Lenze E94AYAD SAFETY MODULE SM300 – 9400 Servo Drives
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Product Information
The Lenze E94AYAD SAFETY MODULE SM300 is an extended functional safety expansion card designed for integration into Lenze 9400 HighLine and StateLine servo drives. Operating on a 24 V DC auxiliary supply with a voltage range of 20.4 V DC to 28.8 V DC and a rated current consumption of 0.1 A, this direct drive slot plug-in unit adds integrated motion safety capabilities to multi-axis servo systems. The module incorporates 8 safe digital inputs—configurable as either 8 single-channel or 4 dual-channel inputs—alongside 2 dual-channel safe digital outputs with pluggable terminal connections. By executing motion safety functions including Safe Torque Off (STO), Safe Stop 1 (SS1), Safe Stop 2 (SS2), Safe Operating Stop (SOS), Safely-Limited Speed (SLS), Safe Speed Range (SSR), Safe Direction (SDI), Safely-Limited Increment (SLI), Safely-Limited Position (SLP), and Drive Controlled Acceleration (DCA), the SM300 brings comprehensive functional safety directly into the drive architecture.
Connecting external safety sensors, switches, and field wiring to the E94AYAD is done via terminals X81, X82, and X83. For higher-level safety networks, the module supports PROFIsafe over PROFINET or PROFIBUS when combined with optional fieldbus modules. Commissioning or replacing an SM300 option card requires uploading or restoring the machine safety configuration using Lenze Engineer software (Version 2.0 or higher with Safety Editor). Safety parameters and checksums are stored on non-volatile memory onboard the module and backed up on the 9400 base unit memory card. Putting a spare unit into service is rarely plug-and-run; the replacement module must receive the validated safety project download and execute the parameter confirmation process to resolve parameter CRC checks. ABC Industrial Parts can support maintenance teams needing spare donor hardware or parameter extraction assistance during replacement procedures.
Operational status and system faults are monitored through front-panel diagnostic indicators labeled RDY, ERR, and BUS / COM, as well as diagnostic event history logs in Lenze Engineer and drive operator panel displays. A solid green RDY LED indicates normal operation, while flashing green signifies an initialized module awaiting configuration, and red or off status points to an initialization fault or internal hardware failure. Active safety errors trigger a solid red ERR LED, whereas parameter CRC mismatches cause flashing red indications. Initial troubleshooting includes checking the 24 V DC auxiliary supply, verifying module seating and connector pin integrity in the drive slot, and testing field wiring across terminals X81, X82, and X83 for signal discrepancies. When internal component defects occur or persistent hardware fault codes arise, board-level repairs cannot be serviced in the field; installing a replacement module or utilizing tested exchange units through ABC Industrial Parts provides a rapid path back to production.
Technical Specifications
| Manufacturer | Lenze |
| Part Number | E94AYAD |
| Model / Type | SAFETY MODULE SM300 |
| Component Type | Safety Module |
| Product Family | 9400 Servo Drives |
| Compatible Drives | Lenze 9400 HighLine and StateLine Servo Drives |
| Supply Voltage | 24 V DC |
| Supply Voltage Range | 20.4 - 28.8 V DC |
| Rated Current Consumption | 0.1 A |
| Safe Digital Inputs | 8 single-channel or 4 dual-channel |
| Safe Digital Outputs | 2 dual-channel |
| Safety Functions Supported | STO, SS1, SS2, SOS, SLS, SSR, SDI, SLI, SLP, DCA |
| Safety Protocol Support | PROFIsafe (optional via fieldbus module) |
| Configuration Software | Lenze Engineer (Version 2.0 or higher with Safety Editor) |
| Lifecycle Status | Discontinued |
Programming and Configuration
Parameterization and safety programming for the Lenze E94AYAD SM300 are carried out using Lenze Engineer software version 2.0 or higher featuring the integrated Safety Editor tool. Through this programming environment, technicians define motion safety functions, input configurations for single or dual-channel operation, discrepancy monitor timing, and velocity limit thresholds required for safe operation.
The SM300 utilizes onboard non-volatile memory to store parameter checksums and safe configuration data. A duplicate backup is held on the memory card of the host Lenze 9400 base unit. During initial commissioning or spare module replacement, a mandatory parameter validation and confirmation process must be executed within the Safety Editor to store valid CRCs and establish system readiness.
Communication and System Integration
The E94AYAD connects directly into the designated option card slot of Lenze 9400 HighLine and StateLine servo drives, communicating over the internal drive bus architecture. Physical connections for local safety sensors, switches, and dual-channel outputs are established through pluggable terminal strips X81, X82, and X83.
For higher-level network integration, optional fieldbus communication modules can be added to enable PROFIsafe protocol operation over PROFINET or PROFIBUS networks. This configuration permits safety PLCs to directly command motion safety functions and process diagnostic status from the SM300 over fieldbus without additional hardwired safety connections.
Diagnostics and Status Indication
Visual status diagnostics are available directly on the front panel of the E94AYAD via three dedicated status LEDs: RDY, ERR, and BUS / COM. Extended diagnostic evaluation is available through event history logs accessible in Lenze Engineer software or on the operator panel display of the host 9400 servo drive.
Status LED Indicators
| LED | Color/Status | Meaning |
|---|---|---|
| RDY (Ready) | Green / Red - Solid / Flashing / Off | Green: Ready and operating normally. Flashing Green: Initialized, awaiting configuration. Off/Red: Initialization error or unserviceable internal hardware fault. |
| ERR (Error) | Red - Solid / Flashing | Red: Active safety error or safe state triggered. Flashing Red: Parameter CRC error, invalid configuration, or parameter mismatch. |
| BUS / COM | Yellow / Green - Solid / Flashing / Off | Yellow/Green: Active PROFIsafe communication. Flashing: Communication initialization or bus warning. Off: Communication inactive or fieldbus fault. |
Replacement and Spare Part Considerations
Before replacing an E94AYAD SM300 module, ensure power to the host 9400 servo drive is completely de-energized. Carefully inspect the backplane connector pins on the drive slot and the module plug contacts to prevent bending or electrical damage during insertion.
A replacement module cannot operate until it is loaded with a valid safety project. Using Lenze Engineer software (version 2.0 or higher with Safety Editor), engineers must restore the project configuration and complete the formal parameter confirmation procedure to clear CRC mismatch faults such as C0072.
Because this safety module was discontinued in May 2024, maintaining pre-validated safety project backups and verifying wiring integrity on terminal blocks X81, X82, and X83 is essential for minimizing equipment downtime when swapping modules.
Error Codes & Fault Codes
The following error codes may be displayed during operation or diagnostics:
| Code | Name | Description | Possible Cause | Recommended Action |
|---|---|---|---|---|
| C0070 | Safety module system error | Safety module SM300 detected an internal hardware error or self-test failure. | Internal component defect on SM300 module board or excessive electrical interference. | Cycle 24V supply power to module. If the error persists, replace the SM300 module. |
| C0071 | Safety module communication failure | Communication fault between 9400 drive controller board and SM300 safety option card. | SM300 module not securely seated in drive slot, damaged connector pins, or base unit internal bus fault. | De-energize drive unit, re-seat SM300 module firmly in slot, inspect contacts. Replace SM300 module if communication cannot be established. |
| C0072 | Safety module parameter CRC error | Parameter checksum mismatch or corrupt safety configuration stored in SM300 module. | Unconfirmed parameters loaded, parameter download interrupted, or corrupt flash memory. | Download valid safety project using Lenze Engineer Safety Editor and execute required parameter confirmation/validation process. |
| C0073 | Safety function fault / Discrepancy error | Input discrepancy or cross-circuit detected on safe digital inputs connected to SM300. | Wiring fault on safe inputs, broken wire, stuck switch contact, or discrepancy time exceeded. | Check wiring on safe input terminals X81/X82/X83, verify connected safety sensors/switches, and reset discrepancy condition. |
Frequently Asked Questions
What software is required to program and parameterize the Lenze E94AYAD SM300 safety module?
The module requires Lenze Engineer software version 2.0 or higher equipped with the integrated Safety Editor tool.
Can I swap an E94AYAD SM300 safety card without software intervention?
No. A replacement module requires downloading the application safety project and completing the parameter confirmation validation procedure in Lenze Engineer to clear CRC parameter errors.
Which Lenze drive series support the E94AYAD SM300 module?
The E94AYAD SM300 installs directly into option card slots on Lenze 9400 HighLine and Lenze 9400 StateLine servo drives.
How are fieldbus safety communications handled on the E94AYAD?
The module supports PROFIsafe over PROFINET or PROFIBUS when combined with optional fieldbus communication modules on the 9400 drive.
What causes fault code C0072 on the E94AYAD safety module?
Fault code C0072 indicates a parameter CRC error or checksum mismatch caused by unconfirmed parameters, interrupted downloads, or flash memory issues, which requires a validated parameter reload using Safety Editor.
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