Safety PLC & Controller | Products

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