Solutions

Functional Safety

Contents

Smart control and clear insight for your safety system
A scalable control architecture for every application
Visualisation and monitoring: clear safety status
FAQ
Our Software solutions
Product Line up

Smart control and clear insight for your safety system

In modern industrial environments, the core of any safety system is the safety controller. This component executes certified logic designed to protect personnel. When a safety-related event occurs, rapid identification of the issue and efficient system recovery are essential.
As a company, we respond to this challenge by combining certified, intelligent safety controllers with advanced, high-performance GOT/HMI operator panels. These can be integrated with safety systems to provide clear, concise status reports, turning the safety ‘black box’ into an open, diagnosable system.
Mitsubishi Electric's integrated control and visualization solutions streamline your safety architecture, reduce engineering time, and lower overall costs. Our safety solutions focus on the integration of general and safety logic, along with powerful engineering tools.

A scalable control architecture for every application

From simple devices to complex, distributed lines – safety-compliant solutions are available that meet the specific requirements of machines or production lines.

Simplified safety for small machines: the MELSEC iQ-F Series safety extension modules

Implementing full safety control on small, cost-sensitive equipment can be complex. You want high safety standards without the burden of complex programming. The MELSEC iQ-F Series safety extension modules are designed to easily implement safety control for small-scale equipment.

No programming required: these modules provide safety control without the need to create a program.
Pre-built programs: simply select one of the nine built-in programs using a rotary switch.
Full compliance: the modules are compliant with international safety standards EN ISO 13849-1 Category 4 PL e and IEC 61508 SIL 3.
Easy monitoring: All safety statuses can be monitored in the PLC as non‑safe data, enabling quick and informed reactions.

Looking for a quick, code-free way to meet safety standards on small equipment? Simply connect MELSEC iQ-F Series safety extension modules with the CPU module that performs safety control, enabling both general and safety control in a single system.

Compact power: the MELSEC-WS safety controller

For small- to medium-scale systems, an over-engineered safety PLC is costly and inefficient. You need a powerful, space-saving and easy-to-expand solution. The compact MELSEC‑WS safety controller is ideal for such tasks. It is compliant with standards EN ISO 13849-1 Category 4 PL e and IEC 61508 SIL 3 and addresses critical response time challenges with its innovative technology.

Rapid response: features a fast shut off function that achieves an 8 ms response time regardless of the CPU, helping you shorten safety distances.
Scalable design: its compact base can be expanded up to 144 I/O points, accommodating growing safety needs.
Easy diagnostics: MELSEC-WS safety controllers monitor internal status and error history, making troubleshooting straightforward.

Integrated safety: the MELSEC iQ-R Series

Complex wiring and the use of separate engineering environments for general and safety control can create significant challenges. The MELSEC iQ-R Series addresses these issues with its Safety CPU (R□SFCPU-SET), fully compatible with the iQ Platform. This integrated concept enables general and safety programs to operate within a single controller, greatly simplifying system architecture.

Integrated control: achieve integrated general and safety control, executing both programs on the same controller. This minimizes hardware complexity and communication overhead.
Highest compliance and wide application: the Safety CPU is certified for the highest standards, PL e and SIL 3 (Category 4). It is a recommended solution for medium- to large-scale control for the production line and distributed system.
Useful diagnostic tools: the MELSEC iQ-R Series includes maintenance functions like ‘Event history’ and a ‘Diagnostics’ window that provide detailed information on the cause of the failure and remedial measures, shortening downtime.
Efficient engineering: use the common engineering platform, GX Works3, where general and safety programs are contained within the same project folder, using common labels for data exchange.
Easy integration: EnablesSafety over Network and further reduces cabling efforts, allowing easy integration of all CCLink IE TSN & Field safety devices.

Ready to simplify your control architecture? Discover how the MELSEC iQ-R Series can integrate your safety and general control.

Discover how to make your machines and production lines safer

Safety controllers to make machines and production lines safer

Whether you're securing a single machine or an entire line, this guide gives a clear overview of our safety controller portfolio to build reliable, flexible, efficient systems with minimal wiring and maximum performance. Download the catalogue to find the right safety solution.

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Visualisation and monitoring: clear safety status

Operators and maintenance staff need instant, clear visibility into the machine's safety status to ensure uptime and fast recovery from faults. Monitoring and visualization are key to knowing when safety critical areas of a machine have been activated, and this information helps operators and plant managers to synchronize production across the plant.

Centralised monitoring

Human Machine Interfaces (HMIs) are essential for monitoring safety status and diagnosing issues, directly on the production floor. GOT HMIs panels share information on the production floor and monitor the safety status of equipment, including errors. They can be used for centralized on-site monitoring and can provide remote access and diagnosis, such as setting parameters and alarm diagnostics for servo drives.

On-machine insight:

Clear & simple: HMIs process signals and present them as simple schematics or information on a full color touch screen.
Full range: Mitsubishi Electric’s GOT HMIs range from 3.7” to 15” in both panel mount and pendant styles.
Reduced downtime via diagnostics: instantly pinpoint the cause of a safety stop. Mitsubishi Electric’s MELSEC iQ-R controllers feature detailed event histories and diagnostic windows, and our GOT HMIs can graphically display the status and location of all safety equipment.

Boosted efficiency with MELSOFT GX Works3

MELSOFT GX Works3 is the common engineering platform for MELSEC controllers. It features certified tools to ensure your safety logic is robust and easy to deploy.

Certified safety function blocks: increase programming efficiency and reduce errors by using pre-certified blocks like M+SF_ESTOP_R (emergency stop) or M+SF_ESPE_R (light curtain).
Unified engineering: General and safety programs are stored in the same project, using shared labels to simplify configuration and maintenance.
Advanced diagnostics: Integrated event history and diagnostic windows identify faults and provide recommended actions, reducing troubleshooting time.

Want to accelerate your development cycle? See the full capabilities of MELSOFT GX Works3.

FAQ

Which systems are OPC UA-compatible and can communicate with the cloud?

Our MELSEC iQ-R and iQ-F series controllers support OPC UA, enabling secure, standardized communication from the plant floor to IT and cloud systems.

How can I reduce downtime caused by safety stops?

Downtime is not reduced by the safety function itself, but by superior diagnostics. Our iQ-R controllers log detailed event histories, and our GOT HMIs provide non-safe visualisation to show operators the exact location of the fault, enabling a much faster restart.

Do I need to be a safety expert to program?

Our GX Works3 software simplifies the process by providing certified, pre-made Safety Function Blocks (FBs) for common devices like e-stops, light curtains, and two-hand controls. For simple machines, our iQ-F safety extension modules require no programming at all – just select a pre-built program with a rotary switch.

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