Beckhoff Sistema Library Page

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.

The Beckhoff Sistema Library is more than just a convenience—it is a strategic asset for modern automation engineers. By embedding ISO 13849-1 calculations directly into TwinCAT 3, it:

Whether you are building a small packaging machine or a multi-axis CNC machining center, integrating Tc3_Sistema into your PLC project ensures that your safety calculations are as agile and reliable as your control logic.

Next Steps:

In the era of Industry 4.0, safety should not be a static sticker—it should be a living calculation. With the Beckhoff Sistema Library, it finally is.

This article was written for control systems engineers, safety professionals, and automation integrators seeking to master TwinCAT 3 functional safety. For specific applications, consult a certified functional safety engineer and refer to the latest Beckhoff documentation and IFA guidelines.

The library implements the standard formula for Performance Level:

[ PL = \textFunction of ( \textCategory, \textMTTFd, \textDC, \textCCF ) ]

Where:

The FB_Sistema_Channel function block handles these parameters.

Before writing a single line of code, draw your machine states (using FB_StateMachine) and your sequence steps (using FB_StepChain). This forces rigorous thinking about transitions, especially error paths. beckhoff sistema library

Abstract Beckhoff’s System Library (System Manager, TwinCAT libraries and System Functions) provides a comprehensive suite of software components and runtime services for industrial automation based on the PC-based control paradigm. This paper describes the architecture and key components of the Beckhoff System Library, explains how its major modules fit into control, motion, and I/O systems, presents deployment and integration best practices, and provides practical examples, performance considerations, and migration guidance for engineers adopting or optimizing Beckhoff-based automation solutions.

  • Integration model: TwinCAT function blocks and high-level APIs expose System Library functionality into PLC (IEC 61131-3) programs, TwinCAT C/C++, and .NET.
  • Module lifecycle: device detection via ESI/ESD/AMS/ADS; automatic mapping of PDOs/GSD/DTDs; consistent device naming/data access through System Library descriptors.
  • Parameterization: Use device configuration editors, ESI files or GSD files for device-specific parameters; persist configuration in the project for reproducible deployments.
  • Build & deploy: Build PLC/NC projects, activate configuration to target runtime; System Library resolves device mappings at activation.
  • Commissioning: Use System Manager and TwinCAT tools for network health, distributed clock sync verification, and motion tuning.
  • Example B: Machine retrofit
  • Example C: Redundant controller for critical process
  • Device mapping:
  • Performance:
  • Diagnostics:
  • Safety:
  • Third-party devices:

    • Appendix A — Quick Reference: Common TwinCAT/System Library Objects

    Appendix B — Example PLC Pseudocode Snippet (Structured Text)

    VAR
  Axis1 : AXIS_REF;
  MoveFB: FB_MoveAbsolute;
END_VAR
MoveFB.Axis := Axis1;
MoveFB.Position := 1000;
MoveFB.Velocity := 200;
MoveFB.Execute := TRUE;

    References and further reading (select official sources and product manuals recommended for implementation).

    The Beckhoff SISTEMA library is a collection of safety-related parameters for Beckhoff components (like TwinSAFE I/Os and logic units) designed for use in the SISTEMA software. This tool allows engineers to evaluate the Performance Level (PL) of safety functions according to ISO 13849-1. 1. Downloading the Library

    You can find the Beckhoff SISTEMA library files (typically with a .slb or .ssplib extension) through the following official channels:

    Beckhoff Download Finder: Search for "SISTEMA" on the Beckhoff Download Finder to locate the latest safety data.

    Direct FTP/Web Directory: Files are often hosted in the TwinSAFE documentation directory on Beckhoff's download server.

    IFA Website: The IFA (Institute for Occupational Safety and Health) maintains a list of manufacturer libraries, though it often directs users to the manufacturer's own site for the latest versions. 2. Importing into SISTEMA

    Once you have downloaded the file (usually a .zip containing the library): Extract the file to a local folder. Open SISTEMA software. Go to Library -> Local library in the menu.

    Click Add library and browse to the extracted Beckhoff file. To understand the magic of the Beckhoff implementation,

    Note: If you are using SISTEMA 3.0 or higher and have an older .slb file, you may be prompted to use the SISTEMA Library Version Converter to update the format. 3. Using the Library in Your Project

    Select Components: After importing, you can search the library for specific Beckhoff terminals (e.g., EL1904 for safe inputs, EL2904 for safe outputs).

    Modeling Safety Functions: Drag and drop the component into your SISTEMA safety function. The library automatically populates critical safety values like MTTFd, DCavg, and Category.

    Reference Application Guide: For complex setups, Beckhoff provides a TwinSAFE Application Guide that includes sample calculations and hardware interconnections that have been pre-verified by TÜV SÜD. Commonly Used Safety Components Software: SISTEMA libraries - IFA - DGUV

    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. Whether you are building a small packaging machine

    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.

    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.

    Call the function block cyclically or on-demand:

    fbEStop(
    Enable := TRUE,
    Config := stConfig,
    Result := eStop_Result,
    bCalculate := TRUE   // Rising edge triggers calculation
);