Systeme Lauer SIMATIC S5 Serial Interface Board PCS 810-1

The Systeme Lauer PCS 810-1 is a specialized serial interface board designed to connect Lauer operator panels and industrial computers to Siemens SIMATIC S5 programmable logic controllers. This board translates between the Lauer protocol and the Siemens 3964R protocol, enabling seamless communication between Lauer HMI devices and S5 PLCs for both data exchange and programming.

Product Specifications

• Model: PCS 810-1

• Type: SIMATIC S5 Serial Interface Board

• Compatible Controllers: Siemens SIMATIC S5 (all CPU series)

• Interface Type: Serial RS-232 (TTY compatible)

• Protocol: Siemens 3964R (point-to-point)

• Baud Rate: 1200 to 38400 bps (selectable)

• Data Format: 7/8 bits, even/odd/no parity (configurable)

• Connector: 15-pin D-sub on board, with supplied cable

• Power Supply: 5 V DC from backplane

• Current Consumption: 300 mA max

• Form Factor: Eurocard 6U, single height

• Compatible Systems: Lauer PCS, VPC, and EPC series

• Operating Temperature: 0°C to 50°C

Functional Description

The PCS 810-1 board acts as a protocol translator, allowing Lauer panels to communicate directly with S5 PLCs without additional hardware or software drivers. It implements the full Siemens 3964R protocol, including automatic data block checking, retransmission, and handshake control. The board supports both ASCII and binary data formats, making it flexible for various data exchange requirements.

This board is particularly valuable for legacy system migration, allowing modern Lauer HMI panels to be retrofitted into existing S5 installations. It also supports remote programming of S5 PLCs via the Lauer panel, simplifying maintenance and updates.

Installation and Setup

Insert the board into an available slot in the Lauer panel or industrial PC. Connect the serial cable between the board's 15-pin connector and the S5 PLC's programming port or CPU interface. Configure the communication parameters (baud rate, parity, stop bits) using jumpers on the board or via the panel's configuration menu. The board automatically handles the 20 mA current loop conversion if required.

Configuration and Addressing

The board's DIP switches allow selection of the S5 CPU type (e.g., 95U, 115U, 135U, 155U) to ensure correct memory addressing. It supports access to both the PLC's program memory and data memory (DB, DX, EB, and EX blocks). The panel can read and write to PLC variables using the standard Lauer tag database.

Diagnostics and Troubleshooting

The board features diagnostic LEDs for power, activity, and error indication. A detailed diagnostic function in the panel software can display the status of the 3964R connection, including CRC errors and retry counts. Common issues include incorrect baud rate matching, missing cable termination, or CPU configuration errors in the S5.

Maintenance and Reliability

This board is built with high-quality industrial components and has an MTBF of 80,000 hours. No routine maintenance is required, but periodic inspection of cable connections and DIP switch settings is recommended.

Integration with Automation Systems

The PCS 810-1 is specifically tailored for S5 integration but can also communicate with other serial devices using the 3964R protocol. It is widely used in automotive, packaging, and materials handling industries where S5 PLCs are still prevalent.

Environmental and Safety

RoHS compliant and CE marked. The board is designed for operation within control cabinets with proper ventilation. It offers galvanic isolation on the serial interface for robust performance in industrial environments.

Technical Support and Documentation

Lauer provides a detailed user manual, S5 configuration guide, and a pin-out diagram. A sample configuration file is available for common S5 CPU types.

Conclusion

The Systeme Lauer PCS 810-1 SIMATIC S5 Serial Interface Board is a vital component for connecting modern Lauer panels to legacy S5 PLCs, ensuring continued usability of existing automation hardware while upgrading operator interfaces.