Beckhoff provides a dedicated SISTEMA library to simplify the process of evaluating safety-related control systems. This tool bridges the gap between Beckhoff's TwinSAFE hardware and the industry-standard SISTEMA software, ensuring that machine builders can easily verify compliance with international safety standards like ISO 13849-1. What is the SISTEMA Software?
SISTEMA (Safety Integrity Software Tool for the Evaluation of Machine Applications) is a free utility developed by the Institute for Occupational Safety and Health of the German Social Accident Insurance (IFA). It helps developers and testers calculate the Performance Level (PL) of safety functions. By automating the mathematical complexity of ISO 13849-1, it reduces the risk of manual calculation errors. The Role of the Beckhoff SISTEMA Library
The Beckhoff SISTEMA library is a structured data file (typically in .slb or .xml format) containing all relevant safety parameters for Beckhoff TwinSAFE components. Instead of manually entering technical data for every digital input, logic terminal, or drive, users can import this library directly into the SISTEMA software. Key data points included in the library: MTTFd (Mean Time to Dangerous Failure) B10d values for electromechanical components DC (Diagnostic Coverage) PFHd (Probability of dangerous Failure per Hour) Key Benefits for Engineers
Using the official Beckhoff library offers several advantages during the design and certification phases of a project:
Time Efficiency: You can drag and drop components into your safety project rather than hunting through data sheets for specific safety values.
Accuracy: Because the data comes directly from Beckhoff, you are guaranteed to use the most current, manufacturer-verified safety values.
Standardized Documentation: The reports generated by SISTEMA using Beckhoff data are widely accepted by regulatory bodies and safety auditors.
Comprehensive Coverage: The library includes data for the entire TwinSAFE ecosystem, from EL series EtherCAT Terminals to integrated safety in AX5000 servo drives. How to Use the Beckhoff SISTEMA Library
The workflow for integrating Beckhoff components into your safety evaluation is straightforward:
Download the Library: Visit the Beckhoff website and navigate to the "Documentation" or "Download" section to find the latest SISTEMA library file.
Import to SISTEMA: Open the SISTEMA software, go to the "Libraries" menu, and select "Import." Point the software to the downloaded Beckhoff file.
Build the Safety Function: In your SISTEMA project, create a new Safety Function (SF). You can then pull Beckhoff components from the library into the "Subsystems" or "Elements" tabs. beckhoff sistema library
Calculate PL: The software will automatically pull the PFHd or MTTFd values and calculate the total Performance Level achieved by your hardware chain. Bridging TwinSAFE and ISO 13849-1
Beckhoff’s TwinSAFE technology is designed for modularity. Since safety logic is processed in the EL6910 or similar logic terminals, the architecture often involves multiple distributed components. The SISTEMA library allows you to model these complex relationships—such as a light curtain connected to an EL1904 input terminal which then triggers an STO (Safe Torque Off) on a drive—with high precision.
💡 Ensure you always download the most recent version of the library, as Beckhoff frequently updates their safety data to reflect new product releases and hardware revisions.
If you tell me which specific TwinSAFE components you are using, I can help you identify the specific safety parameters or architecture categories you'll need to configure in SISTEMA.
Beckhoff SISTEMA Library is a specialized data collection that simplifies the safety evaluation of automated systems using Beckhoff components. It allows engineers to import predefined safety parameters directly into the SISTEMA software
(Safety Integrity Software Tool for the Evaluation of Machine Applications), which is developed by the Institute for Occupational Safety and Health (IFA). 🛠️ Core Purpose
The library eliminates the need for manual data entry of complex safety values. It provides the mathematical proof required to comply with ISO 13849-1
, ensuring that a machine's safety functions meet the necessary Performance Level (PL) Key Benefits
Prevents manual entry errors for MTTFd, B10d, and DC values. Efficiency: Accelerates the documentation process for CE marking. Compliance:
Provides manufacturer-certified data for TwinSAFE and standard components.
Regularly maintained to include the latest Beckhoff hardware. 📦 What’s Included? Beckhoff provides a dedicated SISTEMA library to simplify
The library contains safety-related characteristic values for a wide range of Beckhoff hardware: TwinSAFE Logic:
Parameters for EL6910, KL6904, and other safety controllers. Digital I/O: Safety values for EL1904 (inputs) and EL2904 (outputs). Drive Technology: Data for AX5000 and AX8000 series with integrated safety. Electromechanical Components: B10d values for contactors and sensors where applicable. 🚀 How to Use It Obtain the latest file from the Beckhoff website (usually under "Download" > "Software" > "TwinSAFE"). Open SISTEMA and go to
Use the search function within SISTEMA to find specific Beckhoff part numbers (e.g., "EL1904"). Drag & Drop:
Pull the component into your project's safety function block. SISTEMA will automatically calculate the achieved
based on the library data and your architecture (Category 1-4). ⚠️ Important Considerations Mission Time:
Most values are based on a 20-year mission time; ensure your machine's maintenance cycle aligns. Version Control:
Always check if you are using the latest version of the library, as safety data can be updated based on new field testing. System Boundaries:
The Beckhoff SISTEMA Library is a digital data collection provided by Beckhoff to support machine safety evaluations using the SISTEMA (Safety Integrity Software Tool for the Evaluation of Machine Applications) utility. Purpose and Functionality
Safety Evaluation: The library is used to model and evaluate safety functions under the DIN EN ISO 13849-1 standard.
Reliability Data: It contains product-specific reliability values—such as MTTFdcap M cap T cap T cap F sub d (Mean Time To Dangerous Failure), B10dcap B 10 d
, and diagnostic coverage—required to calculate the achieved Performance Level (PL) of a safety function. Key Components and Features
Workflow Integration: Engineers import these manufacturer-provided libraries directly into the SISTEMA software to avoid manual data entry and ensure accurate safety calculations for TwinSAFE components. Access and Resources
Download: The library files (typically in .slb or .xml format) are hosted on the Beckhoff Download Server under the TwinSAFE documentation section.
TwinSAFE Context: While the SISTEMA library is used for offline calculation, the actual safety logic is developed within the TwinCAT environment using certified safety function blocks.
Support: Detailed technical information and manuals for Beckhoff products, including safety components, can be found in the Beckhoff Information System (Infosys). download/document/automation/twinsafe/SISTEMA - Beckhoff
To understand the magic of the Beckhoff implementation, we first have to look at the source. SISTEMA (Safety Integrity Software Tool for Evaluation and Machine Application) is a software tool developed by the IFA (Institute for Occupational Safety and Health) in Germany. It is the global gold standard for calculating the safety performance of machinery. It answers the critical question: “Is this safety system reliable enough to prevent injury?”
However, out of the box, SISTEMA is a standalone database. You manually look up components, enter data, and generate a report. It is disconnected from the actual code running the machine.
Let’s walk through a simple example: a tank filling process with an inlet valve, a drain valve, and a level sensor.
Without Sistema (CASE statement):
CASE iStep OF
0: // Idle
bInlet := FALSE; bDrain := FALSE;
IF bStart THEN iStep := 10; END_IF
10: // Fill
bInlet := TRUE;
tonFill(IN:= (bLevelHigh), PT:= T#5S);
IF tonFill.Q THEN iStep := 20; END_IF
// ... and so on for mixing, draining, etc.
END_CASE
With Sistema:
FB_StepChain instance.stIdle, stFill, stMix, stDrain.trStart, trFull, trMixed, trEmpty.stFill.Action(): bInlet := TRUE;.trFull.Condition(): RETURN bLevelHigh OR stFill.tTimer.Q;The result is modular, self-documenting code. If you need to insert a "Heat" step between Fill and Mix, you simply add a new step and adjust transitions. You don't risk breaking the CASE logic's index order.