Integrated safety technology
Smart Safe Reaction

Smart Safe Reaction:
Who knew safety could be
so productive?

Contents
5 good reasons to choose integrated safety from B&R06

Maximum productivity

08

Custom configurations10

Safe line integration

12

Global installations

14

Ultimate scalability

16

The perfect hardware for every safety application

18

The safe controller – SafeLOGIC

20

Break free from hardwired safety – SafeLOGIC-X 

23

Safety-rated I/O for any application – SafeIO

24

Only one cable – openSAFETY operator panel

26

Ultrafast safety technology – reACTION for safety

27

Safe drive technology – SafeMOTION

28

100% safe power transmission system – SafeENCODER

30

Kinematics under control – SafeROBOTICS 

32

Simple and safe programming – SafeDESIGNER

34

Technology functions

36

Vendor-independent integration – openSAFETY38

Standards and directives

40

3 steps to your safe machine 

42

04

Smart

Greater flexibility and lower costs
through virtual wiring

Safe

For manufacturing and process control
applications up to SIL 3 / PL e / Cat 4

Reaction
Fastest response times
for maximum safety05

Integrated safety technology

06

5 good reasons to choose
integrated safety from B&R

24/7
Maximum productivity

Global installations

Integrated safety technology

07

Custom configurations

Line integration

Ultimate scalability

Today's safety technology actively supports a machine's functionality while simultaneously safeguarding it against hazards. It adapts to changing
configurations and works reliably anywhere in theworld. No longer limited to a single machine, today's safety solutions span entire lines.

Integrated safety technology

08

Maximum productivity
24/7

To avoid the painfully high cost of stopping production, machinery needs to have availability
designed in from the start. Intelligent safety
technology plays a critical role in preventing
downtime and production outages.
Traditional hardwired safety technology responds to safety events by abruptly shutting
down the machine – often making work moredifficult for service personnel. B&R safety technology, on the other hand, allows production tocontinue at a safely reduced speed even whena safety door is open or an operator reaches
into a protected area. In most cases, a full production stop can be avoided.
Stress-free maintenance
B&R safety technology even makes things easier for service personnel in cases where acomponent needs to be replaced. Configurations and parameters are stored centrally on
the SafeLOGIC controller and distributed via thebus system using certified mechanisms. The
functionality of the safety application remains
intact at all times.
The ability to remove and reconnect fully-wired
cable terminals eliminates the error-prone taskof rewiring sensors and actuators. B&R safety
technology ensures that – even after many ye-

Integrated safety technology

ars and countless maintenance calls – a machine offers the same level of safety that it did
when it was first delivered.
Every millisecond counts
Today's drives pack enough torque to accelerate an axis to top speed in a matter of milliseconds. These highly dynamic systems are responsible for some of the most impressive feats
in industrial production – such as printing presses where the web zips along at 100 kilometers
per hour, or where 400 individual drives operatein unison with microsecond precision to stretch
plastic film. Hardwired safety technology wasn't
able to keep pace with these rapid developments in servo technology.
A machine's moving parts are only dangerous if
they come into contact with a human with acertain amount of speed or force. What can beparticularly hazardous are maximum accelerations caused by encoder slippage, motor commutation errors or faulty control parameter settings. For a safe motion control function, amillisecond can make all the difference in nipping a faulty acceleration or uncontrolled spinin the bud. Smart Safe Reaction from B&R enables safety response times in the sub-millisecond range so that machine builders can safely
enjoy the benefits of highly dynamic drives.

09

The faster the process, the faster the safety technology needs to react to faults

Fast, compact, safe, innovative
A faster response time has a dramatic effect on
the force of impact and the distance required tostop. As a result, machines can be more compact
and can run safely at higher speeds than the limits permitted by traditional speed monitors. Often,
users find themselves able to implement entirely
new processes or machine designs that givethem an edge on the market.

Your advantage< Maximum safety< Faster response times< Smaller machine footprint< New safety concepts

Integrated safety technology

10

Custom configurations

Reconfigure a line via the operator panel without affecting the safety application

The general approach taken with series-produced machinery is to equip it with a suite ofcustomization options. This approach places
special demands on the safety technology that
can't be met by traditional safety solutions.
Smart Safe Reaction from B&R makes machine
options manageable without compromising thesafety level.
The traditional series-produced machine nolonger exists. When you consider all the options they offer, each machine is one of a kind.
The same applies to the safety technology: one
version has a safety door, another doesn't. Witha conventional hardwired solution, each machine variant might as well be a one-off specialty product. Wiring, testing, certifying andmaintaining each one individually is costly andtime-consuming.

Integrated safety technology

One machine with many options
There is an easier way: SafeOPTION from B&R.
Early in the planning stage of the safety solution, designers consider the most extensively
equipped variant of the machine. This maximum
configuration is laid out in Automation Studio's
SafeDESIGNER editor, and the machine functions and safety elements are each assigned toa machine option.
This ensures that the safety solution covers
every machine that could possibly be built fromthe available options. Yet there is only a single
safety application to be tested, validated andmaintained. The options required for any given
machine can simply be enabled via the machine's user interface during commissioning. Neither SafeDESIGNER nor Automation Studio is needed to configure the machine.

11

In other cases, the machine configuration can begenerated automatically from an order system,
and all that's left to do for the technician duringcommissioning is to check and confirm it.
Safe mode selection without the switch
Another use of the SafeOPTION functions is toallow the operating mode to be set safely via
the machine's user interface. There's no longer
any need for a key-operated mode selector
switch. It is also possible to define safety para-

Current User

10:34

Service

10/12/2015

MpSafetyX
Operating mode

New setting

SafeLOGIC response

Setup

Setup is not selected

Automatic

Automatic is selected

Acknowledge

Cleaning

Cleaning is not selected

Maintenance

Maintenance is not selected

RefreshSend

Acknowledge

meters via the HMI application. This is madepossible by components and visualization objects certified for safety applications.
Any B&R panel can serve as the HMI without requiring any extra safety certification. Changes
to the operating mode are archived in a log fileand can be retraced at any time. The same applies to modified safety parameters such as limit values for pressure and temperature.
Existing access protection mechanisms suchas passwords, RFID tags and other technologies can also be used to make sure that theoperating mode is selected safely. Existing
approaches to user authorization can simply be
integrated as-is.

Your advantage

Cancel< Manage machine options with ease
< Configure without development software< Select mode safely via user interface

Integrated safety technology

12

Safe line integration

In a production line, machines from various
vendors must interact. With integrated, network-based safety technology from B&R, theentire line is able to react to safety events in acoordinated way. Safe communication is provided by the bus-independent safety standard
openSAFETY.
On the factory floor, machines from different vendors labor autonomously at their respective tasks.
Conventionally, safety events have only beenhandled locally on the machine that is directly affected. The rest of the machines on the line either
continue with production or are halted. This utter
lack of cross-machine communication has thus
far prevented the various elements of a production network from orchestrating collective reactions to safety events. In the worst case, a single
defective safety door could cripple an entire assembly line.
If sufficiently detailed information about theevent is shared safely across the line, then thevarious machines can coordinate very robust reactions. B&R safety solutions execute orchestrated safety reactions, such as reducing production
speed to avoid halting the entire line.
Common communication basis
Coordinated interaction between machines fromdifferent manufacturers using different fieldbus

Integrated safety technology

systems requires a common communication basis. As a bus-independent protocol, openSAFETY
is the only safety standard on the market that is
up to the task.
openSAFETY communication services are certified
for applications up to SIL 3 in accordance with theinternational IEC 61508 / IEC 61784-3 standards.
Integrated in the safety layer, automated parameterization and configuration services ensure shortcommissioning and changeover times without
sacrificing SIL 3 certification.
OPC UA for plantwide communication
Safety-relevant data is encapsulated in an"openSAFETY Container" and distributed
throughout the production network. openSAFETY's unique design allows the use of different
fieldbus or industrial Ethernet protocols. With
full support for the vendor-independent OPC UA
standard, openSAFETY ensures that safety solutions implemented plantwide enjoy all theadvantages of integrated safety technology
from B&R.
Profile specification for safe data exchange
Ensuring safe data exchange is only half thebattle. A machine also needs to be able to interpret data from other manufacturers. The
data specification is defined in the openSAFETY
line profile.

13

Your advantage< Safely network production lines< Less downtime – more productivity< Vendor-independent communication with
OPC UA

Complex assembly lines rely on secure data exchange

14

Global installations

Network-based safety solutions from B&R are designed to be used anywhere in the world. Integrated diagnostic functions turn any smartphone intoa highly effective troubleshooting instrument able
to perform rapid and precisely targeted remote
service. Across global markets, international certifications guarantee smooth implementation.
System Diagnostics Manager (SDM) is B&R's webbased diagnostics platform. It provides a clear
overview of the status and error data for an entire
machine. An integral component of every B&R automation system, SDM provides information about
safety components as well.
Simple and efficient maintenance
From anywhere in the world, service technicians
can retrieve data from the controller at the click ofa mouse. They have ready access to all types of
information – from the status of drives to current
speed or position values, the states of controllers
and much more. With B&R remote maintenanceproducts, this is all possible while also adhering to
the most stringent IT security guidelines.
Dual-channel evaluation and line diagnostics provide detailed information that helps troubleshootthe safety technology and identify issues such as
short circuits in the valve control signal or problems caused by safety door contact bounce. As an

Integrated safety technology

integral element of every B&R automation system,
SDM provides all of this functionality without having
to plan explicitly for every possible service case in
the machine application.
Closed-cabinet diagnostics
The advantages of SDM really come to bear in situations where – for reasons of security or to safeguard against electrical or explosion hazards – access to the control cabinet is severely restricted.
International certification
Certification by internationally recognized bodies
such as TÜV Süd, Underwriter Laboratories (UL) andGemanischer Lloyd (GL) ensures acceptance andmarket approval for B&R safety products all aroundthe world.

15Your advantage< Integrated web-based diagnostics< Ready for use worldwide< Certification from TÜV Süd, Underwriter

Laboratories (UL) and Gemanischer Lloyd (GL)Highly efficient out-of-the-box diagnostic tools streamline service calls16

Ultimate scalability

SafeLOGIC and SafeLOGIC-X controllers give B&R
safety technology the scalability it takes to create a cost-optimized solution for any application.
Hardware components and software functions
remain fully compatible, regardless of whichsafety controller is selected.
SafeLOGIC-X is a comprehensive, integrated solution for implementing programmable safety on
smaller machines. The safety application is executed on a special safe digital I/O module, reducing not only costs, but also space, power, waste
heat and cabling in the control cabinet.
Easily expandable
Should your safety requirements change overtime, you can easily upgrade your safety solution
with a safety controller from the next performance class. There's no need to adjust the safety application or module parameters – and that
includes safe motion control technology as well.

Integrated safety technology

The functionality of safe machine options andthe overall handling of the system also remainunchanged. The know-how invested in the
SafeLOGIC-X solution continues to generate returns even after switching to a SafeLOGIC controller. That is the decisive advantage of B&R's
Scalability+ solution program.
Scale without sacrificing continuity
With Scalability+, it's just as easy to downscale asafety application. High-performance machinery
is often so complex that the necessary safetyfunctions can only be handled by a powerfulsafety controller. At the same time, a simplified
version of the same machine with fewer safe
sensors and actuators might allow the use of a
SafeLOGIC-X solution. Once again, the overall design of the machine's safety solution remains
fully intact, and the applicable portions of thesafety application are implemented in the
SafeLOGIC-X without any changes.

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B&R‘s Scalability+ ensures system continuity even when switching platforms

Your advantage< Perfect hardware for every application< Reduced costs< Scale up or down without affecting system
continuity< Full range of functionality for smaller
applications

Integrated safety technology

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The perfect hardware for every
safety application

Integrated safety technology

19Innovative software functions paired with robust
hardware designed according to proven principles
of safety – that is the backbone of B&R safety
technology.

Integrated safety technology

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The safety controller
SafeLOGICAs the brains behind B&R's integrated safety
technology, the SafeLOGIC safety controller is responsible for handling all core safety-related
tasks. In addition to running the safety application, the SafeLOGIC controller is also responsible
for managing configurations and parameters.

of all the safety modules. This applies not only
to B&R products, but to all openSAFETY-enabled 3rd-party devices as well. If necessary,
the SafeKEY can simply be moved to a replacement controller and the safety application willcontinue to operate as designed.

High-performance and deterministic
With cycle times as low as 800 µs, the SafeLOGIC
series of controllers delivers the fastest safety
solutions on the market. Even highly complex applications with 100 safety modules and hundredsof signals can be implemented with cycle times
under 10 ms. The real-time POWERLINK network
enables jitter-free data exchange.

Integrated bus controller
The X20SL8101 SafeLOGIC controller features a
POWERLINK interface, integrated I/O interface anddedicated power supply. This ensures that I/Omodules from the X20 family – safety or standard– can all be used side-by-side.

Configuration and parameter management
The SafeLOGIC controller stores all safety-related data on a removable storage device – theSafeKEY. The SafeKEY holds the safety application and its remanent data, the safety-related
machine bus configuration and the parameters

Integrated safety technology

Your advantage< Replace hardware without losing data
< Cycle times < 1 ms
< Safety following network failure

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Modbus TCP/UDP
Name: Max Mustermann
Date: 13.04.2015
Time: 10:37:45
Limit Boiler 1:
Limit Boiler 2:

Name: Max Mustermann
Date: 13.04.2015
Time: 10:37:45
Setup

322

°C

Automatic

322°C

Cleaning

410°C

Maintenance

410

°C

Automation Studio
X20 SafeIO

X20 PLC

openSAFETY

Automation Studio

SafeLOGICX67 SafeIO

X20 SafeIO

X20 SafeIO

openSAFETY
3rd party device

reACTION

ACOPOSmulti SafeMOTIONACOPOS P3

ACOPOSmulti

ACOPOSmulti

ACOPOSmulti

ACOPOSmulti

ACOPOSmulti

ACOPOSmulti

ACOPOSmulti

ACOPOSmulti

ACOPOSmulti

TECHNOLOGY

SafeROBOTICS

Topology of a Smart Safe Reaction network

Full safety following network failure
B&R has set yet another benchmark in integrated safety technology with its new blackoutmode. This feature allows safety applications
to continue to run after a failure of the networkor main controller. It no longer takes an expensive redundancy solution to ensure maximum
availability of the safety application. In addition
to safe reactions such as STO (Safe Torque Off),
it is also possible to program complex sequences to be executed in the event of a network or
controller failure.

Integrated safety technology

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Integrated safety technology

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Break free from hardwired safety
SafeLOGIC-X

SafeLOGIC-X distributes tasks normally performed by a SafeLOGIC controller across existing components
Users with smaller machines are just as eager
as anyone to enjoy the benefits of integrated
safety technology. That's why B&R has developed the ultra compact SafeLOGIC-X safety controller.

fied for SIL 3 / PL e / Category 4, are implemented as two inversely coded tasks that monitor
each other. Ready-to-use service screens in
the HMI application provide an interface for operating and servicing the virtual controller.

For applications with few safe I/O points, a fullscale safety controller is overkill and frequently
cost-prohibitive. The SafeLOGIC-X is no larger
than a safe I/O module, yet offers all the functionality of a full-fledged SafeLOGIC controller.
This is made possible by distributing control
functions across automation components already used in the system.

100% upward compatible
SafeLOGIC-X and SafeLOGIC controllers are completely interoperable. Should you ever need to
expand your safety application, the existing
software can be carried over as-is to the new
hardware.

Up to SIL 3 / PL e / Cat. 4
The safety application itself runs on the
SafeLOGIC-X, while parameter handling andconfiguration management are outsourced tothe standard controller. In SafeLOGIC-X applications, these system functions, which are certi-

Your advantage< Minimized hardware< Space savings< Lower costs< Full functionality

Integrated safety technology

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Safety-rated I/O for any application
SafeIO

Every safety application poses its unique challenges. That's why it's important that I/O modules
offer a variety of channels, both in number andfunction. B&R's diverse portfolio of safety-rated
I/O has the right module for any application.

Integrated safety technology

Safety-rated digital and analog I/O modules are a
key feature of every automation system. In addition to delivering input signals and processing output commands, they also monitor connected sensors and actuators.

25

°C

100%

0%

Analog signal 4 - 20 mA

B&R offers safety-rated I/O for every application

Always the optimum solution
With its rich selection of safety-rated I/O modules, B&R offers the perfect arrangement ofchannels for any safety application. Developers
can choose between safe digital input modules
with 2, 4, 8 or 20 channels. Safe digital output
modules are available with 500 mA, 2 A or even
10 A. Other modules offer safety relays, analog inputs and safe collection of temperature andspeed data.
IP67 for harsh environments
In addition to the X20 SafeIO modules with IP20
protection for cabinet installation, B&R also offers
IP67-rated digital input and mixed modules forharsh environments. These modules are ideal
for implementing decentralized architecturesand saving space in the control cabinet. Functionally, the X67 SafeIO modules are fully compatible with their X20 counterparts.

Your advantage< The perfect module for any task
< IP20 or IP67
< Outputs with 500 mA to 10 A
< Temperature, speed and much more

Integrated safety technology

26

Only one cable
openSAFETY operator panel

openSAFETY operator panels from B&R allow safe
data exchange over the bus system. With the integrated openSAFETY interface, there is no needto wire the E-stop, mode selectors and start buttons separately. The only connections needed are
for the bus and power.
Simple cabling of swing arm systems
Setting up operator panels with numerous
hardwired switches and buttons used to mean
tediously threading cable after cable throughthe swing arm system. With an openSAFETY
operator panel, you can position the HMI exactly where it is needed without having to deal
with unwieldy cable harnesses. Commissioning and service are also simplified, saving additional money in these areas as well. The
E-stop button is just as reliable as its hardwired counterpart.

Integrated safety technology

Arrange buttons and switches as needed
These operator panels are available in a wide
range of configurations, allowing them to be tailored perfectly to any application. In addition todifferent display sizes and ratios, it is also possible to choose between various touch technologies. Just as configurable are the number andarrangement of buttons, switches and the E-stop
button. The operator panels are also available inhousings rated up to IP65. To round it off, B&R
also offers custom HMI devices tailored to theneeds of specific industries and customers.
Your advantage< Reduced cabling< Easier swing arm mounting< Faster installation

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Ultrafast safety technology with
reACTION for safety

SafeIO modules featuring reACTION technology
ensure safety response times of 100 µs – making B&R's programmable safety technology thefastest on the market. What's more, no expensive special hardware is needed to use reACTION technology, and programming is just as
easy as it is for conventional control solutions.
With reACTION technology, time-critical subprocesses are executed directly on the SafeIO
modules to save valuable response time. The
reACTION module handles a portion of the processing, relieving both the controller and the
network and in many cases allowing them tobe scaled down. In most cases, the resulting
savings more than outweigh the added cost of
the reACTION modules.

Your advantage< Response time: 100 µs< Relieves the controller< Relieves the network

Integrated safety technology

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Safe drive technology
SafeMOTION

At B&R, safe motion control functions are integrated directly in the drive system. This cuts
down on cabling and reduces response times.
Integration in the real-time POWERLINK network
allows for perfect coordination between all
safety components.
B&R drives featuring SafeMOTION offer a complete set of safety functions – in accordancewith the IEC 61800-5 safety standard – giving
you the tools to solve even the most demanding
motion control challenges. SafeMOTION functions make it extremely easy to implement the
special operating modes explicitly required byvarious safety standards, including maintenance, setup and process observation.
Fastest reaction times
Reactions to workspace intrusions are triggered
directly in the SafeMOTION module. A safe stop,for example, is initiated within 7 ms. Response
times 10 times faster than with previous solutions mean residual distance and force of impact are reduced by a factor of 100. This makes
it possible to create more compact machine
designs.
Open to 3rd-party components
Safe sin/cos interfaces support integration of
3rd-party motors. Even in cases of atypical motor dimensions or installation in problematic locations, this openness ensures that a suitablesafety solution can always be found.

Integrated safety technology

Broad spectrum of servo controllers
Every performance class of B&R's ACOPOSmulti,
ACOPOSmotor and ACOPOS P3 servo drives supports SafeMOTION. So whether you have a motor-mounted servo drive, an individual axis oreven an application with over 100 axes – youstand to benefit cost-effectively from
SafeMOTION.

Your advantage< Drive-integrated safety technology< Easy setup< Fast reactions

B&R‘s extensive selection of SafeMOTION functions can revolutionize your safety solution

29

Safe Torque Off, single channel

Safe Torque Off

STO1

STO

V

V

0

t0

t

0

t0

t

Safe Maximum Speed

Safely Limited Speed

V

SLS

V

V SLS

V SLS
0

SMS

t0

t1

t

0

t

Safe Stop 1
SS1

V

Safe Stop 2
SS2

V
STO

0

t0

SOS

t1

t

0

t0

t1

t

Safe Operating Stop

Safe Direction

V

V

SOS

S

SDI

0

0

t

t

Safely Limited Increment

Safely Limited Position

S
S max
S min

SLI

S
SLP

0

t

0

Safely Limited Torque

Safely Limited Acceleration
a

T

SLT

SLA

a SLA
acc

T SLT
0

t

0

a SLA
dec

t

t

Integrated safety technology

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Integrated safety technology

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100% safe power transmission system
SafeENCODER
You can't provide a safety function for a drive unless you have reliable information about its speed
and position. Traditionally, this has meant using asecurely mounted encoder. With SafeENCODER,
however, B&R has opened up some exciting alternatives.
SafeENCODER without slip-proof mounting
In many applications, encoder slippage can bedetected by test routines on the drive system.
Available with certified EnDat 2.2 encoders, all of
B&R's standard servo motors support this function as long as active position control is used.
SafeENCODER with slip-proof mounting
For applications involving induction motors or
without position control, B&R offers motors withslip-proof encoder mounting to rule out potential errors. All together, Smart Safe Reaction from
B&R establishes a seamlessly certified chain of
products – from the safety controller to the output shaft.
One cable is enoughA motor traditionally requires two cables – onefor the motor and one for the encoder. Eliminating one of these cables not only results in reduced cable costs, but also less time and effort
when it comes to commissioning and maintenance. As the name suggests, a hybrid motor
cable solution allows the power supply, encoder
data and digital safety information to be transferred between the servo drive and motor using
just a single cable. This reduces both component and commissioning costs, while also eliminating potential sources of error.

Integrated safety technology

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Kinematics under control
SafeROBOTICS
The robot safety cage is out of place in the modern
production hall. If robots are to work harmlessly
hand-in-hand with humans, their movements
must be safety-monitored. That is precisely what's
possible with B&R's SafeROBOTICS library.
To safeguard humans from hazardous situations, the kinematic chain moving the robot
arm must be safety-monitored. It's not enoughto simply monitor individual axes. The only way
to do it is with the combination of safe positionand speed data for all axes in the kinematic
chain.
Fully integrated
The SafeROBOTICS library is integrated in the
B&R Automation Studio engineering environment, where its functions are configured using
the SafeDESIGNER editor. SafeROBOTICS is basedon a generic model, so it's also possible tomonitor axes that deviate from the classic robot kinematic structures, such as robots
mounted on a moving platform. Another possible use is for safe monitoring of the tool mounting point on a CNC machine.
Array of functions
Paired with the impressive processing powerof the SafeLOGIC controller, this comprehensive drive-integrated safety functionality
makes it possible to craft sophisticated andhighly effective safety solutions. Wherever robots and operators work hand-in-hand, for instance, it is possible to limit the speed at thetool center point, robot joints and at the tool

Integrated safety technology

SLS

Safely Limited Speed

@TCP

SLO
@TCP

Safely Limited Orientation

SLPj

SLP

Safely Limited Joint Position

Safely Limited Position#2#1

endpoints. The safety function responsible forthis is called Safely Limited Speed at the Tool
Center Point, or simply SLS@TCP.
Wherever laser or water jet cutters are involved, controlling their aim is a primary safetyconcern. A function that safely limits the orientation of the tool center point can effectively safeguard against the dangers of an errant
jet or beam. It is also possible to define safe
workspaces into which the robot is not permitted to intrude.

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Integrated safety technology

34

Simple and safe programming
SafeDESIGNER

The process of programming a safety application needs to be both easy and reliable. That's
why, in Automation Studio's SafeDESIGNER editor, there's not much programming to do at all.
With certified function blocks and a visual editor, developers do more virtual wiring than code
writing, while at the same time enjoying a muchbroader range of functions than would ever bepossible with a hardwired solution.
The Automation Studio development platform
provides tools for every aspect of industrial automation – from controllers and drives to communication and HMI. SafeDESIGNER is a license-free feature of Automation Studio that
perfectly rounds off its spectrum of advanced
safety technology.
Virtual wiring replaces written code
Users create safety applications by simply dragging and dropping certified function blocks fromthe PLCopen library into the visual editor and wiring them virtually with a few clicks of the mouse.

Integrated safety technology

The signal lines are color-coded, with orange indicating safety-related signals and black representing all other types.
SafeDESIGNER differentiates between the following data types: BOOL, INT, DINT, WORD, DWORD and
TIME, as well as SafeBOOL, SafeINT, SafeDINT,
SafeWORD, SafeDWORD and SafeTIME. This prevents unintentional use of variables with conflicting data types.
Visual project comparison
A key feature of SafeDESIGNER is the ability tocompare projects visually. This helps developers quickly identify changes that have been

35
made to the safety application. They can analyze differences between machine generations
or check which device parameters and time values have been modified.
This function allows the user to compare theproject currently open in Automation Studiowith another version of the same project. It isalso frequently used to check the current project against the version on the machine's safetycontroller.

Importing C code
For more complex solutions, there is the C programming extension, which encapsulates C code
into a function block that can be imported into
SafeDESIGNER. This feature is helpful in situations
where you want to execute existing C code on a
B&R safety controller or when you have mathematical algorithms with floating point calculations (Float, Double data types).

Your advantage< Easy to use< Visual editor< No added costs< Visual project comparison< Visual project comparison< Import C code

Integrated safety technology

36Technology functions

For countless applications, B&R offers ready-touse function packages and libraries that help users create their safety application more quickly
and easily.
Safe PLCopen function blocks
The certified function blocks in B&R's PLCopen library provide a solid functional foundation for any
safety application. Tasks such as two-hand controls, E-stop buttons with restart inhibit, mode
selectors, dead man's switches and various typesof muting can all be solved using these 18 certified, standardized function blocks.
Supplemental libraries offer functions for safe
motion control, safe robotics, safe remanentdata, safe data type conversion and much more.
Together, the certified blocks and vast array offunctions make Automation Studio the ideal tool
for any safety application – whether it's a simple
safeguard for a small machine or an elaborate
solution for an entire steel mill.
Safe storage of remanent data
B&R allows you to store user data securely on aremovable storage device – the SafeKEY. AfterYour advantage< Fast and easy application development< No key switches< Safe storage of user data

Integrated safety technology

startup, the safety controller checks that thedata from the SafeKEY is correct before once
again making it available in the application. Application-specific calibration and limit values can be
stored here securely.

Select the same operating mode via the HMI
application
The certified components provided by mapp
SafeOPTION make it possible to implement safe
operating mode selection and safe parameter
input screens in the machine's HMI application.
There is no longer any need for a key-operated
mode selector switch. Any B&R panel can serveas the HMI without requiring any extra safety
certification.
Function blocks for press applications
With its library for press applications, B&R is oneof the first manufacturers to offer a complete
set of the function blocks specified in PLCopen
Part 4. As a result, users working with safety-critical press applications will have a mucheasier time setting up the necessary safetyfunctions. Tasks like controlling hydraulic valves
or monitoring different press cycle modes areconveniently encapsulated in these ready-touse function blocks.

37

Whether new machine or retrofit – the press functions in SafeDESIGNER meet the latest safety standards

38

Vendor-independent integration
openSAFETYIntelligent light curtains are capable of far more than just presence sensing

The open source safety protocol openSAFETY
enables optimal integration of 3rd-party products. With openSAFETY profiles, they can beincorporated into an automation solution justas easily as a B&R product.
B&R offers considerable savings in safety applications through network-integrated lightcurtains. Light curtains equipped with an
openSAFETY interface eliminate the hardwiring
required for conventional solutions. The first to
bring a network-integrated light curtain to market was Datalogic.

Integrated safety technology

Single-beam evaluation
An additional advantage of openSAFETY light curtains is the ability to evaluate each beam individually. This makes it possible to implement intelligent muting, for example, doing away with thesensors that were necessary for previous muting
solutions.
Easy configuration and diagnostics
With a B&R solution using openSAFETY light curtains, safety functions such as muting and blanking are easily programmed in the Automation
Studio development environment. The amount of39

Safe absolute position and safe speed in one compact device
work needed for commissioning is reduced considerably – especially for series-produced equipment. Diagnostics have also been simplified, withinformation available in plain text instead of having to be decrypted from blinking LEDs.
Lower costs for safe drives
The CD75M safety rotary encoder from
TR-Electronic is a perfect example of how safe
drives can respond to external movements atvery high speed more easily and cost-efficiently
than ever before. This encoder delivers safe position and speed values in openSAFETY format
and can be directly connected to POWERLINK
networks. It is available with SIL 3 / PL e certification and doesn't require external safety modules or any of their associated programming.
The result? Safe monitoring of movement axes
without time-consuming hardware setup.
Safety through cross-checking
The CD75M is able to determine safe values for
position and speed by cross-checking redundant pairs of scanning sensors and processors.
These values are then output via the openSAFETY protocol. During configuration, parameterssuch as the differential and standstill windows,
direction of rotation or integration time are set
up directly over the safe configuration channels of openSAFETY.
Safety-related data in the form of openSAFETY
packages can be transferred via the same me-dium as the process data using the "black
channel" principle. The openSAFETY rotary encoder from TR-Electronic reduces overall complexity as well as hardware and wiring costs. In
addition, innovative features such as automatic configuration of the direction of rotation
or differential and standstill windows can beloaded over the network. The rotary encoderfrom TR-Electronic also provides preset electronic adjustment, which allows the current
position value to be applied as the new actual
value.
Innovative safety concept
The use of a single communication mediummeans that it couldn't be easier for the user toaccess and implement every bit of safe andnon-safe data in the application. This not only
greatly simplifies and maximizes diagnostics
with the CD75M, it also allows the use of innovative functions without requiring extra work.
The rotary encoder from TR-Electronic featuring
openSAFETY integration truly opens up entirely
new safety concepts.

Your advantage< Less hardware< Shorter commissioning times< Easy maintenance< No wiring errors

Integrated safety technology

40Standards and directives
International regulations provide a foundation
for uniform product standards and are essential
to the widespread acceptance of safety-related
components.
Within the European market, cross-border commerce is facilitated by EU directives and harmonized standards. Of these, the definitive regulatory
framework for machine manufacturers is Machinery Directive 2006/42/EC. The most significant
harmonized standards for compliance with themachinery directive are ISO 13849-1 and IEC 62061.
Compliance with these standards and the machinery directive supports machine manufacturers
when issuing declarations of conformity. The procedure for evaluating conformity requires an analysis of potential dangers followed by a risk assessment. The safety level required for the safetyfunction can be determined using the risk graphs
provided in the various standards.

As internationally recognized standards, ISO
13849-1 and IEC 62061 provide the basis forworldwide use of safety systems and components designed in accordance with their requirements. Supplemental national regulations
may apply, and these must be evaluated andapplied on a case-by-case basis. Fundamentally, however, the two safety standards provide
an internationally uniform framework for the requirements to be met by safety technology inmachine manufacturing.
All safety technology products from B&R meetthe requirements of both ISO 13849-1 and IEC
62061. The products' conformity with applicablestandards is always certified by the following
independent testing organizations:<< TÜV Süd<< UL (Underwriter Laboratories)

Performance level
per ISO 13849-1 (PL)Probability of a dangerous
failure per hour (1/h)

Safety integrity level
per IEC 62061 (SIL)a≥ 10-5 to < 10-4-b

≥ 3x10-6 to < 10-5

SIL 1

c

≥ 10-6 to < 3x10-6

SIL 1

d

≥ 10-7 to < 10-6

SIL 2

e

≥ 10-8 to < 10-7

SIL 3

Integrated safety technology

41

Safety definitions

CCF
Common cause failure

Failures of different items resulting from a single event, where thesefailures are not consequences of each otherDC
Diagnostic coverage

Measure for the effectiveness of diagnostics, which can be determined
as a ratio between the failure rate of the observed dangerous failures
and the failure rate of total dangerous failures

FVL
Full variability language

Type of programming language that provides the capability of implementing a wide variety of functions

LVL
Limited variability language

Type of programming language that provides the capability of combining predefined, application-specific library functions to implement the
specified safety requirements

Category

Classification of the safety-related parts of a control system according
to their resistance against malfunction and their subsequent behavior in
the event of a malfunction

MTTFd
Mean time to dangerous failure

PFHD
Probability of dangerous failure perhour

PL
Performance level

PLr
Required performance level

SIL
Safety integrity level

Expected average time before a dangerous failure occurs

Average probability of a dangerous failure per hour

Discrete level that specifies the ability of safety-related parts of a control system to perform a safety function under foreseeable conditions

Performance level (PL) applied in order to achieve the required risk
reduction for each safety function

One of four discrete levels used to specify the safety integrity of thesafety functions assigned to the E/E/PE safety-related system, whereby
4 is the highest level and 1 the lowest

Integrated safety technology

3

4

5

5

> 2 weeks to ≤ 1 year

> 1 day to ≤ 2 weeks> 1 hour to ≤ 1 day≤ 1 hour2

3

4

Reversible:
Professional medical treatment required

Irreversible:
Broken limb, loss of one or more fingers

Irreversible:
Death, loss of an eye or limb

1) Other measures

1

Severity (S)Very highProbable

Possible

Rare

Negligible

Probability ofoccurrence (P)Reversible: First aid required

Effects2> 1 year

Frequency and duration of exposure (F)IEC 62061

SIL 2(o.m.)1

5-7

SIL 2

SIL 1

(o.m.) 1

8-10

Class (C)Impossible

Rare

Probable

SIL 3

SIL 2

SIL 1

SIL 3

SIL 3

SIL 2

SIL 1

(o.m.)

14-15

1

5

3

1

11-13

Source: ÖVE/ÖNORM EN 62061:2005

SIL 2

3-4

5

4

3

2

1

Possibility to circumvent or
limit the damage

S2

S1

F2

F1

F2

F1

P2

P2
P1

P2
P1

P2
P1

P1

e

d

c

b

a

PLr

High risk

Low risk

Source: DIN EN ISO 13849-1:2007

ISO 13849-1

Key1
Starting point for assessing the impact on risk reduction
PLr Required performance level
Risk parameters
Sx Severity of injury
Fx Frequency and/or duration of the exposure to the hazard
Px Possibility to circumvent the danger or limit the damage

1

Risk analysis

3 steps to your safe machineopenSAFETY

X67 and X20 Safe I/O
SafeMOTION

SIL 2

SIL 1

Not permitted

60% to < 90%

< 60%

SIL 2

SIL 3

SIL 3

SIL 3

Source: ÖVE/ÖNORM EN 62061:2005

SIL 1

SIL 2

SIL 3

SIL 3

SIL 3

≥99%

Hardware fault tolerance

Share of safety-­
related outages

90% to < 99%≥ 10-8 to < 10-7

3

2

≥ 10-7 to < 10-6

2

1

≥ 10-6 to < 10-5

10

Probability of dangerous failure per hour (PFHD)

IEC 62061
PL

e

d

c

b

a

B
t.
Ca one
n
g
av
DC

1
t.
Ca one
n
g
av
DC

2
t.
Ca low
g
v
a
DC

DC

av

g

2
t.
Ca iumed
m

ISO 13849-1

Calculating the PL / SIL achieved

SafeDESIGNER

Safety integrity level

SafeLOGIC3t.
Ca low
g
v
a
DC

av

g

1
2
3

DC

av

g

4
t.
Ca high

Source: DIN EN ISO 13849-1:2007

DC

3
t.
Ca iumedm

SafeENCODER

Easy to implement with B&R safety technology

B&R Corporate Headquarters
Bernecker + Rainer
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