Schneider TSXSAY1000 Master Module

Vollständiger Produktname: Modicon Premium AS‑Interface V2 Master Module (AS-i Master)

It is a rack-mounted module for Premium (TSX57) SPS. End-of-life (EOL: 2021‑01‑23), end of service: 2026‑12‑31. Für neue Projekte nicht empfohlen; only available for spare parts and retrofit of legacy equipment.

1. Modellcode-Definition

TSX: Prefix for Modicon Premium series

SAY: AS-i bus master module

1000: Version V2, supports standard and extended addressing

2. Kernspezifikationen

3. Funktionsbeschreibung
4. Acts as the AS-i bus master for Premium PLC to connect field AS-i sensors and actuators (Näherungsschalter, Magnetventile, modular I/O, usw.), greatly simplifying field wiring.
5. Front panel integrated diagnostic LEDs for quick troubleshooting of AS-i bus faults, slave disconnection and address conflicts.
6. Supports acquisition from AS-i analog slaves, not limited to discrete signals only.
7. Compatible with AS-i safety slaves (Sicherheitseingang / safety output).
8. Ersatzmodell

Official Recommended Replacement: BMXEIA0100 (M340 PLC AS-i Master Module)

Notiz: Platform migration from Premium TSX57 to M340 requires rack, CPU and software replacement. It is not a direct plug-and-play replacement. For legacy systems, only used / surplus TSXSAY1000 can be sourced as spare parts.

5. Installation & Wartungsrichtlinien
6. Installation: DIN rail mounting in Premium rack, X-Bus backplane communication; Schutzart IP20, Nur für den Schrankeinbau.
7. AS-i Bus: Use dedicated AS-i yellow flat cable; AS-i power supply must be installed at both ends of the bus. SUB-D connector spare: Phoenix Contact 1841909, Schneider internal part number W815891970101A.
8. Fehlerbehebung

FAULT red LED: Bus short circuit, Stromausfall, duplicate slave address

A/B LED: Indicate AS-i A/B dual group slaves

32 LEDs: Corresponding slave online status; OFF = slave lost

4. Checkliste für die Gebrauchtinspektion

Power on and verify PWR/OK LED without faults

All front panel LEDs light normally, no damage

SUB-D connector free of oxidation and intact pins

Rack gold-plated contacts without burn marks

Perform bus scan test with AS-i power supply and AS-i slave

6. Klärung häufiger Missverständnisse

❌ Not an analog output module. Some vendors incorrectly label it as AO module. It is an AS-i fieldbus communication master module.

TSXSAY1000 (Premium AS-i V2 Master Module) Anwendungsfälle

Core feature: TSXSAY1000 is the AS-i bus master mounted on Premium PLC rack. Suitable for scattered field I/O, large quantity of sensors, solenoid valves and safety signal acquisition. One AS-i yellow flat cable transmits data and power simultaneously, drastically reducing hardwiring work. All cases are legacy projects (Premium platform, Unity Pro programming), mainly for retrofit and maintenance of existing equipment. Premium platform is not recommended for new projects.

Fall 1: Automotive Component Assembly Line (Typische Anwendung)

Projektübersicht

Hauptcontroller: TSXP573623M Premium CPU + TSXSAY1000 AS-i master module for one assembly station bus

AS-i slaves: Näherungssensoren, fotoelektrische Sensoren, station pushbutton boxes, solenoid valve islands, AS-i safety slaves (Sicherheitstore, Not-Aus)

I/O count: A/B dual group, around 42 AS-i slaves; includes discrete I/O and a small number of analog slaves (pressure sensor AS-i modules)

Systemarchitektur

Premium Rack (TSXP57+TSXSAY1000) → SUB-D Connector → AS-i Yellow Flat Cable → Field AS-i Slaves

Reason for TSXSAY1000 Selection

1. Assembly stations are distributed. Traditional hardwiring requires separate cables from each sensor back to control cabinet, with high cost of cables, trunking and wiring labor. AS-i single cable connects all points in series.
2. AS-i Safety support: Safety gate and E-stop signals transmitted via AS-i safety channel, natively supported by TSXSAY1000.
3. Front panel 32-channel diagnostic LEDs allow maintenance personnel to identify offline slaves at a glance for fast fault location.

Steuerlogik

Material presence detection at station, cylinder solenoid valve actuation, safety gate interlock, Not-Aus-Schutz

Analog pressure acquisition (press-fit pressure) uploaded to PLC for press-fit judgment

Schmerzpunkte & Wartung

Fehler: AS-i flat cable insulation damage, poor contact from piercing terminals. TSXSAY1000 FAULT LED alarm, read bus diagnostic word in Unity Pro.

Einschränkung: Max bus length ≤100m; AS-i repeater required for longer distance.

Retrofit Alternative

Full Premium platform replacement: M340 + BMXEIA0100 AS-i master

Fall 2: Food Packaging Line (Horizontale Schlauchbeutelmaschine / Case Packer)

Projektübersicht

Premium TSXP57254M + TSXSAY1000; case conveying line with multi-section belt conveyors, material stop cylinders and detection photoelectric sensors

AS-i slaves: Fotoelektrische Sensoren, material presence switches, Magnetventile, AS-i modular I/O

Prozessanforderung

Multi-section conveyor sorting, material detection, material stop and reject. Field I/O points scattered along long conveying line.

Vorteile

1. Humid environment in packaging workshop. AS-i flat cable with piercing connection, fast wiring, M12 waterproof slaves.
2. Simple configuration in Unity Pro for TSXSAY1000, automatic slave scan and I/O mapping.
3. Add new slaves directly on AS-i bus when expanding stations, no massive recabling.

Typischer Fehler

Insufficient AS-i power capacity. Voltage drop occurs when multiple solenoid valves energize simultaneously, causing temporary slave dropout reported by TSXSAY1000.

Fall 3: Automated Warehouse Conveyance & Pallet Detection

Projektübersicht

Pallet inbound conveyor section in automated warehouse, Premium PLC + TSXSAY1000 to manage scattered detection points on conveyor line

AS-i slaves: Pallet presence photoelectric sensors, position proximity switches, stop cylinder solenoid valves, pallet oversize detection

Verfahren

Pallet inbound, position identification, stop and release. I/O points spread along long conveyor, control cabinet installed at one end of warehouse.

Auswahlbegründung

Traditional point-to-point wiring incurs extremely high cable cost. AS-i cable routed along conveyor cable tray with single drop branches. TSXSAY1000 supports up to 62 discrete AS-i slaves, sufficient for one inbound conveyor line.

Notiz: For multi-bus warehouse projects, multiple TSXSAY1000 modules can be installed on Premium rack (bis zu 8 modules for TSX573 and above) to expand multiple independent AS-i buses.

Fall 4: Valve Island & Level Switch Acquisition in Wastewater Treatment Plant (Prozessindustrie)

Projektübersicht

Wastewater pre-treatment, mechanical bar screens and sludge discharge valve banks; Premium PLC, TSXSAY1000, field AS-i valve islands + Niveauschalter

AS-i slaves: Pneumatic valve AS-i valve islands, Niveauschalter, flow switches, 4-20mA AS-i analog modules

Verfahren

Bar screen start/stop, on/off control of sludge discharge valves, liquid level monitoring. Valve groups distributed around tanks under humid and corrosive environment.

Merkmale

TSXSAY1000 supports AS-i analog slaves for direct acquisition of liquid level and pressure analog signals, eliminating large quantity of additional analog input modules.

Consideration

AS-i bus is not suitable for ultra-long distance wiring across tanks; AS-i repeater required if length exceeds 100m.

Summary of TSXSAY1000 Application Profile

✅ Suitable Scenarios

1. Scattered field sensors and actuators, large volume of discrete I/O (fotoelektrisch, proximity, Magnetventile)
2. Systems requiring AS-i safety bus (Sicherheitstore, Not-Aus)
3. Small volume analog acquisition (Druck, liquid level via AS-i slaves)
4. Retrofit and spare part replacement of legacy Premium systems

❌ Ungeeignete Szenarien

1. High-speed process and heavy analog volume applications (Profibus / Modbus TCP preferred)
2. Long bus distance (>100m without repeater)
3. Neue Projekte (Premium platform EOL, M340+BMXEIA0100 recommended)

Configuration Guidelines (Unity Pro)

1. Insert TSXSAY1000 into hardware tree of Premium rack
2. Configure AS-i V2, Standard / extended addressing
3. Bus scan to identify group A / B slaves
4. Automatically map AS-i input and output to PLC internal variables
5. Read module diagnostic word for SCADA alarm (bus fault, slave dropout)

Schneider Modicon Premium AS-i V2 Master Module TSXSAY1000 Full Technical Specifications

Produktpositionierung: AS‑Interface V2 fieldbus master module for Premium PLC rack. EOL, configured by Unity Pro software.

1. Grundlegende Informationen

2. Bus Communication Parameters

3. Elektrische Parameter

4. Rack Configuration (Max TSXSAY1000 Quantity per Premium CPU)

5. Front Panel LEDs & Operation Buttons

LED-Statusanzeigen

1. PWR OK (Grün): Backplane power supply of module normal
2. FAULT (Rot): AS-i bus fault, Kurzschluss, slave loss, address conflict
3. A/B (Grün): A-group / B-group slave group indicator
4. 32 Diagnostic LEDs: NEIN.0~31, slave online status; OFF = slave offline

Buttons

1. A/B: Toggle display between A-group and B-group slave status
2. MODUS: Offline / online switch, slave initialization, infrared address setting support
3. Umweltfreundlich & Mechanische Spezifikationen

7. Funktionelle Highlights
8. Supports AS-i Safety safety bus, safety slave connection for safety gate and emergency stop signal acquisition.
9. Supports AS-i analog slaves for pressure, liquid level analog signal acquisition.
10. Built-in bus diagnostics; diagnostic word readable in PLC program for SCADA alarm.
11. Supports automatic bus scan, slave address detection and conflict detection.
12. Limitation Notes
13. ❗ Not an I/O module. It is a fieldbus communication master module without local I/O points.
14. EOL spare part only, not recommended for new projects. Official hardware migration: M340 + BMXEIA0100.
15. AS-i bus is not suitable for high-speed mass analog transmission; AS-i repeater required when bus length exceeds 100m.