CODESYS Virtual Safe Control: Simplifying Functional Safety with Containerized Automation
17th March, 2025
Efficiency and safety are of utmost importance in the field of industrial automation. Even in the event of a malfunction, functional safety guarantees that systems continue to function as intended. One of the most exciting advancements in this area is CODESYS Virtual Safe Control, a technology that allows safety-critical applications to run on standard hardware. At SALZ Automation, we’ve taken this a step further by integrating it into a containerized automation system managed by Kubernetes.
This blog post covers, what CODESYS Virtual Safe Control is, how we use it, and why this approach is significant for contemporary automation.
What is CODESYS Virtual Safe Control?
CODESYS is a popular software platform used for programming industrial controllers like PLCs (Programmable Logic Controllers). CODESYS Virtual Safe Control is a specialized version designed for functional safety. It allows safety-related control logic to run in a virtualised environment, meeting strict safety standards like IEC 61508 and ISO 13849.
CODESYS Virtual Safe Control uses a method called "diversified encoding," which is based on the well-known "coded processing" technique. This approach offers the same degree of safety as conventional dual-channel hardware solutions as it guarantees the operation of safety application across two logical software channels. The software can control safe fieldbus I/Os via the Ethernet-based safety protocol PROFIsafe.
The big advantage? You don’t need expensive, specialized safety control hardware. Instead, safety applications can run on standard industrial PCs or servers. This reduces costs, simplifies system design, and makes it easier to integrate safety functions into modern IT infrastructures.
Advantages of CODESYS Virtual Safe Control
By eliminating the need for specialized safety hardware, CODESYS Virtual Safe Control significantly reduces hardware and wiring costs. This makes it an attractive option for companies looking to optimize their budgets without compromising on safety.
The software can run on any standard x86 hardware, and ARM-based platforms are in development. This flexibility allows it to be used in a wide range of applications, from small machines to large industrial plants. Additionally, the software can be easily integrated into existing CODESYS environments, making it a versatile solution for various automation needs.
Updates and maintenance can be performed quickly and easily. Since the software runs in a virtual environment, updates can be applied without significant downtime. This ensures that systems remain up-to-date with the latest safety standards and features.
Each safety application runs in its own isolated environment, reducing the risk of cross-contamination and enhancing overall system security. This is particularly important in industries where data integrity and security are paramount.
As industries evolve, the ability to quickly adapt to new requirements and technologies is crucial. CODESYS Virtual Safe Control provides a future-proof platform that can easily integrate with emerging technologies and standards.
SALZ Automation’s Containerized Approach
At SALZ Automation, we used the innovative CODESYS Virtual Safe Control solution and simplifed the container handling and further implemented the resulting application in a cluster-based architecture. These solutions use Docker and Kubernetes (K8s) to manage and orchestrate our control system.
And this is how it works:
1. Containerizing Safety Applications
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By deploying CODESYS Virtual Safe Control in Docker images, we ensure that each safety application runs in an isolated environment.
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The mechanism for creating Docker containers from SALZ is tailored to the requirements of automation.
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This makes security applications portable, easy to implement and simple to update.
2. Running CODESYS in Containers
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The CODESYS runtime environment is containerized and can be loaded and executed on the controller either via Codesys Engineering or via the optimized SALZ Automation container handling.
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This means that they currently run on every SALZ Automation controller.
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The safety applications developed in the CODESYS Engineering environment are loaded into containers and managed together with other automation components.
3. Orchestrating with Kubernetes
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Kubernetes is an open source platform for managing container applications, known as pods. K8s automates the deployment, scaling and loading of pods.
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Each pod is a lightweight, self-contained unit and can contain multiple applications required to run the application.
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Applications can thus run with high availability in the cluster and be moved automatically. The (re)start, e.g. in the event of a hardware failure, takes place automatically.
4. Edge and Cloud Flexibility
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Our system works both at the edge (close to the machines) and in the cloud.
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Time-critical tasks are executed edge-based to reduce latency, while non-time-critical tasks can be moved to the cloud.
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This hybrid approach ensures optimum performance and resource utilization - regardless of functional safety.
5. SALZ Data Exchange Layer (D.E.L.)
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Our proprietary D.E.L. (Data Exchange Layer) technology facilitates high-speed data exchange between real-time and non-real-time applications
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It ensures seamless integration and communication of data and information from functionally secure and non-secure applications.
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Learn more about SALZ D.E.L. (Data Exchange Layer)
Why This Approach is Better
- No need for expensive, specialized safety control hardware. Safety applications run on standard industrial PCs or servers.
- Need to add a new safety function? Just deploy a new container. No need to overhaul the entire system.
- Containers can be updated or replaced without shutting down the entire system.
- Kubernetes provides built-in fault tolerance. If a POD fails, it’s automatically restarted or moved to another device. This ensures that safety-critical applications are always available.
- CODESYS Virtual Safe Control ensures compliance with international safety standards.
- Containerization reduces resource waste, lowering operational costs.
- Kubernetes automatically scales applications based on demand, ensuring efficient resource use.
- Kubernetes ensures updates are rolled out smoothly, minimizing downtime.
- Using open standards like Docker and Kubernetes means the system can easily integrate new technologies. Customers can adapt to future needs without replacing their entire automation system.
- Containerization makes it easier to track and audit safety functions, which is important for certification.
Why the Industry Should Adopt This Approach?
The modern automation landscape demands solutions that are not only safe and reliable but also flexible and cost-effective that integrate with IT Systems. Here’s why the SALZ Automation approach is the way forward:
- Digital Transformation: Containerized automation aligns with Industry 4.0 goals, enabling smarter factories and better integration with IoT devices. It’s a key step toward digital transformation in manufacturing and other industries.
- Faster Innovation: Containers make it easy to test and deploy new applications, speeding up innovation. Companies can respond quickly to changing market demands.
- No Vendor Lock-In: Using open standards means customers aren’t tied to a single vendor for hardware or software. This encourages competition and drives innovation.
- Sustainability: Containerization optimizes resource use, reducing energy consumption and environmental impact. Running safety applications on standard hardware also contributes to sustainability goals.
Conclusion
CODESYS Virtual Safe Control, combined with modern container creation and handling via Kubernetes, is changing functional safety in industrial automation. We at SALZ Automation are proud to play a pioneering role with this innovative approach. It is everything that modern automation needs.
As industries continue to evolve, adopting this technology will be key to staying competitive. Whether you’re in manufacturing, energy, or logistics, the SALZ Automation system offers a smarter, safer, and more efficient way to meet your automation needs.
The future of automation is here, and it’s simpler than you think. Are you ready to embrace it?
Stay tuned for more blog in this series, where we explain/discuss the working of these new tools and technology.
Do you have questions? We’re here to support you!!
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For any further information or your individual offer, please feel free to contact our Technical Sales directly:
Christian Kürten.
christian.kuerten@salz-automation.com
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