Virtual safety controller according to IEC 61508 SIL3 without hardware binding

CODESYS^® Virtual Control Systems and Safety Control Systems in Accordance with IEC 61508 SIL3

– hardware-independent across various platforms

CODESYS Virtual Control SL and Virtual Safe Control SL at SPS 2026

The focus was on the virtual PLC as a full-fledged control system within a software container: Functional control systems and safety control systems compliant with IEC 61508 SIL 3 run in parallel on the same standard hardware, are programmed within a single CODESYS project, and are managed using the Deploy Control SL add-on.

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Two products. One virtualized control architecture.

Runtime: CODESYS Virtual Control SL

The IEC 61131-3-compatible runtime system is provided as a container image on Linux with real-time support. Multiple instances can run independently of one another on standard x86 or ARM hardware (both with 64-bit architecture).

Functional PLC Applications
Scalable control instances
Centralized deployment and maintenance
Industrial Ethernet for fieldbus I/O

Safety: CODESYS Virtual Safe Control SL

The virtual safety controller complements the functional controller. Diversified Encoding and Coded Processing divide the safety application into two logical channels without requiring any action on your part as the user. The base software is certified for applications in accordance with IEC 61508 SIL3.

Safety applications up to SIL3
Certified by TÜV Süd for standard x86 or ARM hardware
Two-channel architecture in software
PROFIsafe and FSoE
Project configuration with CODESYS Safety Extension

Together on one platform

A project

Functional and safety applications are created in the CODESYS Development System, with the safety application serving as a child application of the functional PLC. Data is exchanged directly between them.

A deployment

You can manage both images using Deploy Control SL in the CODESYS Development System, Docker Compose, Kubernetes, OpenShift, or the CODESYS Automation Server.

A piece of hardware

Logic, motion, visualization, and safety all run on the same standard device—in the control cabinet or in the data center, and in separate virtual controllers if needed.

Benefits

Why virtualize control systems?

Reduce costs and space

Multiple physical controllers can be replaced by virtual instances on a shared platform. This reduces wiring, power requirements, and space needs. The performance reserves of high-performance edge devices, IPCs, or servers are utilized to their fullest potential.

Scale flexibly

New control units and functions are created using software, without the need to install new hardware for each expansion. The control unit's functionality and performance depend solely on licenses, provided that the base hardware is powerful enough.

Centralized maintenance

Firmware, application, and security updates can be managed centrally and rolled out to multiple instances. Management can be handled by either OT or IT staff.

Resolving hardware dependencies

The PLC application is independent of the specific computer architecture and can run on suitable standard platforms.

Security by Design

Application components can be encapsulated in isolated containers and structured like microservices. Simplifying updates to the base software strengthens the system's security.

Integrate safety

Functional and safety-related control systems can be operated on the same infrastructure and configured in the same engineering system. There is no need for expensive and often underperforming certified safety hardware.

Software and hardware architecture

Multiple functional and secure control instances run in isolated containers on a Linux real-time system. An optional hypervisor can integrate additional operating systems and third-party software. Field devices and I/Os are connected via Industrial Ethernet, while a central license server provides the application-based licenses.

Getting started in four steps

The prepared images are instantiated on the target system. With Deploy Control SL, virtual controllers can be created, started, stopped, configured, and deleted directly from the CODESYS Development System. Alternatively, IT tools and scripts can be used.

Select a platform

Provide suitable x86 or ARM hardware running Linux, with real-time support and a container engine.

Deploy images

Instance and configure functional—and, if necessary, secure—virtual controllers from pre-built images.

Configure applications

Create functional and secure applications in the CODESYS Development System.

Manage centrally

Scale, update, diagnose, and manage instances separately.

Use Cases

Typical Use Cases

Centralize production lines

Consolidate physical PLCs on IT-managed servers or industrial PCs and roll out updates centrally.

Modularizing machines

Separate multiple control functions on an IPC and version, test, and maintain them independently.

Structuring complex applications

Divide HMI, fieldbus, application, and other functions into clearly separated container instances.

Virtualizing safety

Implement safety functions up to SIL3 on suitable standard hardware without a dedicated safety CPU.

Motion applications

Also implement time-critical Motion-CNC-Robotics applications via virtual controllers and Industrial Ethernet.

Migrate in stages

Virtual control systems complement traditional PLCs in situations where consolidation makes technical and economic sense.

Webinars on the topic

The recordings from the CODESYS Webinar Series 2026 provide an in-depth look at the topics—each featuring a live demonstration.

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Virtual PLCs explained