SIMATIC Fail-safe Controllers
Controllers with integrated safety functions - flexible and completely scalable
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.
Safety Evaluation with TIA Selection Tool
You can have it both:
Configure and order your I/O systems with the TIA Selection Tool and use the same tool for your safety evaluation.
Safety Evaluation with TIA Selection Tool makes it even faster and more convenient to draw up proofs of safety in accordance with IEC 62061 and ISO 13849-1.
Seamlessly 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.Controller solution for basic and stand alone automation tasks with safety related functions
The fail-safe SIMATIC S7-1200 Controllers are based on the S7-1200 standard CPUs and offer additional safety-related functions.
The portfolio comprises 3 CPUs with safety functionality offering two different variants each. They can be used for safety-oriented tasks according to IEC 61508 up to SIL 3 and ISO 13849-1 up to PL e.
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.
Safety-related programs are created in the TIA Portal. The STEP 7 Safety engineering tool offers commands, operations and blocks for safety-related programs in the LAD and FBD languages. To this end, there is a library with pre-configured, TÜV-approved blocks for safety-related functions.
SIMATIC S7-1200 - CPU 1212 FC
Entry-level device in the class of fail-safe basic controllers
- 2 different variants available
- 100 KB work memory / 2 MB Load memory
- 4 fast counters with max. 100 kHz
- With 8 DI /6 DQ and 2 AI integrated
- Expandable by:
- 1 signal board (SB)
- 2 standard or fail-safe signal modules (SM)
- 3 communication modules (CM)
SIMATIC S7-1200 - CPU 1214 FC
More memory and more expansion possibilities
in comparison to CPU 1212 FC
- 2 different variants available
- 125 KB work memory / 4 MB Load memory
- 6 fast counters with max. 100 kHz
- With 14 DI /10 DQ and 2 AI integrated
- Expandable by:
- 1 signal board (SB)
- 8 standard or fail-safe signal modules (SM)
- 3 communication modules (CM)
SIMATIC S7-1200 - CPU 1215 FC
More memory, an additional Ethernet port and analog outputs
in comparison to CPU 1214 FC
- 2 different variants available
- 150 KB work memory / 4 MB Load memory
- 6 fast counters with max. 100 kHz
- 2 Industrial Ethernet ports with integrated switch
- With 14 DI /10 DQ and 2 AI/2AQ integrated
- Expandable by:
- 1 signal board (SB)
- 8 standard or fail-safe signal modules (SM)
- 3 communication modules (CM)
Fail-safe digitale module SM 1226
The fail-safe signal modules for digital inputs and outputs (DI and DQ) correspond to the standard modules with respect to their size. Their functional safety is certified according to EN 61508.
They are designed for safety-related use up to SIL 3 according to EN 62061 and PL e according to ISO 13849.
Three modules are available:
A DI module offering 16 digital inputs, a DQ module with 4 digital outputs 2 A each and another DQ with 2 relay outputs, 2 x 5A, 30VDC/250V AC.
Controller solution for demanding applications with fail-safe and standard functionality
SIMATIC S7-1500 controllers are designed for use in all areas of production automation. They demonstrate their special strengths in applications for medium and high-end machines, when high performance, a wide range of technological functions, flexibility and versatile communication features are required. All failsafe S7-1500 controllers provide safety functions and allow easy connection of
PROFIsafe devices via PROFIBUS and PROFINET. The process signals (including safe signals) can be recorded either centrally via signal modules or remotely via PROFINET.
The benefits at a glance
- Onboard status display:
Diagnostic messages available without a programming device (PG) - Modular, scalable station configuration:
Requirement-based expansion with fail-safe SIMATIC S7-1500 / ET 200MP modules - Maximum protection against manipulation:
Additional password protection for the fail-safe program
SIMATIC S7-1500 F CPUs
The S7-1500 controller portfolio comprises 6 CPUs with safety functionality.
The fail-safe versions have a larger memory for standard and fail-safe applications and fail-safe communication via PROFIsafe with PROFINET/PROFIBUS, and guarantee functional safety to SIL 3 in accordance with IEC 62061 and PL e in accordance with ISO 13849.
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.
SIMATIC S7-1500 Fail-safe Technology CPUs
Technology CPUs are scalable in performance, memory and quantity structure. They come with an extended scope of motion control functionality (gear and cam disk synchronism, kinematics with up to four interpolating axes), larger memory for standard, motion control and fail-safe applications as well as future-proof communication with OPC UA and PROFINET.
Fail-safe digital input and output modules SM 526
The fail-safe S7-1500 /ET 200MP I/O modules allow the processing of safety related as well as standard programs. Their functional safety is certified in accordance with IEC 61508 (2nd Edition). They are designed for safety-related use up to SIL 3 according to IEC 62061 and PL e according to ISO 13849.
SIMATIC ET 200SP and ET 200pro Fail-safe CPUs
Controller solution for series machines with limited space and machines with distributed architecture offering safety functions.
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.
Fail-safe CPUs - CPU 1510SP F-1 PN and CPU 1512SP F-1 PN
The fail-safe ET 200SP CPUs enable standard and safety program processing. They are certified to EN 61508 (2nd Edition) for Functional Safety and are suitable for use in safety-related applications up to SIL 3 according to IEC 62061 and PL e according to ISO 13849.
The 151xSP F CPUs can be expanded with ET 200SP standard and fail-safe modules as well as decentrally via PROFINET / PROFIsafe with any ET 200 systems.
For IT security, additional password protection has been set up for F configuration and F program. The CPUs can be used as a PROFINET IO controller or as distributed intelligence (PROFINET I-Device) in discrete manufacturing technology. The integrated PROFINET IO IRT interface is designed as a 3-port switch so that a line structure can be established in the plant via ports 1 and 2 and also a PG / PC or HMI device can be connected via port 3.
Fail-safe CPUs - CPU 1513pro F-2 PN and CPU 1516pro F-2 PN
The fail-safe CPUs are the right choice for safety related applications that also contain distributed automation structures alongside central I/O and require protection level IP 65/67.
They can be used as a PROFINET IO Controller or as distributed intelligence (PROFINET I-Device). The integrated PROFINET IO IRT interface is designed as a 3-port switch so that a linear topology can be set up in the system.
The additional integrated PROFINET IO RT interface with separate IP address can be used, for example, for network separation to operate additional PROFINET IO devices.
In addition, the fail-safe CPUs offers comprehensive control functionalities as well as the ability to connect drives via standardized PLC-open blocks.
The ET 200pro system can be used for controlling autonomous technological functional units, e.g.:
- Conveyor systems, switches
- Lifting stations
- Positioning tasks
- Workstations in the powertrain segment of the automotive industry
The fail-safe CPU's potential applications are therefore extended manufacturing cells with preprocessing, whereby stand-alone operation is also an option. Cabinet-free installations are possible due to the high IP67 degree of protection.
PC-based distributed controller solution for fail-safe applications.
The SIMATIC ET 200SP Open Controller with fail-safe functionality is a PC-based controller in the design of the ET 200SP I/O system. Here, the pre-installed S7-1500 software controller is used as fail-safe version with Safety Integrated. The integrated safety function makes the system very compact and saves space in the control cabinet because the additional safety controller that is usually required is not necessary here. Its compact design and modular expansion option make this controller particularly well suited for series production of machinery.
The ET 200SP Open Controller is also available as a fail-safe Technology CPU using the S7-1500 T/F Software Controller.
Open Controller solution for standard automation tasks with safety-related functions
The fail-safe ET 200SP Open Controller is supplied with a pre-installed fail-safe S7-1500 Software Controller (F-CPU) or as a complete system with software controller and HMI software. The operating system is Windows 10 IoT Enterprise 64 bit.
Open Controller solution for Motion Control tasks with safety-related functions
Traditional motion control functions, such as absolute gearing and camming, are joined by kinematics control with up to four interpolating axes as required, for example, for pick-and-place tasks. The system offers predefined kinematics, such as cartesian portals, roller pickers, SCARA robots, and delta pickers. A free transformation interface allows seamless integration into the user’s kinematics.
Users parameterize the kinematics with a graphically supported and intuitively operable configuration editor, and program the movements in space in the usual SIMATIC STEP 7 programming environment via standardized function modules in accordance with PLCopen.
The fail-safe ET 200SP Open Controller is supplied with a pre-installed fail-safe S7-1500 Software Controller (TF-CPU) or as a complete system with software controller and HMI software. The operating system is Windows 10 IoT Enterprise 64 bit.
The Software Controller with Safety Integrated for machines that benefit from the advantages of a PC-based solution
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.
Failsafe Software Controller
SIMATIC S7-1500 software controllers as failsafe CPU implement PC-based automation tasks also for safety-oriented control tasks on SIMATIC IPC. The S7-1500 software controller shows its strength, especially when you want to integrate high-level languages into the automation function or when a direct connection to operating-system-based software is required.
- Integrated Motion Control functionalities for controlling speed-controlled and positioning axes, support for external encoders, cams/cam tracks, and measuring inputs
- Integrated web server for diagnostics and user-defined websites
- Integrated Ethernet, Profinet and Profibus interfaces
- Integrated OPC UA server for standardized communication paths
- SIMATIC ODK 1500S for the development and integration of control functions and function libraries with the high-level languages C, C++, C# or Visual Basic
- No additional safety controller is required with failsafe SIMATIC software controllers; in addition, ready-to-use libraries are available for fail-safe functions
The CPU 1508S F is optimized for PC-based fail-safe control tasks with larger quantity strucures on the IPC627D and IPC827D Box PCs and the IPC677D Panel PC. The CPU 1508S also supports the IPC427E and IPC477E Microbox PCs.
Licensing
Sophisticated fail-safe motion and drive control
The SIMATIC Drive Controller combines what demanding machine concepts need: Motion Control functions of the fail-safe technology CPUs with the versatile SINAMICS S120 drive system – all in one compact controller.
Integrating the fail-safe Technology CPU and the SINAMICS control unit (CU) within the chassis of a SINAMICS CU saves a lot of space in the control cabinet. The strengths of the SIMATIC Drive Controller combined with the SINAMICS S120 multi-axis system come to the fore in systems with three, four, or more axes. The package also includes integrated safety functions, so no separate safety CPU is needed. Like all other SIMATIC products, the engineering takes place in the TIA Portal, saving time on parameterization, which is completed easily in a single environment. The many interfaces and the new “cross-PLC synchronous operation” enable the efficient creation of modular machine designs.
Contact
The direct way to your SIMATIC Safety Integrated contact
You have questions concerning our SIMATIC Safety Integrated systems? You want to discuss your specific challenges with us or are looking for the right project partner? Contact our regional offices – we are looking forward to hearing from you!
