Overview
Overview
Safety PLC Controller is a TÜV-certified, redundant-CPU safety controller engineered to bring a machine or process to a safe state within milliseconds of an emergency. It implements SIL 3 per IEC 61508 and PL e / Category 4 per ISO 13849-1 across emergency stops, light curtains, safety mats, two-hand controls, interlocks, and safe motion functions — without compromising production uptime.
Built for plants that have to comply with ISO 13849, IEC 62061, OSHA 1910.212, and the EU Machinery Directive. Replaces the spaghetti of safety relays and force-guided contactors with a single programmable safety logic platform that is auditable, expandable, and TÜV pre-certified for fast machine sign-off.
- SIL 3 / PL e / Cat 4 — redundant CPU, 2oo2D diagnostic voting, 100 % DC
- < 15 ms reaction time — trigger to safe output OFF within one safety scan
- Certified function blocks — E-stop, muting, EDM, 2-hand, STO/SS1, light curtain
- SOE log @ 1 ms — sequence-of-events for forensic incident analysis
How It Works
Two CPUs run the same safety program in lock-step. Each safety input is read on two independent channels (A and B); the CPUs compare every cycle and only assert a safe output when both agree. Any disagreement triggers a deterministic safe state within milliseconds. The whole chain is proof-tested automatically at intervals you configure and reported in the audit trail.
- Dual-channel input — every safety device wired with two redundant channels
- 2oo2D voting — both CPUs must agree; divergence → safe state
- Certified logic — only TÜV-pre-certified function blocks may be used in safety paths
- Safe outputs (OSSDs) — pulse-tested two-channel outputs to contactors / drives
- SOE journal — 1 ms time-stamped record of every transition, signed and immutable
Features
- Redundant CPU lockstep — two CPUs, two power rails, two safety I/O channels
- Certified block library — ESTOP, Muting, EDM, Two-Hand, Reset, STO, SS1, SLS, SOS
- Black-channel comms — PROFIsafe / CIP Safety / openSAFETY over standard Ethernet
- Mixed safety + standard — one controller handles both safety and machine logic, isolated
- Auto proof testing — 80 µs pulse tests every cycle on every channel, full DC 99 %
- 1 ms SOE log — the only way to defend an incident root-cause investigation
- SISTEMA library — export PFH/PFD per safety function for documentation pack
- IEC 62443 cyber — signed firmware, role-based access, security log feed to SIEM
Use Cases
- Machine guarding — presses, robots, CNC, packaging machines with E-stop + interlock guard
- Robot cells — light curtain muting, safe-speed monitoring, collaborative-mode switching
- Burner management — SIL 2/3 burner safety per NFPA 85 / EN 12952
- Bulk handling & mining — pull-cord, belt-rip, gravity-trip, conveyor interlocks
- Pharma / process — LO/TO, ATEX zone interlocks, high-integrity pressure-protection
- AGV / mobile robots — bumper, scanner, e-stop integrated through safe fieldbus
Specifications
- Safety integrity: SIL 3 (IEC 61508), PL e / Cat 4 (ISO 13849-1), SIL CL 3 (IEC 62061)
- Architecture: Two CPUs in lockstep, 2oo2D voting, HFT = 1, SFF > 99 %
- Reaction time: < 15 ms input-to-OSSD typical, configurable down to 4 ms
- Capacity: 256 safety I/O on-board, 1,000+ via safety remote I/O
- Reliability: PFD 3.2×10⁻⁵ / hr typical, MTBF 380 yr, proof test 1 yr
- Comms: PROFIsafe, CIP Safety, openSAFETY, FSoE over Profinet / EIP / EtherCAT
- Environment: −25 to +60 °C, IP20, conformal coat option, 5 g vibration
- Certifications: TÜV Süd / Rheinland, CE, UL, EAC, IEC 62443-4-1 / 4-2 cyber
Product information
| Product name | Safety PLC & Controller |
|---|---|
| Category | Factory Automation |
| Type | Hardware |
| Procurement | Contact / Negotiable |
Customisation options
- Safety integrity level — SIL 2 / PL d (cost-optimised) or SIL 3 / PL e (machinery directive max)
- I/O capacity — 32, 64, 128, or 256 on-board safety I/O; expand to 1,000+ via safe remote nodes
- Safe fieldbus — PROFIsafe, CIP Safety, openSAFETY, FSoE; pick to match your existing PLC platform
- Reaction time — standard 15 ms, fast 8 ms, or ultra-fast 4 ms for press/robot applications
- Block library pack — basic (E-stop, Reset, EDM), motion (STO, SS1, SLS, SOS, SBC), or burner-management (NFPA 85)
- Cyber hardening — standard, IEC 62443-4-2 SL-2, or SL-3 with full SIEM integration
- Conformal coating — standard, conformal-coat for marine/offshore, or ATEX Zone 2 enclosed
- Documentation pack — SISTEMA report, risk assessment template, validation checklist, TÜV certificate
Ordering & lead time
Standard lead time depends on current stock. For volume orders, please contact our team for a structured quote including BOQ, freight, installation and warranty terms.
Support
Engineering support, installation guidance and warranty claims are handled by our customer success team. Reach us at support@sgtsystems.com or via the channels listed on our Contact page.