Lauer PCS Series Operation Console Configuration Guide

Lauer PCS Series Operation Console Configuration Guide

Introduction: The Engineering Value of PCS Series Operation Console

The Lauer PCS series is a programmable control console that includes four models: PCS 009, PCS 090, PCS 095, and PCS 095.1, each offering display and button configurations of different sizes. The core design concept of this series of devices is "the same hardware, endless changes" - through a set of hardware with different parameter configurations, it can cope with thousands of operating scenarios without complex I/O wiring and extensive wiring.

Main differences among different models:

PCS 009: 4-line x 20 character LCD, 8 function keys (with green LED), 10 key numeric keypad, suitable for compact operation requirements

PCS 090: 2-line x 40 character LCD, 8 function keys (with green/yellow dual color LED), suitable for simple text display scenarios

PCS 095/095.1: 4-line x 40 character LCD, 16 function keys (with green/yellow dual color LED), PCS 095.1 additionally supports printer interface and 4 data recording switches

All models support RS232/TTY, RS422/RS485 serial communication, with a front panel protection level of IP65, operating temperature of 0-50 ℃, and storage temperature of -25~70 ℃. The configuration software PCSPRO runs in the MS-DOS/DR-DOS environment and downloads project data to the device Flash EEPROM through programming cable PCS 733. This article is based on the official technical manual and systematically outlines its core functions such as communication principles, variable formats, menu configuration, and priority management, helping engineers quickly master this classic HMI tool.

Communication principles and data area structure

2.1 Communication Model

The communication between PCS and PLC adopts the "shared data area" model, which supports a maximum of 256 words (W0~W255, 16 bits per word). The communication direction is bidirectional:

PCS → PLC: Write button status, preset values, PCS status information

PLC → PCS: Write LED control, command words, message bits, variable values

Two principles of data exchange:

Expander driver: Running expander program in PLC to process PCS data packets, suitable for systems that support indirect addressing

Direct drive (such as AS511. DRV): directly reads and writes PLC fixed data area, suitable for systems that do not support indirect addressing or scan cycle sensitivity

2.2 Data Area Allocation (Standard Driver)

Regional character range direction function

System area W0~W3- used internally by the driver, W3 is a communication error word

Functional area W4~W14 PCS → PLC press key positions (W4~W5), PCS status (W6~W9), LED status (W10~W11), command words (W13~W14)

Message area W15~W22 PLC → PCS 128 message bits (corresponding to message text 0~127)

Expansion area W23~W29 mixed PCS 095/095.1 for F9~F16 buttons (W23) and additional LEDs (W24~W25)

Variable area W30~W255 mixed external variables (actual value/preset value)

Detailed explanation of variable system

3.1 Variable classification

PCS supports 650 external variables (user-defined) and 6 internal variables (predefined). Variables are divided into three categories:

ACTUAL (actual value): displayed only and cannot be modified

NOMINAL (preset value): can be displayed and modified

NOMINAL-P (protected preset value): can only be modified when W14 position 7=1, usually controlled by key switch or DIL switch

3.2 Detailed Explanation of Variable Format

BIT variable: Maps two strings to a 0/1 state of a certain bit. Immediately write the modifications to the PLC. For example, the "CLOSED/OPEN" status display.

STRING variable: maps 256 values of a byte to 256 strings. After modification, press ENTER to confirm writing. Suitable for multi state selection (such as "Service/Setting UP/AUTOMATIC").

CSTRING variable: Similar to STRING, but immediately written to PLC after modification without pressing ENTER.

BCD variables (BCD-1/2, BCD0-1/2): Display BCD encoded values in PLC as decimal numbers. BCD-1 is 4 bits (1 word), BCD-2 is 8 bits (2 words). BCD0 variant displays leading zeros.

BIN/VBIN variables: Convert binary values in PLC to decimal display. BIN is unsigned, VBIN is signed (±). Supports scaling, decimal point, and leading zero control. Subtype-1 (16 bits) and -2 (32 bits) are calculator style inputs; -A and - B are shifted inputs (from right to left).

WORD variable: Display 16 bit words in binary (KM), hexadecimal (KH), or double decimal (KY) format. It can be modified one by one in the menu.

ASCII variable: A string of up to 16 characters (8 characters) that supports any ASCII code input.

TIMER variable: 3-digit BCD time value+time base (0-3), suitable for timer setting.

Menu system and variable editing

4.1 Menu Structure

PCS supports up to 127 menus, with a maximum of 255 nodes per menu. Each node corresponds to an operation text (0~127), which can contain up to 4 variables (PCS 009/095) or 8 variables (PCS 090). The PLC starts the menu by writing the menu number (1-127) through W14 bits 0-6, and ends the menu by writing 0.

Menu navigation:

The first defined node is the Start Node

Arrow keys navigate between nodes, with arrow key LEDs indicating available navigation directions

Node number feedback in W6 digits 8-15

4.2 Variable Editing Rules

Preset value modification: Press the number keys to enter, press ENTER to confirm writing to PLC

Offset input: such as "10+" (adding 10 to the existing value), only applicable to BCD and BIN variables

CLR key: Restore to last read PLC value

BIT and CSTRING: Write immediately after modification without the need for ENTER

Write verification: PCS will read the PLC twice, compare the written value with the read value, and issue a warning if there is a discrepancy

4.3 Preset value status feedback

W8: High byte=last modified preset value word address; Low byte=number of bytes written (0=BIT variable, 2=16 bits, 4=32 bits)

W9: Bitmask, indicating which bit in the BIT variable has been modified

Message management and priority

5.1 Priority Level

PCS adopts 7-level priority management, and low priority can be interrupted by high priority:

Priority name triggering method

0 (minimum) default text displayed when there are no other activities

2 Menu PLC writes menu number through W14

Triggered by 4 information message bits, with the attribute of "information"

6 warning message triggered, attribute is "Warning"

8 fault message bit triggered, attribute is "fault"

12 Help Press HLP Key

Highest communication error interface or startup test error

5.2 Message Configuration

128 message bits (W15~W22), corresponding to 128 message texts

Each message can be individually configured with priority (information/warning/fault) and deletion mode (1-4)

Delete Mode 1: PLC Reset Message Bit Clears

Delete Mode 2: Manually press CLR to clear and reset PLC bit at the same time

Delete Mode 3: Manually press CLR to clear (without resetting PLC bit)

Delete Mode 4: Clear CLR only when PLC bit has been reset

5.3 Display and Storage Behavior

PLC can control the display and storage behavior of messages through W12:

Display mode (W12 bits 8-10): 0=static, 1=flashing

Storage mode (W12 bits 0-5): 00=first message (no manual selection), 01=first message (can be manually selected), 10=last message (no manual selection), 11=loop display

Function keys and LED control

6.1 Button Status (W4~W5)

When the button is pressed, the corresponding position is 1

PCS 009/090：F1~F8（W4）， Control key (W5)

PCS 095/095.1: Additional F9~F16 (W23 high byte)

6.2 LED Control (W10~W11, W24~W25)

Each function key is equipped with green and yellow LEDs (PCS 009 only green). Each LED is controlled by two bits for status:

Wx bit Wx+1-bit LED status

0 0 OFF

0 1 anti flicker (25% bright)

1 0 ON

1. Blinking (75% bright)

6.3 System Status LED

? (Input request): Waiting for key operation

! (Menu/Message): Display Information/Warning/Fault

ERR (Communication Failure): Constant light=Communication not started, flashing=Communication interrupted

PCSPRO configuration and debugging process

7.1 Configuration steps

Running PCSPRO on PC (MS-DOS/DR-DOS environment)

Define variables (select format, address, text, limit values)

Create text (default text, menu text, message text, help text)

Configure menu structure (node connections, operation text allocation)

Select PLC driver (corresponding to PLC brand and protocol)

Generate data records and download them to PCS (using PCS 733 cable)

7.2 DIL switch setting

DIL function

1~4 PLC bits available to users (W4.4~W4.7)

5-6 driver configuration parameters (baud rate/interface selection)

7 programming baud rates (ON=115.2k, OFF=38.4k)

8 operating modes (OFF=normal operation, ON=stop)

9 EEPROM write protection (ON=writable, OFF=write protected)

10 Contrast Adjustment (ON=Adjustable, OFF=Locked)

Important: After programming, be sure to set DIL9 to OFF, otherwise data storage may not be guaranteed.

7.3 Common Fault Diagnosis

SYS LED is constantly on: The device is in offline or configuration mode. Possible cause: The configuration cable PCS 733 is still connected, and the DTR level on the PC side makes DSR effective

ERR LED flashing: Communication established but interrupted, check cable and DIL5/6 configuration

Message not displayed: Confirm that the message bit is within the range of W15~W22, and W13 bits 0~3 allow the corresponding message word to be transmitted

The preset value cannot be modified: Check if W14 bit 7 (NOMINAL-P editable) and whether the variable is defined as NOMINAL/NOMINAL-P

PCS 095.1 Additional Features

8.1 Offline menu and data recording switching

Press HELP+CLR to enter the offline menu

Use the+/- keys to select data records (0-3), press ENTER to confirm and reset

DIL11 and DIL12 determine the selection of data recording after power on

8.2 Printer Functions

PCS 095.1 has a built-in printer interface that supports:

Hard copy: W13 bit 12 rising edge trigger, print current screen content

Message printing: W13 bit 13 set to 1 enables message printing queue

Internal variable configuration: timeout (ZA), interface selection (ZB), handshake protocol (ZC), output direction (ZD), baud rate (ZE), data bits (ZF), stop bits (ZG), checksum (ZH)