liteServer Rough.mini Compact and Robust Scene Illumination Device
“
Specifications
- Power Supply of the Luminaire: 24VDC
- Power Supply: Direct current
- Maximum Power Consumption: 20W
- Housing Material: Stainless steel (AISI 316/L
– 1.4404)
Product Information
Electrical Parameters
The luminaire operates on a power supply of 24VDC with a maximum
power consumption of 20W.
Other Technical Data
The housing material is made of stainless steel (AISI 316/L –
1.4404).
Illustration of the Model Key
Explanation of the model key components:
- Product name and module specification
- Housing combination (stainless steel 1.4404) with diameter
details - Power supply details (24VDC)
- COB-LED white with color temperature of 5000K
- SAMCON Production type details
- Terminal block termination and electrical connection
details
Connection Cable
- Outer Diameter: Mention outer diameter
here - Conductor Design: Details about conductor
design - Bending Radius: Details about bending
radius - Temperature Range: Temperature range of the
cable - Outer Sheath/Characteristics: Characteristics
of the outer sheath
Technical Specification of the Illuminant / LED
Illumination
- LED Type: COB-LED (InGaN), single phosphor
dot, non-matrix arranged, divergent, non-focusing - Power Consumption: 16W
- Max. Power Consumption: 20W @ 24VDC
- Rated Current: 460mA
- Color Temperature: 5000K cold white
- Luminous Flux Max.: 2490lm
- Beam Angle: Mention beam angle details
here
Product Usage Instructions
Operating the liteServer via External Triggers (PCS /
I/Os)
Instructions on how to operate the liteServer using external
triggers like PCS or I/Os.
Operating the liteServer via Internal Triggers
(mag.ON-technology)
Detailed steps on operating the liteServer using internal
triggers such as mag.ON-technology.
Tests Prior to Switching on Voltage
List of tests that need to be performed before switching on the
voltage.
Exchanging the Illuminant / LED-Block
Guidelines on how to exchange the illuminant or LED-block in the
device.
Frequently Asked Questions (FAQ)
Q: What is the maximum power consumption of the luminaire?
A: The maximum power consumption of the luminaire is 20W at
24VDC.
Q: What is the housing material of the product?
A: The housing material is stainless steel (AISI 316/L –
1.4404).
“`
liteServer® Rough.mini
User Manual
Content
1 Introduction ……………………………………………………………………………………………….. 4 2 Technical Data ……………………………………………………………………………………………. 4
2.1 Electrical parameters……………………………………………………………………………….4 2.2 Other technical data ……………………………………………………………………………….. 4 2.3 Illustration of the model key………………………………………………………………………5 2.4 Connection cable……………………………………………………………………………………. 6 2.5 Technical specification of the illuminant / LED illumination …………………………… 6 3 Safety Instructions ……………………………………………………………………………………… 7 4 Installation …………………………………………………………………………………………………. 8 5 Electrical connection ………………………………………………………………………………… 10 5.1 Potential equalization ……………………………………………………………………………. 11 5.2 Connection and protection …………………………………………………………………….. 12 5.3 Use cases and their wiring …………………………………………………………………….. 14
5.3.1 Operating the liteServer via external triggers (PCS / I/Os)……………………………………………… 16 5.3.2 Operating the liteServer via internal triggers (mag.ON-technology)…………………………………. 16
5.4 Tests prior to switching on voltage ………………………………………………………….. 17 6 Exchanging the illuminant / LED-block ………………………………………………………. 18
6.1 Work preparation…………………………………………………………………………………..18 6.2 Opening the housing …………………………………………………………………………….. 19 6.3 Replacing the LED block ……………………………………………………………………….. 20 6.4 Closing of the housing……………………………………………………………………………21 7 Maintenance / Servicing / Alterations …………………………………………………………. 22 8 Repairs and Maintenance ………………………………………………………………………….. 22 9 Disposal / Recycling …………………………………………………………………………………. 22 10 Drawings, 3D models and further documentation ……………………………………. 22 11 Notes …………………………………………………………………………………………………….. 23
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Table of Figures
Table 2.1 Model key …………………………………………………………………………………………. 5 Table 4.1 Mounting accessory…………………………………………………………………………….9 Figure 5.1 PE connection liteServer® Rough.mini ……………………………………………….. 11 Table 5.1 Potential equalization…………………………………………………………………………11 Figure 5.2 liteServer® Rough.mini T21-VA1.2.K1.BOR-LL.N xxx.2-K…………………….12 Figure 5.3 liteServer® Rough.mini T21-VA1.2.K1.BOR-LL.N xxx.2-T ……………………. 12 Table 5.2 Electrical connection LED module ………………………………………………………. 13 Figure 5.4 liteServer® Rough.mini terminal box termination ………………………………….. 13 Table 5.3 Supply protection LED module …………………………………………………………… 14 Table 5.4 Use cases and assocciated wiring……………………………………………………….15 Figure 5.5 Magnetic control mag.ON commands ………………………………………………… 16 Figure 5.6 Magnetic control mag.ON Video…………………………………………………………16 Figure 6.1 Removal of the LED block ………………………………………………………………… 20 Figure 6.2 Installation of the new LED block………………………………………………………..20
Revision history
Product: Title: Doc. -Id. Author: Date: Latest update:
liteServer® Rough.mini User manual liteServer® Rough.mini 250701-PT21BA-SHe-liteServer-Rough.mini_en_rev.00.docx Sabine Heinz July 1st, 2025 July 1st, 2025
Rev.- Index Date
0
01.07.2025
Name S.Heinz
Remarks Compilation of the document, based on liteServer Ex.mini
Authorization of the Supervisor
Digital unterschrieben von Alexander Kruse
Alexander Kruse DN: cn=Alexander Kruse, o, ou, email=a.kruse@samcon.eu, c=DE Datum: 2025.08.14 11:40:41 +02’00’
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1 Introduction
The liteServer® Rough.mini is a compact and robust scene illumination device (type T20) which is manufactured by SAMCON Prozessleittechnik GmbH. The liteServer® Rough.mini is based on efficient and durable LED technology in circuit board construction (COB). The emitted radiation includes visible white light in color spectrum of color temperatures (5000K). The luminaire can be used flexibly for a wide variety of industrial applications. It is suitable either for area illumination purposes, but also for selective illumination for short and medium object distances in plant and process monitoring. The device is therefore perfectly suited to complement and support camera systems in dimly lit areas. The liteServer® Rough.mini can be switched via I/Os and directly on site via a magnet (mag.ON technology).
2 Technical Data
2.1 Electrical parameters
Power supply of the luminaire: Power supply: Maximum power consumption:
24 VDC ± 5% 20 W @ 24 VDC
2.2 Other technical data Housing material:
Stainless steel (AISI 316/L – 1.4404)
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2.3 Illustration of the model key
1) Product name
liteServer® Rough.mini.
2)
3)
Power LED
24.
WL
24.
WL
4) Beam angle
100 100
5) Type
T21T21-
6) Housing combination
VA1.2.K1.BORVA1.2.K1.BOR-
7) Temp. range
8) Cable
9) Termination
LL.NLL.N-
xxx.2- K xxx.2- T
Table 2.1 Model key
Explanations:
1)
liteServer® Rough.mini =
Functional description of the liteServer® Series (technical data /
specification of the individual module)
liteServer® Rough.mini =
Housing combination (stainless steel 1.4404) with diameter
ØVA1=79mm
2)
24. =
Power supply 24VDC
WL =
COB-LED white, color temperature 5000K
3)
100 =
Beam angle 100°
4)
T21 =
SAMCON Production type 21
5)
VA1.2.K1.BOR =
VA1.2.K1.BOR=
VA1.2.K1.BOR=
VA1.2.K1.BOR=
Housing (stainless steel 1.4404) with diameter ØVA1=79mm T11 VA0.x housing with medium body length (LVA1.2.R = 158mm) K1 cable gland flange (axial cable gland, standard) Borosilicate sight glass DIN7080 standard execution
7)
LL.N
Temperature range (-50°C to +50°C)
8)
xxx.2 =
xxx.2 =
Length of the connection line in meter at delivery. The standard cable length is 5 m, minimum / maximum cable length is: 001…100 [m] Cable type 2; Ölflex Heat 125MC 4×0,75
9)
K =
T =
Terminal block termination Electrical connection of the illuminant 24VDC (see chapter electrical connection) Terminal box termination (optional) Connection of luminaire (see electrical connection)
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2.4 Connection cable
ÖLFLEX HEAT 125 MC
Electron beam cross-linked cables for increased application requirements; connecting cable
Outer diameter: Conductor design: Bending radius: Temperature range: Outer sheath/characteristics:
7.4mm 4×0.75mm2 (ø=1.4mm), fine-wired tinned Custrands acc. IEC 60228 or VDE 295 15 x outer diameter at installation 4 x outer diameter after installation -35°C … +120°C (at point of installation) -55°C … +125°C (fixed installed) Electron beam cross-linked, based on polyolefin copolymer, black, halogen free, flame resistant (EN 60332-1-2), UV and oil resistant
2.5 Technical specification of the illuminant / LED illumination
A cold white high-power COB LED with a nominal power of 16.0 W is used in this device as a radiation source for visible light.
The COB LED is characterized by the following technical properties:
LED Type:
COB-LED (InGaN), single phosphor dot, non-matrix ar-
ranged, divergent, non-focusing
Power consumption:
16W
Max. power consumption:
20W@24VDC
Rated current:
460mA
Color temperature:
5000K cold white
Luminous flux max.:
2490lm
Beam angle:
100°
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3 Safety Instructions
It is absolutely mandatory to adhere to the national safety regulations and regulations for prevention of accidents, as well as to the safety instructions given below in this User Manual!
Attention! Only original parts from SAMCON Prozessleittechnik GmbH may be used for repair. Repair works affecting the explosion protection may only be carried out in accordance with the regulations applicable in the country of use and only by SAMCON Prozessleittechnik GmbH. Attention! Prior to installation, please consider external sources of heat or cold! The permissible temperature range must absolutely be observed! Attention! The sight glass must not be directly covered by foreign objects. The light must be able to leave the optics of the protective housing unhindered. Regular cleaning intervals of the sight glass should be observed in order to avoid adhesion and dust deposits. Risk of burns from hot surfaces (80°C)! Do not stare into the direct beam. Danger of impairment of vision due to high exposure to light!
Prior to the first use, you should test the luminaire corresponding to the instructions given in the chapter Commissioning. Please observe the national safety regulations and regulations for prevention of accidents, as well as to the safety instructions given below in this User Manual!
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4 Installation
For the liteServer® Rough.mini’s installation and operation, the relevant national regulations, as well as the generally accepted rules of technology shall prevail. Before mounting the liteServer®, thoroughly check it for any transportation damages, especially at the housing and cable. Installation, electrical connection, and the first commissioning must only be carried out by qualified personnel. Work preparation:
Attention! Prepare your work carefully and in accordance with the relevant regulations.
To ensure the best scene lighting plan the installation site carefully (consider light conditions, object distance or size, angle and minimum object distance to the focus).
· Use appropriate tools and aids. · When working, ensure a safe stand. · Make sure that any static charge is avoided. Install the liteServer® Rough.mini at the desired location. Mounting options and conditions, accessories, as well as safety guidelines are described in the installation manual of the T21 liteServer® Series.
Attention! Prior to the luminaire installation, take external sources of heat or cold into account! Observe the permissible temperature range! Drawings for drill hole patterns and further information can be viewed on our product page: Quicklink: https://www.samcon.eu/en/products/liteserver-rough/liteserver-roughmini/
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Optional mounting accessories Wall bracket WMB-…
Pole adapter PMB-…
Hinge attachment SCH-…
WALL MOUNT BRACKET WMB-VA0.x/VA1.x Wall bracket for devices of zhe T21-VA0.xSeries Suitable for hanging luminaires on walls. Material: Stainless steel 1.4404 Weight: 0.68 kg Dimensions: 80 x 100 x 205 mm
POLE MOUNT BRACKET PMB- VA0.x/VA1.x Pole adapter for VA wall mount Material: Stainless steel 1.4404 Suitable for pole diameters between 50 and 105 mm Load bearing capacity: 45 kg Dimensions:120 x 180 (x 130 at pole Ø 60 mm)
Hinge attachment SCH-VAx.x Hinge attachment for easy mounting on round sight glasses acc. to DIN 28120/28121 or similar for VA Material: Stainless steel AISI 316L/1.4404 Weight: 0.04 kg Dimensions WxHxD [mm]: 29.2x40x73.1
Table 4.1 Mounting accessory
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5 Electrical connection
Attention! The electrical connection of the equipment must be executed by qualified personnel only! Attention! It is mandatory that the housing of the liteServer® Series has to be grounded via a PE-connection! Attention! If possible, carry out initial commissioning when the outside temperature is above 0°C to prevent condensation inside the housing. The liteServer® Rough.micro is manufactured with a cable pigtail reflecting the desired cable length. Any electro-technical or mechanical work inside the enclosure which is done by the user is prohibited and not required. The ending of the liteServer’s cable connection is furnished with a terminal block termination.
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5.1 Potential equalization
Gland: ADE 1F2 Type 4 – M20x1.5 (Capri)
Ölflex HT125
Figure 5.1 PE connection liteServer® Rough.mini
The potential equalization (earthing of the housing) is mandatory in order to avoid electrostatic charging and hence spark generation. The screw terminal on the housing’s rear side is intended for this purpose (q.v. figure 5.1). The profile of the potential equalization has to reflect the national grounding instructions (min. 4 mm2).
Connection table:
Potential
Color (IEC 60757)
PE
GN/YE
Profile 4 mm2 (fix)
Comment Screw terminal: Slotted screw M4 x 0.7 (DIN 84) with washer Ø 9 mm (DIN 125A). 3Nm tightening torque has to be observed!
Table 5.1 Potential equalization
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5.2 Connection and protection
Power supply of the luminaire: Power supply: Maximum power consumption: Short circuit protection
24 VDC ± 5% 20W @ 24VDC
Figures 5.2 and 5.3 illustrate the cable termination for the liteServer Rough.mini.
GND
Figure 5.2 liteServer® Rough.mini T21-VA1.2.K1.BOR-LL.N xxx.2-K
Figure 5.3 liteServer® Rough.mini T21-VA1.2.K1.BOR-LL.N xxx.2-T
Via the black cable the illuminant is supplied with voltage. Attention! No reverse polarity protection! It is essential to ensure the correct polarity when making the electrical connection!
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Attention! The supply line must have a sufficient cross-section. The cable protection must comply with national and international regulations.
Attention! Use only terminals approved by SAMCON.
The power supply has to be done via the black (BK) as well as the blue (BU) connection strand. Connection table:
Potential DC+ DC GNDTrigger 1 Trigger 2
Color (IEC 60757) BK BU BN GY
Potential level +24 V DC 0 V DC / GND
Profile
Remarks
0.75 mm² AWG22, fine stranded wire
0.75 mm² AWG22, fine stranded wire
0.75 mm² AWG22, fine stranded wire
0.75 mm² AWG22, fine stranded wire
Table 5.2 Electrical connection LED module
Figure 5.4 liteServer® Rough.mini terminal box termination
The dimensioning of the equipment or the supply protection depends on: – The cable length – The national regulations
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The following safety recommendations may serve as a basis:
Supplied
Length sys- Recommended Comments
power
tem cable protection
24 V DC
< 100 m
800 mA – mT
In case the transmission range exceeds
100 m and it is intended to supply the luminaire with
24 V DC, please make sure to use an adjustable
power supply in order to compensate voltage drops
Table 5.3 Supply protection LED module
The release current of the protection has to be less than the maximum short-circuit current of the power supply (switch-mode power supply)!
5.3 Use cases and their wiring
The liteServer Rough.mini can be switched in the following different ways:
Use case 1
Continous operation
Switching the light on and off when the operating voltage is switched on and off.
Wiring
2 Switching via
AXIS VAPIX output module
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3 Switching via a process control system (PCS)
4 On-site magnetic
circuit Switching via the internal trigger
(I-Trigger) Magnetic switch
5 Control via PLC and magnetic circuit I/O of camera/(PLS) and magnetic switch control
Table 5.4 Use cases and assocciated wiring
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5.3.1 Operating the liteServer via external triggers (PCS / I/Os) The liteServer Rough.mini can be controlled via a process control system or via I/Os (e.g., the output module of a camera). This allows the light to be switched on, for example, via a camera’s motion detection or via individual controls starting at a certain brightness level. 5.3.2 Operating the liteServer via internal triggers (mag.ON-technology) The on-site circuit with magnet works according to the following commands.
Figure 5.5 Magnetic control mag.ON commands
The magnet must be held to the magnet-sensitive area for the desired duty cycle. Watch our video: ,,SAMCON – magON Magnetsteuerung für Ex-Leuchten” http://go.samcon.eu/magOn
Figure 5.6 Magnetic control mag.ON Video
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5.4 Tests prior to switching on voltage Attention! Prior to commissioning, all tests as indicated by the national regulations have to be executed. In addition, it is mandatory that the proper functioning of the operating device in accordance with this user manual and all other applicable regulation has been executed. Attention! Incorrect installation and operation of the liteServer may lead to a loss of warranty! Attention! If possible, carry out initial commissioning when the outside temperature is above 0°C to prevent condensation inside the housing.
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6 Exchanging the illuminant / LED-block
The illuminant should only be exchanged if it is defect. It must be replaced by an original spare part of the same model. In this special case it is allowed and necessary to open the housing. All required steps are described in this user manual; the descriptions stated in the T21 liteServer® Series installation manual have to be observed! 6.1 Work preparation
Attention! Please carry out any pre-operational work carefully and in accordance with the applicable regulations. · Use appropriate tools · Make sure you have a secure foothold · Avoid static charge
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6.2 Opening the housing
Opening the housing is only allowed to replace a defect LED. Afterwards, the housing has to be closed again! The steps below have to be followed very carefully:
Attention: For opening the liteServer®’s stainless steel housing T11 VA1.2.K1.BOR, it is mandatory to follow the step-by-step instructions as stated in the T21 Ex installation manual! Loosen the six M4 cylinder-head hexagon screws (DIN 912/ ISO 4762) together with their spring rings (DIN 127A) on the rear side of the cable and power supply flange. Caution: do not touch the screw threads with your skin or clothes! On the threads, there is LOCTITE® 243TM (chemical basis is dimethacrylate ester) applied to prevent the bolted connection from unintentional loosening because of impacts and vibrations. Carefully pull out the cable and supply flange to the rear, as straight as possible. Because of negative pressure, it may be difficult to remove the flange. The cylindrical clearance fit (H8f7 – DIN ISO 286) of the housing body and flange may not be tilted! Caution: do not touch the cylindrical fit surface with your skin or clothes! On the surface, there is oil lubricating paste to protect the surface against fretting corrosion and mechanical stresses. When you open the housing, pay attention that you do not damage the GYLON® flat seal (blue, RAL5012) and do not make it dirty! The flat gasket is loosely attached to the cable and power supply flange. It is fixed only by the bolted connections! Pull out the luminaire carefully and pay attention not to clamp the cables.
Attention! Beware not to damage the surface of bore hole and shaft (fit) at the gap preventing the transmission of ignition.
Attention! Please make sure not to damage housing sealings and to keep them clean.
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6.3 Replacing the LED block To replace the LED-block the 5 grub screws on the side must be carefully loosened. The LED block is plugged in and can easily be removed after loosening the grub screws. Seperate it at the plug contacts.
Figure 6.1 Removal of the LED block
Insert the plug of the new LED replacement block into the connection socket of the housing flange. Make sure that the plug contacts and contact surface of the aluminium heat sink are clean and undamaged. After successfully replacing the LED block, the grub screws must be tightened again. Only use new, original grub screws. Tightening torque is 1.2 Nm! Loctite 243 may be used for screw locking.
Figure 6.2 Installation of the new LED block
When touching electrical components, potential equalization (grounding of the body) has to be observed (ESD clothing, PE wristband etc.)! When closing the housing, the cable routing has to be observed! In order to avoid collisions and mechanical strain within the closed housing as well as to observe the necessary bending radius, the cable has to be looped.
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6.4 Closing of the housing Attention: For closing the stainless steel T11 VA1.2.K1.BOR housing of the liteServer® Rough.mini, the instructions of the T21 installation manual have to be followed step by step! For closing the housing, proceed in reverse order as when opening. Use exclusively original screws included in the supply. Check whether the threaded holes are undamaged and clean. Before closing, it is also absolutely imperative to check the gap (circular cylindrical fit).
ATTENTION: In case of any mechanical damages that happened to the flameproof joint, the housing must not be used anymore!
ATTENTION! Do not lock-in any foreign objects in the housing
Dismantled screw locks (spring washers DIN 127A) must be used again. The GYLON® gasket must be used in undamaged condition, according to the flange hole pattern, and placed between the flange and the hull. The lateral position of the flat surface / contact surface is arbitrary. If, when closing the housing, you see that the surface of the fitting gap is dirty or insufficiently lubricated, clean it with a clean cloth and de-grease it with a suitable cleaning agent. Then re-grease it with lubricant suitable for this specific application (e.g., Molykote® P-40 gel for standard applications or special grease OKS 403 in the event of heavy seawater influence). The screwed connections of flange and body components must always be tightened crosswise to a torque of 3 Nm! Do not tighten the screw too strongly! It can cause rupture of the cylinder head or over-stretching the threads, and thus to impairment of the pressure resistance or ignition protection class. The screws must be provided with a little LOCTITE 243.
Cylinder head screws used for connection of the housing body with the flanges, always have to be tightened evenly and crosswise with a tightening torque of 3 Nm
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7 Maintenance / Servicing / Alterations
The national regulations concerning the maintenance and servicing of electrical devices are to be observed. The required maintenance intervals are specific to the individual devices. The operating company has to determine these intervals depending on the application parameters. During maintenance, focus has to be put on checking parts concerning the ignition protection category such as the integrity of the housing, the sealings and the cable glands. If maintenance measures are necessary they have to be initiated and/or executed.
8 Repairs and Maintenance
Repairs must only be carried out with original parts of SAMCON Prozessleittechnik GmbH. Damaged housings have to be replaced completely. If in doubt, return the applicable part to SAMCON Prozessleittechnik GmbH. Repairs must only be carried out by SAMCON Prozessleittechnik GmbH or a qualified electrical technician authorized by SAMCON Prozessleittechnik GmbH in accordance with nationally applied regulations. Rebuilding of or alterations to the devices are not permitted.
9 Disposal / Recycling
When disposing of the device, nationally applicable regulations must be observed. This document is subject to alterations and additions.
10 Drawings, 3D models and further documentation
Drawings, 3D models and more you can find in the download: https://www.samcon.eu/en/products/lightserver-rough/liteserver-roughmini/
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11 Notes
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Schillerstrasse 17, 35102 Lohra-Altenvers www.samcon.eu, info@samcon.eu fon: +49 6426 9231-0, fax: – 31
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