SIMATIC Safety Integrated – all built in

One controller, one engineering, one communication for standard and fail-safe automation

SIMATIC Safety Integrated is the seamless integration of machine safety in the SIMATIC automation system. The system, comprising both hardware and software, offers the advantage of having the safety functions already built in, so no second, additional system is needed.   This genuine integration not only results in potential savings on hardware and engineering, but also gives you the opportunity to achieve the perfect match between safety and machine design.

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SIMATIC Safety Integrated

Integrated safety for your future automation solution

In the age of Industrie 4.0, production lines not only have to be highly flexible, they also need to be available and cost-efficient. At the same time, they must comply with the necessary safety requirements. As the demands placed on the manufacturing industry in adapting to market needs increase, so do the challenges facing machine builders.

SIMATIC Safety Integrated implements consistent safety solutions based on Totally Integrated Automation (TIA) by seamlessly integrating safety functions into standard automation systems. By putting these together with the SINAMICS drives and its integrated safety functions using PROFINET or PROFIBUS via PROFISAFE, Siemens offers maximum integration and consistency.

Learn more about the benefits of SIMATIC Safety Integrated – all built in

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Hot Topics

Overview of safety news and highlights

SIMATIC Safety Integrated lets you improve your machine safety in all kinds of applications, quickly and efficiently.
Safety portfolio

Seamless integrated safety technology for improved safety and productivity

Our end-to-end, fail-safe portfolio covers all requirements and can be flexibly scaled as required. Integrating safety into the hardware and software portfolio gives you advantages when it comes to installation, and maximum availability combined with maximum safety.
Engineering

Efficient engineering in the TIA portal

Standard technology and security technology in a single system

The option package Step 7 Safety Advanced/Basic is seamlessly integrated into the TIA Portal, and enables rapid familiarization and efficient engineering of safety functions thanks to the use of a single user interface and the opportunities for simulation.

 

Further information:

❯ STEP 7 TIA Portal brochure

Article: Making safety engineering faster (SPS Magazine) (German)

SIMATIC STEP 7

With the option package SIMATIC Step 7 Safety Advanced or SIMATIC Safety Basic , you can use all the benefits of the TIA Portal to create your safety functions too. Safety programs can be created in the programming languages LAD and FBD. PLCSIM also makes testing possible without anyhardware.

Flexibility

Use “ready-made” function blocks (e.g. emergency stop) out of the Step 7 Safety Library, or create and use your own in-house safety functions . This makes it possible to match the safety functions perfectly to the machines. 

Savings through standardization

Both programs/modules and hardware configurations can be saved in libraries and are secured using a unique CRC. This permits re-use and reduces the time and expense needed for testing. 

Testing without hardware

Programs can be tested in the TIA Portal, including the safety functions, using PLCSIM or PLCSIM Advanced with no need for hardware. This means the safety functions can be tested in advance to ensure correct implementation. 

Change management

Every module, and the entire program, is allocated a CRC that makes it possible to identify changes quickly. The overall signature can be easily displayed on the screen of the S7-1500 CPU, or via the web server, for example.

Controller

Fail-safe controllers for more flexibility

Complete scalability with integrated safety functions

The SIMATIC controller portfolio with integrated safety functions has the right controller for all your automation needs. The range of SIMATIC controllers includes Basic, Advanced, Distributed as well as Software Controllers, offering impressive scalability and functional integration. SIMATIC controllers can be flexibly expanded at any time with plug-in I/O modules, and function and communication modules. The fail-safe input and output signals can be recorded or controlled either via I/O modules or via PROFINET using PROFIsafe.

SIMATIC controllers are certified for applications in accordance with IEC 62061 to SIL 3 and EN ISO 13849-1 to PL e.

 

Further information:

Brochure: The intelligent choice for your automation tasks – SIMATIC Controllers

❯ Overview of the SIMATIC controllers 

When high performance, a wide range of technological functions, flexibility and versatile communication features are required.

The CPUs are designed to allow the required safety functions to be perfectly integrated into the overall solution. The active safety program including its CRC, can be conveniently identified via the onboard screen, and diagnostic messages can be read in clear text.

The fail-safe Basic Controllers can also take charge of monitoring safety functions like a protective door with tumbler. The connection to the fail-safe sensor and actuator technology is either local via fail-safe signal modules, or remote via PROFIsafe.

Thanks to their compact design, Distributed Controllers are particularly suitable for series machine manufacturing. The integrated safety function makes the system particularly compact, since the absence of the safety controller that would otherwise be required saves space in the control cabinet. They can be accommodated in small control boxes directly on the machine.

In networked plants, connection to a production line’s central control cabinet is realized via PROFINET.

The CPU1507S F, a software controller with Safety Integrated, enables PC-based automation solutions to run on a SIMATIC IPC with a Windows operating system. The software controller shows its particular strengths when special automation functions have to be integrated using the programming languages C or C++ or when a close connection of Windows software to the software controller is required. Because the CPU1507S F can also perform safety-related tasks, there is no need for a second system to take care of these.

I/O

SIMATIC ET 200 – the ideal I/O, even for fail-safe tasks

With SIMATIC ET 200, a wide variety of I/O systems are available for standard and fail-safe automation – for solutions in the control cabinet or without a control cabinet directly at the machine. The modular design allows you to easily scale the ET 200 systems in small steps, for example, to expand with fail-safe I/O modules. The products can be consistently integrated into the automation system using PROFINET and/or PROFIBUS via PROFIsafe. All fail-safe I/O modules are certified for use in applications in accordance with IEC 62061 up to SIL 3 and EN ISO 13849-1 up to PL e.

 

Further information:

❯ Brochure: SIMATIC ET 200 for decentralized automation tasks

❯ SIMATIC ET 200 I/O systems

SIMATIC ET 200 I/O for the control cabinet

Design

The fail-safe I/O modules can form part of a mixed operating structure with standard modules. 

They can be connected either directly alongside a CPU or remotely via PROFINET/PROFIBUS.

Diagnostics

They offer all necessary monitoring options, e.g. for short-circuits or cross-circuits and channel-discrete detailed diagnostics. 

Identified faults are normally dealt with only by passivizing the affected channel. 

Fail-safe motor starters

In addition to the fail-safe I/O modules, fail-safe motor starters can also be operated directly within the station.

New: analog recording of current measurements

The fail-safe F-AI analog module can be used to record measurements of current safely and reliably.

The modules have high channel density and low parts variance.

Set-up

The fail-safe I/O modules can form part of a mixed operating structure with standard modules. 

They can be connected either directly alongside a CPU or locally via PROFINET/PROFIBUS.

Diagnostics

They offer all necessary monitoring options, e.g. for short-circuits or crossover circuits and channel-discrete detailed diagnostics. 

Identified faults are normally dealt with only by passivizing the affected channel.

This is particularly flexible in its engineering, assembly and wiring, requiring minimal input. It is used mainly in the process industry and offers ideal integration into SIMATIC PCS 7 and other distributed control systems. As a fail-safe I/O, it allows direct installation in areas characterized by gas and dust where there is a risk of explosion.

SIMATIC ET 200 I/O without control cabinet

Set-up

The fail-safe I/O modules can form part of a mixed operating structure with standard modules.

They can be connected either directly alongside a CPU or locally via PROFINET/PROFIBUS.

Diagnostics

They offer all necessary monitoring options, e.g. for short-circuits or crossovers and channel-discrete detailed diagnostics. 

Identified faults are normally dealt with only by passivizing the affected channel. 

Fail-safe motor starters and frequency converters

In addition to the fail-safe digital I/O, the ET 200pro also offers the opportunity of incorporating fail-safe motor starters and frequency converters directly into the station.

Functional machine safety with no control box? That’s what you get with the new ET200 block I/O for processing fail-safe digital signals in a set-up that needs no control cabinet. The module contains both fail-safe inputs and outputs. Channel-discrete diagnostics can potentially enable rapid fault location and rectification.

Operation and Monitoring

Power and safety in your hands – with SIMATIC HMI Mobile Panels

SIMATIC HMI Mobile Panels with connection to PROFINET increase flexibility and convenience for the user by transferring the features and performance of the SIMATIC HMI Comfort Panels to mobile operator panels. Even complex process and plant images are displayed clearly and in detail on the brilliant widescreen display. Engineering is efficient in the TIA Portal with SIMATIC WinCC. It features an innovative style editor which allows you to easily customize the user interface for your own corporate design. 

For custom integration of HMI devices in the safety architecture, SIMATIC HMI Mobile Panels provide a built-in emergency stop button and a three-stage acknowledgment button. The connection can be wired via connection boxes, either on the control cabinet or flexibly installed in the plant.

 

Further information:

❯ Brochure: SIMATIC HMI

❯ SIMATIC Advanced HMI Panel-based

SIMATIC HMI Mobile Panels 2nd generation offer even more performance, flexibility, convenience and quality – making mobile operation and monitoring even safer and more efficient.

The F versions with emergency stop and a stop button on the top and an acknowledgment button on the back of the device allow the safety solution to be flexibly configured. The emergency stop button is active, and lights up in red, only when the device has been incorporated in a safety circuit.

Drive technology

SINAMICS converter for a fail-safe response

SINAMICS drives with integrated safety functions allow easy implementation of safety concepts in which the electromechanical components and related wiring previously needed can be omitted.

Communication via PROFIsafe ideally coordinates the way the SINAMICS drives work together with the fail-safe SIMATIC control system, as well as SINUMERIK and SIMOTION, and this is very easy to implement via the TIA Portal.

 

Further information:

Safety functions in detail

What makes SINAMICS converters special is their integrated safety functions, i.e. they need no additional modules. The safety functions can be flexibly incorporated in the overall application.

For every motion profile we provide the right components for motor movement, helping you achieve cost-effective and powerful safety designs.

Communications

PROFIsafe and ASIsafe – communicating safely

With Siemens products for industrial communication, you ensure greater efficiency throughout the company by using proven standards. Safety Integrated uses your existing network structure for safety-relevant data, which allows you to achieve enormous savings.

Using PROFINET and PROFIsafe lets you set up your safety system solutions more flexibly, enabling them to exchange data safely – and wirelessly. ASIsafe enables the direct connection of components with a safety focus, like emergency stop or position switches.

 

Further information:

Industrial communication

PROFINET – the leading industrial Ethernet standard for automation – also supports safety-related communications in the form of PROFIsafe.

In addition to the huge potential for savings in wiring, the flexibility of PROFINET/PROFIsafe means that using it provides totally new opportunities like secure wireless connections over WLAN.

This applies both to vertical communication between controllers and devices and horizontal communication between controllers.

AS-Interface (AS-i) is an effective and powerful bus system which connects all sensors and actuators on the lowest field level with the higher-level control, easily, safely and consistently.

The safety-related version of AS-Interface facilitates the transmission of standard and secure data on one and the same bus system – TÜV-certified, up to PL e / Cat. 4 or SIL 3.

Siemens Industry Online SupportFind out the many ways you can use SIMATIC Safety Integrated.

Discover sample applications

References

SIMATIC Safety Integrated in practice

Discover how SIMATIC Safety Integrated is proving itself every day in all kinds of applications around the world.
Discover more fascinating user reports on the fail-safe SIMATIC S7-1200.

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