Product Overview

The Schneider TSXDSY08R5 is an eight-channel relay output module belonging to the Modicon Premium automation platform. It provides relay-based switching between PLC control logic and external electrical loads, allowing a Premium controller to operate equipment supplied by either AC or DC circuits.

Unlike transistor output modules, which are generally used for electronic switching, the TSXDSY08R5 uses mechanical relay contacts. Each of its eight outputs has one normally open (NO) contact. This makes the module suitable for applications involving contactor coils, solenoid valves, auxiliary relays, and other electrical devices that require isolated switching contacts.

A typical application is an industrial pumping station. The PLC can use individual relay outputs to operate pump contactors, control auxiliary ventilation, switch lubrication equipment, and activate alarm circuits. Each output follows the corresponding control command from the PLC, allowing several electrical loads to be managed through one module.

The module supports nominal output voltages of 12–24 V DC and 24–240 V AC, with corresponding operating limits of 10–34 V DC and 20–264 V AC. Its conventional free-air thermal current is 3 A. These characteristics make it suitable for switching a range of industrial control loads, provided the actual load current and switching category remain within the specified electrical ratings.

The TSXDSY08R5 uses a screw terminal block for field connections and occupies a standard module position in a Modicon Premium rack. External fast-acting fuses are required for output overload and short-circuit protection. When switching inductive loads, appropriate suppression components must also be installed to control voltage spikes generated when relay contacts open.

For maintenance and replacement work, particular attention should be paid to the output contact arrangement, external fuse protection, operating voltage, and load characteristics. The TSXDSY08R5 should also be distinguished from the TSXDSY08R5A, which has a different relay protection arrangement and electrical ratings.

Technical Specifications

Product Features

• Eight relay-based discrete output channels.
• One normally open contact per output.
• Supports both AC and DC output circuits.
• Nominal switching voltage of 24–240 V AC and 12–24 V DC.
• Conventional free-air thermal current of 3 A.
• Activation response time below 8 ms.
• Deactivation response time below 10 ms.
• AC inductive overvoltage protection through RC circuits and MOV components.
• DC inductive overvoltage protection through discharge diodes.
• External fast-acting fuses for overload and short-circuit protection.
• Screw terminal block for field wiring.
• Standard Modicon Premium rack installation.
• Suitable for contactors, solenoid valves, auxiliary relays, and industrial switching circuits.

Working Principle

The TSXDSY08R5 receives discrete output commands from the Modicon Premium PLC and uses its internal relay contacts to switch external electrical circuits.

Its operating sequence can be represented as:

PLC Logic → Modicon Premium Rack → TSXDSY08R5 → Relay Contacts → External Electrical Load

When the PLC program activates an output channel, the corresponding relay operates and closes its normally open contact. Current can then flow through the external circuit, energizing the connected device.

When the PLC removes the output command, the relay returns to its normal state and the contact opens, interrupting the external circuit.

For example, consider a machine with several motor-driven sections. The PLC can assign individual outputs to motor contactor coils, allowing each section to be started or stopped according to the production sequence. Other channels can operate solenoid valves or auxiliary equipment.

The module supports AC and DC switching circuits, but the appropriate external protection depends on the connected load.

When switching an AC inductive load, such as a contactor coil, an RC suppression circuit and MOV are used to limit switching overvoltage. For DC inductive loads, a discharge diode is installed across the preactuator to suppress the voltage generated when the circuit is interrupted.

An important distinction is that the TSXDSY08R5 is a relay output module without built-in output overload and short-circuit protection. External fast-acting fuses must therefore be installed for each channel or an appropriate group of channels.

The module’s response time is below 8 ms during activation and below 10 ms during deactivation. These switching characteristics should be considered when coordinating output commands with machine sequences and external contactors.

Role in a Modicon Premium PLC Control Architecture

Within a Modicon Premium control system, the TSXDSY08R5 provides the electrical switching interface between PLC logic and external equipment.

The CPU executes the control program and updates the output states through the rack backplane. The TSXDSY08R5 responds to these commands by operating its eight relay contacts.

A typical arrangement is:

Field Inputs → Modicon Premium CPU → Rack Backplane → TSXDSY08R5 → Contactors / Valves / Auxiliary Loads

In a production machine, the CPU may monitor safety interlocks, limit switches, and operating conditions before activating a corresponding relay output. The TSXDSY08R5 then switches the external control circuit.

For example, one channel may energize a contactor coil, another may operate a lubrication solenoid, and a third may activate an alarm relay. This arrangement keeps the PLC’s control logic separate from the electrical loads being switched.

Industrial Applications

Installation and Maintenance

1. Verify the Module Reference: Confirm that the installed module is TSXDSY08R5. Do not confuse it with TSXDSY08R5A, which has a different relay protection configuration.
2. Check Rack Compatibility: Verify that the Modicon Premium rack supports the module format and that the selected installation position is appropriate.
3. Inspect the Terminal Block: Check the screw terminal block for damaged contacts, loose connections, or signs of overheating before connecting field wiring.
4. Confirm Output Voltage: Verify that the connected electrical loads operate within the specified DC or AC voltage limits.
5. Check Load Current: Ensure that the actual load current and switching category are compatible with the module’s 3 A conventional free-air thermal current rating.
6. Install External Fuses: Fit suitable fast-acting fuses for individual output channels or appropriately grouped channels to protect against overload and short circuits.
7. Provide Inductive Load Suppression: Install RC circuits and MOV components for AC inductive loads, or discharge diodes for DC inductive loads.
8. Separate Control and Power Wiring: Keep low-level control wiring away from high-current motor cables and other sources of electrical interference.
9. Check Contact Assignments: Verify that each normally open relay contact is connected to the intended external device and corresponds to the correct PLC output address.
10. Test Relay Switching: Activate each output through the PLC program and check whether the corresponding external circuit switches correctly.
11. Inspect Relay Contact Condition: During maintenance, check for contact wear, abnormal heating, or switching irregularities, particularly on channels operating inductive loads frequently.
12. Document Output Circuits: Record the connected equipment, operating voltage, fuse rating, suppression arrangement, and PLC channel assignment for future troubleshooting.

Related Components

Recommended Related Models

Key Advantages

• Eight relay outputs for controlling multiple external circuits.
• Supports both AC and DC switching applications.
• Normally open contacts accommodate common industrial control circuits.
• Suitable for contactors, solenoid valves, and auxiliary relays.
• Short relay activation and deactivation response times.
• Integrated suppression arrangements for AC and DC inductive loads.
• Standard Modicon Premium rack installation.
• Screw terminal connections for conventional industrial wiring.

Technical FAQs

Can the TSXDSY08R5 switch both AC and DC loads?

Yes. The module supports nominal output voltages of 24–240 V AC and 12–24 V DC. The corresponding operating limits are 20–264 V AC and 10–34 V DC. The connected load must also comply with the applicable current and electrical switching ratings.

Does the TSXDSY08R5 have built-in overload protection?

No. The TSXDSY08R5 is specified as a relay output module with unprotected outputs. External fast-acting fuses must be installed for each channel or an appropriate group of channels to protect against overload and short circuits.

What protection is required when connecting contactor coils?

The required suppression method depends on the coil supply. For AC inductive loads, an RC circuit and MOV are used to limit switching overvoltage. For DC inductive loads, a discharge diode is installed across the preactuator. Correct suppression helps reduce electrical stress on relay contacts.

Can the TSXDSY08R5 directly switch a three-phase motor?

The module should not be used as a direct motor power switching device. Its relay contacts are intended for compatible control circuits, such as contactor coils. For a three-phase motor, the PLC output should operate a suitably rated contactor or motor control arrangement, with the motor power circuit handled by the appropriate switching and protection equipment.