Lenze E94AYAE SM301 Safety Module
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Product Information
The Lenze E94AYAE SM301 is a functional safety module designed as a plug-in expansion board for Lenze L-force Servo Drives 9400 HighLine. Operating on a 24 V DC supply, this safety module integrates safe motion control capabilities directly into the drive chassis, enabling certified safety compliance up to Performance Level e (PL e) per EN ISO 13849-1 and Safety Integrity Level 3 (SIL 3) per IEC 61508. The SM301 module supports integrated 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), and Limited Torque (LTI). Featuring four dual-channel safe digital inputs and two dual-channel safe digital outputs on plug-in screw terminals, the unit allows direct connection of emergency stop switches and safety sensors without requiring external safety relays.
Connecting and commissioning a replacement Lenze E94AYAE safety module requires parameter downloading and configuration alignment before the drive system can be put into service. Physical connections are established through the plug-in screw terminal block for local safety inputs and outputs, while fieldbus-based safety systems can integrate PROFIsafe communication through optional PROFINET or PROFIBUS fieldbus modules installed in the host drive. Safety parameter sets and monitored safety zones are programmed using Lenze Engineer software V2.0 or higher. A replacement module cannot function as a plug-and-play unit; it requires downloading the safety configuration project, performing checksum validation, and completing password-protected parameter confirmation in non-volatile memory. ABC Industrial Parts can assist in sourcing replacement modules and navigating parameter extraction or project alignment to minimize machinery downtime.
System status and fault detection are handled through onboard LED indicators, fieldbus diagnostic registers, and drive system software. The RDY LED displays operational status with solid green for normal operation, flashing yellow during initialization or configuration, and red when an internal hardware fault occurs. The BUS / SAFE LED provides feedback on safe states and PROFIsafe connection integrity. Diagnostic information is accessible via the EASY Starter diagnostic tool, Lenze Engineer software, and the host drive's diagnostic buffer. Common operational faults include input discrepancy errors (code 28931) from dual-channel switch wiring, safety parameter checksum errors (code 28932) requiring a project re-download, or module communication errors (code 28930) caused by improper mechanical seating in the safety slot. When internal hardware errors such as code 28929 persist after power cycling, internal component failure is present, and exchanging the unit through ABC Industrial Parts provides a direct route to restoring production.
Technical Specifications
| Manufacturer | Lenze |
| Part Number | E94AYAE |
| Model / Type | SM301 |
| Component Type | Safety Module |
| Product Family | L-force Servo Drives 9400 HighLine |
| Supply Voltage | 24 V DC |
| Safe Digital Inputs | 4 (Dual-channel) |
| Safe Digital Outputs | 2 (Dual-channel) |
| I/O Connection Type | Plug-in Screw Terminals |
| Supported Fieldbus Protocol | PROFIsafe (Optional via PROFINET/PROFIBUS fieldbus module) |
| Safety Rating | SIL 3 (IEC 61508) / PL e (EN ISO 13849-1) |
Programming and Configuration
Configuring the Lenze E94AYAE SM301 safety module requires Lenze Engineer software V2.0 or higher, which includes a dedicated integrated safety editor. The software allows technicians to define safety zones, configure Safe Motion functions such as SLS velocity thresholds and SDI direction monitoring, and set parameter discrepancy times for dual-channel safe inputs. Parameter sets are written directly to non-volatile memory on the module, securing settings against power loss.
During initial commissioning or replacement, the safety parameter transfer process requires a validation procedure. Once parameters are downloaded to the module, a reference checksum is generated and verified against the expected value. The technician must perform a parameter confirmation step in Lenze Engineer to validate the checksum and finalize the safety configuration. Password protection ensures that safety settings cannot be altered without authorization during machine operation.
Communication and System Integration
The E94AYAE SM301 safety module interfaces directly with host Lenze L-force Servo Drives 9400 HighLine via the internal backplane connection inside the drive's designated safety slot. For discrete safety wiring, the module provides four dual-channel safe digital inputs and two dual-channel safe digital outputs operating at 24 V DC, accessible via plug-in screw terminals for direct sensor and interlock wiring.
For networked safety architectures, the SM301 supports PROFIsafe safety communication when used in combination with optional 9400 PROFINET or PROFIBUS fieldbus option modules installed in the drive controller. PROFIsafe integration allows remote control systems to manage safety functions, transfer safety status registers directly to the master PLC, and clear soft faults over the network while maintaining certified SIL 3 and PL e safety standards.
Diagnostics and Status Indication
The Lenze E94AYAE SM301 safety module offers multiple diagnostic pathways for monitoring safety states and troubleshooting system errors. Onboard status displays include the RDY and BUS / SAFE dual-color LED indicators, providing immediate physical feedback on module operational readiness, initialization, PROFIsafe communication, and safety trip states. Diagnostic data is also aggregated within the 9400 drive system diagnostic buffer.
Detailed software-based troubleshooting can be performed using the EASY Starter diagnostic view or the Lenze Engineer safety diagnostic tool. These tools allow maintenance personnel to inspect live input and output states, monitor real-time motion safety feedback like actual motor velocity during SLS monitoring, read active error codes, and evaluate PROFIsafe status registers to pinpoint fieldbus or channel discrepancies.
Status LED Indicators
| LED | Color/Status | Meaning |
|---|---|---|
| RDY | Green / Yellow / Red - Solid Green / Flashing Yellow / Red | Green: Safety module ready and operational; Flashing Yellow: Initialization/Configuration; Red: Hardware or internal fault detected. |
| BUS / SAFE | Green / Red - Solid Green / Red | Green: Safe state active / PROFIsafe connection active; Red: PROFIsafe communication error or safe state violation. |
Replacement and Spare Part Considerations
When replacing a failed Lenze E94AYAE SM301 module, exact part number matching is required to ensure hardware compatibility with the host Lenze L-force Servo Drive 9400 HighLine backplane slot. Before inserting the replacement module, inspect the backplane connector pins on both the module and the drive chassis to prevent connector damage or communication faults (code 28930). Verify that all plug-in screw terminals are properly assigned to their corresponding dual-channel safe input and output field wiring.
Installing a replacement safety module requires re-commissioning the safety configuration. Because safety parameters are stored in non-volatile memory on the individual module with checksum protection, a replacement unit will not operate until the project configuration is downloaded using Lenze Engineer V2.0 or higher. After project transfer, perform the mandatory parameter confirmation procedure to clear checksum fault 28932 and establish operational readiness.
Error Codes & Fault Codes
The following error codes may be displayed during operation or diagnostics:
| Code | Name | Description | Possible Cause | Recommended Action |
|---|---|---|---|---|
| 28929 | Safety Module System Error | Internal hardware or cross-check error detected within Safety Module SM301. | Internal component failure, severe EMC disturbance, or corrupted safety memory. | Power cycle unit. If error persists, internal hardware fault is present — replace safety module E94AYAE. |
| 28930 | Safety Module Communication Error | Communication failure between Safety Module SM301 and host 9400 drive controller board. | Module improper mechanical seating, bent pins on backplane connector, or host drive backplane fault. | Check physical seating of module in drive slot; check connector pins; replace module if seating is correct and error persists. |
| 28931 | Input Discrepancy Error | Discrepancy time exceeded between dual-channel safe inputs. | Wiring fault on safe input switches, defective switch channel, or discrepancy time set too short in configuration. | Check wiring on dual-channel input contacts, measure signal timing, and verify discrepancy parameter setting in Lenze Engineer. |
| 28932 | Safety Parameter Checksum Error | Checksum of safety parameters stored in module does not match expected reference checksum. | Corrupted parameter memory, incomplete safety download, or unconfirmed configuration change. | Re-download safety configuration project via Lenze Engineer and complete parameter confirmation step. |
| 28933 | SLS Velocity Fault | Safely-Limited Speed (SLS) limit exceeded. | Drive speed exceeded configured SLS threshold during active safe motion monitoring. | Inspect motion command profile, verify encoder feedback accuracy, and check SLS limit configuration. |
Frequently Asked Questions
What software is required to configure the Lenze E94AYAE SM301 safety module?
The E94AYAE SM301 safety module requires Lenze Engineer Software V2.0 or higher with the integrated safety editor for parameter setup and safety project downloads. EASY Starter can also be used for diagnostic views and status monitoring.
Is the Lenze E94AYAE safety module a plug-and-play replacement?
No. A replacement E94AYAE module must be configured before operation. Safety parameters must be downloaded using Lenze Engineer V2.0 or higher, followed by a checksum confirmation step to store settings in non-volatile memory.
Which servo drives are compatible with the E94AYAE SM301 module?
The E94AYAE SM301 module is designed specifically as a plug-in expansion module for Lenze L-force Servo Drives 9400 HighLine, inserting directly into the drive's designated safety module slot.
How do I resolve a Safety Parameter Checksum Error (code 28932) on the E94AYAE?
A checksum error occurs when stored parameters do not match the expected reference checksum. Re-download the safety project using Lenze Engineer and execute the parameter confirmation procedure to resolve the fault.
Can the E94AYAE SM301 communicate over fieldbus networks like PROFIsafe?
Yes. The E94AYAE supports PROFIsafe fieldbus communication when the host Lenze 9400 drive is equipped with compatible PROFINET or PROFIBUS fieldbus option modules.
What should I do if the RDY LED remains solid red on the SM301 module?
A solid red RDY LED indicates an internal hardware fault or system error (code 28929). First power cycle the drive system. If the fault persists, internal hardware damage is present and the E94AYAE module must be replaced.
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