LAUER PCS807 Profibus‑DP Module – 24V DC, 5.0VA

General Description

The LAUER PCS807 is a dedicated Profibus‑DP communication module designed to add Profibus DP slave capability to LAUER PCS series operator panels and controllers. This compact plug‑in module enables seamless integration of LAUER HMI devices into distributed automation systems based on the Profibus fieldbus standard. It is powered directly from the host panel’s 24 V DC supply with a low power consumption of just 5.0 VA, making it energy‑efficient and suitable for panel‑mount installations.

Hardware Architecture and Protocol Support

The module is built around the Siemens SPC3 protocol chip, ensuring full compliance with DP‑V0 (cyclic data exchange) and DP‑V1 (acyclic services for parameterization and diagnostics). The galvanically isolated RS‑485 transceiver provides robust communication in electrically noisy industrial environments, with isolation voltage of 1.5 kV. A 9‑pin D‑sub connector (female) serves as the bus interface, and an integrated termination switch (ON/OFF) allows easy configuration of the bus termination resistor network.

Performance and Data Exchange

The PCS807 supports all standard Profibus baud rates from 9.6 kbit/s up to 12 Mbit/s, with auto‑detection of the bus speed. It provides configurable I/O data lengths up to 244 bytes input and 244 bytes output, which are mapped to the host panel’s internal variables via the LAUER configuration software. The module stores the I/O mapping, slave address, and diagnostic parameters in an onboard EEPROM, ensuring that settings are retained after power‑off. For DP‑V1, acyclic read/write services allow the master to access detailed diagnostic data and to modify parameters without interrupting the cyclic communication.

Diagnostic and Status Indication

• Green LED (RUN): Steady on when cyclic communication with the master is established and data exchange is active.

• Red LED (ERR): Flashes with specific patterns to indicate configuration errors, bus timeout, address conflicts, or hardware faults.

• Yellow LED (BUS): Blinks to indicate bus traffic – a useful visual check for network activity.

• Diagnostic Buffer: Stores the last 20 bus events (errors, warnings, status changes) for offline analysis, accessible via the host panel’s service menu.

• Watchdog Timer: Monitors the cyclic data exchange; if communication is lost for more than 100 ms, the module sets all outputs to a user‑defined safe state (configurable via the software).

Electrical Specifications

• Supply Voltage: 24 V DC (±20 %) – derived from the host panel’s power bus

• Power Consumption: 5.0 VA (approx. 210 mA at 24 V)

• Isolation Voltage: 1.5 kV (between bus and logic circuits)

• Bus Connector: 9‑pin D‑sub (female), pinout per Profibus standard (pin 3 = B, pin 8 = A, pin 5 = GND)

• Termination: Internal switchable 220 Ω / 390 Ω network

• EMC Compliance: EN 61000‑6‑2 (immunity) and EN 61000‑6‑4 (emission)

Mechanical and Environmental Data

• Housing: Polycarbonate, UL94 V‑0, compact size

• Dimensions: 70 mm x 50 mm x 22 mm (excluding connector)

• Weight: 75 g

• Protection Class: IP20 (when mounted inside the host panel)

• Operating Temperature: 0 °C to +55 °C

• Storage Temperature: –20 °C to +70 °C

• Relative Humidity: 10 – 90 % (non‑condensing)

Installation Procedure

Before installation, ensure the host panel is powered off and disconnected from the mains. Locate the fieldbus expansion slot on the rear of the LAUER panel (typically marked “Slot B” or “Fieldbus”). Remove the protective cover and insert the PCS807 module, carefully aligning the pin header with the slot. Secure the module with the two retaining screws (torque 0.5 Nm). Connect the Profibus cable to the 9‑pin D‑sub connector – use a standard Profibus cable (purple, twisted‑pair) with a metal connector shell. Set the termination switch: if the module is at the physical end of the bus segment, set to “ON”; otherwise, set to “OFF”. Set the slave address (1‑125) using the rotary switch on the front of the module. After mounting, power on the panel – the green RUN LED should illuminate within a few seconds. If the red ERR LED flashes, check the bus wiring, termination, and master configuration.

Integration with Profibus Master

To integrate the PCS807 into a Profibus DP network, import the provided GSD file (LAUER_807.GSD) into the master PLC’s engineering tool (e.g., Siemens TIA Portal, Step 7, or any other DP master configuration tool). The GSD file defines the module as a standard DP slave with configurable I/O modules – the user can select the required I/O length (e.g., 8 bytes input/8 bytes output, 16/16, or up to 244/244). Assign the same slave address as set on the rotary switch. Download the new configuration to the master and switch to RUN. The module will establish cyclic communication with the master; the host panel’s variables will now be accessible from the PLC. Use the diagnostic LEDs and the master’s diagnostic buffer to verify proper operation. If the module does not appear in the master’s station list, check the cable continuity, termination, and address setting.

Maintenance and Troubleshooting

The PCS807 is maintenance‑free under normal operating conditions. Periodically inspect the bus cable and connector for tightness and corrosion. Common fault scenarios and corrective actions:

• Red LED flashing rapidly: Configuration error – verify that the I/O length selected in the GSD matches the mapping defined in the host panel.

• Red LED steady on: Hardware fault – replace the module.

• Yellow LED off: No bus activity – check cable continuity, termination, and master status.

• Communication intermittent: Check for electromagnetic interference; ensure proper shielding and grounding.

The module’s diagnostic buffer can be read via the host panel’s service menu (under “Fieldbus Status”). If the module fails, replace it with an identical unit – no configuration changes are required if the address and mapping remain the same. The module is not user‑repairable; any internal failure requires replacement.

Compatibility and Ordering

The PCS807 is compatible with all LAUER PCS panels (800 and 900 series) and LCA controllers that have the expansion slot. The part number for this 24 V DC / 5.0 VA version is PCS807‑24V. Variants with higher isolation or extended temperature range are available on special request. When ordering, specify the exact part number and any custom requirements. The standard delivery includes the module, a printed pin‑out diagram, and a GSD file on CD.