SERCOS News - Issue 1 - 2008

Issue 1/2008 

The Real-Time Ethernet Magazine 

Intelligent packaging 

ROVEMA introduces packaging machine with 

SERCOS III communications 

Sercos-Inside: 

Safe and fit for the future 

SERCOS III master simulator for 

development and test facilities 

Product-News: 

Beckhoff I/O-System for SERCOS III

2 Editorial 


Real-time Ethernet: 

Speed is not everything! 

Ethernet is generally recognized to be a 

powerful and future-proof bus system 

which is particularly notable for its low 

cost and standardized physical design. 

Hence it always sounds highly promising, 

at least at first, whenever new 

types of bus system are based on 

Ethernet. At second glance, however, 

this image becomes somewhat clouded, 

not so much because of the technology 

or the possibilities offered by 

Ethernet but more because of the 

number of incompatible solutions competing 

with each in the market. 

The latest development is that solutions 

are now already being offered 

on the basis of Gigabit Ethernet. It 

should come as no surprise that the 

subject has become an issue for those 

companies and users’ organizations in 

particular which experience performance 

disadvantages because of the 

respective transmission method used. 

What is not mentioned here is that certain 

disadvantages have to be taken 

into account if Gigabit Ethernet is used, 

such as more complex cabling, for example, 

and higher costs and CPU loads 

for software-based solutions. 

Thanks to its highly efficient protocol, 

SERCOS III is already able to meet the 

performance requirements of all applications 

today, meaning that there is 

no need to switch to Gigabit Ethernet. 

Instead it enables concepts to be implemented 

which offer genuine added 

value for machine manufacturers. In 

particular this means manufacturerindependence 

and worldwide acceptance, 

as reflected in the standardized 

device profiles and the CIP Safety on 

SERCOS safety concept. 

We hope you have an enjoyable read. 

Peter Lutz, 

General Manager 

SERCOS International e.V. 

Küblerstraße 1, D-73079 Süßen 

Phone: +49 (0) 7162/9468-65 

Fax: +49 (0) 7162/9468-66 

e-mail: p.lutz@sercos.de 

www.sercos.de 

Quick-Info 1-0801 

 

 

 

A1 

 

 

 

a 

company 

 

 

 

 

 

 

SERCOS III 

Hardware for master and slave 

Driver software for master and slave 

Controls and IO systems 

Starterkits 

Design - Consulting - Training 

 

AUTOMATA GmbH & Co. KG · info@automata.de · www.automataweb.com 

Tel. + 49 (0) 82 33 / 79 16 - 0 · FAX + 49 (0) 82 33 / 79 16 - 19


Sercos-Inside 

3 

Safe and fit 

for the future 

Many companies have several networks running in parallel, making it impossible 

or unprofitable to communicate with each other. This makes cooperation more 

difficult and results in functional losses. Yet it would be helpful if a die-casting 

machine was able to report a fault, not just to the staff on site, but also to the 

production planning systems, material management as well as the manufacturer. 

A direct connection between the PC of a developer located at headquarters and 

the control of an assembly line of a subsidiary factory could make updates much 

faster and more cost-efficient. Therefore companies are increasingly coming to use 

a unified protocol to transfer information from A to B. Here Ethernet and TCP/IP, the 

basis of the Internet and office communication, have become dominant. 

As factory automation has much higher 

requirements as to the robustness, 

reliability and safety of the information 

networks, Ethernet in the industrial 

environment looks somewhat different 

from Ethernet in the office. The 

most important requirement Industrial 

Ethernet has to meet is real-time communication, 

i.e. the assurance that important 

information will be transferred 

immediately or within a guaranteed 

time frame. This is the only way to coordinate 

complex processes. Common 

Ethernet allows a unit to block the line 

for all other participants for as a long as 

it takes to transmit its data completely. 

This leads to the typical "freezing" of the 

network, for instance when someone 

is sending an e-mail with a volume of 

several megabytes to many recipients. 

Two seconds of delay may not be a problem 

in the office, but in a machine, 

which has to coordinate 80 work cycles 

per minute, it would be disastrous. 

The second important feature is reliability. 

Heat, dust and vibration can never be 

prevented at a workplace. Strong magnetic 

fields may induce currents in cables 

that are insufficiently protected. And a 

cable failure is always possible where 

many parts are moving. None of these 

factors may be allowed to jeopardize 

the work capabilities, and the same 

applies to the safety from external access. 

However desirable it is to make communication 

easy, unauthorized access 

must be prevented in every case. 

The term of Industrial Ethernet actually 

covers various different practical solutions. 

Around a dozen solutions are 

offered, six of which – systems such as 

SERCOS III, PROFINET RT or EtherNet/IP – 

can be seen as the relevant market participants 

with enough international support 

and a sufficient number of clients. 

However, there are enormous differences 

in some cases. Some systems may 

offer real-time functions but with only 

limited synchronicity, which guarantees 

that several modules work in the same 

system cycle. Others are based on a close 

connection between the control and 

network functionality, which means 

that the user is restricted in his choice 

of automation systems. Others again 

might be open but demand rigid network 

planning with numerous control 

units which make modifications difficult 

and also make simple standard 

communication very slow. 

Today's field busses and Industrial Ethernet 

systems offer some basic functions 

which allow carrying out typical control 

tasks. As the complexity of the application 

increases, the requirements for the 

network increase as well. For instance, 

real-time applications that require the 

precise interaction of several electric 

drives or need fast processing of sensor 

data depend on a network with a guaranteed 

high performance. This is exactly 

the domain of SERCOS III. Thanks to 

Fast Ethernet with a throughput of 100 

megabits per second and possible mini-

4 Sercos-Inside 


Block I/O - easy integration of I/O signals 

in SERCOS III 

mum cycle times of only 31.25 µs (the 

blink of an eye takes approx. 330,000 

µs), the fast transfer of the information 

is guaranteed. Also, the architecture 

enables direct communication between 

the executing units (slaves) so as to keep 

reaction times down to a minimum. To 

optimise the network, SERCOS III does 

not require expensive additional network 

components, such as switches or 

hubs. The integrated network functions 

ensure that TCP/IP packets can also be 

transmitted next to the real-time data. 

The reliability is increased by a robust design, 

a ring structure of the lines against 

the consequences of a cable break, as 

well as the secured data transmission 

via a certified safety protocol. The data 

is protected automatically, which require 

no additional hardware. 

Since October 2007, the SERCOS III real 

time Ethernet solution has been part 

of mandatory IEC standards. The vote 

for SERCOS III as the international standard 

was unanimous. This reflects the 

worldwide importance of the SERCOS 

interface. SERCOS II was already standardized 

worldwide. In parallel to standardization 

of third generation SERCOS, 

IEC decided to incorporate the existing 

IEC 61491 SERCOS II standard into the 

new IEC 61158/ 61784-1 standards series. 

The SERCOS drive profile was included 

in the new IEC 61800-7 standard. All 

three SERCOS generations are now part 

of the IEC standards. 

2 million SERCOS nodes are currently installed 

worldwide, and the IEC decision 

is goods news for SERCOS developers 

and users. The evolution of SERCOS is 

characterized by continuity and a clear 

migration path. The common interface 

ensures interoperability between 

products from different manufacturers 

which use the same standardized interfaces, 

commands and synchronization 

methods. More than 80 different manufacturers 

now offer SERCOS-enabled 

products. 

At the field level, which is where communication 

between individual drives, 

sensors and controllers takes place, 

SERCOS III real time functions guarantee 

the required level of precision. Connectivity 

to higher level control systems is 

extremely simple. Companies gain direct 

access to data at the lowest production 

level, and every Ethernet-enabled computer 

can be connected to a SERCOS III 

port without any additional hardware 

or software. The computer can link into 

corporate TCP/IP communications without 

putting production-level runtime 

performance at risk. 

This works because in addition to real 

time communications, SERCOS III has a 

channel for non real time information 

(NRT). The completely transparent integration 

of real time and non real time 

data enables users to operate a large 

mix of devices on the same network. 

In contrast to other Industrial Ethernet 

solutions, SERCOS III does not require 

additional hubs and switches, and it 

does not use any additional protocols. 

Connectivity is completely transparent, 

because Ethernet systems without a 

SERCOS III ID are automatically allocated 

to the NRT channel. A 100 Mbit 

data rate supports data exchange between 

many devices in parallel without 

compromising the integrity of real time 

communications. 

Transparent integration of real time 

and non real time data allows companies 

to completely rethink their systems 

strategies. SERCOS III brings two worlds 

Highest precision - with cycle times till 31,25µs 

together. All nodes speak the same 

language. Different modules can even 

share the same cables without compromising 

integrity and reliability. 

SERCOS III, like previous SERCOS generations, 

is based on the field-proven 

hardware synchronization solution as it 

offers the greatest reliability. Every module 

comes with a special logic module 

which coordinates the SERCOS nodes 

with each other. This eliminates any 

need for additional expensive con trol 

points in the form of hubs and switches, 

and the network coordinates itself automatically. 

Synchronization is therefore 

one of the basic features of every SERCOS 

solution, not a feature which has to be 

added on each time with additional 

modules or protocols. 

At the same time the cycle time of 31.25 

μs in real-time mode does not mean 

that one individual module would take 

up the complete range for itself alone. 

Instead, it is possible for up to eight 

drives in Motion Control applications 

to be supplied with 8 bytes of cyclical 

data and for them to send the same 

number of diagnoses as well. This is 

sufficient for the most demanding tasks 

currently conceivable in mechanical 

engineering. Even high-precision CNC 

machines have minimal cycle times of 

500 µs. Thanks to the greater efficiency 

of SERCOS techno logy it will not 

be long before there will be no applications 

which would make it necessary 

to have a higher network speed. Moreover, 

Fast Ethernet also offers sufficient 

reserves for TCP/IP communication in 

production – especially because SERCOS 

is very efficient in the use of resources. 

Flexibility is a success factor in production 

and Industrial Ethernet is a protocol 

which allows planning and production 

to be coordinated with each other with-


5 

Motion and I/O: 

Together with SERCOS III 

SERCOS III coupler for the WAGO-I/O-SYSTEM 

• Full support for Sercos III V. 1.20 protocol and 

SERCOS safety based on CIP safety 

• Compatible with the SERCOS III I/O profile 

• Additional I/O fieldbus no longer required 

• I/O nodes synchronous with motion cycle 

• Redundancy possible through ring topology 

• 100 Mbit/s 

• Cross communication 

• Additional standard IP channel 

www.wago.com



Standard ethernet componets - save costs 

and simplifies systemarchitecture 

out long lead times. In practice, however, 

a modern network is expected to 

be able to do even more than this. Flexibility 

also means being able to combine 

individual modules to form new solutions 

at low cost. Intelligent control 

systems turn machines into reusable 

modular systems, the components of 

which can be combined anew as requirements 

dictate. The network therefore 

has to be highly flexible. As a general 

rule individual components (slaves) are 

controlled by a controller (master). This 

results in the typical linear bus structure 

of a section of production. In turn, the 

individual controllers can communicate 

with each other via a joint network, or 

gateway, segment. 

As well makes it possible for data to 

be exchanged directly between a sensor 

and a drive which are controlled by 

separate controllers. This reduces the 

load on the central control system and 

also cuts data flows in the network. This 

so-called C2C (control-to-control) crosscommunication 

between masters, such 

as two PLCs, for example, provides the 

basis for the distributed control of complex 

production lines. This flexibility in 

communication, which leads to reduced 

reaction times between master or slave 

devices and, therefore, in the overall 

process, permits the synchronous actuation 

of axes at any time, even where 

several SERCOS networks are involved. 

The technology which makes crosscommunication 

between the individual 

nodes possible not only contributes to 

the efficiency and flexibility of SERCOS 

solutions, it also increases safety because 

it enables a SERCOS III network 

to be organized on the basis of a ring 

structure. In the event of a cable failure, 

therefore, a redundant signal route is 

available. This is not the case in the classical 

Ethernet which uses switches and 

routers for coordinating data flows. The 

SERCOS network, in contrast, coordinates 

itself and offers flexible strategies: 

a classical linear structure in order 

to save materials or a redundant ring 

structure for greater safety. The engineers 

have the choice of selecting the 

most suitable cabling to meet requirements 

without having to think about 

additional elements for the network 

infrastructure. 

The same applies to the safety of data 

transmission. SERCOS offers a certified 

safety protocol as standard to ensure 

that information is safely transferred. 

SERCOS safety complies with the requirements 

of safety standard IEC 61508 up 

to Safety Integrity Level 3 (SIL 3). This 

covers risks arising out of or in connection 

with system failures and which may 

netX 50 

netX 50 – networX on Chip 

• 16 or 32 bit network controller with two 

communication channels for field bus or real-time 

Ethernet with integrated PHY / Switch / Hub 

• EtherCAT with 8 FMMUs / Sync-Manager 

and 6 KB IO data 

• Controller for IO-Link master and CCD sensor 

• Hardware platform for IOs and IO-Link gateways


Sercos-Inside 

7 

pose a risk to the health of employees, 

to the environment, etc. For example, a 

sensor used for detecting a dangerous 

axis movement or an overheated drive 

is also supposed to ensure that the 

machine is made safe in a controlled 

manner and also switched off. Previously 

this required separate cables. SERCOS 

III allows all safety-related information 

to be transferred via the existing data 

cables so that in the event of an emergency 

it can be guaranteed that the 

power supply will be shut off if the 

emergency stop button is actuated. 

The elimination of additional hardware 

reduces costs without any compromise 

on safety. 

SERCOS safety is protected against potential 

errors such as repeats, losses, 

insertions, incorrect sequences, corruption, 

delays and the confusion of 

secure and standard data. The security 

protocol is certified in accordance with 

IEC 61508 and was also tested by the 

German TÜV in respect of safety requirements. 

To ensure that data is transmitted 

securely SERCOS safety uses the 

CIP safety protocol of the ODVA. It is 

used by a range of communication 

standards such as DeviceNet, Control- 

Net and Ethernet/IP and allows users to 

use the same safety mechanisms on different 

platforms. This makes it possible 

to connect several CIP-based networks 

together on a consistent basis. 

Offering a combination of high performance, 

flexibility and verifiable safety, 

SERCOS III meets all the requirements 

of a modern, consistent automation 

network. It offers the required everyday 

suitability thanks to the field-proven 

capabilities of the SERCOS protocol 

and the forward compatibility of a realtime 

Ethernet solution. Thanks to Fast 

Ethernet and synchronous cycle times 

of 31.25 µs, the third generation of 

SERCOS not only delivers impressive 

performance data at the top end, it also 

masters complex automation tasks. For 

example, it can allow up to 330 drives 

with 4 byte input/output data and 8 

digital I/Os each to communicate with 

each other in a cycle of a single millisecond. 

SERCOS III therefore delivers a 

level of performance which more than 

meets the requirements of today’s 

highly developed production machines. 

In addition, it also permits the rapid 

processing of process data via distributed 

I/O modules in central control 

systems. 

Contact: 

Bosch Rexroth AG 

Division Electric Drives and Controls 

Daniel Grimm 

Phone +49 (0) 9352/40-5245 

Fax +49 (0) 9352/40-35245 

e-mail: daniel.grimm2@boschrexroth.de 

www.boschrexroth.de 

Quick-Info 1-0802 

netX – The future of communication 

netX on Chip netX 5 netX 50 netX 100 netX 500 

CPU including – 

Product announcement 

1st quarter 2008 

ARM 966E-S / 200 MHz 

8K Data / 8K Inst.TCM 

ARM 926EJ-S / 200 MHz 

8K Data / 16K Inst.-Cache 

8K Data TCM 

ARM 926EJ-S / 200 MHz 

8K Data / 16K Inst.-Cache 

8K Data TCM 

Internal memory 64K SRAM 96K SRAM / 64K ROM 144K SRAM / 32K ROM 144K SRAM / 32K ROM 

Memory bus (external memory) – SDRAM / SRAM / Flash SDRAM / SRAM / Flash SDRAM / SRAM / Flash 

Communication channels 

with integrated... 

2 

Switch / Hub 

IEEE 1588 

2 

PHY / Switch / Hub 

IEEE 1588 

3 


IEEE 1588 

4 


IEEE 1588 

Host interface 

8 / 16 / 32 Bit DPM 

SPI 

8 / 16 / 32 Bit DPM or 

16 Bit Extension Bus 

8 / 16 Bit DPM or 


8 / 16 Bit DPM or 


Peripherals 

SPI 

USB / UART / I2C / SPI 

IO-Link-Controller 

CCD-Controller 


PWM / Encoder / ADC 


PWM / Encoder / ADC 

Grafik-Controller 

Housing 

LBGA 17x17 mm 

228 Pins / 1 mm grid 

PBGA 19x19 mm 


PBGA 22x22 mm 


PBGA 22x22 mm 


Power supply 

Power consumption 

Operating temperature 

1.8 V / 3.3 V 

tbd. 

- 40… + 85 °C 

1.5 V / 3.3 V 

1.2 W 

- 40… + 85 °C 

1.5 V / 3.3 V 

1.5 W 

- 40… + 85 °C 

1.5 V / 3.3 V 

1.5 W 

- 40…+ 85 °C 

Typical applications 

Network-Access-Controller for 

diverse Host CPUs 

COM-Interface / EA 

IO-Link Master / Ident 

COM-Interface / EA 

Gateway / Motion / Ident 

COM-Interface 

HMI 

For more information, visit www.hilscher.com 

or see us at the HANNOVER MESSE 2008 in hall 11, booth 11-A62 

www.hilscher.com info@hilscher.com



a 

company 

SERCOS III master simulator for 

development and test facilities 

The software tool MDT-Parser includes the complete 

SERCOS III master functionality and runs on Windows ® 

XP. Thanks to the integrated script language, the tool 

enables the easy programming of test sequences and 

supports development of SERCOS III slaves and the automation 

of system and serial tests. Because the software 

components are also available as Windows ® DLLs, 

they can be easily integrated in an already existing test 

environment. 

Free of charge SERCOS III 

master DLL 

The MDT-Parser is based on a complete 

master implementation for 

passive PCI cards with SERCON100M 

FPGA. Beside the main functions like 

control of communication phases, 

communication via service channel 

and exchange of real-time data, all 

other services specified by the SER- 

COS III standard are supported. The 

number of master interfaces and connected 

slaves is freely configurable. 

Communication settings, properties 

of the connected slaves and the communication 

links between the connected 

devices are defined by means of a 

XML configuration file. 

The master DLL is available free of 

charge and runs under Windows XP. 

The necessary real-time environment 

and a simple application example are 

already included. The installation of 

a real-time operating system is not 

required. 

MDT-Parser 

Script language 

Besides the SERCOS commands the 

script language provides variables, 

functions to control the program flow, 

display functions as well as arithmetic 

and bit operations. For the documentation 

of procedures and test results 

extensive protocol functions are available. 

With this feature it is also possible 

to record command sequences for the 

later execution as script file. 

The MDT-Parser is available in different 

formats: as a simple console application, 

as a tool with a graphical user 

interface or as a DLL without own user 

interface. The DLL version allows the 

easy integration into existing test 

environments. 

Field of application 

Typical application areas for the 

SERCOS III master DLL and the MDT-Parser 

are the development and veri fication 

of SERCOS III slaves and the device manufacturing 

and test facilities. It enables 

the quick and easy creation of hardand 

software environments needed for 

system and production testing. 

Contact: 

AUTOMATA GmbH 

Christoph Melzer 

Gewerbering 5 , D-86510 Ried 

Phone +49 (0) 8233/7916-0 

Fax +49 (0) 8233/7916-99 

e-mail: info@automata.de 

www.automataweb.com 


The software tool MDT-Parser is a 

command-line interpreter based on 

the SERCOS III master DLL. All functions 

and services provided by the 

master DLL are available as commands. 

The command syntax - e.g. 

the nomenclature of parameters - is 

following the SERCOS standard. 

Software structure of MDT-Parser


9 

 

What all have 

 

 

Only SERCOS has 

Plug-and-play – 

standardized and 

non-proprietary. 

SERCOS III – the independent real-time high-performance fieldbus. 

Our customers deservedly expect only the very best solutions for drive and control 

technology. The core for such solutions is a comprehensive communication system. 

This is why we actively support the development of SERCOS III. It incorporates two 

standards: the proven real-time mechanisms and the internationally established Ethernet 

technology. SERCOS III is standardized from the protocol to the unit data, and has been, 

from the beginning, designed by a team of people from several companies. As a result, 

the high-intelligence devices of Rexroth are unlimitedly compatible for plug-and-play. 

Bosch Rexroth. The Drive & Control Company 

 

Bosch Rexroth AG 

www.boschrexroth.com/sercos 

 

 

Hydraulics 

 

 

Pneumatics

10 Application 


ROVEMA introduces packaging machine 

with SERCOS III communications 

At ROVEMA, intelligent packaging means the 

responsible, innovative design of individual 

components and entire process sequences. The 

company supplies complete solutions for sophisticated, 

complex packaging applications. Forming, 

filling, sealing, case packing and retail packaging 

for today‘s market require a holistic approach 

which goes beyond the individual component 

level to include the specific customer process. 

A very powerful and highly flexible 

control system is needed to support the 

broad product portfolio and the highly 

complex packaging operations. Rovema 

has been using its own proprietary PCbased 

P@ck-Control system for many 

years on its packaging machines. Motion 

control, PLC and visualization are the 

main features of ROVEMA control solutions. 

The motion control subsystem is 

based on centralized control architecture. 

P@ck-Control takes total control of axis 

coordination and position control. The 

interface to the speed-controlled drives 

has traditionally been a conven tional 

+/-10Volt interface with incremental 

encoder feedback. Interbus-S has provided 

the link between the integral software 

PLC in the P@ck-Control system 

and the outside world. 

The engineers at Rovema have designed 

the Ethernet-based SERCOS III real 

time communications system into the 

new P@ck-Control generation. A new 

VPL260 tubular bag machine with this 

communications interface will be on 

display for the first time at Interpack 

2008. The machine also features continuous 

volumetric filling. Communications 

with the speed-controlled 

drives and digital I/Os flow through 

the SERCOS III interface. Two highspeed, 

high-precision linear motors, 

which drive the longitudinal sealing 

tools, put the real time performance 

of the bus system to the test. 

There has been general agreement for 

some time among the control system 

engineers at ROVEMA that the +/-10 

Volt interface will have to be replaced 

by a future-proof Ethernet-based bus 

system. Given the large selection of 

systems on the market, it was no easy 

task for ROVEMA to make the right 

choice. One major criterion was of 

course the bus system's ability to support 

complex ROVEMA control technology. 

The availability of drives and I/Os 

and acceptance by ROVEMA customers 

worldwide were also important 

consi derations. However, support for 

ROVEMA - individual packaging solutions 

power ful and strictly standardized 

communications, I/O and drive profiles 

was the decisive factor. The +/-10 

Volt interface was able to accommodate 

special customer configurations, 

and the new solution will have to offer 

the same flexibility in the future. To 

achieve this goal, the drives and I/Os 

have to speak the same language. 

Another goal of migration to a stateof-the-art 

bus system is to exploit highperformance, 

low-cost hardware components 

which reduce connectivity 

costs. Following an in-depth analysis of 

the competing bus systems, the decision 

in favor of SERCOS III was made 

at the beginning of 2007. With the aid


Application 

11 

of defined profiles and open standards, 

the design team succeeded in integrating 

the real time Ethernet system into 

our machines within twelve months. 

The SERCOS III (Serial Real Time Communication 

System) is based on the proven 

real time mechanism of the SERCOS 

interface. It exploits the principle of cyclic 

data transfer in a precisely defined 

window. Hardware-based synchronization 

provides a solid basis for dependable 

implementation of sophisticated 

motion control functions, for example 

electronic drives and cams in packaging 

machines where up to 30 axes have to 

execute coordinated, high speed motion 

with highly accurate path control . 

In parallel with real time processing, 

SERCOS III can also handle standard IP 

data traffic (e.g. TCP/IP). ROVEMA P@ck- 

Control can exchange messages with 

open, standardized SERCOS III interface 

gives ROVEMA a universal drive and automation 

interface which is compatible 

with drives and devices from a whole 

range of manufacturers. This interface is 

based on the international standards IEC 

61784/61158 (communication) and IEC 

61800-7 (drive profile), and it offers the 

investment protection of standardized 

Ethernet to our customers. Susceptibility 

to electromagnetic interference is 

lower compared to analogue systems, 

and simplified wiring along with a 

reduc tion in component count enhance 

packing machine reliability. 

ROVEMA's has introduced third generation 

SERCOS to support the development 

of tomorrow's packaging machines, 

and the technology will be on 

display at Interpack 2008. Only one 

interface, namely a SERCOS III master 

The principle 

Product enters the system 

through the forming tube 

The forming collar shapes 

the flat film into a round 

film tube 

Low friction rollers guide the 

film to the forming area 

Vertical sealing bars seal 

the edges of the film 

tube together 

Film transport belts pull the film 

through the forming area 

Cross sealing jaws create 

top and bottom seals in the 

pouches 

other devices on the network. SERCOS III 

supports seamless, future-proof communications. 

In combination with the 

complex, centralized P@ck-Control automation 

system, ROVEMA's Ethernetbased 

solution expands existing diagnostic 

and remote maintenance capabilities 

down to the drive and I/O level. 

SERCOS III has replaced the traditional 

field bus for direct control of I/Os, 

monitoring subsystems and other field 

bus devices on ROVEMA packaging 

machines. This functionality along with 

the entire set of motion control functions 

will exploit the advantages of the 

real time Ethernet system. SERCOS III 

support for high-speed communications 

eliminates the need for additional 

hardware in the control computer. The 

card, needs to be installed on the PCbased 

control computer which is running 

P@ck-Control. 

Contact: 

ROVEMA Verpackungsmaschinen GmbH 

Reiner Zentgraf 

Industriestr. 1, D-35463 Fernwald 

Phone + 49 (0) 641/409-454 

Fax + 49 (0) 641/409-397 

e-mail: reiner.zentgraf@rovema.de 

www.rovema.de 


You expect more than just programming 

according to IEC 61131-3? 

CoDeSys: Integrated visualization to 

be displayed on different clients 

(local/target/web)! 

More information on our website: 

www.3s-software.com/index.shtml?en_Visualization_V3 

CoDeSys Users’ Conference: 

www.users-conference.com 

HANOVER FAIR 2008 

Hall 9 - Booth D47 

3S-Smart Software Solutions GmbH 

Memminger Str. 151 · 87439 Kempten/Germany 

Tel. + 49-8 31-5 40 31-0 · www.3s-software.com 

We software Automation.

12 News 


++++ NEWS ++++ NEWS ++++ NEWS ++++ NEWS ++++ Quick-Info 1-0805 

Easy-I/O implemented 

successfully into the first FPGAs 

The single chip controller for the universal 

real-time Ethernet solution SERCOS III, 

which has been available since early 2007, 

has been integrated into the first slave 

devices. On the basis of the Easy-I/O, 

Phoenix Contact was able to make a 

digital as well as an analogue Inline block 

I/O ready for the market with a minimum 

integration effort and therefore in a 

minimum of development time. The compact 

Inline block I/O modules are used in 

particular where a limited number of I/O 

signals needs to be processed for little 

cost. In addition to the use of the Easy 

I/Os in the individual block I/O modules, 

Rexroth has integrated the Easy I/O into a 

pneumatic valve carrier system, enabling 

complete system solution via SERCOS III 

as a communication system. The licensefree 

IP Core for FPGAs has been developed 

especially for I/O devices, measuring 

sensors, speed sensor and valve 

clusters and is available as a free download 

for interested parties, together 

with a complete documentation. Registration 

is done on the SERCOS Homepage 

www.sercos.de 


S/IP protocol specification 

for SERCOS III passed 

With the S/IP protocol specification 

SERCOS International has passed a 

further important building block for the 

Real-time Ethernet technology SERCOS III. 

The new protocol enables direct communication 

as well as uniform data 

exchange between devices, without 

a SERCOS III master or a subsidiary 

SERCOS III communication being necessary. 

Even in cyclic real time operation 

the S/IP protocol can still be used. In 

this case the S/IP telegrams are transferred 

into the NRT channel (Non Real- 

Time) of SERCOS III, without having 

a negative influence on the real time 

behaviour of the network. Apart from 

simple reading and writing the parameters 

of a device, S/IP also supports 

the possibility of combining several 

tasks and sending them to the final 

device for processing. Furthermore 

apart from fixed, preset, standardised 

protocol services, manufacturer specific 

services can also be added, which 

makes SERCOS III particularly flexible 

for users and developers. With the 

new S/IP protocol the vertical integration 

of devices into a production system 

is improved. The set-up, but also remote 

maintenance and diagnosis of SERCOS 

III devices can be carried out by means 

of S/IP over the intranet or internet. 


IXXAT Automation develops portable 

safety stack for CIP Safety on SERCOS 

On the basis of a cooperation with 

SERCOS International, IXXAT develops a 

portable stack software for the safety 

protocol CIP Safety on SERCOS. The 

stack uses the SMP (SERCOS Messaging 

Protocol), which enables the representation 

of the CIP data and services on 

configured, cyclic data containers in 

the SERCOS telegram. The stack software 

can be used for SERCOS master as 

well as SERCOS slave implementation 

and consists of a CIP Safety layer and a 

CIP Safety on SERCOS adaptation layer. 

The software will be pre-certified by 

TÜV and BGIA according to IEC 61508 

SIL3 to facilitate considerably the development 

and certification of safetyrelevant 

automation devices. Beside 

the cooperation relating to CIP Safety 

on SERCOS, the company IXXAT is also 

planning to realize a SERCOS III interface 

module based on the universal 

IXXAT “Industrial Ethernet Module”, 

where the complete SERCOS III functionality 

is integrated into an FPGA component 

by the manufacturer Altera and 

made available for connection to host 

systems via a universal interface.


Sercos-Inside 

13 

Workshops·Fairs·Roadshows 

Exhibitions 

Plug-Fest 

Hannover Messe 2008 FA/PA 2008 SPS/IPC/DRIVES 2008 ISW, University of Stuttgart 

April 21–25, 2008, Hannover June 10–13, 2008, Beijing November 25–27, 2008, Nuremberg May 28-29, 2008 

Seminars 

Roadshow / China 

User Seminar 

Beijing/Shanghai/Guangzhou/Shenyang/Wuhan 

June 11, 2008, Beijing/China September 15–26, 2008 

End of September 2008, Paris/France 

For further information please contact: 

October 14, 2008, Munich/Germany 

Developer Seminar 

SERCOS International e. V. · Peter Lutz 

Phone: +49 (0)7162/9468-65 

October 15, 2008, Munich/Germany 

Fax: +49 (0)7162/9468-66 

info@sercos.de 


Impressum 

Publishing, concept and design: 

STROBL GmbH, Ilsfeld-Auenstein, Phone +49 (0) 70 26 / 9 60 17 

e-mail: info@stroblgmbh.de 

Responsible for content: Peter Lutz, SERCOS International e. V. 

Publication does not imply that the solutions described or the 

designations used not protected by trademark, patent or 

intellectual property rights. 

Real-Time Ethernet in the format of the industrial standard 

Communication interfacing using a serial host or shift register 

interface has become a standard on the market. 

With the netIC, Hilscher makes a compatible hardware available 

for all real-time Ethernet systems equipped with two ports and 

integrated PHYs, Hub und Switch. 

• Modbus RTU protocol as a host interface 

• UART, SPI, I2C, shift register interface 

• Direct connection to 2x RJ45 port and LEDs 

• 3.3V supply voltage, 32 pin DIL base, 21 x 42 mm 



www.hilscher.com info@hilscher.com

14 Product-News 



I/O system for Sercos III 

Bus Coupler EK9750 

for SERCOS III networks 

www.beckhoffautomation.com 

With the new EK9750 Bus Coupler, Beckhoff provides an I/O solution 

for Sercos III networks. The powerful and ultra fast I/O system 

will be available for Sercos III, making a large selection of terminals 

available for users. The Terminal system distinguishes itself by 

its high performance, flexible topology and simple configuration. 

Distributed I/Os can be inexpensively integrated into an industrial 

network. The coupler supports the new Sercos III I/O profile and 

communicates seamlessly in Sercos III networks. 

Beckhoff relies on open, international standards and communication 

interfaces for their entire automation portfolio, to the advantage 

of their users. 


First soft master implementation for SERCOS III 

SERCOS III Master based on Software 

for demanding Motion-solutions 

www.profimatics.com 

Current SERCOS III products use a specific SERCOS lll hardware for 

both the master and the slave. This hardware takes on important 

functions, in order to ensure quick processing and synchronization 

of real-time data. With the soft master introduced for the first time 

by Profimatics a SERCOS III Master can now be realized without using 

special hardware. Instead of that, a standard Ethernet controller is 

used. The SERCOS-specific hardware functions are moved to the 

hardware-related and real-time capable part of a master driver; so 

that the master can be realized completely in software. 

With the help of modern processors and network controller the soft 

master can also be used for demanding motion applications. Furthermore 

it is compatible with normal 

SERCOS III networks which facilitates the 

implementation of this solution into existing 

applications of the user. 


Rexroth IndraMotion MLC: Powerful System Solution with 

Motion, Logic and Robot Control 

More power with more functions: 

Rexroth IndraMotion MLC 

www.boschrexroth.com 

Rexroth offers its controller-based control system IndraMotion MLC 

in a new version combining motion and logic control with robot 

control on a uniform platform. In addition to the 32-axis solu tion, 

IndraControl L65 now provides a more powerful device version 

with 64 axes for all applications with high motion control requirements. 

The IndraControl L65 control platform is a powerful hardware 

version permitting synchronization of up to 64 axes. This control 

platform uses Ethernet-based SERCOS III as standard drive interface 

and for controlling the master axis 

network. Another new system function 

of IndraMotion MLC is the control of hydraulic 

drives.


Product-News 15 


Digital and Analog I/Os on SERCOS III 

Inline Block I/O on SERCOS III 

www.phoenixcontact.com 

The new SERCOS III digital and analog module from Phoenix 

Contact’s compact Inline Block IO product line lets you quickly and 

easily connect sensors and actuators to the SERCOS III network. 

The digital module features 16 digital inputs and 16 combined 

digital inputs and outputs. The combined input/output channels 

can function without internal parameterization by simply connecting 

a sensor or actuator. The low delay times of the inputs and 

outputs (ton typ. 50 µs, toff typ. 150 µs) allows the use of control 

programs such as a motion control application. 

The analog module has four inputs and two outputs that can be 

configured individually and independently of each other. The four 

differential inputs can receive analog current signals of 0 mA to 20 mA, 

4 mA to 20 mA and ±20 mA or voltage signals of 0 V to 10 V, ±10 V, 

0 V to 5 V and ±5 V and also measure the temperature by means 

of a resistance thermometer (RTFs) Current and voltage signals are 

available for each channel on the output side. Both the inputs and 

the outputs feature 16-bit resolution. Due to its short conversion 

times and fast process data operation, the analog version is particularly 

well-suited for testing and control 

applications. 

netSwitch with Ethernet-Port for SERCOS III 

The Real-Time-Ethernet system SERCOS III realizes a deterministic, jitterfree data 

transmission to control and synchronize drives or other decentralized devices. On 

the basis of a time-slot mechanism, any other Ethernet frames can be transmitted in 

the so-called NRT channel (Non-Real-Time). For this, the frames have to be inserted 

synchronously into the SERCOS network and buffered in case of higher data traffic. 

• links SERCOS III with Standard Ethernet network 

• simple configuration and status via web interface 

• 64 KB buffer memory for Ethernet telegrams 

• with one or four Ethernet ports 



www.hilscher.com 

info@hilscher.com

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SERCOS News - Issue 1 - 2008

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