Safety Programming in PLC Basic Program Plus – Application Example
Overview
This application example demonstrates how to structure and program safety functions using PLC Basic Program Plus on a SIMATIC S7-1500F controller integrated with SINUMERIK ONE. The focus is on creating a clear, scalable, and reusable safety programme structure that interacts seamlessly with the standard user programme.
Application Objective
The objective of this application is to illustrate a standardised approach for safety programming that ensures reliable machine shutdown, safe operation, and compliance with relevant safety standards.
Application Scope
The application covers safety programming concepts, including emergency stop evaluation, safety door control, safety-integrated drive functions, data exchange between safety and standard programs, and diagnostic messaging.
System Architecture
Controller:
– SIMATIC S7-1500F (integrated in SINUMERIK ONE)
Safety Concept:
– Separation of safety and standard programs
– Safety machine data model
– Safety interface data blocks for IO and axes
Program Structure
The safety programme is divided into independent function modules that are grouped within controller blocks. Logical data is exchanged via a centralised safety machine data model, ensuring scalability and easy maintenance.
Main Safety Functions
– Emergency stop evaluation
– Safety door monitoring and locking
– Control of Safety Integrated functions (SS1, SS2, SLS, SOS)
– Mode selection (Setup / Production)
– Test stop and brake test functions
Data Exchange Concept
Data exchange between the safety programme and the standard user programme is implemented using dedicated data blocks. This enables coordinated operation while maintaining a clear separation between safety and standard logic.
Typical Industrial Applications
– Machine tools with SINUMERIK ONE
– CNC machining centers
– Automated production machines requiring functional safety
Key Benefits
– Structured and scalable safety program design
– Improved readability and maintainability
– Easier troubleshooting and diagnostics
– Compliance with safety standards
– Reusable program modules
