeed in re-enabling the drives automatically, you can re-enable the drives manually by pressing the Setups >
Enable Control soft key.

Drive parameters used by the CNC

The CNC sets very few parameters for the SERCOS drives. The CNC automatically sets the parameters in the table
below for the drives when the SERCOS ring phases up. The parameter value shown in the table is the IDN format
specified by the SERCOS standard.
 If your cutting machine has absolute encoders, see Parameters for absolute encoders on page 18.
Parameter Value
Position polarity IDN S-0-0055.0.0
Velocity polarity IDN S-0-0043.0.0
Torque polarity IDN S-0-0085.0.0
Drive storage mode IDN S-0-0269.0.0

(Bosch Rexroth drives only)
IDN data structure
IDNs follow this format:
15 14 12 11 8 0
X X X X X X X X X X X X X X X X
 Bit 15: 0 = Standard data (normative), 1 = product data (determined by the drive or I/O module manufacturer)
 Bits 14 – 12: Parameter set 0 – 7
 Bits 11 – 0: Data block number from 0 to 4095
About absolute encoders

Absolute encoders allow the use of stored position information in the motors and drives so that the cutting machine does
not require re-homing after a power cycle. Both the motor and drive must support battery backup so that they can store
the position information. Hypertherm CNCs support absolute encoders in Bosch Rexroth and Kollmorgen AKD drives.
A cutting machine with absolute encoders should only require homing in the following situations:
 When it is first commissioned
 If any of the motors have been removed from the rack
 If any of the battery backups for the motor encoders fail
Home position in the CNC is the Absolute Home Position plus the Home Offset Distance (if used), which are set in the
axis setup screen. When you complete homing the cutting machine, the CNC updates the home position in each drive.
 When the CNC updates the home position, it briefly halts the drive (in the case of Bosch Rexroth IndraDrive drives)
or turns off the drive enable outputs (in the case of Kollmorgen AKD drives).

Absolute encoder setup
Absolute encoder setup varies depending on whether you have Bosch Rexroth drives or Kollmorgen AKD drives.
 For Bosch Rexroth drives: In the IndraWorks Ds software, you can set up Force Absolute Encoder Evaluation in
the Motor Encoder screen. This feature lets you set up a monitoring window that looks for a difference in position
between the physical position of the axis and the position recorded by the absolute encoder. If the physical position
of the axis exceeds this distance, the drive sends an error to the CNC.
To set this up, in the Motor Encoder screen, select Force Absolute Encoder Evaluation and enter a distance value
for the Encoder Monitoring window.
 For Kollmorgen AKD drives: In the WorkBench software, enter a valid distance in the FB1.INITPWINDOW
parameter; for example, 65536 (1 motor revolution at 16-bit resolution, which is recommended).
Parameters for absolute encoders
The CNC also sets the following parameters in the drives for absolute encoders:
Parameter Value
Position feedback type IDN S-0-0277.0.0

Note: For Bosch Rexroth drives,
set bits 8 and 6 to 1. See IDN data
structure on page 17.
Position feedback status IDN S-0-0403.0.0
Set absolute position procedure IDN S-0-0447.0.0

command
Set absolute position control IDN S-0-0448.0.0
SERCOS Sensor THC setup for plasma cutting machines

The Sensor THC (torch height control) regulates the torch height relative to the workpiece using arc voltage feedback.
The Sensor THC requires an independent drive axis that does positioning. The drive for the THC axis is part of the
SERCOS ring. The THC drive must operate in Velocity Mode (Operation Mode is set in the drive software).
Sensor THC voltage divider card
Connector J2 on the Sensor THC voltage divider card (VDC3), installed in the plasma system, has connections to the
SERCOS drive.
 Analog output from the voltage divider card must be connected to an analog input on a drive, not on an I/O module in
an I/O bus coupler. This is because the arc voltage analog input requires the update rate to be 4 ms or faster, but
1 ms is recommended.
 Nozzle Contact Sense and Nozzle Contact Enable both require negative logic. They can connect to the drive or the
I/O module.
The inputs and signals on J2 are shown in the following table.

VDC3 Pin VDC3 Signal Drive I/O
1 24 VDC Common Not connected
2 +24 VDC Not connected
3 Nozzle Contact Sense Negative logic digital input
4 Nozzle Contact Enable Negative logic digital output
6 Analog Out + Analog input +
7 Analog Common Analog common
8 Earth Ground
 THC
Refer to the section of this document that applies to your drive type for specific instructions on connecting the Sensor
to the drive. For Bosch Rexroth drives, see Sensor THC connections to the Bosch Rexroth IndraDrive drives on
page 41. For Kollmorgen AKD drives, see Sensor THC connections to the Kollmorgen AKD drives on page 60.
SERCOS setup screen
The CNC requires that the drive I/O or bus coupler I/O be enabled. Choose Setups > Password > Machine Setups >
SERCOS to open the setup screen.

On the setup screen, make the following selections:

 Drive I/O: Select All I/O to enable the drive I/O (recommended). Select None if the drives do not have available I/O
or you do not intend to use the drive I/O.
 Inline I/O Modules at Address 50: Select Yes if you are using an I/O bus coupler to expand the total number of I/O
in the SERCOS ring.
Troubleshooting tips
If you have trouble phasing up the SERCOS ring, follow these guidelines to help identify the issue.
 Check the cable type. SERCOS III requires CAT5e shielded cables. Unshielded CAT5 cables are not capable of the
faster transmission speeds required for SERCOS III.
 Check the cables from P1 on the CNC to Drive 1, and then from drive to drive. Be sure the cables are properly
seated in their connectors on the drives and CNC and that there are no breaks in the cables.
 The CNC supports SERCOS passwords 1SA, 2SA, and so on through 12SA. Use these passwords to troubleshoot
or to prevent drives from phasing up. See Troubleshooting Tips in the section of this document that applies to your
drive type for specific instructions.
 If the CNC is displaying error messages or having difficulty enabling the drives, see About machine enable/disable
inputs on page 16.
To check the drive address
Depending on your drive type, use one of these procedures to verify the SERCOS drive addresses.
For Bosch Rexroth drives (IndraWorks Ds software)
IndraWorks Ds shows the drive address in the Axis Status screen. Choose Diagnostics/Service > Axis Status.
For Kollmorgen AKD drives (WorkBench software)
WorkBench can be configured to display the drive address in the Watch panel. Complete the following steps to enable
the Watch panel and add the drive address.
1. In WorkBench, choose View > Toggle Watch Panel to display the Watch panel.
2. In the first empty row, click in the Parameter column to view the available parameters.

3. Enter the S3.ADDRESS parameter to view the drive address in the Watch panel.
SERCOS drive faults
If there is an error, the CNC displays an Error 52 SERCOS Drive Fault window like Figure 3. The window shows the drive
address and fault message for the specific drive that has faulted. The drives generate the specific SERCOS error codes
that the CNC displays. If one of these errors appears, consult the drive documentation for troubleshooting information.
Figure 3 - SERCOS drive fault error window


Section 2
SERCOS III for Bosch Rexroth Drives
Hypertherm CNCs with Phoenix software version 9.73.0 or later support the SERCOS III interface to the following
Bosch Rexroth IndraDrive servo drive amplifiers. For a list of compatible inline I/O bus couplers, see Bus couplers on
page 6. The IndraWorks Ds software, used to program the Bosch Rexroth drives, is provided on the CNC.
 Bosch Rexroth IndraDrive Cs Basic or Economy: Bosch Rexroth IndraDrive Cs Basic (CSB02.1A) or
IndraDrive Cs Economy (CSE) with multi-Ethernet support, drive firmware type MPB, and firmware version 16V24,
17V14 or later, or 18V06 or later.
 We recommend that you don’t mix Basic and Economy drives. Phoenix uses a cyclic rate
of 1 ms with the Basic drives and a cyclic rate of 2 ms with the Economy drives. But the
SERCOS master can only operate with one cyclic rate. So if you mix the Basic and the
Economy drives within the ring, then the cyclic rate can only operate at 2 ms, which
reduces the performance of the Cs Basic drives.
 Bosch Rexroth IndraDrive C: Bosch Rexroth IndraDrive C with drive firmware type MPB and firmware version
18V06 or later.
 All drives in the SERCOS III ring must use the same firmware version.
The IndraDrive drives have the following I/O:
 7 digital inputs
 1 digital output
 1 analog input
Use the following resources to learn more about the Bosch Rexroth IndraDrive drives and the IndraWorks Ds software:
 IndraWorks Ds Help file, provided on the Hypertherm CNC.
 References available on the Bosch Rexroth website at www.boschrexroth.com.
Work in partnership with your Bosch Rexroth representative to size the drives and motors for your cutting machine.
Cutting machine specifications and mechanics are beyond the scope of this document.

2 – SERCOS III for Bosch Rexroth Drives
Launch the IndraWorks Ds software

To launch the software from Phoenix, choose Setups > Diagnostics > Drives and Motors.
SERCOS III drive and CNC setup

The following are the basic steps for setting up the SERCOS III drives and the CNC. Complete these steps before
phasing up the ring for the first time. The remainder of this section provides additional information on drive addresses,
I/O, troubleshooting, and other topics.
Drive settings
Most parameters in the Bosch Rexroth IndraDrive drives can be left at their default settings. Hypertherm CNCs use the
parameters listed below. Set the first group of parameters in the drive. The CNC automatically sets the second group of
parameters during ring phase-up.
These settings are made in the drive using the IndraWorks Ds software.
1. Select the motor you are using, or configure the drive to automatically detect the motor. This loads the default
parameters that are correct for the selected motor and drive combination.
2. Operation Mode: For each drive, check the primary operation mode, as follows:
Axis Type Operation mode
Linear Transverse, Rail, Dual Gantry, or Position Control Lagless,
Transverse 2 Encoder 1
Torch height control Sensor THC Velocity Control
Rotary A, B, or C axis Position Control Lagless,
(Rotate and Tilt axes in Phoenix) Encoder 1
Pipe Transverse 2 Position Control Lagless,
(Rotating Dual Transverse) Encoder 1
3. Master Communication Protocol: Set to SERCOS III.
4. Drive Address: The drive address must match the axis number required by the CNC.
 You can set all the drive addresses to 1 and allow Phoenix to address the drives. See
About drive addresses and axis assignments on page 11 to learn more about addressing
the axes and drives.
5. Scaling: This is similar to the Encoder Counts per mm (inch) setting in the CNC. Determine the Encoder Counts
for the CNC first, then set the scaling depending on the axis type and machine mechanics.
6. Bipolar Velocity Limit: Similar to following error in the CNC, the Bipolar Velocity Limit is the maximum error between
the commanded velocity and the actual velocity of the motor. How you set this value depends on your system
mechanics. If you set this value too low, it can cause needless faults in the system.
7. Motor/Encoder: Use this setting if your drives support absolute encoders. Absolute encoders require battery
backup, which is used to save position information. See About absolute encoders on page 17.

The following settings are made automatically in the drive by the CNC when you first phase up the ring.
 Operation Mode: The operation mode depends on the type of axis as set up in the CNC, and the CNC automatically
makes this setting when you first commission the system. See the table on page 24 for the operation modes.
 Servo Loop Update Rate: The CNC sets the update rate for all drives to the same value, usually 1ms.
 Encoder Polarity: This parameter sets the positive or negative input direction of the encoder to establish proper
counting for positive machine motion.
 Torque Polarity: This parameter sets the travel direction of the axis.
 Drive Storage Mode: At ring phase-up, this parameter writes all of the drive parameters into the drive RAM instead
of the EEPROM, which extends the life of the EEPROM.
CNC settings
1. Choose Setups > Password > Machine Setups > Axes. For each axis, the Encoder Counts and Encoder Polarity
are the key values for setting up the SERCOS ring:
a. Set the desired Encoder Counts per mm (inch) for each axis. Encoder Counts per mm (inch) in the CNC must
match the scaling units in the drive using the IndraWorks Ds software. Based on your desired encoder counts,
you calculate the position resolution for the drives. You set the position resolution and the mechanical
characteristics of the cutting machine using the IndraWorks Ds software. For more information and examples,
see Scaling and units settings on page 28.
 We recommend a maximum of 20,000 encoder counts per mm (500,000 encoder

counts per inch). For rotary axes, we recommend a maximum of 10,000,000 encoder
counts per revolution.
b. Set the Encoder Polarity for each axis. This sets the positive or negative input direction of the encoder to
establish proper counting for positive machine motion.You will need this value for a setting in the SERCOS III
drive.
2. In the SERCOS III screen, select whether you will be using drive I/O and/or I/O provided by an I/O bus coupler. All
Drive I/O is the recommended setting.
Internet Protocol (IP) addresses
 Ifneed
you want to connect a PC or laptop to the SERCOS ring and use IndraWorks while the ring is running, then you
to assign IP addresses to the SERCOS drives as follows. If you do not want to connect a PC or laptop, you can
skip this section.
Each drive in the SERCOS ring must have a unique IP address for communication between the IndraWorks Ds software
and the drives. Bosch Rexroth drives default to the IP address of 192.168.0.1. For ease of setup, assign the IP
addresses to the SERCOS drives as shown in the following table. The CNC does not use the IP addresses.

IP address Drive address

192.168.0.1 1
192.168.0.2 2
192.168.0.3 3
192.168.0.4 4
192.168.0.5 5
192.168.0.6 6
192.168.0.7 7
192.168.0.8 8
192.168.0.9 9
192.168.0.10 10
 IP addresses are different from SERCOS drive addresses. See Address the SERCOS III drives on page 13 for more
information about SERCOS drive addresses.
Drive I/O
The Bosch Rexroth IndraDrive drives each support 7 digital inputs, 1 digital output, and 1 analog output. The CNC
automatically sets the Inline I/O Modules at Address 50 to Yes during ring phase-up.
These I/O addresses are specific to the IndraDrive drives. Phoenix addresses the I/O for the drives as shown in the
following table, starting with Drive 1 and continuing in drive address order:
Drive address Digital inputs Digital output Analog input
1 1–7 1 5
2 8 – 14 2 6
3 15 – 21 3 7
4 22 – 28 4 8
5 29 – 35 5 9
6 36 – 42 6 10
I/O bus coupler at 43 7 11
address 50 – first
input or output
 Analog inputs 1 – 4 are reserved by the utility card in the CNC.

 The Bosch Rexroth IndraDrive drives require overtravel switches to be wired to drive inputs 4 and 5. On Drive 1,
inputs 4 and 5 map to Phoenix inputs 4 and 5. On Drive 2, inputs 4 and 5 map to Phoenix inputs 11 and 12.

SERCOS axis setup screen

Each axis on a SERCOS CNC contains the same parameters as the SERCOS axis setup screen shown below.
Complete the following settings in this screen before phasing up the SERCOS ring.
 SERCOS Drive Address: The CNC automatically assigns an address to each drive axis. The drives are numbered
sequentially and need to match the Master Communication Address set in the drive using the IndraWorks Ds
software.
 Encoder Counts per mm (inch): Set your desired encoder counts per mm (inch). Based on your desired encoder
counts, you calculate the position resolution for the drives. You set the position resolution and the mechanical
characteristics of the cutting machine using the IndraWorks Ds software. For more information, see Scaling and units
settings on page 28.
 We recommend a maximum of 20,000 encoder counts per mm (500,000 encoder counts

per inch). For rotary axes, we recommend a maximum of 10,000,000 encoder counts per
revolution.
 Encoder Polarity: This parameter changes the encoder input polarity to establish proper counting for positive
machine motion.
 The remaining parameters on the SERCOS axis setup screen are common to all axes on the CNC. Refer to the
Phoenix V9 Series Installation and Setup Manual for information on these parameters.

Scaling and units settings

This section provides examples of linear, rotary, pipe, and Sensor THC axis mechanics and setups.
First you enter your desired Encoder Counts per mm (inch) on the SERCOS axis screens on the CNC. Based on your
desired encoder counts, you calculate the position resolution for the drives. Then you use the IndraWorks Ds software to
program the drives with the mechanical characteristics of the cutting machine.
Linear axis
 Linear axes include Transverse, Rail, Dual Gantry, Transverse 2 (non-rotating), and Sensor THC. For an example of a
Sensor THC axis setup, see Sensor THC axis on page 38.
In this example, your desired encoder counts are 5,000 counts per millimeter (100,000 counts per inch).
On the SERCOS axis setup screen, set the Encoder Counts per mm (inch) to 5,000 counts per millimeter
(100,000 counts per inch).
 The remaining parameters on the SERCOS axis setup screen are common to all axes on
the CNC. Refer to the Phoenix V9 Installation and Setup Manual for information on all
axis parameters.

In IndraWorks, set the following parameters on the Scaling / Units Extended screen:
Scaling Parameter Settings
Position  Linear  Resolution / Unit: 0.0002 mm
(0.00001 in. for English)
 Absolute
 Factor: 2 (1 for English)
 Load reference
 Exponent: -7 (-5 for English)
 User-defined
Velocity  Linear  Resolution / Unit: 0.002 mm/min
(0.0001 in/min for English)
 Load reference
 User-defined
Acceleration  Linear  Resolution / Unit: 0.02 mm/s2
(0.001 in/s2 for English)
 Load reference
 User-defined
 Once you enter Resolution / Unit, IndraWorks calculates Factor and Exponent for you.
 To determine the position Resolution / Unit, take the inverse (1/X) of the desired encoder
counts. For example, if you want 5,000 encoder counts per mm, the position resolution
is 0.0002 (1/5,000=0.0002).
 We recommend you set the velocity resolution to the position resolution multiplied by
10 (0.0002 X 10 = 0.002). We recommend you set the acceleration resolution to the
position resolution multiplied by 100 (0.0002 X 100 = 0.02).

The Transverse axis has the following machine characteristics:

Gear box ratio: 50:1
Rack pitch diameter: 57.15 mm (2.25 inches)
In IndraWorks Ds, set the following parameters in the Mechanical Gear screen:
Position data in: absolute format

Feed constant k: Pitch diameter X pi = feed constant
57.15 mm X 3.14159 = 179.542 mm
(2.25 inches X 3.14159 = 7.068 inches)
Input revolutions of load gear n1: 50
Output revolutions of load gear n2: 1

Rotary axis
 Rotary axes are used for bevel cutting and include Rotate, Tilt, and CBH.
In this example, your desired encoder counts per revolution are 3,600,000. On the SERCOS axis setup screen, set the
Encoder Counts per rev to 3,600,000.

axis parameters.
Position  Rotary  User-defined
 Modulo  Resolution / Unit: 0.0001 degrees
 Load reference  Rotational pos. resolution: 3 600 000
Velocity  Rotary  Resolution / Unit: 0.001 rpm
 Load reference  Factor: 1
 User-defined  Exponent: -3
Acceleration  Rotary  Resolution / Unit: 0.01 rad/s2
counts, multiplied by 360. For example, if you want 3,600,000 encounter counts per
revolution, the user-defined resolution for position is 0.0001 (1/3,600,000 X
360=0.0001).
 We recommend you set the velocity resolution to the position Resolution / Unit
multiplied by 10 (0.0001 X 10 = 0.001). We recommend you set the acceleration
resolution to the position resolution multiplied by 100 (0.0001 X 100 = 0.01).

The Rotate axis has the following machine characteristics:

Mechanics: Rotary actuator
Position data in: Modulo format

Mode: Shortest distance

Pipe axis
For pipe and tube cutting, you set up the Transverse 2 (also known as the Dual Transverse) axis as a Pipe (Rotary) axis.
This is also referred to as a Rotating Dual Transverse axis.
 Set up the Pipe axis as a Rotary axis, but without modulo.

In this example, your desired encoder counts per revolution are 3,600,000.
On the SERCOS axis setup screen, set the Encoder Counts per rev to 3,600,000.

 Normally the drive address in the CNC needs to match the Master Communication
Address set for the drive in IndraWorks Ds. But for a Pipe axis, they might not match.
axis parameters.

Position  Rotary  User-defined
 Absolute  Resolution / Unit: 0.0001 degrees
 Load reference  Rotational pos. resolution: 3 600 000
Velocity  Rotary  Resolution / Unit: 0.001 rpm
Acceleration  Rotary  Resolution / Unit: 0.01 rad/s2
counts, multiplied by 360. For example, if you want 3,600,000 encounter counts per
revolution, the user-defined resolution for position is 0.0001 (1/3,600,000 X
360=0.0001).
 We recommend you set the velocity resolution to the position Resolution / Unit
multiplied by 10 (0.0001 X 10 = 0.001). We recommend you set the acceleration
resolution to the position resolution multiplied by 100 (0.0001 X 100 = 0.01).

The Pipe axis has the following machine characteristics:

For this example, in IndraWorks Ds, set the following parameters in the Mechanical Gear screen:


Sensor THC axis
In this example, your desired encoder counts are 800 counts per mm (for English for this example, use 20,000 counts per
inch). On the SERCOS axis setup screen, set the Encoder Counts per mm (inch) to 800 counts per millimeter
(20000 counts per inch).
axis parameters.

Position  Linear  Resolution / Unit: 0.00125 mm
(0.00005 in. for English)
 Absolute
 Load reference
 User-defined
Velocity  Linear  Resolution / Unit: 0.0125 mm/min
(0.0005 in/min for English)
 Load reference
 User-defined
Acceleration  Linear  Resolution / Unit: 0.125 mm/s2
(0.005 in/s2 for English)
 Load reference
 User-defined
counts. For example, if you want 800 encoder counts per mm, the position resolution is
0.00125 (1/800=0.00125).
 We recommend you set the velocity resolution to the position resolution multiplied by
10 (0.00125 X 10 = 0.0125). We recommend you set the acceleration resolution to the
position resolution multiplied by 100 (0.00125 X 100 = 0.125).

In this example, the Sensor THC axis has the following machine characteristics:
Gear box ratio: 5:1
Lead screw pitch: 5.0 mm/revolution
(0.19685 inch/revolution)

Feed constant k: Pitch diameter X pi = feed constant
5.0 mm X 3.14159 = 15.70795 mm
(0.19685 in. X 3.14159 = 0.61842 inch)

Sensor THC connections to the Bosch Rexroth IndraDrive drives

Connector J2 on the Sensor THC voltage divider card (VDC3), installed in the plasma system, connects to the SERCOS
drive.
 Analog output from the voltage divider card must be connected to an analog input on a drive, not on an I/O module in
an I/O bus coupler. This is because the arc voltage analog input requires the faster communications speed provided
by the drive.
 Nozzle Contact Sense and Nozzle Contact Enable are both negative logic and must be wired to a negative logic
input and output.

VDC3 Pin VDC3 Signal IndraDrive Drive I/O
6 Analog Out + Analog input + on Bosch
Rexroth drive connector X32
7 Analog Common Analog common on Bosch
Rexroth drive connector X32
8 Earth Ground

Analog output from J2 connects

to X32 on drive.
Connector for drive digital I/O
J2 (positive logic)
J1
X32 connector for analog input

J3
Voltage divider card (VDC3)
Notes:
 The digital I/O for nozzle contact sense should be configured for negative I/O logic on the
drive or I/O module.
 Drive I/O is positive logic.
 J1 connects AC power to the VDC3.
 J3 connects to high voltage connections of the plasma supply (Shield, Work, Electrode,
Ground).

 Check the firmware version in IndraWorks Ds. For Bosch Rexroth IndraDrive Cs Basic (CSB02.1A) or IndraDrive Cs
Economy (CSE) drives, we require drive firmware type MPB and firmware version 16V24, 17V14 or later, or 18V06
or later. For Bosch Rexroth IndraDrive C drives, we require drive firmware type MPB and firmware version 18V06 or
later.
 Each drive has an LCD display that shows messages; for example, when you re-enable the cutting machine after a
power cycle or stop:
Drive message Description
P-1 The drive is ready for phase-up; no fault.
Bb The ring is phased up but there is no AC power to the
drives.
Ab The ring is phased up with AC power to the drives;
stand by.
Af The drive is enabled.
Ah The drive is enabled but halted from motion. This is
used during absolute homing when a new position
reference is assigned.
 If one of the drives fails to show one of these messages, or shows a different message,
consult the Bosch Rexroth documentation for more information.
 For more information about re-enabling the cutting machine after a power cycle or stop,
see Enable the cutting machine after a power cycle or stop on page 16.
 Correcting Rail or Dual Gantry positions: In a SERCOS III ring with drives using absolute encoders, when you
remove a pinion from the drive rack to do maintenance on a Rail or Dual Gantry axis, you must reposition the pinion
manually before re-enabling the drives. Absolute encoders remember position and communicate it to the CNC. The
CNC will attempt to correct the difference in position between the Rail and Dual Gantry axis. This motion could
cause mechanical damage to the cutting machine. Contact your table manufacturer or drive supplier for
additional assistance in correcting this condition.
 The CNC supports SERCOS passwords 1SA, 2SA, and so on through 12SA. Use these passwords to troubleshoot
or to prevent drives from phasing up. To use the SERCOS passwords with the Bosch Rexroth IndraDrive drives,
follow these steps:
1. Disconnect the drives you do not want to phase up from the ring. For example, to phase up only Drive 1,
disconnect the cable that connects it to the next drive in the ring before entering the 1SA password. Connect
Drive 1 to Drive 2 but disconnect Drive 2 from the ring before entering the 2SA password, and so on.
2. If your SERCOS ring includes I/O modules, disconnect and disable them before entering the SERCOS
passwords. Choose Setups > Machine Setups > SERCOS and select No for Inline I/O Modules at Address
50 to disable the I/O modules.
3. Use the passwords in sequence starting with 1SA.
4. To start troubleshooting, enter the password 1SA to phase up only Drive 1. If that is successful, connect Drive 2
and enter the password 2SA to phase up both Drives 1 and Drive 2, then 3SA and so on.
5. When testing is complete, enter the password SA or cycle power to the CNC to re-enable all drives in the ring.


Section 3
SERCOS III for Kollmorgen AKD Drives
Hypertherm CNCs support the SERCOS III interface to Kollmorgen AKD servo drive amplifiers. For a list of compatible
inline I/O bus couplers, see Bus couplers on page 6. The WorkBench software to program Kollmorgen AKD drives is
provided on the CNC.
Compatible Kollmorgen AKD drives use the part number format AKD-PXXXXX-NBS3-XXXX and firmware version
01-13-05 or later. Phoenix version 9.76.1 or later is also required.
These drives support:

 7 digital inputs (an additional input is reserved for a dedicated use)
 2 digital outputs
 1 analog input
 1 analog output
Use the following resources to learn more about the Kollmorgen AKD drives and the WorkBench software:
 WorkBench help file (1.8.7.34650), provided on the Hypertherm CNC.
 AKD™, AKD™ BASIC, AKD™ PDMM Installation Manual and other references, available on the Kollmorgen website
at www.kollmorgen.com.
Work in partnership with your Kollmorgen representative when sizing the drives and motors for your cutting machine.
Cutting machine specifications and mechanics are beyond the scope of this document.
Launch the WorkBench software

To launch the software from Phoenix, choose Setups > Diagnostics > Drives and Motors.
SERCOS III CNC and drive setup

The following are the basic steps for setting up the Kollmorgen AKD drives with the Hypertherm CNC. Complete these
steps before phasing up the ring for the first time. Additional information on drive addresses, I/O, and other topics can be
found in the sections following this overview.

3 – SERCOS III for Kollmorgen AKD Drives
CNC settings
1. Assign the axes in the Machine Setups screen. Encoder Counts per mm (inch), Encoder Polarity, and Emulated
Counts/motor rev are the key values for setting up each axis:
 For AKD drives, Emulated Counts/motor rev is always set to 65536.
 See Set drive units on page 48 for examples of calculating encoder counts.
 Encoder Polarity sets the positive or negative input direction of the encoder to establish proper counting for
positive machine motion.
2. In the SERCOS III screen, select whether you will be using drive I/O and/or I/O provided by an I/O bus coupler. The
recommended setting is All Drive I/O.
Drive settings
Most parameters in the Kollmorgen AKD drive can be left at their default settings. Hypertherm CNCs use the parameters
listed below. Set the first group of parameters in the drive. The CNC automatically sets the second group of parameters
during ring phase-up.
These settings are made in the drive using the Kollmorgen WorkBench software.
1. After you add a drive, choose Settings to expand the tree view of the parameters you can set in the drive.
2. Select the motor connected to the drive from the motor database included with WorkBench. The WorkBench
software can also automatically detect many of the compatible motors. After WorkBench identifies the motor, it
automatically loads the correct settings and tuning information for the motor.
3. Operation Mode: For each drive, choose the operation mode at the top of the WorkBench screen as follows:
Axis Type Operation mode
Linear Transverse, Rail, Dual Gantry, or Position

Transverse 2
Sensor THC Torch height control Velocity
Rotary A, B, or C axis Position

(Rotate and Tilt axes in Phoenix)
Pipe Transverse 2 (Rotating Dual Position

Transverse)
4. Communication: Make sure that Drive Type is set to SERCOS III.
5. Drive Address: The drive address must match the axis number required by the CNC.
 You can set all the drive addresses to 1 and allow Phoenix to address the drives. See
About drive addresses and axis assignments on page 11 to learn more about addressing
the axes and drives.
6. Units: Set the mechanical dependent units in the WorkBench software, and then enter the Encoder Counts per
mm (inch) in the CNC. See Set drive units on page 48 for instructions.

7. Limits: The motor limits may be set automatically when WorkBench identifies the motor and loads its parameters
from the motor database. You can reduce the limits on this screen if needed.
The following settings are made automatically in the drive by the CNC when you first phase up the ring.
 Operation mode: The operation mode depends on the type of axis as set up in the CNC, and the CNC automatically
makes this setting when you first commission the system. See the table above for the operation modes.
 Encoder polarity: This parameter sets the positive or negative input direction of the encoder to establish proper
counting for positive machine motion.
 Drive polarity: This parameter sets the travel direction of the axis.
Internet Protocol (IP) addresses
 Ifneed
you want to connect a PC or laptop to the SERCOS ring and use WorkBench while the ring is running, then you
to assign IP addresses to the SERCOS drives as follows. If you do not want to connect a PC or laptop, you can
skip this section.
Each drive in the SERCOS ring requires a unique IP address to communicate with the WorkBench software. Kollmorgen
AKD drives can be set to have dynamic or static IP addresses. Dynamic IP addresses can be convenient since the
network DHCP assigns them automatically. If a network DHCP is not present, the drive assumes an automatic private IP
address of 169.254.xxx.xxx. Refer to the Kollmorgen AKD drive installation manual for more information on selecting static
or dynamic IP addresses using the rotary switches on the drive. The CNC does not use the IP addresses.
 IP addresses are different from SERCOS drive addresses. See Address the SERCOS III drives on page 13 for more
information about SERCOS drive addresses.
Drive I/O
The Kollmorgen AKD drives each support 7 digital inputs, 2 digital outputs, 1 analog input, and 1 analog output. A digital
input 8 is non-programmable and reserved by the drive for “output stage enable.” Phoenix ignores input 8. The CNC
automatically sets the Inline I/O Modules at Address 50 parameter to Yes during phase-up. The CNC then numbers
the I/O as shown in the following table:
Drive address Digital inputs Digital outputs Analog inputs Analog output
1 1–7 1–2 5 1
2 8 – 14 3–4 6 2
3 15 – 21 5–6 7 3
4 22 – 28 7–8 8 4
5 29 – 35 9 – 10 9 5
6 36 – 42 11 – 12 10 6
I/O bus coupler at address 50, 43 and above 13 and above 11 and above 7 and above
first input or output

Set drive units

The CNC commands the Kollmorgen AKD drives every 1 ms. The position information transmitted by the CNC and read
by the drives is in encoder counts. The WorkBench software allows you to select meaningful units that match the units
that the CNC displays in the Machine Setup screens. Although it is not required that you set these parameters in
WorkBench, we strongly recommend that you do. Keeping the WorkBench and Phoenix settings the same makes setup
and troubleshooting easier.
The WorkBench software automatically applies these settings to the drive. The unit settings in the drive reflect the last
settings made in the Units screen before exiting. However, you can save the settings to non-volatile drive memory by
choosing the Save to Drive button in the WorkBench toolbar.
The following are examples for selecting units on a linear, rotary, pipe, and THC axis, then setting the Encoder Counts
per mm (inch) and Emulated Counts/motor rev to enter in the axis setup screen in the Phoenix software.
Set units for a linear axis
 Linear axes include Transverse, Rail, Dual Gantry, Transverse 2 (non-rotating), and Sensor THC. For an example of a
Sensor THC axis setup, see Set units for a Sensor THC axis on page 57.
In this example, the Rail axis has the following machine characteristics:
Belt/Pulley: 1:2
Lead screw pitch: 32 mm/revolution

(1.259 inches/revolution)
In WorkBench, set the following parameters in the Settings and Units screens for the Rail axis drive.
 In this example, combine both the gear box ratio and the belt/pulley ratio for a total gear ratio of 15:2.

Select Field Bus and Position Mode in the Settings screen:
Enter the machine characteristics into the Units screen:

On the CNC, enter the Encoder Counts per mm (inch) and the Emulated Counts/motor rev in the Machine Setup >
Rail screen:
Use this formula to calculate the Encoder Counts per mm (inch):
15 motor 1 load
65536 counts
revolutions revolution
15360 counts
X X =
per mm
1 motor 2 load
32 mm
revolution revolutions
 For AKD drives, Emulated Counts/motor rev is always set to 65536.

The remaining parameters on the SERCOS axis setup screen are common to all axes on the CNC. Refer to the Phoenix
V9 Installation and Setup Manual for information on all axis parameters.

Set units for a rotary axis
 Rotary axes are used for bevel cutting and include Rotate, Tilt, and CBH.
In this example, the Rotary axis has the following machine characteristics:
Mechanics: Disk (Angular)
In WorkBench, set the following parameters in the Settings, Units, and Modulo screens for the Rotary axis drive.
In the Settings screen, set Command Source and Operation Mode as follows:

In the Units screen, enter the machine characteristics as follows:
On the Modulo screen, enable modulo and then enter the Modulo Range Begin/End values and Direction For
Absolute Motion Task.

Set Modulo Range Begin to 0. To determine the Modulo Range End setting, use this formula:
102 motor
65536 counts
revolutions
6684672 counts
X =
per revolution
1 motor 1 load
On the CNC in the Rotary axis setup screen, enter the Encoder Counts per rev and the Emulated Counts/motor rev
as follows:

Set units for a pipe axis
For pipe and tube cutting, you set up the Transverse 2 (also known as the Dual Transverse) axis as a Pipe (Rotary) axis.
This is also referred to as a Rotating Dual Transverse axis.
 Set up the Pipe axis as a Rotary axis, but without modulo.

In this example, the Pipe axis has the following machine characteristics:
In WorkBench, set the following parameters in the Settings, Units, and Modulo screens for the Pipe axis drive.
In the Settings screen, set Command Source and Operation Mode as follows:

In the Units screen, enter the machine characteristics as follows:
On the Modulo screen, make sure that modulo is disabled.

On the CNC in the Rotate axis setup screen, enter the Encoder Counts per rev and the Emulated Counts/motor rev
as follows:
Use this formula to calculate the Encoder Count per rev:
75 motor
65536 counts
revolutions
4915200 counts
X =
per revolution
1 motor 1 load


Set units for a Sensor THC axis
In this example, the Sensor THC axis has the following machine characteristic:
Gear box ratio: 5:1
Lead screw pitch: 5.08 mm/revolution

(0.20 inches/revolution)
In WorkBench, set the following parameters in the Settings and Units screens for the Sensor THC axis drive.
On the Settings screen, set Command Source and Operation Mode as follows:

Enter the machine characteristics into the Units screen:

On the CNC, enter the Encoder Counts per mm (inch) and the Emulated Counts/motor rev in the Machine Setup >
Sensor THC Axis Setup screen:
Use this formula to calculate the Encoder Counts per mm (inch):
5 motor 1 load
65536 counts
revolutions revolution
64503.94
X X =
counts per mm
1motor 1 load 5.08 mm
revolution revolution


Sensor THC connections to the Kollmorgen AKD drives

Connector J2 on the Sensor THC voltage divider card (VDC3), installed in the plasma system, connects to the SERCOS
drive.
 Analog output from the voltage divider card must be connected to an analog input on a drive, not on an I/O module,
because the arc voltage analog input requires the faster communications speed the drive provides.
 Nozzle Contact Sense and Nozzle Contact Enable connect to the I/O module. Both require negative logic.
VDC3
J2 pin VDC3 Signal AKD Drive I/O
number
6 Analog Out + Analog input + on AKD drive

connector X8, pin 10
7 Analog Common Analog common on AKD drive

connector X8, pins 7 and 9
8 Earth Ground

Analog output from J2 connects

to X8 on drive.
J2 X7
J1 X8
Connectors X7 and X8 for

digital I/O (positive logic)
J3
X8 connector for analog input
Voltage divider card (VDC3)
Notes:
 The digital I/O for nozzle contact sense should be configured for negative I/O logic on the
drive or I/O module.
 The WorkBench software can set the drive I/O polarity.
 J1 connects AC power to the VDC3.
 J3 connects to high voltage connections on the plasma supply (Shield, Work, Electrode,
Ground).
 Use WorkBench to check the firmware version in the drives. For Phoenix version 9.76.1 or later, we require
Kollmorgen AKD drives with the part number format AKD-PXXXXX-NBS3-XXXX and firmware version 01-13-05 or
later.
 Each drive has an LED display that shows messages. When the drive initializes, it displays a sequence of characters:
-- [ ] o0 then o1 for a velocity axis, and o2 for a position axis. When the drive is enabled, it displays a dot next to the
number: o1. and o2. These are programmable and may differ from what is described here.
 The CNC supports SERCOS passwords, 1SA through 12SA, that can be used for troubleshooting or for preventing
drives from phasing up.
Use the passwords in sequence starting with 1SA.
1. To start troubleshooting, enter the password 1SA to phase up only Drive 1. If Drive 1 phases up successfully,
enter the password 2SA to phase up both Drives 1 and Drive 2, then 3SA and so on.
2. When testing is complete, enter the password SA or cycle power to the CNC to re-enable all drives in the ring.


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SERCOS® III

for Hypertherm® CNCs

Field Service Bulletin

© 2015 Hypertherm, Inc. All rights reserved.

1 SERCOS III Overview ................................................................................................................... 5

SERCOS III Field Service Bulletin 808000 3

For Bosch Rexroth drives (IndraWorks Ds software) ........................................................................................... 20

2 SERCOS III for Bosch Rexroth Drives .................................................................................. 23

3 SERCOS III for Kollmorgen AKD Drives .............................................................................. 45

4 SERCOS III Field Service Bulletin 808000

SERCOS III Field Service Bulletin 808000 5

SERCOS III equipment supported by Hypertherm CNCs

Beckhoff EK9700 bus coupler and I/O modules

 This equipment requires Phoenix 9.76.0 or later.

EK9700 Beckhoff bus coupler

EL1008 8-channel digital input terminal, 24 VDC, 3 ms

EL2008 8-channel digital output terminal 24 VDC, 0.5 A

EL3064 4-channel analog input terminal 0–10 V,

EL4004 4-channel analog output terminal 0–10 V, 12-bit

6 SERCOS III Field Service Bulletin 808000

Bosch Rexroth fieldbus coupler and I/O modules

 This equipment requires Phoenix 9.73.0 or later.

R-IL S3 BK DI8 DO4-PAC SERCOS III fieldbus coupler, 8 digital inputs,

R-IB IL AO 2/U/BP-PAC Analog output module, 2 analog outputs,

R-IB IL AI 2/SF-PAC Analog input module, 2 analog inputs: 0 to 20 mA/4

WAGO® bus coupler and I/O modules

 This equipment requires Phoenix 9.76.0 or later.

750-351 SERCOS III bus coupler, 2-port, 100 Mbit/s, digital

750-459 4-channel analog input module, ±10 V/0-10 V

750-530 8-channel digital output module, 24 VDC

750-430 8-channel digital input module, 24 VDC

750-559 4-channel analog output module, ±10 V/0-10 VDC

750-627 Internal data bus extension end module (for

750-628 Internal data bus extension coupler module

750-1500 16-channel digital output module, ribbon cable,

750-1400 16-channel digital input module, ribbon cable,

750-600 End module, no function (physical end cap)

SERCOS III Field Service Bulletin 808000 7

Part number Length

223102 61.0 m (200 feet)

223101 45.5 m (150 feet)

223100 30.5 m (100 feet)

223099 23.0 m (75 feet)

223008 15.0 m (50 feet)

223223 10.5 m (35 feet)

223119 7.5 m (25 feet)

223222 6.0 m (20 feet)

223212 3.0 m (10 feet)

223380 1.5 m (5 feet)

223382 0.6 m (2 feet)

223381 0.3 m (1 feet)

8 SERCOS III Field Service Bulletin 808000

SERCOS III system overview

SERCOS III master card

SERCOS III To laptop or CNC

Double ring Single ring

 The communications between master and slaves, shown with the

General requirements for SERCOS III

SERCOS III Field Service Bulletin 808000 9

Figure 2 - Example of a SERCOS ring with the drives and axes