SCHNEIDER TSX Premium System Operation and Maintenance

HE10 connector module: Use 20 core flat cables or pre fabricated bundled cables. Multiple lengths available: TSX CDP 301 (3m), 501 (5m) for direct connection; And fine core cables (0.08mm ², suitable for TELEFAST 2 interface, current ≤ 100mA) or 0.34mm ² cables (≤ 500mA).

5.3 External Power Supply and Wiring

Sensor power supply: It is recommended to use an independent 24V DC power supply, which is protected by a 0.5A fast fuse. The sensor power supply voltage must be maintained within the tolerance of the rated value (19-30V). If the on-site 24V does not meet the TBTS standard, the 0V terminal must be connected to the protective ground.

Pre actuator power supply: also requires fast fuse protection. For high current output, it is recommended to install separate fuses at each common terminal and select wires with sufficient cross-sectional area.

Cable separation: To avoid AC coupling noise, power cables (power supply, contactors) must be routed separately from I/O signal cables, with a minimum spacing of 200mm. The use of shielded cables can further suppress interference.

5.4 Sensor Voltage and Terminal Block Monitoring

Sensor voltage monitoring: All input modules continuously monitor the sensor supply voltage. When the voltage is below the threshold, the module reports a fault (I/O indicator light is always on). This is the first step in troubleshooting the issue of 'input points not changing'.

Terminal block monitoring: All terminal block I/O modules are equipped with micro switches to check if the terminal block is properly locked. If the terminal block is missing or loose, the module reports a "terminal block fault" (I/O indicator light flashes). Be sure to confirm that the terminal block is fully inserted after repair.

Practical diagnosis and troubleshooting

6.1 Meaning of processor LED indicator lights

Meaning of LED color status

RUN green constant light, PLC running normally

RUN green flashing PLC in STOP state

RUN green goes out, PLC fault, no program, or program is invalid

ERR red constant module failure, system or power failure

ERR red flashing application error, PCMCIA memory card or communication card malfunction

I/O red constantly on, I/O configuration error or module failure

TER port is communicating with the yellow constantly lit TER port

Common handling: If ERR flashes, check if the application has been zeroed or if the range has exceeded the limit; If the I/O is constantly on, reconfigure the rack and check if all I/O module models match the actual ones.

6.2 Troubleshooting of Input Module

Fault phenomenon: The channel indicator light is not on, but the on-site sensor has been activated.

Possible reasons:

Sensor power loss or low voltage (below 19V).

The input point filtering time is set too high, while the sensor pulse width is smaller than the filtering time (especially for DEY 16FK programmable filtering).

The leakage current of the 2-wire proximity switch is large, causing the input to fail to reset to 0. At this point, a 1k Ω resistor needs to be connected in parallel.

Diagnostic steps:

Measure the voltage on the module terminals: 24V DC input should be ≥ 11V in state 1 and ≤ 5V in state 0. If the voltage is normal but the indicator light does not light up, it may be due to internal optocoupler damage.

View the "sensor supply fault" position in the module status word through PL7 Junior software.

6.3 Short circuit tripping recovery of output module

Phenomenon: A certain output point indicator is flashing, and the I/O red light is constantly on.

Reason: Short circuit or overload of the output channel triggers electronic protection.

Recovery process:

Disconnect the power supply of the on-site actuator and check if there is a short circuit or overcurrent in the load.

If configured for automatic reactivation, the module will automatically attempt to recover after 10 seconds; If the fault has been resolved, the output will return to normal.

If configured for manual reactivation, the system bit (such as% S50) needs to be called through the PLC program or the "Reset I/O" command needs to be executed through the programming terminal.

If the circuit trips again after reactivation, it indicates that the load fault has not been resolved or the channel has been damaged (the module needs to be replaced).

Attention: The relay output module has no electronic protection, and short circuits can burn out contacts or even PCB wiring. It is necessary to install fuses externally.

6.4 Abnormal output rollback status

Phenomenon: After the PLC shuts down, some outputs still remain at 1, causing the actuator to not disconnect.

Reason: "Fallback" is set to "Keep State" in the module configuration. When the PLC enters STOP or malfunctions, the rollback setting determines the output behavior. For safety related loads (such as valves for emergency stop control), they should be configured to 'roll back to 0'.

Modification method: On the hardware configuration page of PL7 Junior, select the corresponding output module and set it to "0" in the "Fallback" tab.

6.5 Communication Failure: TER Port Cannot Connect to Programmer