Enabling shop-floor IoT with Schneider TeSys ecosystem

Enabling shop-floor IoT

For most organisations, Industry 4 is still a moveable feast. However, manufacturers buying new equipment will expect their purchases to be IoT ready or compliant-whatever that might mean. Specifically, this poses a problem for OEMs and machine builders who prefer to standardise their control systems.

Schneider Electric is addressing this by enabling shop-floor IoT using a machine ecosystem linking across its products. One of the component parts is the TeSys Island.

TeSys island

TeSys island will switch, protect, and manage motors and other electrical control panel loads up to 80Amps. Its digital load management system makes machines smarter and more reliable by working as an Industry 4.0 compliant data provider. It reduces machine time to market enabling OEMs to support normal and Industry 4 installations.

Simplified application, selection and system configuration mean faster machine implementation and device-related data for system diagnostics. It is simple to incorporated into most automation systems and supports fieldbuses like EtherNet/IP as well as Modbus TCP.

The TeSys Island is for high performance machines across a range of industries. Basically, these include:

– Food & beverage

– Material working

– Material handling

– Small pumps

– Packaging


The TeSys island is a modular system comprising of motor starters and digital/analogue I/O modules. Its single connection to the field bus accommodates up to 20 modules without needing auxiliary wiring. The intelligence resides within the bus coupler module which acts as the brains of the complete island. It also offers a simpler and more reliable way to manage machine loads, based on data insights and fully integrates into EcoStruxure.


TeSys avatars

Using Schneider’s new TeSys avatars saves machine builders save time when selecting and configuring their motor starters. Avatars are digital objects with integrated pre-programmed functions freeing up machine builders from having to write line by line code. Using an avatar ensures correct integration into the system, the connection to the bus coupler, and optional I/O modules. The pre-defined functionality can be adopted to the application using its intuitive menu settings. Integration into a Modicon PLC or 3rd party PLCs is performed using function blocks.


Avatars are reusable and help reduce the time to market. The commission function also supports testing of individual avatar functions without needing a PLC. This means function testing is greatly simplified.


Enabling shop-floor IoT

The digitised TeSys island allows machine builders to remotely monitor installed devices and also provide their clients with a cloud-based predictive maintenance service. The system also transmits warnings before tripping occurs, such as highlighting an abnormal state in a motor. This means users can then act to avoid unplanned downtime.


Finally, Schneider Electric’s open IIoT ready architecture platform is enabling shop-floor IoT connected hardware and software products such as TeSys island, Modicon M262, and EcoStruxure Machine Advisor to both the cloud and to local edge environments.

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