TL Sam v1.02 Bl-En

Technical documentation
Safety Module for
Twin Line units
SAM
Order no.: 0098441113177

Edition: V1.02, 08.2004
30
Radar!
-2
SAM
SAM safety module

0098441113177, V1.02, 08.2004
SAM
Table of content
Glossaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .V-5
Product names . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .V-6

Technical terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .V-7
Written conventions and note symbols . . . . . . . . . . . . . . . . . . . .V-9
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.2.1 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.2.2 Overview of operating mode selection . . . . . . . . . . 1-5
1.2.3 Other monitoring functions . . . . . . . . . . . . . . . . . . . 1-6
1.3 Safety in machine and system design . . . . . . . . . . . . . 1-7
1.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.3.2 Classification of risks . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.3.3 Electronic safety devices in machine and
system design . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Danger categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.3 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3.1 Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.4 Qualifications of personnel . . . . . . . . . . . . . . . . . . . . . 2-3
2.5 Directives and standards . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.6 Declaration of confirmity and CE mark . . . . . . . . . . . . 2-5
2.7 BG certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.8 Dokumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -2-7
3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1 Electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 SUB-D plug connector . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
4 Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Application cases . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3 Basic calculations for braking times and
braking distances . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.4 Basic calculation for the electrical installation . . . . . . . 4-6
4.4.1 Power consumption with multi-axis wiring . . . . . . . 4-6
4.4.2 Voltage drops with multi-axis wiring with a
SAM adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
0098441113177, V1.02, 08.2004
5 Installation and setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1 Safety instructions for installation and commissioning 5-1
5.2 Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . 5-1
SAM safety module -1

SAM
5.3 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.3.1 Connecting the 24V power supply . . . . . . . . . . . . . 5-2
5.3.2 Detecting cross connections . . . . . . . . . . . . . . . . . 5-3
5.3.3 Wiring types fpr control devices . . . . . . . . . . . . . . . 5-4
5.3.4 Multi-axis wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.3.5 Multi-axis wiring with SAM adapter . . . . . . . . . . . . 5-6
5.4 Stopping in emergency . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5.4.1 Internal safety relay function . . . . . . . . . . . . . . . . . 5-7
5.4.2 External safety relay . . . . . . . . . . . . . . . . . . . . . . . 5-14
5.5 Stop position monitoring with protective devices
open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5.6 Reduced speed with deactivated protective
devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
5.7 Safety door confirmation . . . . . . . . . . . . . . . . . . . . . . 5-23
5.8 Safety door interlocking . . . . . . . . . . . . . . . . . . . . . . . 5-24
5.9 Restricting the braking distance . . . . . . . . . . . . . . . . 5-25
5.10 Status query by an external controller . . . . . . . . . . . . 5-26
5.10.1 Status query via status outputs . . . . . . . . . . . . . . 5-26
5.10.2 Status query via field bus . . . . . . . . . . . . . . . . . . . 5-28
6 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 Configuration tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1.1 SAMCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.1.2 SAMCLONE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.2 Comissioning test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
7 Diagnosis and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.1 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 Operating states and transitions . . . . . . . . . . . . . . . . . 7-2
7.3 Error response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.4 Error display and troubleshooting . . . . . . . . . . . . . . . . 7-4
7.5 Table of error numbers for the SAM module . . . . . . . . 7-7
8 SAM parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 SAM user parameters . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.3 SAM action and status parameters . . . . . . . . . . . . . . . 8-4
9 Accessories and spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9.1 List of accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1.1 Connector cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.2 SAM adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
10 Service, Maintenance and Warranty . . . . . . . . . . . . . . . . . . . 10-1

0098441113177, V1.02, 08.2004
10.1 Service address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
-2 SAM safety module

SAM Glossaries
Glossaries
Abbreviations
Abbreviation Meaning
E Incremental encoder
I/O Inputs/Outputs
EMC Electromagnetic compatibility
EC European Community
EU European Union
FMEA Failure Mode and Effects Analysis
HMI Human-Machine Interface, plug-in hand-held operating unit
Inc Increment
IT system I: isolated; T: terre (Fr.), earth
System without potential to earth, not earthed
LED Light Emitting Diode
M Motor
M1..M4 Module slots of the Twin Line unit
PC Personal Computer
PELV Protected Extra-Low Voltage
SAM Safety Monitor, safety module for Twin Line units
SM Stepper motor
PLC Programmable Logic Controller
SUB-D Multipole connector
0098441113177, V1.02, 08.2004
SAM safety module V-5

Glossaries SAM
Product names
Abbreviation Product designation Term used

SAM Safety Monitor Module Safety module
SAMCT SAM Configuration Tool Software for configuration of the
SAM module, single parameters
can be modified
SAMCLONE SAM Clone Tool software for configuration of the
SAM module, but only with
complete parameter sets.
TLCT Twin Line Commissioning Operating Software
Tool
TLCxxx Twin Line Controller xxx Positioning controller
Standard unit
TLCxxxP Twin Line Controller xxx Positioning controller
Version P Degree of protection IP54
TLHMI Twin Line HMI HMI hand-held operating unit
TLHBC Twin Line Holding Brake Holding Brake Controller
Controller
0098441113177, V1.02, 08.2004
V-6 SAM safety module

SAM Glossaries
Technical terms
Actual position of the drive system The actual position of the drive system gives the absolute or relative
positions of moving components in the system.
Actual position of the motor See Angular position of the motor
Angular position of the motor The angular position of the motor corresponds to the angular position of
the rotor in the motor housing, and refers to the zero point or index point
of the position sensor.
DC link The DC link generates the necessary direct current for operating the
motor and provides the amplifier with the necessary energy. The DC link
acts as a buffer for energy fed back by the motor.
Default values Preset values for the parameters of the Twin Line unit before initial
commissioning, factory settings.
Direction of rotation Rotation of the motor shaft in a clockwise or anticlockwise direction. A
clockwise direction of rotation is defined as the motor shaft rotating
clockwise as the observer faces the end of the protruding shaft.
Drive solution The drive solution comprises the drive system with the Twin Line Unit
and motor with the system mechanics forming an integral part of the
chain of motion.
Drive system The drive system consists of the Twin Line Unit and the motor.
Encoder Sensor for recording the angular position of a rotating element. The
encoder is mounted on the motor and signals the angular position of the
rotor.
Error class Response of the Twin Line unit to an operational malfunction
corresponding to one of five error classes.
Forcing To change signal states regardless of the hardware switching status in
the unit; with the control tool, for example. The hardware signals remain
unchanged.
HIFA-C Module with Hiperface interface for connecting a Stegmann incremental
encoder.
High/open Signal status of an input or output signal; when no signal is present,
signal voltage is high (high level).
HMI HMI: Human Machine Interface. Human-machine interface handheld
unit that can be connected to the Twin Line unit.
Incremental encoder See encoder.
Internal units Resolution of the power amplifier with which the motor is directed to the
new setpoint. Internal units are given in increments.
Input device Input device is the device which can be connected to the RS232
interface for the purpose of commissioning; it is either the HMI hand-
held operating unit or a PC with the operating software.
Limit switch Switches that signal an overrun of the permissible travel range.
0098441113177, V1.02, 08.2004
Low/open Signal status of an input or output signal; when no signal is present,

signal voltage is low (low level).
Module code Internal electronic code (8 bit) which describes the hardware and the
functionality of modules. This code is stored in an EEPROM in every
module.
Parameter Device data and values that can be set by the user.

Glossaries SAM
Power amplifier This is the unit that controls the motor. The power amplifier generates
currents for controlling the motor in accordance with the positioning
signals from the control unit.
Power controller See Power amplifier
Quick-Stop This function is used in the event of faults, the stop command or for fast
braking of the motor in an emergency.
Resolver Analog encoder for determining the angular position of the rotor. It is
used for returning the actual position of the motor for phase-accurate
control of the motor.
RS232 interface The RS232 port is the communications interface of the Twin Line unit for
connecting a PC or the HMI hand-held operating unit
SAM SAM: Safety Monitor: optional module for the Twin Line unit for
integration of safety functions
User-defined units A user-defined unit corresponds to the maximum precision at which a
distance, speed or acceleration value can be input.
Zero-clamp Taking over the current actual position as the new setpoint position. It is
used with the quick-stop function when the position controller is
switched in at zero speed and set to the current position.
0098441113177, V1.02, 08.2004

SAM Glossaries
Written conventions and note symbols
Action symbols "왘" This action symbol is used for step-by-step instructions which can be
carried out as they are described. If one of the instructions results in a
noticeable response from the unit, this will be described after the
description of the action to be carried out. This will give you direct
confirmation that a particular step has been correctly carried out.
Enumeration symbol "•" The enumeration symbol is used for listing individual points in a given
information group in summary form. If the result of steps or sequences
is described, the step to be carried out is described first.
Menu paths " ➟ " In the Twin Line Control Tool operating software an action can be
launched via 'Menu ➟ Menu item ➟...'. For example, 'File ➟ Save' in the
'File' menu; under the menu item 'Save' saves data from the PC memory
to the data storage medium.
This symbol is used for general notes which give additional information
about the unit.
Passages preceded by this symbol may have to be discussed in more

detail with the local customer service.
0098441113177, V1.02, 08.2004

Glossaries SAM
0098441113177, V1.02, 08.2004

SAM Introduction
1 Introduction
1.1 General
Integration and application of safety The SAM safety module (Safety Monitor) can be used to integrate safety
functions functions for personal protection against dangerous movements into the
Berger Lahr Twin Line positioning controllers. The safety module offers
various operating modes for
• safe monitoring of the motor movement and
• safe removal of the motor power supply
L1 N
I/O
M E
Stop position EMERGENCY
and speed STOP A,B
monitor controller
SAM TLCxxx
Block of
power amplifier
Fig. 1.1 Function blocks
Safe monitoring of the stop position or the reduced speed makes it

possible to leave the motor under power, even with the safety door open
or the protective devices deactivated. The usual switch off the power, is
not required. Time-consuming restart procedures are thus not required.
This reduces downtime. This becomes more important the more
frequently entry to the danger area is required.
These safety functions enable the more stringent safety requirements
for setup mode required by the machine directive to be met
The components required in conventional safety engineering can be
replaced with the SAM safety module. These components include:
• additional position sensors (one per axis)
• Stop position and speed monitor (one per axis)
• safety relays (Emergency Stop relays)
• power contactors
0098441113177, V1.02, 08.2004
SAM safety module 1-1

Introduction SAM
This reduces the costs for components, installation and also the space
required for the system.
Fig. 1.2 External versus integrated safety engineering
The SAM module is installed in module slot M3 (see figure 1.3) of the
Twin Line TLCxxx positioning controllers. The SAM module cannot be
used in the TLDxxx units.
0098441113177, V1.02, 08.2004
Fig. 1.3 Position of the SAM module in a Twin Line unit
1-2 SAM safety module

SAM Introduction
Protective circuit The following system components can be connected to the inputs or
outputs of the SAM modules:
• Emergency Stop control devices
• Push button for unblocking the power amplifier
• Safety door position switches or outputs of a optical protection
device (e.g. light curtain)
• Push button for safety door confirmation
• Operating mode switch for selecting setup mode
• Enabling devices for enabling motor movements in setup mode
• Power contacts for switching external loads, if necessary with linked
contacts
• Electromechanical safety door interlocking
• Inputs of a PLC for status query of the SAM status outputs
Monitoring motor Movement The motor movements are safely monitored by the SAM module. It does
not limit the setpoint defaults for the positioning controller itself.
However, it does safely check that the motor position is retained and that
the motor speed remains at the preset limit values. The process
controller must ensure that these limit values are not exceeded. The
SAM triggers the positioning controller internally to initiate a Quick-Stop
only if the SAM detects non-allowed motor movements.
Incremental encoder If the SAM module is installed, an incremental encoder must also be
used with stepper motor devices. All incremental encoders supported by
the Twin Line unit can be used. Additional wiring of the incremental
encoder is not required specially for the SAM module, because the
connection is established in the Twin Line unit.
0098441113177, V1.02, 08.2004

Introduction SAM
1.2 Functional description
1.2.1 Operating modes

Safe Standstill In the Safe Standstill function the power amplifier controller is blocked
and prevents the motor from starting unexpectedly.
Automatic mode The motor movements are not monitored in Automatic mode, the
power amplifier controller is enabled.
Safe Operational Stop The Safe Operational Stop function monitors the stop position of the
motor to prevent it from starting unexpectedly. The power amplifier
controller is unblocked – the control functions can remain active.
Safely Reduced The Safely Reduced function monitors whether a preset speed is
exceeded. The power amplifier controller is unblocked – the control
30 functions can remain active.
With the SAM module it is distinguished between two operating modes:
Safely Reduced Setup Speed and Safely Reduced Automatic
Radar! Speed.
Safe Decleration The SAM uses the Safe Deceleration function to monitor controlled
braking during a switch to the Safe Operational Stop or the Safely
Reduced Setup Speed. This enables the process controller (e.g. a
Slow PLC) to detect the operating mode change requested by the control
down!
devices and to apply controlled braking to the drive to slow it to the
permissible speed range without initiating an error response.
Radar
in 100m Without this function, the drive would have to be in the permissible
speed range when the request for the new operating mode is made to
avoid an error response.
Safe stopping Process The Safe Stopping Process function with safe monitoring of the
braking ramp monitors the controlled braking of the drive after a Quick-
0098441113177, V1.02, 08.2004
Stop request from the SAM module in connection with an error

response.
POLICE

SAM Introduction
1.2.2 Overview of operating mode selection

The safety functions described in this chapter are available when the
SAM module is ready for operation (status 6). Details of the various
states of the SAM module can be found in the chapter on "Diagnostics
and Troubleshooting", page 7-2.
/ESTOP_A = 0 or n=0
/ESTOP_B = 0 POLICE
Safe Stopping Process Safe Standstill
GUARD1_A = 1 and
GUARD1_B = 1
Automatic mode
GUARD1_A = 0 or
GUARD1_B = 0
n<n_maxRed
Slow
down!
n=0
30 Radar
in 100m
Radar!
Safe Deceleration
Safely Reduced Setup Speed Safe Operational Stop
0 SETUPMODE_A = 0 or
0 SETUPMODE_A = 1 and 1 SETUPMODE_B = 0 or
1 SETUPMODE_B = 1 and
SETUPENABLE_A = 1 and or SETUPENABLE_A = 0 or

and SETUPENABLE_B = 0
SETUPENABLE_B = 1
Fig. 1.4 Selecting operating modes

0098441113177, V1.02, 08.2004

Introduction SAM
1.2.3 Other monitoring functions

Simultaneous switching If signal pairs switch to another status, the SAM checks whether both
inputs switch to the same status within a fixed time window of 10 s. If this
does not occur, an error is reported. Possible causes of error can be
welded contacts or short circuits to other live conductors.
Test of minimum movement When the power amplifier controller is unblocking by the SAM module
(PowerAmp), the motor must move 2° at least once every 36 hours. This
minimum movement is required as a "sign of life" from the incremental
encoder. If it does not occur, an error is reported. This applies also for
automatic mode.
Test of power supply If the 24-V power supply exceeds its allowable operating range, an error
is reported. The power amplifier and the safety-oriented outputs are
switched off immediately.
The power amplifier and the outputs remain switched off until the 24-V
power supply is switched off.
Temperature monitoring The temperature of the SAM module is monitored. If the temperature
exceeds or falls below the permissible operating range, the power
amplifier and the safety-relevant outputs are switched off immediately.
The power amplifier and the outputs remain switched off until the 24-V
power supply is switched off.
Test of outputs The safety-relevant outputs are tested by being switched off cyclically for
≤0.5ms.
0098441113177, V1.02, 08.2004

SAM Introduction
1.3 Safety in machine and system design
1.3.1 General
Safety consciousness The safety consciousness of our society is changing continuously and in
part dynamically.
Risks that were acceptable only a few years ago are no longer
acceptable after accidents, and methods and solutions are being
developed to avoid such accidents. The change in safety requirements
is initiating new standards, laws and directives affecting safety
engineering. The basic human need for protection against dangers
arising from products is demonstrated by the first product liability law,
which was passed in the Codex Hammurabi in 1750 B.C. If a building
collapses and kills a son of the building owner, a son of the builder must
be executed.
The safety requirements of users and operators demands
comprehensive risk management by manufacturers of machines and
systems. This is applied to determine the following:
• all risks
• the probability of damage occurring
• the degree and significance of the damage
• the possibilities of detecting and avoiding the danger.
Risk management encompasses the entire life cycle of the technical

system, assembly, commissioning, fault-free standard operation, fault
tracing, setup and adjustment, inspection and cleaning, maintenance
and disassembly.
Dangers detected during design of machines and systems, such as in a
design FMEA, must be eliminated by removing the causes of the
dangers or by encapsulating or protecting against the damgers with
safety devices or by organisational measures. The manufacturer must
supply comprehensive instructions to allow the user to avoid any
remaining residual risks.
Safety-risk danger Technical systems cannot be used without risk. Risks result from the
functions of the technical system, the design of the system, the work
processes and the business expense for safety and protective
equipment. Technical systems are considered safe when the limit risk is
not exceeded. The limit risk is the greatest acceptable residual risk. It is
determined by subjective and objective influences, by personal
awareness of danger and social acceptance of risks. A technical system
is considered dangerous if it poses greater risks than the limit risk.
0098441113177, V1.02, 08.2004

Introduction SAM
1.3.2 Classification of risks

Under the machine directive it is the machine manufacturer's
responsibility to determine the required category for safety-relevant
parts for the drive solution with Twin Line units as machine components.
Quantitative measurement of the risk is generally difficult or impossible.
The EN954-1 procedure is only concerned with reducing risk, which is
done by the safety-relevant components of the controller. The procedure
uses the following three risk parameters for estimating the risk.
• Seriousness of injuries
• Frequency and/or duration of exposure to danger
• Possibilities for avoiding the danger
As shown in figure 1.5, the parameters can be combined to classify the
risk on a scale from low to high. Depending on the risk, categories can
be derived to which the safety-relevant components of controllers must
conform.
EN 954-1
B 1 2 3 4
S1
P1
F1 P2
S2
P1
F2
P2
S Seriousness of injuries: P Possibility for avoiding the danger:

S1 slight, generally reversible P1 possible under certain
injury circumstances
S2 severe, generally irreversible P2 hardly possible

injury including death
Category:
B, 1,2, 3, 4 Categories for safety-relevant
components of controller
F Frequency and/or duration
of exposure to danger: Preferred category
F1 rare to frequent and/or Possible categories requiring

long duration of exposure additional measures
F2 frequently to continual and/or
0098441113177, V1.02, 08.2004
Measures which may be over-

long duration of exposure dimensioned for the appropriate risk
Fig. 1.5 Risk graph

SAM Introduction
1.3.3 Electronic safety devices in machine and system design

Machine controller components now have safety functions more and
more frequently. Such components are referred to as safety-relevant
controller components. The general design requirements for safety-
relevant controller components are listed in EN 954-1.
The risks arising from a machine can be kept below the tolerable risk
with safety-relevant controller components. The SAM safety module
integrates safety functions into the Twin Line unit range of positioning
controllers and meets the requirements of category 3 in accordance with
EN 954-1. This means that the safety function will always remain active
if one single error occurs. Some but not all errors are detected.
The integration of safety functions into the positioning controller
replaces external safety devices, reduces the total area required, the
wiring expense and the cost for the complete system.
0098441113177, V1.02, 08.2004

Introduction SAM
0098441113177, V1.02, 08.2004

SAM Safety
2 Safety
2.1 Danger categories
Safety notes and general information are indicated by special symbols

in the manual. In addition you will find symbols and instructions affixed
to your Twin Line unit which warn you of possible dangers and help you
to operate the unit safely.
Danger symbols are divided into three danger categories classified by
how serious a danger is.. The symbols shown emphasize the danger
situation to which the warning applies.
DANGER!
This indicates direct personal danger.
Can lead to serious injuries with fatal consequences if not
observed.
WARNING!
Indication of a recognizable danger.
If the warning is ignored, the danger can lead to serious
injury with fatal consequences, and to the unit or system
parts being permanently damaged.
CAUTION!
Indication of a danger.
If this is ignored, minor personal injury and light damage to
the unit or system may result.
Danger of injury
This indicates a danger of injury.
2.2 Safety notes
DANGER!
Electric shock from high voltage!
Follow safety rules when working on electrical systems:
• Switch off the power to the unit.
• Make sure the unit cannot be switched on again inadvertently.
• Confirm that no voltage is present.
• Cover or shield any neighbouring system parts which are live.
DANGER!
Electric shock from high voltage!
Before starting work on the connections of the power unit
6 min or on the motor terminals, wait for the 4 minutes discharge
time (TLC438 6 minutes) and then measure the residual
0098441113177, V1.02, 08.2004
voltage on the DC-link terminals DC+ and DC-. The

residual voltage must not exceed 48 VDC before you start
work on the connections.

Safety SAM
2.3 Intended use
2.3.1 Ambient conditions

Ambient temperature
TLCxxx: 0° C to + 45° C
TLCxxxP: 0° C to + 45° C
Transport and storage temperature - 40° C to + 70° C
Relative humidity
TLCxxx: 15% to 85%
TLCxxxP: 100%
(no condensation permissible)
Installation altitude h < 1000 m above mean sea level
Vibration stress during operation to DIN IEC 68-2-6
Number of cycles: 10
Frequency range: 10 Hz to 500 Hz
acceleration: 20 m/s2
Continuous shocks to DIN IEC 68-2-29
Number of shocks: 1000/direction
(X, Y, Z axes, pos. and neg.
Direction, total 6000)
Degree of protection The SAM module and the SAM adapter must be used only under
ambient conditions that conform to degree of protection IP54. This is
necessary to prevent cross connections and short circuits between
clamps, plug connectors, cables, conductors etc. to the safety-relevant
circuit components through other components.
2.3.2 Intended use

category of safety-related parts The SAM module must be used only for technical protection functions up
to and including category 3 in accordance with EN 954-1, unless
additional measures are implemented.
Configuration The parameter values for the SAM must be selected to ensure that the
required tolerable risk is not exceeded when using the safety function.
Vertical axes Vertical axes which can be dangerous if their weight causes them to
lower unexpectedly must not be operated without additional measures
to secure them from lowering in accordance with EN 954-1.
Installing the module The SAM module is designed for operation with the TLCxxx Twin Line
units. The module is installed in slot M3 in servo and stepper motor units.
The SAM module is only supplied with a Twin Line unit. If you wish to
install the SAM module in an existing Twin Line unit, please contact the
service department of your local dealer.
Motors The use is only admitted with the Berger Lahr Motors VRDM3... and
SER3...
0098441113177, V1.02, 08.2004

SAM Safety
2.4 Qualifications of personnel
Only technicians who are familiar with the contents of this manual are
qualified to configure and commission the SAM module. The technicians
must be able to detect potential dangers that may be caused by
installation, configuration, changing parameter values and generally by
the mechanical, electrical and electronic equipment.
Qualified personnel must be familiar with the current standards,
regulations and accident prevention regulations which have to be
observed when working on the unit.
0098441113177, V1.02, 08.2004

Safety SAM
2.5 Directives and standards
Relevant standards EN 954-1: Safety of machinery, Safety-related parts of control systems,

Part1: General principles for design
EN 60204-1: Safety of machinery, Electrical equipment of machines,
Part1: General requirements
EN 50 178 (VDE 0160): Fitting power systems with electronic
equipment
DIN VDE 0100: Regulations regarding the installation of power systems
with voltages up to 1000 V
DIN VDE 0106-100: Protection against electrical shock; Location of
actuation elements in the vicinity of operating resources liable to
accidental contact
DIN VDE 0470-1: IP degrees of protection
DIN EN 61000-4-1 (IEC 1000-4-1): Testing and measurement
procedures, Section 1: Overview of noise suppression test procedures
DIN EN 61800-3 and prA11: Variable-speed electric drives
0098441113177, V1.02, 08.2004

SAM Safety
2.6 Declaration of conformity and CE mark
EC Declaration of Conformity
Year 2004
BERGER LAHR GmbH & Co.KG
Breslauer Str. 7
D-77933 Lahr
according to EC Directive EMC 89/336/EEC

according to EC Directive Low Voltage 73/23/EEC
The above mentioned directives have been changed by CE Marking Directive 93/68/EEC
according to EC Directive on Machinery 98/37/EEC
We declare that the products listed below meet the requirements of the mentioned EC
Directives with respect to design, construction and version distributed by us. This declaration
becomes invalid with any modification on the products not authorized by us.
Designation: 3 Phase Motor Control Electronics with Safety Module SAM
Type: TLCx1x, TLCx3x, TLCx1xP, TLCx3xP
Product number: 0x634xxxxxxxx, 0x635xxxxxxxx
Applied EN 954-1:1997, category 3

harmonized EN 50178:1998
standards, EN 61800-3:2001, second environment according to Berger Lahr
especially: EMC test conditions
Applied UL 508C
national standards Berger Lahr EMC test conditions 200.47-01 EN
and technical Product documentation
specifications,
especially:
Company stamp:
0098441113177, V1.02, 08.2004
Date/ Signature: 16 February 2004
Name/ Department: Wolfgang Brandstätter/R & D

Safety SAM
2.7 BG certification
0098441113177, V1.02, 08.2004

SAM Safety
2.8 Documentation
Documentation for the Twin Line units on CD-ROM, multilingual

Order no.: 9844 1113 138
Twin Line HMI, manual for the Human-Machine Interface HMI, English
Order no.: 9844 1113 091
Twin Line Control Tool, manual for the operating software, English
Order no.: 9844 1113 095
Installation notes and help for EMC-compliant installation of
BERGER LAHR motor drives,
Order no.: 9844 1113 075
0098441113177, V1.02, 08.2004

Safety SAM
0098441113177, V1.02, 08.2004

SAM Technical data
3 Technical data
3.1 Electrical data
Plug connection Connection: High Density SUB-D

26-pin plug
M3 screw
Category of safety-related parts according to EN 954-1 Categorie 3
24V power supply PELV, DIN 19240,
input
Voltage range (monitored), reverse-polarity protected 20-30 VDC
Ripple < 2 VSS
Input current (without loading the outputs) < 0.02 A
Signal interface digital signal inputs

reverse-polarity-protected
No electrical isolation
debounced, debounce time≥ 1ms
Time window for simultaneous switching
both signals of a signal pair 10s
DC voltage Uhigh 15V to 30V (I ≥ 3 mA)
DC voltage Ulow ≤5V (I ≤ 0.5mA)
Current at 24 V(5KΩ against GND) I ≤ 5mA
Digital signal outputs inductive loadability (150mH/11W)
capacitive loadability (C ≤ 1 µF)
short-circuit proof
DC voltage ≤ 30 V
Switching current:
RELAY_A, RELAY_B, INTERLOCK_OUT ≤ 0.5 A
SAFETY24VDC_A, SAFETY24VDC_B ≤ 0.3 A
AUXOUT1, AUXOUT2 ≤ 0.1 A
Voltage drop at 0.5 A ≤1V
Deactivation time for test ≤ 0.5 ms
maximum time for detection of cross connections
at activated outputs ≤5s
Reaction times EMERGENCY STOP to start of standstill ≤ 20 ms

exceeding speed ≤ 20 ms
overshooting position ≤ 20 ms
Safe Stopping Process violated ≤ 10 ms
Behavior on errors Maximum motor-driven movement 1/2 motor pole pitch

in power amplifier output e.g. stepper motor with 50 pole pairs 3.6°
servomotor with 3 pole pairs 60°
0098441113177, V1.02, 08.2004
servomotor with 4 pole pairs 45°

Motor Maximum speed ≤ 7000 rpm
(depending on drive)

Technical data SAM
3.2 SUB-D plug connector
Pin Signal active default (open) Usage I/O

1 ESTOP_A low low Emergency Stop control devices I
2 GUARD1_A high low Safety door position switch I
3 SETUPENABLE_A high low enabling device I
4 SETUPMODE_A high low operating mode switch I
5 reserved
6 reserved
7 INTERLOCK_IN high low Enable input for safety door interlock logic I
8 SAFETY24VDC_A high Control devices power supply with cross connections O
dedection
9 SAMSTART high low Start signal I
10 SAM24VDC SAM module power supply -
11 SAM24VGND SAM module power supply -
12 reserved I
13 AUXOUT1 high Status output O
14 AUXOUT2 high Status output O
15 RELAY_A high power contactor O
16 RELAY_B high power contactor O
17 GUARD1CONF high low enabling device I
18 INTERLOCK_OUT low safety door interlock O
19 ESTOP_B low low Emergency Stop control devices I
20 GUARD1_B high low Safety door position switch I
21 SETUPENABLE_B high low enabling device I
22 SETUPMODE_B high low operating mode switch I
23 reserved
24 reserved
25 reserved
26 SAFETY24VDC_B high Control devices power supply with cross connections O
dedection
10
SAM24VDC 19 1
ESTOP_B ESTOP_A
SAM24VGND
GUARD1_B GUARD1_A
reserved
0098441113177, V1.02, 08.2004
SETUPENABLE_B SETUPENABLE_A
AUXOUT1
SETUPMODE_B SETUPMODE_A
AUXOUT2
reserved reserved
RELAY_A
reserved reserved
RELAY_B
reserved INTERLOCK_IN
GUARD1CONF
SAFETY24VDC_B SAFETY24VDC_A
INTERLOCK_OUT 26
18 SAMSTART
9
Fig. 3.1 Pin assignment SUB-D plug connector

SAM Planning
4 Planning
The chapter on planning should be considered as an overview. See the

following chapter for details.
4.1 Application cases
Application cases and actions The following list shows some examples of typical applications. This
overview contains design and/or organisational measures that can
assist you with the use of the SAM module.
Application Action See page

Category of safety-related parts unknown Determination of category in accordance with EN 954-1 1-8
System with stepper motor drive Use incremental encoder 1-3
System with enterable danger area Use push button for safety door confirmation 5-5 and 5-23
(GUARD1CONF) or use mechanical measures to prevent
accidental closure of the safety door
Residual risk of unexpected startup with Use enabling device 5-17
Safely Reduced Setup Speed not
acceptable
Connection of power contactors for safety- Use contactors with linked contacts that comply with the 5-11
related switching of other consumers relevant requirements (e.g. EN 60947-5-1) and wire mirror
contacts to the SAMSTART circuit
SAM connection cable not only in Two-channel wiring with cross-connection detection, e.g. by 5-3
cabinet power supply of control devices with SAFE24VDC.
SAM wiring not only in cabinet Two-channel wiring with cross-connection detection, e.g. by 5-3
power supply to control stations with SAFE24VDC or
prevention of short circuits by layout in separate plastic-
sheathed cables
Multi-axis system Use multi-axis wiring or SAM adapter, install SAM adapter in 5-6 or 5-6
IP54 ambient – ensure cable guide for SUB-D plug connector
System with field bus Status query over field bus possible 5-28
Master safety relay Connect SAMSTART input to 24 V and configure automatic 5-14
(Emergency Stop) start
Vertical axes Take action to secure against falling in accordance with 2-2
EN 954-1, if there is a possibility of unwanted lowering
causing a hazard
0098441113177, V1.02, 08.2004

Planning SAM
4.2 Wiring
The following system components are designed for connection to the

SAM inputs and outputs:
• Emergency Stop control devices
• Push button for unblocking the power amplifier
• Safety door position switches or outputs of a optical protection
device (e.g. light curtain)
• Push button for safety door confirmation
• Operating mode switch for selecting setup mode
• Enabling device for enabling motor movements in setup mode
• Power contacts for switching external loads, if necessary with linked
contacts
• Electromechanical safety door interlocking
• Inputs of a PLC for status query of the SAM status outputs
The circuit options for use with the SAM adapter are shown in the
following diagram.
0
24V 0V
1 OK
Emergency Stop
enabling device
operating mode
Safety door
confirmation
safety door
K1
switch
K2
Start
(11)
(10)
(26)
(26)
(26)
(26)
(19)
(20)
(21)
(22)
(17)
(7)
(8)
(1)
(8)
(2)
(8)
(3)
(8)
(4)
(9)
ESTOP_A [1..5] 1
ESTOP_B [1..5] 2
GUARD1_A [1..5] 3
GUARD1_B [1..5] 4
5
6
22
24
23
28
27
SAMSTART [1..5] 15
14
39
40
21
26
25
GUARD1CONF [1..5] 13
SETUPMODE_A [1..5] 7
SETUPMODE_B [1..5] 8
SETUPENABLE_A [1..5]
SETUPENABLE_B [1..5]
SAM24VDC [1..5]
SAM24VGND [1..5]
INTERLOCK_IN [5]
SAFETY24VDC_A [1]
SAFETY24VDC_B [1] SAM adapter
LOCK_OUT [1]
31 AUXOUT1 [2]
32 AUXOUT2 [2]
37 AUXOUT1 [1]
38 AUXOUT2 [1]
30 RELAY_B [2]
35 RELAY_A [1]
36 RELAY_B [1]
29 RELAY_A [2]
9 AUXOUT1 [3]
10 AUXOUT2 [3]
INTER-
INTERLOCK INTERLOCK INTERLOCK INTERLOCK
IN OUT IN OUT IN OUT IN OUT
SAM[1] SAM[2] SAM[3] SAM[4] SAM[5]

34
interlocking
safety door
(14)
(18)
(13)
optional
(15)
(16)
K1 K2
0098441113177, V1.02, 08.2004
linked contacts
PLC
L1 L2 L3 N PE
K1
K2
Other
(xx): Pin no. on SAM module SUB-D connector [x] : Connection to SAM SUB-D socket[x]
consumers
Fig. 4.1 SAM safety module, maximum syfety circuit

SAM Planning
4.3 Basic calculations for braking times and braking distances
The basic calculations below are also available as an EXCEL program

"SAMTEST.xls". Contact your local representative.
Calculating reduced speeds
linear movement rotary movement

Calculating reduced speeds
n Motor nMotor
p gear = gear factor p gear = gear factor
n Spindel nSpindel
h⎢
⎡ mm ⎤ d [mm] diameter of mechanic
⎥ stroke / pitch of axis
⎣U ⎦
⎡ m ⎤
⎡m ⎤ vrot ⎢ ⎥ reduced circumferential speed
vlin ⎢ ⎥ reduced linear speed ⎣ min ⎦
⎣ min ⎦
⎡U ⎤ p gear
⎡U ⎤ p gear n _ max Re d ⎢ ⎥ = v ⋅ ⋅ 1000
n _ max Re d ⎢ ⎥ = v lin ⋅ ⋅ 1000 ⎣ min ⎦
rot
d ⋅π
⎣ min ⎦ h
Converting the stopping distances
d ⋅π
s mech [mm ] = s [U ]⋅
h s mech [mm ] = s [U ]⋅
p gear p gear
Parameterss required from the SAM:
U
Sam . Re dSpeed .n _ max Re d in
min
U
Sam . Re dSpeed .n _ max Auto in
min
U
Sam .Stopping .dec _ QStop in
min ⋅ s
U
Sam . Decelerati on .dec _ NC in
min ⋅ s
Sam . Decelerati on .t _ NCDel in ms
Parameters required from the positioning controller:

0098441113177, V1.02, 08.2004
Motion.aNormNum U
acc = Motion.acc ⋅ in
Motion.aNormDen min ⋅ s
Motion.aNormNum U
dec = Motion.dec ⋅ in
Motion.aNormDen min ⋅ s

Planning SAM
The calculations are based on the following assumptions:

The motor accelerates in a linear fashion at acceleration acc when the permitted
position or speed range is left as a result of a controller error.
Emergency Stop
t acc [s ] = 0 , 018 +
50
dec _ QStop
n [Upm]
n _ max Auto
Sam.RedSpeed. Sam.Stopping.
dec_QStop t break [s ] = t acc +
n_maxAuto dec _ QStop
⎡ n _ max Auto 2 ⎤
s break [U ] =
1
⋅ ⎢ 2 ⋅ n _ max Auto ⋅ t acc + ⎥
tacc t [s] 120 ⎣ dec _ QStop ⎦
tbreak
Safe Operational Stop
n [Upm]
⎡U ⎤
nStart ⎢ = 3 ⋅ acc
⎣ min ⎥⎦
nmax Sam.Stopping.
t acc [s ] = 0,012 +
dec_QStop 50
Motion.acc acc + dec _ QStop
t [s]
tacc ⎡U ⎤
nmax ⎢ ⎥ = nStart + acc ⋅ t acc
slim tbreak
⎣ min ⎦
nmax
tbreak [s ] = t acc +
dec _ QStop
⎡ nmax
2
⎤
sbreak [U ] =
1
⋅ ⎢(nStart + nmax ) ⋅ t acc + ⎥
120 ⎣ dec _ QStop ⎦
0098441113177, V1.02, 08.2004

SAM Planning
Safely Reduced Speed
n [Upm]
t acc [s ] = 0,012 +
50
nexceed Sam.Stopping. acc + dec _ QStop
dec_QStop
Sam.RedSpeed.
Motion.acc ⎡U ⎤
n_maxRed
nexceed ⎢ = acc ⋅ t acc
⎣ min ⎥⎦
bzw.
n_maxAuto tacc t [s]
texceed
What distance is run in what time whilst exceeding the reduced

speed?
nexceed
texceed [s ] = t acc +
dec _ QStop
⎡ nexceed
2
⎤
sexceed [U ] =
1
⋅ ⎢ nexceed ⋅ t acc + ⎥
120 ⎣ dec _ QStop ⎦
Open safety door; stopping with Safe Deceleration (by PLC)

If Sam.Deceleration.dec_NC > 0
(function Safe Deceleration enabled)
t _ NCDel [ms ] 50
t acc [s ] = 0,008 + +
1000 dec _ NC
n [Upm]
n _ max Auto
tbreak [s ] = t acc +
Sam.RedSpeed. Sam.Deceleration.
n_maxAuto dec_NC
dec _ NC
⎡ n _ max Auto 2 ⎤
sbreak [U ] =
1
tacc t [s] ⋅ ⎢2 ⋅ n _ max Auto ⋅ t acc + ⎥
tbreak 120 ⎣ dec _ NC ⎦
Open safety door; stopping with Safe Stopping Process (by quick-stop)
If Sam.Deceleration.dec_NC=0
(function Safe Deceleration disabled)
Values same as with Emergency Stop

n [Upm]
Sam.RedSpeed. Sam.Stopping.
n_maxAuto dec_QStop
tacc t [s]
tbreak
0098441113177, V1.02, 08.2004

Planning SAM
4.4 Basic calculation for the electrical installation
4.4.1 Power consumption with multi-axis wiring
Current consumption [A] Number of SAM modules

1 SAM 2 SAMs 3 SAMs 4 SAMs 5 SAMs
Total without SAM adapter 0.07A 0.14A 0.21A 0.28A 0.35A
Total with SAM adapter 0.25A 0.36A 0.45A 0.52A 0.59A
The load currents of the connected output must still be added to the
table values.
4.4.2 Voltage drops with multi-axis wiring with a SAM adapter
Voltage drop [mV/m] Number of SAM modules Current load

at 0.01786 Ω *mm2/m for Cu 1SAM 2 SAMs 3 SAMs 4 SAMs 5 SAMs
Voltage drop [mV/m] Load 0A 4,5 6.4 8,0 9,3 10,5 see table
current
SAM24VCD from SAM [1..5] outputs 1.0A 22,4 24,3 25,9 27,2 10,5 Current consumption
in feed (at 1mm2) SAM[1..5] 2.0A 40,2 42,1 43,7 45,0 46,2
Voltage drop [mV/m] Load 0A 4,7 5,8 6,8 7,9 8,9 70mA + 20mA/SAM
current
SAM24VDC from SAM [1] 1) 1.0A 57,3 58,3 59,4 60,4 61,5
in the SAM cable (0.34mm2) SAM[1] 2.0A 109,8 110,8 111,9 112,9 114,0
Voltage drop [mV/m] 3,7 4,7 5,8 6,8 7,9 20mA/SAM+

SAFETY24VDC_A or SAFETY24VDC_B in the 50mA/adapter
SAM cable (at 0.34mm2)
oltage drop [mV/m] 0,1 0,2 0,3 0,4 0,4 5mA/SAM

in the control devices circuit (e.g. Emergency
Stop line) (at 1mm2)
Voltage drop [mV/m] 0,3 0,3 0,3 0,3 0,3 5mA/input

Input signal line in the SAM cable (at 0.34mm2)
1) The SAM module whose SAFETY24VDC outputs are used for cross-connection detection.
0098441113177, V1.02, 08.2004

SAM Installation and setup
5 Installation and setup
5.1 Safety instructions for installation and commissioning
Installation
DANGER!
Danger of death from high voltage!
The DC link and power amplifier of the Twin Line unit
remain live when switched off by the SAM.
Before carrying out maintenance and installation
work, disconnect the drive from the power supply with
a system voltage switch, and secure the switch to
prevent it from being switched on.
Commissioning
DANGER!
Danger of personal injury and damage to system parts by
uncontrolled starting of the system!
Block off the danger zone before starting up the Twin
Line unit with SAM module, and ensure that no one is
in the accessible area behind the system.
DANGER!
Danger of personal injury and damage to system parts by
uncontrolled system startup!
Before commissioning check the wiring of the SAM
module. Wiring faults can cause unexpected
responses in the system.
DANGER!
Danger of injury and damage to system components from
unsuitable parameter values!
Setting parameter values that are not suitable for the
system can cause unexpected responses in the
system. Calculate the parameter values very carefully.
5.2 Mechanical installation
The SAM module is only supplied with a new Twin Line unit. If you wish
to fit a SAM safety module to an existing Twin Line unit, please contact
the service department of your local dealer.
0098441113177, V1.02, 08.2004

Installation and setup SAM
5.3 Electrical installation
Module interface To the 26-pin SUB-D connector the other safety-relevant system
components have to be connected.
BERGER LAHR supplies cables and adapters as
accessories that can be used for wiring the system
components with the SAM. For more information see
"Accessories and spare parts", page 9-1.
5.3.1 Connecting the 24V power supply

Power unit Use only 24V PELV power units fot the power supply of theSAM and the
Twin Line unit and earth the 0V terminal.
PE
PE
N
TLCxxx
L
230V AC +24V
31 24VDC
0V 32 24VDC
33 24VGND
24V DC
34 24VGND
39 10 SAM24VDC
40 11 SAM24VGND
Optional SAM terminal adapter SAM SUB-D connector

0098441113177, V1.02, 08.2004
Fig. 5.1 24V terminal
Different power units can be used for the Twin Line unit and SAM
module. However, always connect the 0V terminal of the power
units together, because the GND terminals are not connected in
the unit.

5.3.2 Detecting cross connections

With the SAFETY24VDC_A and SAFETY24VDC_B outputs the SAM
module offers a two-channel 24-V power supply with cross connection
detection. With two-channel wiring and supplying power to the control
devices with these power outputs cross connections between channels
and short circuits to other live conductors can be detected.
Enabling device
Safety door
Emergency Stop
contact
Detected cross
connections Undetectable cross
connections
ESTOP_A
ESTOP_B
SETUPENABLE_A
SETUPENABLE_B
SAFETY24VDC_A
SAFETY24VDC_B
GUARD1_A
GUARD1_B
SAM
Fig. 5.2 cross-connection detection
Only cross connections from signals with the suffix "_A" to signals with
the suffix "_B" that are connected at low resistance to the 24V power
supply can be detected. Cross connections within a redundancy group
(e.g. "_A" to "_A") cannot be detected; they would be detected by the
different input states that occur after opening the corresponding the
control devices.
0098441113177, V1.02, 08.2004

5.3.3 Wiring types fpr control devices
24V 24V
cross-connection detection
Power supply with
control devices
control devices
control devies
xxx_A
xxx_B
xxx_A
xxx_B
xxx_A
xxx_B
SAFETY24DC_A
SAFETY24VDC_B
SAFETY24VDC_A
SAFETY24VDC_B
SAFETY24VDC_A
SAFETY24VDC_B
SAM SAM SAM
Single-channel wiring two-channel wiring Two-channel wiring with

cross-connection detection
Fig. 5.3 Control devices connection types
A single channel control device be sufficient for lower categories

according to EN 954-1or with appropriate wiring.
category Wiring
according to
EN 954-1 single-channel two-channel
B, 1, 2 sufficient possible, but not required

3 possible if wires are laid in sufficient
protected areas, such as in
hard conduit; not
recommended
4 without additional without additional
measures not allowed with measures not allowed with
SAM SAM
0098441113177, V1.02, 08.2004

5.3.4 Multi-axis wiring

If the safety-relevant control devices is installed in a system for multiple
axes with a SAM module, the inputs to the SAM modules must be wired
in parallel. However the SAM module outputs must not be wired in
parallel.
For parallel wiring of multiple axes and for chaining the inputs and
outputs for safety door interlocking the SAM adapter is recommended.
For more information see "Accessories and spare parts, SAM adapter",
page 9-3.
24V
Stop-button
Emergency
K1
Safety door
K2
START
L1 L2 L3 N PE
24V
TwinLine
SAMSTART
ESTOP_A
ESTOP_B
GUARD1_A
GUARD1_B
SAFETY24DC_A
SAFETY24DC_B
M E
SAM Positioning-
controller
RELAY_B
RELAY_A
L1 L2 L3 N PE
24V
ESTOP_A
ESTOP_B
SAMSTART
GUARD1_A
GUARD1_B
SAFETY24DC_A
SAFETY24DC_B
TwinLine M E
SAM Positioning-
RELAY_B
RELAY_A
controller
K1 K2
Fig. 5.4 Multi-axis wiring
The power contactors for switching off the external components can be
connected to any convenient SAM module.
The control devices for cross-connection detection can also be
connected to the SAFETY24DC outputs of any convenient SAM
module.
DANGER!
Safety function may be lost if the plugs are swapped!
0098441113177, V1.02, 08.2004
If the safety-relevant outputs (RELAY, INTERLOCK_OUT) are

swapped, this can result in altered switching behaviour with differently
configured SAM modules.
• Mark the cables!
• Check the connections!

5.3.5 Multi-axis wiring with SAM adapter
0
24V 0V
1 OK
Enabling device for

motor movements
Emergency Stop
Safety door
position switch
setup mode
K1
Safety door
K2
Start
(11)
(10)
(26)
(26)
(26)
(26)
(19)
(20)
(21)
(22)
(17)
(7)
(8)
(1)
(8)
(2)
(8)
(3)
(8)
(4)
(9)
ESTOP_A [1..5] 1
ESTOP_B [1..5] 2
GUARD1_A [1..5] 3
GUARD1_B [1..5] 4
[1..5] 5
6
22
24
23
28
27
SAMSTART [1..5] 15
14
39
40
21
26
25
[1..5] 13
[1..5] 7
[1..5] 8
SAM24VDC [1..5]
SAM24VGND [1..5]
INTERLOCK_IN [5]
SETUPENABLE_A
SETUPMODE_A
SETUPMODE_B
GUARD1CONF
SAFETY24VDC_A [1]
SAFETY24VDC_B [1] SAM-adapter
LOCK_OUT [1]
31 AUXOUT1 [2]
32 AUXOUT2 [2]
37 AUXOUT1 [1]
38 AUXOUT2 [1]
30 RELAY_B [2]
35 RELAY_A [1]
36 RELAY_B [1]
29 RELAY_A [2]
9 AUXOUT1 [3]
10 AUXOUT2 [3]
INTER-

34
interlocking
safety door
(14)
(18)
(13)
optional
(15)
(16)
K1 K2
linked contacts
PLC
L1 L2 L3 N PE
K1
K2
Other
(xx): Pin no. on SAM module SUB-D connector [x] : Connection to SAM SUB-D socket[x]
consumers
(if SAM adapter is not used)
Fig. 5.5 Multi-axis wiring using SAM adapter
The SAM1 slot must always be connected with a SAM module, because
the outputs for the power supply for the control devices with cross-
connection detection (SAFETY24DC) are accessed from this slot.
0098441113177, V1.02, 08.2004
For a more detailed description of the SAM adapter see the chapter on

5.4 Stopping in emergency
5.4.1 Internal safety relay function

Wiring The Emergency Stop function is the basic function of the SAM module.
It unblocks the power amplifier.
The following connections must be wired for this unblocking:
• 24V power supply to SAM24VDC and SAM24VGND
• EMERGENCY STOP control devices to ESTOP_A and ESTOP_B
• Start button to SAMSTART.
If a system of multiple Twin Line units is operated with a SAM module,

up to five SAM modules can be connected by implementation of the
SAM adapter. For more information see "Accessories and spare parts",
page 9-3.
24V 0V
Emergency Stop
Start
(11)
(10)
(26)
(19)
(7)
(8)
(1)
(9)
ESTOP_A [1..5] 1
ESTOP_B [1..5] 2
GUARD1_A [1..5] 3
GUARD1_B [1..5] 4
[1..5] 5
6
22
24
23
28
27
SAMSTART [1..5] 15
14
39
40
21
26
25
SAM24VDC [1..5]
SAM24VGND [1..5]
INTERLOCK_IN [5]
SETUPENABLE_A
SAFETY24VDC_A [1]
LOCK_OUT [1]
31 AUXOUT1 [2]
32 AUXOUT2 [2]
37 AUXOUT1 [1]
38 AUXOUT2 [1]
30 RELAY_B [2]
35 RELAY_A [1]
36 RELAY_B [1]
29 RELAY_A [2]
9 AUXOUT1 [3]
10 AUXOUT2 [3]
INTER-

34
safety door
(18)
optional
retention
0098441113177, V1.02, 08.2004
(xx) : Pin no. on SAM module SUB-D connector [x] : Connection to SAM SUB-D socket [x]
Fig. 5.6 Emergency Stop circuit with internal safety relay funct

Start signal with internal safety relay If the internal safety relay function of the SAM module is used, the
function Automatic Start function must be disabled by configuration.
Fig. 5.7 "Automatic Start" control field, disabled
Parameter Explanation and unit [ ] Range of values Default R/W

Name Idx:Sidx TL-HMI Value rem.
Sam.Miscellaneous. 10:14 2.9.12 General modes Bit 0: Automatic Start 0 R/W
MiscModes (SAMSTART) rem. 1)
0: Start button evaluation:
Pulse
1: Automatic start: Level
1) can only be written with the SAMCT/SAMCLONE configuration tools
The power amplifier must be unblocked by a start signal to the

SAMSTART input. This is always required after
• switching on the 24V power supply,
• after an Emergency Stop command
• and after errors that have caused a shut down (class 2 or 3 errors).
To ensure that the start signal is accepted, the Emergency Stop circuit
must be closed (/ESTOP_A and /ESTOP_B to high) and if required a
pending SAM error message must be reset.
However, the safety door circuit has not to be closed at the same time.
/ESTOP_A
/ESTOP_B
state SAM
SAMSTART thigh = 0,1s..2s

Low?
t
RELAY_A and
0098441113177, V1.02, 08.2004
RELAY_B and
PowerAmp
Fig. 5.8 Generating the start signal for normal Start

To detect any welded contact in the start push button, the SAM module
in Safe Start mode tests the low level at the SAMSTART input during the
status transition 3➟4. The test is done either at
• Closing the Emergency Stop circuit
• Acknowledgment of an error message if the Emergency Stop circuit
has already been closed
• Completed bootup if the Emergency Stop circuit has already been
closed
The SAM module also checks the pulse duration of the start signal. If the
maximum allowable pulse duration is exceeded, the start pulse is
ignored and an error response is triggered.
The start signal at SAMSTART only unblocks the power amplifier
(PowerAmp=1). To switch on the power amplifier, an enable for the
positioning controller is also required.
Status of positioning controller The positioning controller remains in operating status "3" until the power
amplifier control is unblocked, because the blocking of the power
amplifier appears to the positioning controller exactly like a DC link
voltage that is too low.
Safe Stopping Process after If the ESTOP inputs are no longer powered, the drives are stopped in
Emergency Stop (ESTOP) accordance with STOP of category 1 under EN 60204-1. This means
that a controlled stop is initiated before the power to the motor is
interrupted by deactivation of the power amplifier enable. This is mostly
used for Emergency Stop.
For the stopping process the SAM module initiates a Quick-Stop from
the positioning controller and monitors the controlled braking by safe
monitoring of the braking ramp.
The positioning controller always carries out a Quick-Stop on request
from the SAM module. The selection of the signals for Quick-Stop in the
positioning controller have no effect here.
The admissible deceleration ramp is specified with the
"Sam.Stopping.dec_QStop" parameter. The drive must decelerate at
least with the same steepness of this deceleration ramp in the event of
a Quick-Stop request from the SAM module, even under heavy load.
0098441113177, V1.02, 08.2004

n (rpm)
SAM triggers Quick-Stop and
monitors braking process
10ms
50 U/min
Admissible deceleration ramp
(Sam.Stopping. dec_QStop)
Quick-Stop-ramp:
TLCx1x : Settings .dec_Stop
TLCx3x: Settings.I_maxSTOP
t [s]
PowerAmp n=0
1
200 ms
0 t [s]
POLICE
Safe Stopping Process Safe Standstill
Fig. 5.9 Safe Stopping Process
The braking ramp is not monitored within the first 10 ms. This delay time
is available to the positioning controller as a response period.
The greatest speed value that was calculated within the 10ms delay
time plus an extra 50 rpm is always used as the start value for monitoring
the deceleration ramp. This adapts it to the actual speed situation.
If the stopping procedure was successful because the drive decelerated
faster than the admissible deceleration ramp, the stop position is
monitored for another 200 ms after the drive has come to a stop. This
delay time allows the positioning controller a delayed deactivation of the
controller to generate a holding torque until the holding brake is closed
before the power amplifier is finally blocked by the SAM module (Safe
Standstill).
If the drive does not fulfill the admissible deceleration ramp during a
Quick-Stop requested by the SAM module, the power amplifier is
blocked immediately and the motor performs an uncontrolled stop. In
contrast with the procedure with fixed switch-off deceleration period, this
prevents the drive from continuing to run or even accelerating in the
event of an error.

0098441113177, V1.02, 08.2004
Sam.Stopping. 10:16 2.9.13 Max. admissible deceleration UINT 32 # 0...32786009 0 R/W

dec_QStop ramp for Safe Stopping rem.
1)
Process
(Quick-Stop) [rev/(min*s)]
1) can only be written with the SAMCT/SAMCLONE configuration tool

The "Sam.Stopping.dec_QStop" parameter should be set as high as

possible to guarantee short braking paths and times. The upper limit is
oriented to the Quick-Stop braking ramp of the drive system. If the value
is set so high that the drive system cannot fulfill the admissible
deceleration ramp, the SAM module will block the power amplifier. As a
consequence the motor will perform an uncontrolled stop. Servo and
stepper motor units have different parameters for the Quick-Stop
braking ramp:
unit Quick-Stop Setting Sam.Stopping.dec_QStop

parameters
TLCx1x Settings. dec_Stop Sam.Stopping.dec ≤ Settings.dec_Stop*Motion.aNormNum / Motion.aNormDen
TLCx3x Settings. I_maxSTOP Sam.Stopping.dec ≤ Dν/Dτ
Dν/Dτ: Calculating the steepness of the Quick-Stop ramp under test with the
recording function of the TLCT commissioning software.
Recording the requested The braking ramp and the requested deceleration ramp can be recorded
deceleration ramp with the TLCT commissioning software. To do this select the recording
values:
• SamTrace: recording object for data in the SAM module
• n_act: actual speed
SamTrace is zero as long as the deceleration ramp is not monitored.

Therefore, this value is appropriate as trigger object:
• recording object for data in the SAM module (23/11)
• unequal 0
If the requested deceleration ramp has not been met 5 times, the SAM
module generates an error, which can only be reset by switching the 24V
power supply off and on. This allows unwanted subsequent
modifications of the Quick-Stop parameters to be detected if they cause
the stopping procedure to be unsuccessful and as a result the motor
performs an uncontrolled stop.
The Safe Standstill does not disconnect the electrical power safely! The
power amplifier is not disconnected from the power system. The power
switch must be off to ensure that there is no electrical hazard.
Switching other consumers If additional consumers are to be safely switched with the SAM module
or if multiple contacts are required, contactors with linked contacts can
be connected to the RELAY_A and RELAY_B outputs. The mirror
contacts of the contactors must be connected in series to the start button
(SAMSTART). The SAM module can only be switched on if the contacts
are correctly released. If mains power is switched with the contactors,
they must meet the standards for safe power isolation.
Switch-off time for other consumers If necessary, the switch-off for the other consumers can be delayed –
either after a fixed delay period or when the motor has come to a stop.
The switch-off time can be configured with the "Sam.Stopping.t_Relay"
0098441113177, V1.02, 08.2004
parameter.


Sam.Stopping. 10:13 2.9.11 Switch-off time of 0...10000 0 R/W
t_Relay outputs RELAY rem.
see following table 1)
Freewheeling diodes The SAM module outputs have integrated protection against induction
voltages. This makes an additional circuit with freewheeling diodes
unnecessary and this is also not recommended, because it could delay
the switch-off behaviour of the contactors.
24V 0V
Emergency Stop
K1
K2
Start
(11)
(10)
(26)
(19)
(8)
(1)
(9)
ESTOP_A [1..5] 1
ESTOP_B [1..5] 2
GUARD1_A [1..5] 3
GUARD1_B [1..5] 4
[1..5] 5
6
22
24
23
28
27
SAMSTART [1..5] 15
14
39
40
21
26
25
[1..5] 7
[1..5] 8
SAM24VDC [1..5]
SAM24VGND [1..5]
INTERLOCK_IN [5]
SETUPENABLE_A
SETUPMODE_A
SETUPMODE_B
SAFETY24VDC_A [1]
LOCK_OUT [1]
31 AUXOUT1 [2]
32 AUXOUT2 [2]
37 AUXOUT1 [1]
38 AUXOUT2 [1]
30 RELAY_B [2]
35 RELAY_A [1]
36 RELAY_B [1]
29 RELAY_A [2]
9 AUXOUT1 [3]
10 AUXOUT2 [3]
INTER-

34
optional
(15)
(16)
K1 K2
linked contacts
L1 L2 L3 N PE
K1
0098441113177, V1.02, 08.2004
K2
other (xx) : Pin no. on SAM module SUB-D connector [x] : Connection to SAM SUB-D socket [x]
consumers
Fig. 5.10 Emergency Stop circuit with internal safety relay function and
contactors for additional consumers

Event Sam.Stopping.t_Relay Switch-off time of RELAY outputs

Class 1 error x no switch-off
Class 2 error 0 ms immediately without delay
or EMERGENCY STOP 1 ms if the motor has come to a stop
2 ms if the motor has come to a stop and the potential at the
INTERLOCK-IN input is high (i.e. all motors in the daisy chain have
come to a stop).
≥3ms if the delay time t_Relay [ms] is expired
Class 3 or 4 errors x immediately without additional delay
n [Upm]
t [s]
INTERLOCK_IN n=0 t_Relay [ms]
1
0 t [s]
RELAY &
0 t [s]
t_Relay: 0 1 2 >3
Fig. 5.11 Switch-off time for other consumers

0098441113177, V1.02, 08.2004

5.4.2 External safety relay

If the SAM module is connected to an external safety relay (central
master), the "automatic start" function can be selected by configuration.
Automatic start
Fig. 5.12 "Automatic Start" control field, disabled

Sam.Miscellaneous. 10:14 2.9.12 General modes Bit0, Automatic Start 0 R/W
MiscModes (SAMSTART), rem.
0: Start button evaluation: Pulse 1)
1: Automatic Start: Level
If switching on or resetting the master Emergency Stop module requires

a start signal already, an additional start signal evaluation by the SAM
module is not required.
0098441113177, V1.02, 08.2004

0098441113177, V1.02, 08.2004
29 RELAY_A [2] (8)

SAM
22
(26)
30 RELAY_B [2] 21
(1)
ESTOP_A [1..5] 1
35 RELAY_A [1] (19)
ESTOP_B [1..5] 2
SAM safety module

36 RELAY_B [1]
Emergen. Stop
SAFETY24VDC_B [1]
SAFETY24VDC_A [1]
INTER-
Safety relay
(Emergency
34
Stop master)
LOCK_OUT [1] ON
37 AUXOUT1 [1] 24
38 AUXOUT2 [1] 23
31 AUXOUT1 [2] GUARD1_A [1..5] 3

32 AUXOUT2 [2] GUARD1_B [1..5] 4
9 AUXOUT1 [3]
10 AUXOUT2 [3]
26

25
SAM[1]
SETUPENABLE_A [1..5] 5
IN
SETUPENABLE_B [1..5] 6
OUT
(xx) : Pin no. on SAM module SUB-D connector

INTERLOCK
28
SAM[2]
27
IN
OUT
INTERLOCK
SAM-
SAM[3]
IN
optional
OUT
INTERLOCK
(9)
SAMSTART [1..5] 15
terminal adapter
SAM[4]
IN
INTERLOCK_IN [5] 14
Fig. 5.13 Emergency Stop circuit with external safety relay

(10)
SAM24VDC [1..5] 39
OUT
INTERLOCK
(11)
SAM24VGND [1..5] 40
24V 0V
SAM[5]
[x] : Connection to SAM SUB-D sockwet [x]

Installation and setup
5-15
Start signal for Automatic Start With the Automatic Start function the SAM module does not require a
start pulse for starting up but only a static 24V signal at the SAMSTART
input.
/ESTOP_A
/ESTOP_B
t
state SAM
High?
SAMSTART
t
RELAY_A and Low level, if mirror contacts
RELAY_B and are wired in series
PowerAmp
100 ms
switch on delay
t
Fig. 5.14 Generating the start signal for Automatic Start
The SAM module in Automatic Start mode checks the high level at the
SAMSTART input during the status transition 3 ➟ 4.
This check also prevents switch-on during Automatic Start if the linked
contacts connected in series to the SAMSTART input are not correctly
released by the optional contactors.
Switch-on delay during The fixed switch-on delay ensures that the high level at the SAMSTART
Automatic Start input is not disconnected by the linked contacts immediately on
detection of the powered Emergency Stop inputs, if they are connected
in series for this purpose. This allows other SAM modules, whose inputs
may be switched in parallel over the SAM adapter, to detect the high
level. If in a multi axis installation the error acknowledgment is not
conducted simultaneously, ensure that the error is finally acknowledged
at the positioning controller whose SAM module controls the contactors.
0098441113177, V1.02, 08.2004

5.5 Stop position monitoring with protective devices open
Automatic mode The Automatic Mode function is for production operation. While the SAM
module is ready for operation (status 6) and the GUARD1_A and
GUARD1_B inputs are powered, meaning that the connected safety
door is closed, the drive can be traversed without restrictions by the
SAM module. There is no movement monitoring. If the safety door is
open, Safe Operational Stop is activated, unless setup mode has been
enabled as described in the next chapter.
Safe Operational stop The Safe Operational Stop safety function monitors the stop position of
the motor to prevent it from starting unexpectedly. The power feed to the
motor remains on, the power amplifier is unblocked – the control
function can remain activated.
This allows access to the danger area without switching off power to the
drive. When the safety equipment is enabled again, the machining
process can be continued immediately from the point where it was
interrupted.
Safe deceleration The SAM uses the safe deceleration function to monitor controlled
braking during a switch to the safe mode stop or the safe reduced setup
speed . This enables the process controller (e.g. a PLC) to detect the
operating mode switch requested by the control station and to apply
controlled braking to the drive to slow it to the permissible speed range
without initiating an error response.
Without this function, the drive would have to be in the permissible
speed range when the request for the new operating mode is made to
avoid an error response.
0
n [rpm] and 1 or
Sam.Deceleration. t_NCDel
admissible
deceleration ramp
50 rpm (Sam.Deceleration. dec_NC )
t [s]
n=0
Slow
down!
Radar
in 100m
Automatic Safe Deceleration Safe Operational Stop Automatic
Fig. 5.15 Changing the operating modes

0098441113177, V1.02, 08.2004
This example shows a mode switch triggered by opening the safety

door. The braking ramp is not monitored within the configured delay time
"t_NCDel".

The SAM module remains in the current mode for this delay time. This
delay time is available for the process controller, to detect the opening
of the safety door and triggering the braking process. The greatest
speed value that was calculated within the delay period plus an extra 50
rpm is always used as the start value for monitoring the deceleration
ramp. This adapts it to the actual speed situation. On expiry of the
configured delay period, the SAM module begins monitoring the braking
ramp, starting from the calculated start value and the configured
deceleration ramp "dec_NC".
If the braking process was successful because the drive decelerated
faster than with the requested minimum deceleration, the mode
switches to Safe Operational Stop after the drive has come to a stop.
If the control devices selected setup mode, a mode switch to Safely
Reduced Setup Speed would have already occurred as soon as the
speed is less than the configured setup speed.
If the drive does not meet the admissible deceleration ramp, an error
response with Safe Stopping Process is sent. The drive is brought to a
stop with Quick-Stop and then switches to Safe Operational Stop after
Error; thus the drive remains active.

Sam.Deceleration. 10:12 2.9.19 Delay time for safe UINT16 # 0...500 0 R/W 1)
t_NCDel deceleration
(PLC response time) [ms]
Sam.Deceleration. 10:11 2.9.18 Max. admissible UINT32 # 0...32786009 0 R/W 1)
dec_NC deceleration ramp for safe 0: Function switched off
deceleration (immediate transition to
(with PLC) [rev/(min*s)] Safe Operational Stop or
Speed monitoring
The status of the inputs, e.g. for the safety door, can be queried by an
external controller for evaluation via status outputs or via field bus; see
the section on "Status query by an external controller", page 5-28.
0098441113177, V1.02, 08.2004

0098441113177, V1.02, 08.2004
(26)
SAM
29 RELAY_A [2] 22
(8)
30 RELAY_B [2] 21
(1)
ESTOP_A [1..5] 1
35 RELAY_A [1] (19)
ESTOP_B [1..5] 2
Emergency Stop
SAM safety module

36 RELAY_B [1]
SAFETY24VDC_B [1]
SAFETY24VDC_A [1]
INTER-
34
LOCK_OUT [1]
(26)
37 AUXOUT1 [1] 24
(8)
38 AUXOUT2 [1] 23
(2)
31 AUXOUT1 [2] GUARD1_A [1..5] 3
(20)
32 AUXOUT2 [2] GUARD1_B [1..5] 4
Safety door
9 AUXOUT1 [3]
10 AUXOUT2 [3]
26

25
SAM[1]
SETUPENABLE_A [1..5] 5
IN
SETUPENABLE_B [1..5] 6
OUT
(xx) : Pin no. on SAM module SUB-D connector

INTERLOCK
28
SAM[2]
27
IN
OUT
INTERLOCK
SAM[3]
IN
optional
OUT
INTERLOCK
(9)
SAM-adapter
SAMSTART [1..5] 15
Start
SAM[4]
IN
INTERLOCK_IN [5] 14
Fig. 5.16 Production mode with access to the danger zone

(10)
SAM24VDC [1..5] 39
OUT
INTERLOCK
(11)
SAM24VGND [1..5] 40
[x] : Connection to SAM-D socket [x]

24V 0V
SAM[5]
Installation and setup
5-19
5.6 Reduced speed with deactivated protective devices
If it is necessary to operate the machine during specific work processes

with the protective devices deactivated, according to the machine
directive dangerous movements are only permitted under more
stringent safety conditions, such as reduced speed.
With the function Safely Reduced Setup Speed the SAM module
ensures that the maximum permitted speed is not exceeded.
Wiring The following connections must be wired for this purpose:
• Operating mode switch to SETUPMODE_A and SETUPMODE_B
• Enabling device to SETUPENABLE_A and SETUPENABLE_B
0
24V 0V
operating mode switch

1
Emergency Stop
enabling device
Safety door
Start
(11)
(10)
(26)
(26)
(26)
(26)
(19)
(20)
(21)
(22)
(8)
(1)
(8)
(2)
(8)
(3)
(8)
(4)
(9)
ESTOP_A [1..5] 1
ESTOP_B [1..5] 2
GUARD1_A [1..5] 3
GUARD1_B [1..5] 4
5
6
22
24
23
28
27
SAMSTART [1..5] 15
14
39
40
21
26
25
[1..5] 13
[1..5] 7
[1..5] 8
SETUPENABLE_A [1..5]
SAM24VDC [1..5]
SAM24VGND [1..5]
INTERLOCK_IN [5]
SETUPMODE_A
SETUPMODE_B
GUARD1CONF
SAFETY24VDC_A [1]
SAFETY24VDC_B [1]
SAM-adapter
LOCK_OUT [1]
31 AUXOUT1 [2]
32 AUXOUT2 [2]
37 AUXOUT1 [1]
38 AUXOUT2 [1]
30 RELAY_B [2]
35 RELAY_A [1]
36 RELAY_B [1]
29 RELAY_A [2]
9 AUXOUT1 [3]
10 AUXOUT2 [3]
INTER-

34
optional
0098441113177, V1.02, 08.2004
(xx) : Pin no. on SAM module SUB-D connector [x] : Connection to SAM SUB-D socket [x]
Fig. 5.17 Setup mode wiring

To select the Safely Reduced Setup Speed, power must be applied to

the inputs for the operating mode switch and the enabling device, while
the inputs for the safety guard are deactivated..
Safely Reduced Setup Speed If the Safely Reduced Setup Speed function is active, the maximum
admissible speed of the drive is the setup speed, which is specified in
the parameter "SAM.RedSpeed.n_maxRed".
The SAM module does not limit the setpoint values for the speed, this
must be done on the process controller side. If the speed is exceeded
even so, the SAM module initiates a stopping process ending with Safe
Operational Stop. The power amplifier is thus not blocked so long as the
stopping process initiated by the SAM Quick-Stop request was
successful. The setup mode can be continued after resetting the SAM
error in the positioning controller.
Spatially Safely Reduced Speed If the SAM module is to be used for a system that initiates movements
in two or three spatial dimensions (cartesian robot), the speeds in the
direction of the axes must be added vectorally to a spatial speed when
selecting the value for the parameter "Sam.RedSpeed.n_maxRed". This
makes the resulting speed greater than the speed in the direction of the
individual axes. If a maximum spatial speed is to be set by the Safe
Reduced Setup Speed function, the value for the parameter
"Sam.RedSpeed.n_maxRed" must be specified with the formulas
below.
Number of axes Formula for "Sam.RedSpeed.n_maxRed"

1 n_maxRed = max. allowable spatially speed
2 n_maxRed = max. allowable spatially speed / √2
3 n_maxRed = max. allowable spatially speed / √3

SAM.RedSpeed. 10:18 2.9.14 Safely Reduced Setup Speed UINT16# 0...12000 0 R/W
n_maxRed [rpm] rem.
1)
1) can only be written with the SAMCT / SAMCLONE configuration tool

0098441113177, V1.02, 08.2004

Safe Deceleration With the function Safe Deceleration the SAM module monitors the
controlled braking during a switch to the Safe Operational Stop or the
Safely Reduced Setup Speed. This enables the process controller (e.g.
a PLC) to detect the operating mode switch requested by the control
devices and to apply controlled braking to the drive to slow it to the
permissible speed range without initiating an error response (see also
page 5-17).
0 0 0
1
and 1 or 1
and
n [Upm]
n_maxRed t_NCDel
50 U/min Admissible
deceleration ramp
(Sam.Deceleration. dec_NC )
t [s]
n=0
Slow
30 down! 30
Radar! Radar Radar!
in 100m
Safely Reduced Safe Deceleration Safe Operational Stop Safely Reduced

Setup Speed Setup Speed
Fig. 5.18 Changing the operating modes
Enabling device The optional enabling device is used to reduce the residual risk resulting
from a possible unexpected startup with the Safely Reduced Setup
Speed. This is particularly applicable if the motor is stopped and the
operator assumes that the drive is in Safe Operational Stop. However,
if only the Safely Reduced Speed function is enabled, the motor may
start unexpectedly with reduced speed.
The drive system can only traverse in setup mode with the enter key
when the enter key is actuated, otherwise Safe Operational Stop is
enabled.
If the residual risk resulting from a non-permitted startup at reduced
setup speed is acceptable, the SETUPENABLE_A and
SETUPENABLE_B inputs can be permanently wired instead of using an
enabling device to the active level (24 V or SAFETY24VDC).
The status of the inputs (e.g. safety door, mode selection switch, enter
key) can be queried by an external controller for evaluation via status
outputs or via field bus; see the section on "Status query by an external
controller", page 5-26.
0098441113177, V1.02, 08.2004

5.7 Safety door confirmation
Push button for safety Typical applications of the optional push button for safety door
door Confirmation confirmation are systems with enterable danger area where the safety
(GUARD1CONF) door can be closed with persons beeing in the danger area. Such
systems present a special safety risk. Accidental closing of the safety
door must not result in danger.
This can be done by preventing the safety door from closing by
mechanical means or by using the acknowledge key.
The push button for safety door confirmation must be installed outside
the safety area in a position where the interior of the danger zone can be
seen. Automatic operation will only be possible when the safety door is
closed and the push button for safety door confirmation has been
actuated.
The closed safety door does not require a special acknowledgment after
switching on the 24V power supply. The push button for safety door
confirmation must be connected to the GUARD1CONF input.
GUARD1_A and
24V 0V GUARD1_B
OK 1
0
t
confirmation
Safety door
GUARD1CONF thigh = 0,1s..2s

1
(11)
(10)
(17)
OK
39
40
0 t
SAM24VDC [1..5]
SAM24VGND [1..5]
Automatic mode
Fig. 5.19 Effect of the push button for safety door confirmation
If the push button for safety door confirmation is used, the safety door
without confirmation function must be disabled.
Safety door without

confirmation
Fig. 5.20 "Safety door without confirmation" control box, disabled

0098441113177, V1.02, 08.2004
Parameter Explanationn and unit [ ] Default R/W

Sam.Miscellaneous. 10:14 2.9.12 General modes Bit1: Safety door without 0 R/W
MiscModes confirmation (GUARD1CONF), rem.
0: With confirmation button 1)
1: Without confirmation button

5.8 Safety door interlocking
Controlling safety door interlocking Interlocking of the safety door prevents personnel from entering the
danger zone during operation. This prevents dangers caused by
coasting system components.
There is a safety-oriented single-channel INTERLOCK-OUT output for
controlling a safety door interlock. The output is active (24V) if the motor
is at a stop or the power amplifier is blocked. The function of the SAM
module is designed for a interlock that operates on the spring power
principle, i.e. the interlock is actuated without power.
SAM 3 SAM 2 SAM 1

INTERLOCK_IN INTERLOCK_OUT INTERLOCK_IN INTERLOCK_OUT INTERLOCK_IN INTERLOCK_OUT
Fig. 5.21 Controlling safety door retention
A daisy-chain for a multi-axis system can be structured by linking

INTERLOCK_OUT and INTERLOCK_IN, in which the last SAM module
only signals stopped drives if all connected axes are stopped.
If the INTERLOCK_IN input is not used in a daisy-chain, the use of the
input can be disabled in the configuration with the "Ignore
INTERLOCK_IN" setting.
Ignore INTERLOCK_IN
Fig. 5.22 "Ignoriere INTERLOCK_IN" control box, activated

Sam.Miscellaneous. 10:14 2.9.12 General modes Bit 3: Ignore INTERLOCK_IN, 0 R/W
MiscModes 0: Safety door interlocking rem.
1)
depends on INTERLOCK_IN
1: safety door interlocking is
independent of INTERLOCK_IN
1) can only be written with the SAMCT / SAMCLONE configuration tool.
In the SAM adapter, which is available as an accessory for connecting

multiple SAM modules, the INTERLOCK_IN and INTERLOCK_OUT
signals are wired to build a daisy-chain. See the chapter "SAM Adapter",
page 9-3.
0098441113177, V1.02, 08.2004

5.9 Restricting the braking distance
Safely Reduced Automatic Speed The path required by the drive to come to a stop after opening the safety
door depends on the maximum assumed working speed. If the system
does not use the full speed range of the drive, the working speed can be
safely monitored with the Safely Reduced Automatic Speed function
"Sam.RedSpeed.n_maxAuto" and this restricts the braking distance.
This allows the safety clearances in a system to be minimised.

Sam.RedSpeed. 10:19 2.9.15 Safely Reduced Automatic UINT16 # 0...12000 0 R/W
n_maxAuto Speed [rpm] 0: no speed monitoring in rem.
1)
Automatic mode
The SAM module also does not limit the setpoint values for the speed
with Safely Reduced Automatic Speed.
0098441113177, V1.02, 08.2004

5.10 Status query by an external controller
An external controller can query various states of the SAM module.

There are two basic options for this: query via the message outputs or
communication over field bus.
5.10.1 Status query via status outputs

The traditional status query is at the controller I/O level. The status of
inputs, outputs and error states can be output through the AUXOUT1
and AUXOUT2 outputs. The information given out can be configured
separately for each status output.
Note: the status outputs are not approved for safety relevant use!
AUXOUT1
I/O
PLC AUXOUT2 SAM
I/O
0
1
TLCxxx
SAM adapter
31 AUXOUT1 [2]
32 AUXOUT2 [2]
37 AUXOUT1 [1]
38 AUXOUT2 [1]
9 AUXOUT1 [3]
10 AUXOUT2 [3]

(14)
(13)
optional
PLC
Fig. 5.23 Status query via status outputs

0098441113177, V1.02, 08.2004


Sam. 10:6 2.9.16 Function of the UINIT32 # 0...4294967295 0 R/W
1)
Miscellaneous. status output AUXOUT1 Bit: 0...14: Selection of status for
ModeOut1 output
00000001h: /ESTOP
00000002h: GUARD1
00000008h: SETUPMODE
00000010h: SETUPENABLE
00000040h: GUARD1CONF
00000200h: DriveReleased
00010002h: RELAY
00010010h: INTERLOCK_OUT
00010200h: drive stopped (n=0)
00010400h: Setup speed
(n<n_maxRed)
0002001Eh: Error class 1...3
Bit 15: Inversion
0: Status not inverted
1: Status inverted
Sam. 10:7 2.9.17 Function of the UINIT32 # 0...4294967295 0 R/W
1)
Miscellaneous. status output AUXOUT2 Bit: 0...14: Selection of status for
ModeOut2 output
00000001h: /ESTOP
00000002h: GUARD1
00000200h: DriveReleased
00010002h: RELAY
00010200h: drive stopped (n=0)
(n<n_maxRed)
Bit 15: Inversion
1: Status inverted
0098441113177, V1.02, 08.2004

5.10.2 Status query via field bus

All parameters of the SAM module can be read via a standard field bus,
if one is available. An external controller can query the states of the
inputs, outputs and other information from the SAM module without any
additional wiring required.
For more information on the SAM parameters see the chapter "SAM
Parameters", page 8-4.
SAM
0
PLC field bus 1
TLCxxx
PLC
field bus
Fig. 5.24 Status query via field bus
0098441113177, V1.02, 08.2004

SAM Configuration
6 Configuration
6.1 Configuration tools
The SAM module can only be configured with special SAM configuration
tools. With TLCT, TL-HMI or, if available, via field bus the SAM module
parameters can be read only. Two configuration tools are available:
• SAMCT (SAM Configuration Tool): This is for use by safety
representative for running a new configuration.
• SAMCLONE (SAM Clone Tool): This is for use by technicians
(e.g. maintenance or service technicians) for duplication of stored
parameter sets.
Both SAM configuration tools are strongly oriented to TLCT, the

standard commissioning tool, and they are operated similarly. SAMCT
and SAMCLONE can be installed on a PC that communicates with the
positioning controller via the standard commissioning port (RS232).
Compatibility SAMCT and SAMCLONE are upwards compatible, i.e. older versions of
the SAM module can be configured with newer versions of the tools. Use
only SAMCT and SAMCLONE version 1.002 and follow-ups.
If you require a newer version of SAMCT or SAMCLONE, please contact
the service department of your local representative.
Status of the The SAM module can only be configured if the positioning controller is
positioning controller in "disabled" unit status (status 3, 4 or 9). To achieve this status, the
positioning controller must stop at status 3 when booting up, or it must
be switched to status 4 by disabling "ENABLE". Another option is to
trigger an Emergency Stop.
0098441113177, V1.02, 08.2004

Configuration SAM
6.1.1 SAMCT
The parameters of the SAM module can be modified individually with
SAMCT.
Fig. 6.1 Configuration tool SAMCT
0098441113177, V1.02, 08.2004

SAM Configuration
Password protection Parameter writing is password-protected. The factory setting for the
password is SAM4SAFE. The password is checked in the SAM module.
The password can have up to eight characters and the user can change
it in the menu "Parameter ➟ Change configuration password".
Fig. 6.2 Input of password
Commissioning test After a new configuration or modification of the configuration, an

commissioning test must always be run before the system can be
operated with the SAM module. See the "Commissionimg test" section
in this chapter on page 6-4.
Storage The SAM parameters can be saved to a PC data medium with the
SAMCT program. This must only be done after a successful
commissioning test in all circumstances.
6.1.2 SAMCLONE
This tool is provided for configuring the SAM module if a unit is replaced
for service. When using SAMCLONE only complete SAM parameter
sets can be saved to a data medium and reloaded into a SAM module.
If only SAMCLONE is supplied to the service technicians for configuring
the SAM module, this means that less qualified technicians can be used,
because they will be unable to modify single SAM parameters with this
tool. However, technicians must still be informed of the dangers of
configuration with an incorrect data set.
DANGER!
Safety functions can be lost if incorrect data are used!
• Check the file name!
• Check the name of the user device name!
User device name The user device name of the positioning controller are is saved in the
SAM parameter file and displayed before loading into the SAM module
as a check for identification of the parameter sets.
Password protection Password key in is not required for configuration with SAMCLONE. The
password of the SAM module is set during configuration to be the same
as the password on the device from which the data was saved.
Therefore, the original password is valid after replacing a unit.
0098441113177, V1.02, 08.2004

Configuration SAM
6.2 Commissioning test
Target The commissioning test checks that the correct parameters were
selected for the SAM module during configuration. The SAM
commissioning test does not test the electrical installation.
Maturity date A complete commissioning test must always be run after:
• Initial configuration
• Changes to the values of safety-relevant parameters
DANGER!
Serious injury and damage to system components!
The commissioning test must be conducted by electrical
technicians only (see the "Safety", section "Qualifications
of Personnel", page Kapitel „Qualifications of personnel“
auf Seite 2-3 ), who have the technical training, knowledge
and experience to assess the work done and to detect and
avoid possible dangers.
Commissioning protocol The commissioning test must documented in the form of an

commissioning protocol. A template is shown on page 6-5. If EXCEL is
available, you can also use the EXCEL program SAMTEST.xls, which
enables the commissioning test to be run semi-automatically. See
Series units The complete commissioning test does not need to be repeated for
series units. The data set that has been verified on one axis can be
transferred to systems with identical axes with the SAMCLONE
configuration tool. This applies particularly for cases where units are
replaced for service.
0098441113177, V1.02, 08.2004

SAM Configuration
Commissioning protocol
SAM Commissioning Protocol
1. General Information
Project:
Station:
Axis name:
Positioniersteuerung:
Motor:
Liniarachse:
Getriebe:
Name of tester:
Legend: still open:

tested:
not present / not used:
2. Configuration
Sam.Miscellaneous. ResEnc
MiscModes [ ] Automatic start
[ ] Guard1 without acknowledgment
[ ] Ignore INTERLOCK_IN
ModeOut1
ModeOut2
Sam.RedSpeed. n_maxred
n_maxAuto
Sam.Deceleration. t_NCDel
dec_NC
Sam.Stopping. dec_Qstop
t_Relay
3. Options for electrical circuits

Value read for Automatic Start as per planning
Value read for safety door acknowledgment as per planning
Value read for INTERLOCK_IN as per planning
4. Mechanical
Transmission ratio as per planning
5. Safe stopping Process (Emergency Stop)

Standstill successful
Shutoff via RELAY outputs succesful
6. Safe Deceleration (PLC)

Safe Deceleration successful
7. Safely Reduced Speed

Safely Reduced Setup Speed:
setup mode possible (n<n_maxRed)
0098441113177, V1.02, 08.2004
Correct error response when exceeded (n>n_maxRed)

Safely Reduced Automatic Speed:
Value read as per planning
Date:
Signature:
Fig. 6.3 Template for the commissioning protocol

Configuration SAM
0098441113177, V1.02, 08.2004

SAM Diagnosis and troubleshooting
7 Diagnosis and troubleshooting
7.1 Diagnosis
Status display in the TLCT The TLCT commissioning tool for the Twin Line units has its own tab in
the dialog box for the SAM in the menu item "Twin Line ➟ Diagnosis ➟
Device hardware". This tab shows the status of the inputs and outputs
and the operating states of the SAM module.
Status query over field bus Read access to the status parameters of the SAM module is available
via field bus. The access is the same as to the positioning controller
parameters.
This allows the status of the inputs and outputs and the SAM module
operating status to be read out via field bus. For more information see
"Status query via field bus" on page 5-28.
0098441113177, V1.02, 08.2004
Fig. 7.1 TLCT tab with SAM information

Diagnosis and troubleshooting SAM
7.2 Operating states and transitions
The samState 7-segment display on the SAM tab in the

"Twin Line➟Diagnosis➟Device hardware" menu of the TLCT shows the
operating status of the SAM module in coded form.
An state machine runs independently of the Twin Line unit in the SAM
module. The operating states and transitions are similar to the status
display of the Twin Line units.
samState: samOpMode:
Safe Standstill
Initiation
succsesful
Operational malfunction samState: samOpMode:
Power amplifier unblocked Safe Standstill

(PowerAmp = 1) and
RELAY outputs active SAM24VDC
24V
SAM24VGND
samState: samOpMode: samState: samOpMode:

Error class 3 or 4 FAULT_RESET
Error class < 4
Safe Standstill Safe Standstill
n=0 &
t_Relay
ESTOP = 1 ESTOP = 0
samState: samOpMode: samState: samOpMode: SamDisbale (via field bus or TLCT)
ESTOP = 0
oder
POLICE
Safe Standstill
Safe Stopping Process
Error class 2
SAMSTART = Puls / 1
samState: samOpMode: samState: samOpMode:

FAULT_RESET
Safe Operational Stop Automatic mode

n=0 30
0098441113177, V1.02, 08.2004
Speed
Camera!
Error class 1
POLICE
Safely Reduced Speed
Safe Stopping Process
Safe Operational Stop
Fig. 7.2 Status displays and transitions of the SAM module

7.3 Error response
The SAM module triggers an error response when a malfunction occurs.

Depending on the severity of the malfunction, the SAM module
responds in accordance with one of the following error classes and also
triggers a corresponding error response in the positioning controller.
The following table shows the connection between the stop categories in
accordance with DIN EN 60204 and these error responses.
Error Stop Meaning

class category
0 - Message only, no interruption of operation
1 2 Safe stopping process (Quick-Stop), when stopped

transition to Safe Operational Stop after Error
mode. (controller remains active). Outputs
RELAY_A and RELAY_B are not switched off
POLICE
2 1 Safe stopping process (Quick-Stop), when stopped

transition to Safe Standstill mode (no power to
motor).
RELAY_A and RELAY_B outputs switched off, time
delayed if necessary.
POLICE
3,4 0 Immediate Safe Stanstill, motor performs an

uncontrolled stop.
Immediate switch-off of RELAY_A and RELAY_B
outputs.
0098441113177, V1.02, 08.2004
Error class in accordance with Twin Line definition

STOP categories in accordance with DIN EN 60204-1

7.4 Error display and troubleshooting
Error display A SAM operational malfunction is displayed on the positioning controller

7-segment display:
• Operating state "7": non-admissible movement by SAM
detected (status 7 is not only caused
by the SAM).
• flashing"F": operational malfunction was triggered

by SAM (e.g. by Emergency Stop).
• flashing decimal point:SAM warning

(e.g. temperature prewarning)
Additional error displays may be :

• the error response of the positioning controller
• in the TLCT commissioning software within the status bar
• in the error memory log, all SAM module error messages begin with
"SAM":
Error messages that begin with "SAM: system error:" require
replacement of the unit.
• bit-coded in the "Status.FltSig" parameter
Bit 17: SAM error,
Bit 30: SAM warning
Resetting errors (Fault reset) When the SAM module malfunction has been corrected, the error
message on the positioning controller can be reset
• by setting the FAULT_RESET input signal
• by the operating software with the Reset button
• by switching off the positioning controller 24V power supply
Class 4 errors cannot be reset, i.e. the drive system can return to
operation only after the 24V power supply to the Twin Line unit has been
switched off and then on again.
0098441113177, V1.02, 08.2004

Troubleshooting
Error Possible causes Troubleshooting

Automatic mode not possible even with Push button for safety door Connect / press push button for safety door
safety door closed confirmation not connected / confirmation at GUARD1CONF!
not pressed
Safety door confirmation not Change and test SAM configuration
switched off, if not required (SAMCT):
Sam.Miscellaneous.MiscModes:
Guard1 without confirmation!
SAM remains in status 2 24V power supply not Connect SAM24VDC and SAM24GND!
connected to SAM
TLCx1x (stepper motor), error message: Motor "stalls" Enable follow error monitoring (TLCT):
E152B: "SAM: error in position detection Settings.Motor monitoring:
(unequal values) RM active so the controller detects "stalling"
itself.
Reduce Value for Quick-Stop ramp (TLCT):
Settings.dec_Stop. Stopping process must
be tested again!
Reduce acceleration values Motion.acc and
Motion.dec! (TLCT)
Moving axis manually after Do not move axis manually after fault reset!
fault reset
SAM password forgotten SAM password has been Load a data set from another SAM whose
changed or forgotten password is known into the controller with
SAMCLONE. Set the desired configuration
with SAMCT and the known password!
Error message: Error text file TwinLine.err not Install new version from TLCT!
"Error text unknown" current
TLCx1x (stepper motor), error message: Delay of Quick-Stop caused by Configure Motion.Ruckfilter ≤ 5ms! (TLCT)
E1504 "SAM: error on Safe Stopping jerk filter
Process: insufficient braking ramp (Quick-
Stop)" although
Sam.Stopping.dec_QStop <
Settings.dec_Stop *
Motion.aNormNum / Motion.ANormDen
Motor current too low and thus Increase motor current Settings.I_acc!
insufficient torque (TLCT)
Error message: Setpoint settings for speed too Reduce setpoint settings, take calibration
E1506: "SAM: Safely Reduced Setup high factors into account!
Speed exceeded "
Strongly oscillating mechanics TLCx1x (stepper motor): (TLCT)
Motion.Start-Stop speed lower
Select setpoint settings for speed up to
20rpm less than
Sam.Redspeed.n_maxRed
TLCx1x (stepper motor), error message: Toggling the motor when Enable automatic mode or safe mode stop
0098441113177, V1.02, 08.2004
E1506: "SAM: Safely Reduced Setup enabling power amplifier when enabling power amplifier or disable
Speed exceeded" after enabling power causes short, quick Settings.SM_toggle. (TLCT)
amplifier movements
Error message: "SAM: system error:..." SAM hardware fault detected Replace position controller

Error classifikation All errors are assigned to one of five error classes, as listed in the table
below.
An error response occurs only in the listed states.
Error Monitoring Error Remarks

active in SAM class
status
Violating stop position during Safe Operational Stop 6 1
Violating stop position during Safe Operational Stop after 7 3 In the case of error,
error after Safe Stopping Process
Exceeding speed limit during Safely Reduced Automatic 6 1
Speed
Exceeding speed limit during Safely Reduced Setup Speed 6 1
Insufficient braking ramp during Safe Deceleration 6 1 Braking procedure by PLC
Insufficient braking ramp during Safe Stopping Process 7,8 3 Braking process with Quick-
Stop
Repetative errors (5x) during Safe Stopping Process 9 3 Counted since switching on
24VDC
Emergency Stop triggered 6,7 2 Emergency Stop actuated
Minimum movement not retained (min. 2° every 36 hours) 6,7 3
Configuration error: Incremental encoder resolution or 6 3 If positioning controller is in
minimum deceleration not configured status 6
Starting pulse to SAMSTART too long 4 2 If configuration
Automatic Start
No low-level at SAMSTART 3➟4 2 If configuration
Automatic Start
No high-level at SAMSTART 3➟4 2 If configuration
Automatic Start
Pulse for safety door confirmation at GUARD1CONF too long 3..7 2 If configuration
safety door without
confirmation
No high-Level at INTERLOCK_IN within 10s during Safe 8 3 If
Stopping Process SAM.Stopping.t_Relay=2
No Low-Level at INTERLOCK_IN 3...7 2 If configuration
Ignore INTERLOCK
Internal system error, allocatable 3..9 2 ➟ 4 1) e.g. defect in I/O unit
Internal system error, not allocatable 2..9 4
Cross connection at SAFETY24VDC 3..9 2 ➟ 41)
Unequal input signals at signal pairs V 2 after 15 s
0098441113177, V1.02, 08.2004
Non-permitted operating conditions 2..9 4

(temperature, power supply)
Prewarning operating temperature 2..9 0
1) First controlled stopping process (class 2 error), then the error changes status so that it cannot reset (class 4 error), because
correcting the cause of the malfunction requires the 24V power supply to be switched off.

7.5 Table of error numbers for the SAM module
The error numbers and error texts can also be found in the file
Twinline.err in the TLCT or SAMCT installation directory.
Error Error Meaning

number class
E1500 - SAM: class 1 error forced
E1504 3 SAM: Error at Safe Stopping Process; Insufficient Break ramp (Quick Stop)
E1505 1 SAM: safe operational stop disobeyed
E1506 1 SAM: Safely Reduced Setup Speed exceeded
E1507 - SAM: safe limited increments exceeded
E1508 - SAM: safe limited absolute position exceeded
E1509 - SAM: terminal positions exceeded
E150A 2 SAM: Emergency Stop triggered
E150B 0 SAM: not ready for Fault Reset
E150C 0 SAM: not ready for SAM Disbale
E150D 3 SAM: Safe OPerational Stop in fault state disobeyed
E150E 0 SAM: Parameter is not readable
E150F 0 SAM: Parameters not writable in this state
E1510 0 SAM: Wrong password
E1511 0 SAM: timeout at parameterdownload (default values loaded)
E1512 0 SAM: Parameter not existend
E1513 0 SAM: Parameter checksum not writable in this state
E1514 0 SAM: Parameter checksum wrong (default values loaded)
E1515 0 SAM: Warning: low temperature
E1516 0 SAM: Warning: high temperature
E1517 2 SAM: 24 VDC overvoltage
E1518 4 SAM: 24 VDC undervoltage
E1519 2 SAM: short circuit at outputs of channel A to GND
E151A 4 SAM: System error: 5V supply voltage
E151B 4 SAM: System error: 5V supply voltage
E151C 2 SAM: SAM24VDC overvoltage (SW)
0098441113177, V1.02, 08.2004
E151D 2 SAM: SAMSTART: Max. admissble puls length exceeded

E151E 2 SAM: System error: RAM (cross circuit)
E151F 4 SAM: System error: stack overrun
E1520 4 SAM: System error:program sequence control Communication
E1521 4 SAM: System error:program sequence check (idle Task)
E1522 4 SAM: System error:program sequence check (MS Task)

Error code table SAM part 2
Error Error Meaning

number class
E1523 2 SAM: cross circuit at output
E1524 2 SAM: System error: input
E1525 2 SAM: System error: PROM checksum error
E1526 0 SAM: Parameter value out of range
E1527 2 SAM: Parameter block checksum error
E1528 2 SAM: System error: SPI Framing Error
E1529 2 SAM: Unequal input states
E152A 2 SAM: Cross circuit at output (unequal states)
E152B 2 SAM: Error in position aquisition (unequal values)
E152C 2 SAM: Error in speed aquisition (unequal values)
E152D 2 SAM: Error in IO current monitoring
E152E 2 SAM: System error: Error in SAM24VDC monitoring (unequal values)
E152F 2 SAM: System error: Drive Release / SAM jumper
E1530 2 SAM: System error: SAM24VDC overvoltage cut off unit
E1531 2 SAM: System error: SPI short circuit
E1532 2 SAM: System error: UART short circuit
E1533 0 SAM: EEPROM wrong chechsum (default values loaded)
E1534 0 SAM: SAM module exchanged (default values loaded)
E1535 4 SAM: System error: position aquisition (commutating position)
E1536 2 SAM: Unequal checksum of parameters
E1537 0 SAM: SAM Boot Program: illegal address
E1538 1 SAM: Safely Reduced Operating Speed exceeded
E1539 2 SAM: Input SAMSTART low instead of high (Auto Start)
E153A 2 SAM: Input SAMSTART high instead of low (Safe Start)
E153B 2 SAM: Guard confirmation: Max. admissible puls length exceeded
E153C 2 SAM: System error: Unequal states of SAM state machines
E153D 0 SAM: FAULT RESET not possible (non resetable error)
E153E 2 SAM: wrong voltage at inputs
E153F 2 SAM: Output AUX_OUT_A (cross circuit to other output)
E1540 2 SAM: Output INTERLOCK_OUT_A (cross circuit to other output)
E1541 2 SAM: Output RELAY_A (cross circuit to other output)
E1542 2 SAM: Output SAFETY24V_A (cross circuit to other output)
0098441113177, V1.02, 08.2004
E1543 2 SAM: Output AUX_OUT_A (cross circuit to 24V)

E1544 2 SAM: Output INTERLOCK_OUT_A (cross circuit to 24V)
E1545 2 SAM: Output Relay_A (cross circuit to 24V)
E1546 2 SAM: Output SAFETY24V_A (cross circuit to 24V)
E1547 2 SAM: System error: Output drive of channel A defective
E1548 2 SAM: System error: Input ESTOP_A

Error code table SAM part 3
Error Error Meaning

number class
E1549 2 SAM: System error: Input GUARD1_A
E154A 2 SAM: System error: Input SETUPENABLE_A
E154B 2 SAM: System error: Input SETUPMODE_A
E154C - SAM: System error: Input SAFETY_REF_A
E154D - SAM: System error: Input GUARD2_A
E154E 2 SAM: System error: Input INTERLOCK_IN
E154F 2 SAM: System error: Input GUARD1CONF
E1550 2 SAM: Short circuit at output of channel B to GND
E1551 4 SAM: System error: UART Overrun/Framing error
E1552 2 SAM: ResEnc (resolution of encoder) is set to 0
E1553 2 SAM: System error: CPU synchronization
E1554 2 SAM: No motor movement for 36h
E1555 2 SAM: System error: Time out high-priority tests (5 sec)
E1556 2 SAM: System error: Time out low-priority tests
E1557 2 SAM: dec_Qstop (max. admissible break ramp) is set to 0
E1558 - SAM: Output AUX_OUT_B (cross circuit to other output)
E1559 2 SAM: Output INTERLOCK_OUT (cross circuit to other output)
E155A 2 SAM: Output RELAY_B (cross circuit to other output)
E155B 2 SAM: Output SAFETY24V_B (cross circuit to other output)
E155C - SAM: Output AUX_OUT_B (cross circuit to 24V)
E155D 2 SAM: Output INTERLOCK_OUT (cross circuit to 24V)
E155E 2 SAM: Output RELAY_B (cross circuit to 24V)
E155F 2 SAM: Output SAFETY24V_B (cross circuit to 24V)
E1560 2 SAM: System error: Output drive of channel B defect
E1561 2 SAM: System error: Input ESTOP_B
E1562 2 SAM: System error: Input GUARD1_B
E1563 2 SAM: System error: Input SETUPENABLE_B
E1564 2 SAM: System error: Input SETUPMODE_B
E1565 - SAM: System error: Input SAFEFUNCIN_B
E1566 - SAM: System error: Input GUARD2_B
E1567 2 SAM: System error: Input INTERLOCK_IN_B
E1568 2 SAM: System error: Input GUARD1CONF
0098441113177, V1.02, 08.2004
E1569 2 SAM: SAM24VGND not connected

E156A 2 SAM: System error: Temperature sensor
E156B 2 SAM: Difference 24VDC - SAM24VDC to big
E156C 4 SAM: SAM24VDC Overvoltage (HW)
E156D 4 SAM: Switch off temperature (HW)
E156E 2 SAM: System error: Unequal SamOpMode
E156F 2 SAM: System error: AD converter

0098441113177, V1.02, 08.2004

SAM SAM parameters
8 SAM parameters
8.1 Overview
Parameter table The parameter table contains information required to enable programs
such as the TLCT commissioning software or the HMI handheld unit to
identify a parameter. The parameter table can also provide information
on setting options, presets and parameter properties. Note that the
parameters of the Twin Line unit and the SAM module are grouped into
functionally similar blocks, referred to as parameter groups. A
parameter table has the following features (example):

Group.Name Idx:Sidx Value rem.
Sam. 10:18 Safely reduced setup speed UNIT16 # 0...12000 0 R/W
RedSpeed. [rpm] rem.
1)
n_maxRed
where:
• Group.Name: Parameter designation made up of a combination of
the name of the parameter group (="group") and the name of that
specific parameter (="name").
• Idx:Sidx: ("Idx") and subindex (="Sidx") for identification of a
parameter, input options with the TLCT operating software in the
"Monitor" window, selection of the parameter in field bus mode.
• Explanation and unit [ ]: Detailed explanation of the parameter
and its unit
• Range of values: Includes the data type, the variable numerical
range for the parameter and the bit assignment of the parameter.
The data type is significant for operation via field bus.
• Default value: Value set by the manufacturer.
• R/W: Information on reading and writing the values
(R:= read and W:= write)
"R/-" means that values are read-only,
"R/W" means that values can be read and written
"R/W 1)" means that values can be read and written, but can only
be written with the SAMCT/SAMCLONE
• rem.: Information on whether the value is remanent; i.e. it is
retained in the memory even after the unit is switched off.
In the case of the remanent SAM parameters the user does not
need to save the data in the remanent memory before switching off
the unit.
"rem." means that values are remanent.
0098441113177, V1.02, 08.2004

SAM parameters SAM
8.2 SAM user parameters

Name Idx:Sidx Value rem.
Sam. 10:4 Incremental encoder resolution UINT32 # 0...65535 0 R/W 1)
Miscellaneous. [inc/rev] 4000: Stepper motor rem.
ResEnc 4096: Servomotor
Sam. 10.14 General modes UINT16 # 0...15 0 R/W 1)
Miscellaneous. Bit 0: Automatic start (SAMSTART) rem.
MiscModes 0: Start button evaluation Pulse
1: Automatic start: Level
Bit 1: Safety door without confirmation
(GUARD1CONF)
0: With confirmation button
1: Without confirmation button
Bit 2: reserved
Bit 3: Ignore INTERLOCK_IN
0: Safety door interlocking depends on
INTERLOCK_IN
1: Safety door interlocking is independent
of INTERLOCK_IN
Sam. 10:6 Function of the UINIT32 # 0...4294967295 0 R/W 1)
Miscellaneous. status output AUXOUT1 Bit: 0...14: Selection of status for output rem.
ModeOut1 00000001h: /ESTOP
00000002h: GUARD1
00000200h: PowerAmp
00010002h: RELAY
00010200h: Drive stopped (n=0)
(n<n_maxRed)
Bit 15: Inversion
1: Status inverted
Sam. 10:7 Function of the UINIT32 # 0...4294967295 0 R/W 1)

Miscellaneous. status output AUXOUT2 Bit: 0...14: Selection of status for output rem.
ModeOut2 00000001h: /ESTOP
00000002h: GUARD1
00000200h: PowerAmp
00010002h: RELAY
00010200h: Drive stopped (n=0)
(n<n_maxRed)
0098441113177, V1.02, 08.2004

Bit 15: Inversion
1: Status inverted
Sam. 10.18 Safely Reduced Setup Speed UINT16 # 0..0.12000 0 R/W 1)
RedSpeed. [rpm = 1/min.] rem.
n_maxRed

SAM SAM parameters

Sam. 10.19 Safely Reduced Automatic UINT16 # 0...12000 0 R/W 1)
RedSpeed. Speed 0: no speed monitoring rem.
n_maxAuto [rpm = 1/min.] in automatic mode
Sam. 10:12 Delay time for UINT16 # 0..0.500 0 R/W 1)
Deceleration. Safe Deceleration rem.
t_NCDel (PLC response time) [ms]
Sam. 10:11 Max. admissible deceleration UINT32 # 0...32786009 0 R/W 1)
Deceleration. ramp for safe deceleration 0: Function switched off rem.
dec_NC (with PLC) [rpm*s)] (immediate transition to Safe Operational
Stop or speed monitoring)
Sam. 10.16 Max. admissible deceleration UINT32 # 0...32786009 0 R/W 1)
Stopping. ramp for safe stopping process rem.
dec_Qstop (Quick-Stop)
[rpm*s)]
Sam. 10.13 Switch-off time of UINT16 # 0...10000 0 R/W
Stopping. outputs RELAY 0: immediately without delay rem. 1)
t_Relay 1: if drive stopped (n=0)
2: if drive stopped (n=0) and
INTERLOCK_IN= high
≥3: if delay time t_Relay [ms]
is expired
0098441113177, V1.02, 08.2004

SAM parameters SAM
8.3 SAM action and status parameters

Sam. 7.18 Input word 0, channel A UINT16 R/-
IW0_A
Bit 0: /ESTOP_A
Bit 1: GUARD1_A
Bit 2: reserved
Bit 3: SETUPMODE_A
Bit 4: SETUPENABLE_A
Bit 5: reserved
Bit 6: GUARD1CONF
Bit 7: reserved
Bit 8: SAMSTART
Bit 9: INTERLOCK_IN
Sam. 9.18 Input word 0, channel B UINT16 R/-
IW0_B
Bit 0: /ESTOP_B
Bit 1: GUARD1_B
Bit 2: reserved
Bit 3: SETUPMODE_B
Bit 4: SETUPENABLE_B
Bit 5: reserved
Bit 6: GUARD1CONF
Bit 7: reserved
Bit 8: SAMSTART
Bit 9: INTERLOCK_IN
Sam. 7.20 Output word 0, channel A UINT16 R/-
QW0_A
Bit 0: SAFETY24VDC_A
Bit 1: PowerAmp_A
Bit 2: RELAY_A
Bit 3: AUXOUT1
Bit 4: INTERLOCK_OUT
Sam. 9.20 Output word 0, channel B UINT16 R/-
QW0_B
Bit 0: SAFETY24VDC_B
Bit 1: PowerAmp_B
Bit 2: RELAY_B
Bit 3: AUXOUT2
Bit 4: INTERLOCK_OUT
Sam. 9.22 Status of SAM status automatic UINT16 R/-
SamState machines
Bit 0...7:
0x01: START
0x02: NOT READY TO
SWITCH_ON
0x03: SWITCH ON DISABLED
0x04: READY TO SWITCH ON
0x06: OPERATION ENABLED
0x07: QUICK_STOP
0098441113177, V1.02, 08.2004
0x08: FAULT REACTION ACTIVE

0x09: FAULT
Sam. – Position determined by SAM INT32
p_actSAM [inc at 1000 inc/rev]

SAM SAM parameters

Sam. 9:15 Revision status of SAM software UINT32 R/-
SamVer Bit 0...11: SAM software revision
Bit 12...15: SAM software version
Bit 16...27: Bootstrap revision
Bit 28...31: Bootstrap version
Example: 0x10011102:
Bootstrap V1.001 SAMSoftw.
V1.102
Sam. 9:16 Program number UINT16 R/-
SamPrgNo Program number:
Bit 4..17: 3-character program
number
Bit 0.. 3: 1-character program
variation
Example: 0x30F0:
PR783-00
Sam. 9:23 Operating mode UNIT 32 R/-
SamOpMode Bit 0...15: samOpMode:
0: Safe stop
1: Automatic mode
2: Safe Operational Stop
3: Safely Reduced Setup Speed
4: Reserved
5: Safe Stopping Process
6: Safe Deceleration
7: Safe Operational Stop after error
8: Safely Reduced Automatic Speed
Bit 16...31: samOpState

Bit 18: GUARD1 confirmed
Sam. 9:24 Diagnosis data UINT 32 R/W

Diagnosis Write:
Set return value for
read access.
1: Operating time [s]
2: Configuration time [s]
Read:
Specified read value
Sam. 9:26 Sam Disable UINT16 R/W
SamDis This can be used to suppress an error Bit 0:
response if the axis is moved 0: no action
manually in positioning controller 1: Switch SAM status from
status "4". The SAM switches off the 6 ➟3
power amplifier controller and thus
the movement monitoring.
This is only possible in status "3" and
0098441113177, V1.02, 08.2004
"4" of the positioning controller!

SAM parameters SAM
0098441113177, V1.02, 08.2004

SAM Accessories and spare parts
9 Accessories and spare parts
9.1 List of accessories
Accessory parts are:
Qty. Usage Order no.

1 TL-SAM adapter
1 SAM cable for connecting SAM module and 6204 2500 220
SAM adapter
1 Documentation for Twin Line units including 6250 1469 xxx 1)
SAM module on CD-ROM, multilingual
1 SAMCT (SAM Configuration Tool), software for 9844 1113 138
configuration of the SAM module), single
parameters can be modified.
1 SAMCLONE (SAM Clone Tool), software for 2)
configuration of the SAM module, but only with
complete data sets.
1 SAMTEST.xls, EXCEL program for planning 2)
the SAM configuration and to carry out a semi-
automatic commissioning test.
1) Cable length xxx:015=1.5 m; 030=3 m; 050=5 m; 100= 10 m
2) This software can be obtained by e-mail on request. It will only be sent to the
named safety representative.
SAM cable The SAM cable for 1:1 connection of the SAM module to the SAM
adapter is manufactured of PUR and has a SUB-D plug connector at
both ends.
Cable data • Sheath diameter: 13mm
• Wire cross section: 0.34mm2
• Shielding: none
0098441113177, V1.02, 08.2004

Accessories and spare parts SAM
9.1.1 Connector cable

Colour coding
Pin Signal Explanation Colour

1 ESTOP_A Emergency Stop control devices ws
2 GUARD1_A Safety door position switch br
3 SETUPENABLE_A Enabling device gn
4 SETUPMODE_A operating mode switch ye
5 reserved reserved gr
6 reserved reserved pk
7 INTERLOCK_IN Enable input for safety door interlock bl
logic
8 SAFETY24VDC_A Control devices power supply with rd
cross connections dedection
9 SAMSTART Start signal bk
10 SAM24VDC SAM module power supply vio
11 SAM24VGND SAM module power supply gr/pk
12 reserved reserved re/bl
13 AUXOUT1 Status output wh/gn
14 AUXOUT2 Status output br/gn
15 RELAY_A power contactor wh/ye
16 RELAY_B power contactor wh/gr
17 GUARD1CONF enabling device gr/br
18 INTERLOCK_OUT safety door interlock ye/br
19 ESTOP_B Emergency Stop control devices wh/pk
20 GUARD1_B Safety door position switch pk/br
21 SETUPENABLE_B enabling device wh/bl
22 SETUPMODE_B operating mode switch gr/gn
23 reserved reserved br/re
24 reserved reserved wh/re
25 reserved reserved wh/bk
26 SAFETY24VDC_B Control devices power supply with br/bl
cross connections dedection
0098441113177, V1.02, 08.2004

SAM Accessories and spare parts
9.2 SAM adapter
The SAM adapter can be used to distribute the input signals of a system
over up to five Twin Line units with a SAM module. The outputs for
controlling power contactors, RELAY_A and RELAY_B, are connected
from SAM modules 1 and 2 only to the adapter board, the others remain
unused.
The outputs for detecting cross connections, SAFE24VDC_A and
SAFE24VDC_B, are connected from SAM module 1 only to the adapter.
The INTERLOCK_OUT output is connected to the INTERLOCK_IN
input of the next SAM module. This sets up a daisychain for controlling
the safety door interlocking (see chapter "Safety door interlocking",
page 5-24).
Installation The SAM adapter can be mounted on all standard EN mounting rails
with foot elements. It must be installed in a an environment that meets
the requirements of protection class IP54 . During installation ensure
that an installation height of at least 100 mm measured from the
mounting plate is available to install the adapter, including the SUB-D
connector plug to the five SAM modules. In addition, there must be a
free space of approximately 10 mm on the side with the screw terminals
to allow the DIN rail feet to be unlocked with a screwdriver.
10 10 10 10 10
1 19 1 19 1 19 1 19 1 19
SAM 2
SAM 1
SAM 3
SAM 4
SAM 5
77 mm
High Density SUB-D

sockets for connection
with SAM-modules
double level terminal

21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 LEDs for
Statusdisplay
90 mm
Fig. 9.1 SAM adapter
Terminal strip Connection data for rigid cable: 0.14 to 1.5 mm2
Connection data for flexible cable: 0.14 to 1.0 mm2
0098441113177, V1.02, 08.2004
Tightening torque: 0.22 to 0.25 Nm

Screwdriver:0.4 x 2.5 mm
Plug connection Connection data: high density SUB-D socket,
26-pin
Assignment: as with SUB-D on SAM module
see chapter
"Technical Data", page 3-2

Accessories and spare parts SAM
Adapter board pin assignment
Termina Signal Connected Termina Signal Connected

l with SAM no. l with SAM no.
1 ESTOP_A 1) 1..5 21 SAFETY24VDC_A 1) 1
1) 1)
2 ESTOP_B 1..5 22 SAFETY24VDC_B 1
3 GUARD1_A 1) 1..5 23 SAFETY24VDC_A 1
1)
4 GUARD1_B 1..5 24 SAFETY24VDC_B 1
1)
5 SETUPENABLE_A 1..5 25 SAFETY24VDC_A 1
6 SETUPENABLE_B 1) 1..5 26 SAFETY24VDC_B 1
1)
7 SETUPMODE_A 1..5 27 SAFETY24VDC_A 1
1)
8 SETUPMODE_B 1..5 28 SAFETY24VDC_B 1
9 AUXOUT1 3 29 RELAY_A 1) 2
1)
10 AUXOUT2 3 30 RELAY_B 2
11 reserved 1..5 31 AUXOUT1 2
12 reserved 1..5 32 AUXOUT2 2
1)
13 GUARD1CONF 1..5 33 reserved 1..5
1) 1)
14 INTERLOCK_IN 5 34 INTERLOCK_OUT 1
1) 1)
15 SAMSTART 1..5 35 RELAY_A 1
16 reserved 1 36 RELAY_B 1) 1
17 reserved 2 37 AUXOUT1 1
18 reserved 3 38 AUXOUT2 1
19 reserved 4 39 SAM24VDC 1..5
20 reserved 5 40 SAM24VGND 1..5
1) Status display by LED, 10mA at 24VDC
0098441113177, V1.02, 08.2004

SAM Service, Maintenance and Warranty
10 Service, Maintenance and Warranty
10.1 Service address
Contact your local dealer with any questions or problems. Your dealer
will be happy to give you the name of a customer service outlet in your
area.
Maintenance The Twin Line unit requires no maintenance. Check the filter in the
switch cabinet ventilator regularly. Inspection intervals depend on the
ambient conditions on site.
Have repairs to the unit carried out only by your local dealer to ensure
that the unit continues to operate reliably.
Warranty The seal confirms that no unauthorised person has opened the unit. If
the unit is opened the warranty is void.
SAM e
in sid
0002
The number of the seal identifies the tester and is not necessarily that
shown above.
0098441113177, V1.02, 08.2004

Service, Maintenance and Warranty SAM
0098441113177, V1.02, 08.2004

SAM Index
Index
A
Acceptance test 6- 4
Action and status parameters 8-4
Adapter board
Pin assignment 9-4
Ambient conditions 2-2
Automatic mode 1-4
C
Commissioning 5-1
Safety instructions 5-1
Test 6-3
Commissioning test 6-3
Condition
Incremental encoder 1-3
Connection
Power unit 5-4
D
Danger 1-7
Danger analysis 1-8
Danger categories 2-1
Danger prevention 1-8
Diagnosis 7-1
Documentation 2-7
Duration 1-8
E
Enabling device 5-20
Error classification 7-3
F
Fault Reset 7-4
Functions 1-4, 1-6
Funktion
Safe reduced speed 5-24
G
Generating start signal 5-16
I
Incremental encoder 1- 3
Installation
0098441113177, V1.02, 08.2004
electrical 5- 2
mechanical 5- 1
Intended use 2-2
L
Literature 2-7

Index SAM
M
Minimum movement 1-6
Mode stop 1-4
Module interface
Assignments 5-2
Monitoring functions 1-6
enabling device 5-22
Simultaneous switching 1-6
Status outputs 5-26
Temperature monitoring 1-6
Test of minimum movement 1-6
Test of power supply 1-6
Multi-axis wiring 5-5, 5-6
P
Parameter 8-1
Pin assignment
Adapter board 9-4
SUB-D plug connector 3-3
Power supply 1-6
Power unit
Connection 5-4
R
Reaction times 1
Reset 7-4
Resetting fault 7-4
Risk 1-7
Classification 1-8
Risk graph 1-8
Risk management 1-7
S
Safe mode stop 1-4
Safe reduced speed 1-4, 5-24
Safe Standstill 1-4
Safe Stopping Process 1-4
Safely Reduced Automatic Speed 5-25
Safely Reduced Setup
Speed 1-4, 5-18, 5-20, 5-21, 5-22
Safety 1-7
consciousness 1-7
Safety devices
electronic 1-9
Safety functions 1-4
Safe mode stop 1-4
0098441113177, V1.02, 08.2004
Safe reduced speed 1-4, 5-24

Safety instructions 5-1
Commissioning 5-1
-2 SAM safety module

SAM Index
SAM
Ambient conditions 2-2
Commissiong test 6-3
Configuration 6-3
Diagnosis 7-1
Error classification 7-3
Installation 5-2
Monitoring functions 1-6
Parameter 8-1
Safety functions 1-4
Status objects 8-1
Technical data 3-1
Terminals 5-2
Troubleshooting 7-4
SAMCT
configuration 6-3
SAMTEST 6-4, 9-1
Scale of damage 1-8
Simultaneous switching 1-6
Single-channel wiring 5-4
Speed
reduced 1-4, 5-24
Standards 1-4
Standstill 1-4
Status objects 8-1
Switching
simultaneous 1-6
T
Technical data 3-1
Temperature monitoring 1-6
Template for the commissioning protocol 6-5
Terminals 5-3
Test
Minimum movement 1-6
Power supply 1-6
TLCT 6-1, 7-7
Staus display 7-1
Troubleshooting 7-4
W
Wiring
single-channel 5-4
0098441113177, V1.02, 08.2004

-4
Index
SAM
SAM safety module

0098441113177, V1.02, 08.2004

TL Sam v1.02 Bl-En

Uploaded by

Copyright:

Available Formats

TL Sam v1.02 Bl-En

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

TL Sam v1.02 Bl-En

Uploaded by

Copyright:

Available Formats

Technical documentation

Safety Module for

Twin Line units

Order no.: 0098441113177

SAM safety module

Product names . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .V-6

3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

5 Installation and setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

SAM safety module -1

5.3 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.4 Stopping in emergency . . . . . . . . . . . . . . . . . . . . . . . . 5-7

7 Diagnosis and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 7-1

8 SAM parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

9 Accessories and spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

10 Service, Maintenance and Warranty . . . . . . . . . . . . . . . . . . . 10-1

10.1 Service address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

-2 SAM safety module

SAM safety module V-5

Abbreviation Product designation Term used

0098441113177, V1.02, 08.2004

V-6 SAM safety module

Low/open Signal status of an input or output signal; when no signal is present,

SAM safety module V-7

0098441113177, V1.02, 08.2004

V-8 SAM safety module

Written conventions and note symbols

Passages preceded by this symbol may have to be discussed in more

SAM safety module V-9

0098441113177, V1.02, 08.2004

V-10 SAM safety module

Fig. 1.1 Function blocks

Safe monitoring of the stop position or the reduced speed makes it

SAM safety module 1-1

Fig. 1.2 External versus integrated safety engineering

0098441113177, V1.02, 08.2004

Fig. 1.3 Position of the SAM module in a Twin Line unit

1-2 SAM safety module

SAM safety module 1-3

1.2 Functional description

1.2.1 Operating modes

Stop request from the SAM module in connection with an error

1-4 SAM safety module

1.2.2 Overview of operating mode selection

Safe Stopping Process Safe Standstill

SETUPENABLE_A = 1 and or SETUPENABLE_A = 0 or

Fig. 1.4 Selecting operating modes

SAM safety module 1-5

1.2.3 Other monitoring functions

0098441113177, V1.02, 08.2004

1-6 SAM safety module

1.3 Safety in machine and system design

Risk management encompasses the entire life cycle of the technical

SAM safety module 1-7

1.3.2 Classification of risks

S Seriousness of injuries: P Possibility for avoiding the danger:

S2 severe, generally irreversible P2 hardly possible

F1 rare to frequent and/or Possible categories requiring

Measures which may be over-