TM5SDO4R Modicon TM5 Relay Output Module 4DO 230V AC 5A

The TM5SDO4R is a Modicon TM5 digital output module equipped with four electromechanical relay outputs.

It is designed to switch compatible AC and DC loads that cannot be controlled directly by a standard 24 V DC transistor output module.

Each relay output can switch up to 5 A within the specified voltage and load limits.

The module supports 230 V AC and 30 V DC rated load circuits, making it suitable for contactor coils, interface relays, indicator devices and other industrial loads that require relay-contact switching.

The defining feature of the TM5SDO4R is its electrically operated relay output architecture.

Unlike the TM5SDO4TA high-current transistor module, the TM5SDO4R can switch both AC and DC circuits and does not require the load to share the TM5 24 V DC output supply.

However, the relay outputs are mechanical devices. Their switching speed is slower than transistor outputs, their contacts have a finite electrical life and external circuit protection is required.

The module does not provide internal short-circuit or overload protection for the switched load circuits.

Key Features

• Four electromechanical relay outputs
• Switches compatible AC or DC loads
• 230 V AC rated output
• 30 V DC rated output
• Maximum 5 A per output
• Maximum 10 ms relay response
• 20 million mechanical operations
• 500,000 electrical operations at 5 A
• 500 V AC channel-to-bus isolation
• Designed for mixed-voltage load switching

Typical Applications

• Contactor coil control
• Interface relay switching
• Warning lamps
• Heater control circuits
• Machine auxiliary loads

Four Relay Output Channels

The TM5SDO4R provides four controller-commanded relay outputs.

Typical connected loads may include:

• AC contactor coils
• DC contactor coils
• Interface relays
• Warning beacons
• Audible alarms
• Small heating circuits
• Auxiliary machine circuits

The suitability of each load must be checked against its voltage, steady-state current, inrush current and switching category.

AC and DC Load Capability

The relay contacts can switch compatible AC and DC circuits.

Rated AC Voltage

230 V AC

Permitted AC Range

184–276 V AC

Rated DC Voltage

30 V DC

Permitted DC Range

24–36 V DC

The load circuit uses an external power source. The module does not generate 230 V AC or 30 V DC.

5 A Per-Channel Rating

Each relay output is rated for a maximum current of 5 A under the specified conditions.

This value must not be interpreted as a universal rating for every load type.

The practical switching capacity depends on:

• Resistive or inductive load
• AC or DC operation
• Inrush current
• Switching frequency
• Power factor
• External suppression
• Ambient temperature
• Contact life requirement

Motors, transformers, lamps and capacitive loads can produce inrush currents much higher than their normal operating current.

Output Common Current

Official data specifies a maximum of 10 A per output common.

The common-terminal current and wiring must be checked according to the actual grouping of the output circuits.

Do not size the common conductor only from the current of one channel.

The combined current through a common terminal must remain within:

• Terminal rating
• Module rating
• Wire rating
• External fuse rating
• Applicable electrical standards

Relay Output vs Transistor Output

TM5SDO4R Relay Output

Can switch compatible AC and DC loads.

Uses mechanical contacts.

Has slower switching.

Provides separation between the control electronics and external load circuit.

Requires external load protection.

TM5SDO4TA Transistor Output

Switches 24 V DC loads only.

Uses solid-state electronics.

Provides faster switching.

Supports up to 2 A per channel and 4 A total.

Includes electronic short-circuit and thermal protection.

The two modules are intended for different load architectures.

10 ms Switching Response

The maximum switching times are:

Turn-On Time

10 ms

Turn-Off Time

10 ms

This is suitable for general machine-control loads such as contactors, alarms and auxiliary circuits.

It is not intended for:

• High-speed pulse generation
• Pulse-width modulation
• Fast valve timing
• Stepper control
• Motion-control pulses

A transistor output module should be selected for high-frequency switching.

Mechanical and Electrical Life

Mechanical Durability

Approximately 20 million operations

Electrical Durability

Approximately 500,000 operations at 5 A

Mechanical durability is measured without the same electrical load stress applied during normal switching.

Electrical life depends strongly on:

• Load current
• Load type
• Switching voltage
• Switching frequency
• Inrush current
• Arc suppression
• Ambient conditions

Reducing switched current can significantly extend contact life.

No Internal Short-Circuit Protection

The TM5SDO4R does not provide internal short-circuit protection for its load circuits.

An output short circuit may damage:

• Relay contacts
• Terminal wiring
• External supply
• Connected equipment
• Module conductors

Each load branch should use correctly rated external protection.

No Internal Overload Protection

The relay outputs do not include electronic overload monitoring.

The module does not automatically:

• Limit load current
• Shut down an overloaded channel
• Reset after a fault
• Report transistor-style thermal overload

External fuses or circuit breakers are required according to the load and wiring design.

External Fuse Requirement

Official wiring information specifies external protection for the switched circuits.

A typical documented arrangement uses:

5 A, 250 V, Time-Delay Fuse

Final fuse selection must consider:

• Load current
• Inrush current
• AC or DC breaking capacity
• Wire size
• Relay-contact rating
• Local electrical requirements

Do not replace a fuse with a larger value simply to prevent nuisance operation.

Inductive Load Protection

Contactors, solenoids and relays are inductive loads.

When switched off, they can generate a voltage transient that causes contact arcing and reduces relay life.

Suitable suppression may include:

• Flyback diode for DC coils
• RC snubber
• Varistor
• Manufacturer-approved suppression network

The suppression device must match the load voltage and required release time.

Contact Wear

Mechanical relay contacts wear every time they switch an electrical load.

Signs of contact deterioration may include:

• Increased contact resistance
• Intermittent switching
• Contact welding
• Delayed load operation
• Excessive heating
• Failure to open

For frequently cycled loads, a transistor output or external solid-state relay may provide a longer operating life.

Channel Isolation

The relay load circuits are separated from the internal TM5 bus electronics by specified insulation.

Channel-to-Bus Isolation

500 V AC RMS

However, official product data states that there is no insulation between output channels.

The module should therefore not be advertised as having four fully isolated output channels without confirming the exact terminal and common arrangement.

External Load Supply

Every switched load requires an appropriate external supply.

Examples include:

• 230 V AC cabinet supply
• 24 V DC auxiliary supply
• 30 V DC control circuit
• Separately protected machine circuit

The relay output functions as a controlled electrical contact. It does not generate load voltage.

Mixed-Voltage Applications

Relay technology makes it possible to switch different types of load circuits within the module’s approved wiring architecture.

Before using multiple voltages in the same module, confirm:

• Terminal grouping
• Insulation requirements
• Creepage and clearance
• Common-terminal arrangement
• Wiring segregation
• Local standards
• Approved wiring diagram

Do not mix hazardous and extra-low voltage circuits unless the official system design and applicable regulations permit it.

Module Power Consumption

The relay coils and internal electronics are supplied from the TM5 bus.

TM5 Bus Current Draw

Approximately 160 mA at 5 V DC

Maximum Power Dissipation

Approximately 2.3 W

The switched load current does not come from the TM5 bus. It is supplied by the external AC or DC load circuit.

Operating Environment

Horizontal Installation Without Derating

-10 to 55°C

Horizontal Installation With Derating

-10 to 60°C

Vertical Installation

-10 to 50°C

Storage Temperature

-40 to 70°C

These values describe the ambient temperature around the module, not the temperature of the controlled load.

TM5SDO4R vs TM5SDO4TA

TM5SDO4R

Four relay outputs

230 V AC or 30 V DC load switching

5 A maximum per channel

10 ms maximum response

No internal short-circuit protection

TM5SDO4TA

Four transistor outputs

24 V DC loads only

2 A maximum per channel

300 microsecond maximum response

Electronic short-circuit and thermal protection

TM5SDO4R is selected for voltage flexibility and relay-contact switching.

TM5SDO4TA is selected for faster 24 V DC actuator control.

TM5SDO4R vs TM5SDO4T

TM5SDO4R

Relay output technology

AC or DC loads

5 A per output

Slower mechanical switching

TM5SDO4T

24 V DC transistor outputs

0.5 A per output

Fast solid-state switching

No mechanical contact wear

The correct module depends on the load voltage and switching frequency.

TM5SDO4R vs TM5SDO2R

TM5SDO4R

Four relay outputs

Higher channel count

Suitable for four auxiliary load circuits

TM5SDO2R

Two relay outputs

Lower channel count

Suitable for smaller relay-output requirements

Confirm the terminal block and output mapping before replacing one module with another.

Not a Power Distribution Module

The TM5SDO4R should not be described as a power distribution node.

It does not:

• Supply the TM5 I/O power segment
• Generate TM5 bus power
• Replace TM5SPS1 or TM5SPS2
• Distribute 24 V DC to downstream modules
• Perform load-current management

It receives controller commands and opens or closes relay contacts.

Not a Safety Output Module

TM5SDO4R is a standard machine-control output module.

It must not be described as:

• Fail-safe output
• Safety relay
• Emergency-stop module
• SIL-rated output
• Performance Level output

Safety-related loads require an approved safety architecture.

Replacement Identification

Correct Model Number

TM5SDO4R

Product Type

Four-Channel Relay Output Module

Rated Load Voltage

230 V AC or 30 V DC

Maximum Current

5 A per Output

Output Technology

Electromechanical Relay

Before replacement, confirm:

• Exact model number
• Number of relay outputs
• Load voltage
• Load current
• Inrush current
• AC or DC circuit
• Output common arrangement
• Terminal block
• Bus base
• External fuse
• Suppression device
• Controller output mapping

Do not select a replacement only by the four-channel count.

Installation Guidelines

Disconnect the TM5 station supply.

Disconnect all external load supplies.

Verify that AC and DC circuits are de-energized.

Record the existing output assignments.

Label all common and switched conductors.

Confirm each load voltage and current.

Check the load inrush current.

Verify the external fuse rating.

Verify inductive-load suppression.

Confirm the bus base and terminal block.

Install the electronic module securely.

Connect wiring according to the approved diagram.

Maintain separation between voltage classes.

Restore the TM5 supply.

Restore each load supply safely.

Test outputs one at a time.

Verify contactor, lamp or relay operation.

Check for abnormal heating or contact noise.

Return the machine to service after functional verification.

Installation should be completed by qualified automation and electrical personnel.

FAQ

Q1: What is TM5SDO4R?

A1: It is a Modicon TM5 digital output module with four electromechanical relay outputs.

Q2: Can it switch AC loads?

A2: Yes. It is rated for compatible loads around 230 V AC within the specified voltage range.

Q3: Can it switch DC loads?

A3: Yes. It supports compatible DC load circuits rated around 30 V DC.

Q4: What is the maximum current per output?

A4: The maximum stated current is 5 A per output under approved load conditions.

Q5: Is it a transistor output module?

A5: No. It uses mechanical relay contacts.

Q6: Does it have short-circuit protection?

A6: No. External circuit protection is required.

Q7: Does it have overload protection?

A7: No. The load circuit must use correctly selected external protection.

Q8: How fast does it switch?

A8: Maximum turn-on and turn-off times are approximately 10 ms.

Q9: Can it be used for high-speed pulse outputs?

A9: No. Mechanical relay outputs are not suitable for high-frequency pulse control.

Q10: What distinguishes TM5SDO4R from TM5SDO4TA?

A10: TM5SDO4R switches AC or DC loads through relay contacts, while TM5SDO4TA provides faster, electronically protected 24 V DC transistor outputs.