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The Role of the Beckhoff SISTEMA Library in Functional Safety Design

In the realm of modern industrial automation, the transition toward "smart factories" has heightened the importance of functional safety. As machines become more autonomous and complex, ensuring that control systems respond predictably to failures is critical for protecting human life and equipment. Central to this process in the European market and beyond is ISO 13849-1

, which provides safety requirements and guidance on the principles for the design and integration of safety-related parts of control systems. To simplify the complex mathematical verification required by this standard, the Institute for Occupational Safety and Health of the German Social Accident Insurance (IFA) developed

(Safety Integrity Software Tool for the Evaluation of Machine Applications). Beckhoff Automation supports this ecosystem by providing a free SISTEMA library

, which serves as a vital bridge between high-performance hardware and rigorous safety compliance. Simplifying Safety Calculations

The primary challenge in complying with ISO 13849-1 is the calculation of the Performance Level (PL)

. This involves evaluating various parameters, such as the Mean Time to Dangerous Failure ( cap M cap T cap T cap F sub d ), Diagnostic Coverage ( cap D cap C ), and Common Cause Failures ( cap C cap C cap F

). Manually calculating these for every component in a complex control loop is not only time-consuming but prone to human error. beckhoff sistema library free

Beckhoff addresses this by offering their safety component data in the standardized

(SISTEMA Library) format. This library contains the "safety-related reliability values" for their TwinSAFE components, including digital inputs, outputs, and logic terminals. By importing the Beckhoff library into the SISTEMA software, engineers can simply select the specific hardware they are using, and the software automatically populates the necessary reliability data. This automation ensures that the final PL calculation is based on manufacturer-validated data. Integration with TwinSAFE

The Beckhoff SISTEMA library is specifically designed to reflect the capabilities of the

system. TwinSAFE is Beckhoff’s integrated safety solution that utilizes the Fail Safe over EtherCAT (FSoE) protocol. Because TwinSAFE allows for distributed safety logic—meaning safety functions can be handled over the same network as standard control data—the architecture can become intricate.

The SISTEMA library allows designers to model these distributed architectures accurately. Whether a system uses a centralized safety PLC or distributed safety logic within I/O terminals, the library provides the building blocks to verify that the entire "safety chain"—from the sensor to the evaluation unit to the actuator—meets the required risk reduction target. Accessibility and Industry Standardization

A significant advantage of the Beckhoff SISTEMA library is that it is provided free of charge

. By removing the financial barrier to accessing safety data, Beckhoff promotes a culture of safety-first design among small and medium-sized enterprises (SMEs) that might otherwise struggle with the overhead of compliance. The Role of the Beckhoff SISTEMA Library in

Furthermore, Beckhoff’s commitment to the SISTEMA format aligns with a broader industry trend toward interoperability. Since many other component manufacturers (such as sensor or valve terminal providers) also provide free SISTEMA libraries, an engineer can build a complete, multi-vendor safety model within a single software environment. This "plug-and-play" approach to safety modeling significantly reduces "time-to-market" for new machinery. Conclusion

The Beckhoff SISTEMA library is more than just a data file; it is a critical tool for modern engineering. By providing free, validated reliability data for their TwinSAFE hardware, Beckhoff enables engineers to transition from theoretical safety concepts to documented, compliant machine designs with high efficiency. In an era where industrial complexity is soaring, such tools are indispensable for ensuring that technological progress does not come at the cost of human safety. the library into the SISTEMA software?

Since you cannot run live code, this paper is formatted as a complete technical brief ready for submission to an internal engineering team, a blog, or a conference proceedings (e.g., IEEE International Conference on Industrial Technology).

8. Conclusion

The Beckhoff Tc3_Sistema library is royalty-free software but requires a paid safety runtime license (TF1230) and certified safety hardware to execute. For a single machine or development lab, the total entry cost is approximately €900, which is competitive among industrial safety PLCs. Therefore, answer the question: "Is the Beckhoff Sistema library free?" – Yes, to download and write code; no, to run in production.

Is the Beckhoff Sistema Library Free?

Yes, the core Beckhoff library for controlling standard fieldbus devices, including Festo Sistema modules, is typically provided free of charge.

Here is the crucial distinction every engineer must understand:

The Software Library (TwinCAT) – Free: The .library file you import into TwinCAT 3 (e.g., Tc2_System, Tc2_IOFunctions, or specific Festo libraries) is included in the TwinCAT 3 ADS or TwinCAT 3 PLC environment without additional licensing fees. Beckhoff does not charge for the library itself. The Software Library (TwinCAT) – Free: The
The Runtime Licenses (TwinCAT) – Potentially Paid: While the library file is free, using it requires a valid TwinCAT runtime license on your Beckhoff hardware (e.g., CX series, C6015). If you are using the Engineering environment (TwinCAT XAE) in "Config Mode" or "Free Run," no license is needed. For deployed machines, you must purchase a license from Beckhoff, but this is not a fee for the library.
The Hardware (Festo) – Not Free: The library controls physical hardware. You still need to purchase the Festo valves, manifolds, and CPX terminals from Festo.

Conclusion: The library itself is legally free to download, use, and distribute as part of any TwinCAT installation.

7. Alternatives to Consider

If you need truly free safety logic (no runtime licenses), alternatives are limited but include:

Arduino Opta (with safety-certified library? – No, not SIL rated)
Siemens F-Library – also requires F runtime license (similar cost)
Hardwired relays – zero license cost, but higher wiring and maintenance.

For Beckhoff users, Tc3_Sistema remains the most cost-effective certified safety solution.

Method 2: Using the TwinCAT PLC Control Library Repository (Free)

Open your TwinCAT 3 project in Visual Studio.
In the PLC project tree, right-click "References" .
Select "Add Library" .
Go to the "System" or "Communication" tab.
Search for Tc2_System or vendor-specific libraries like Festo_CPX.
Click OK. The library is downloaded directly from Beckhoff's global repository (no cost).

2.1 The Short Answer