Delta Function Blocks for Safety Systems: Complete Programming Guide

Learning to implement Function Blocks for Safety Systems using Delta's WPLSoft / ISPSoft / DIADesigner-AX is a useful skill for PLC programmers working in Universal. This guide walks through the fundamentals with clear explanations and an illustrative example that you can adapt to a simulator or test bench.

The example uses Delta terminology and references controller families such as DVP-ES2 / EX2 / SS2 (compact entry) and DVP-SX2 / SA2 / SV2 (motion + analogue). Confirm the exact instructions, data types, firmware requirements, and licensing in the current vendor documentation before choosing hardware or deploying a project.

The Function Blocks approach is particularly well-suited for Safety Systems because process control, continuous operations, modular programming, and signal flow visualization. This combination allows you to leverage visual representation of signal flow while managing the typical challenges of Safety Systems, including safety integrity level (sil) compliance and redundancy requirements.

Throughout this guide, you'll find step-by-step implementation guidance, an illustrative code example, and a verification checklist specific to Universal. Whether you're programming your first Safety Systems exercise or transitioning from another PLC platform, use the material as a starting point and validate it in your exact WPLSoft / ISPSoft / DIADesigner-AX version and controller environment.

Delta WPLSoft / ISPSoft / DIADesigner-AX for Safety Systems

WPLSoft / ISPSoft / DIADesigner-AX is a programming environment associated with Delta controller families such as DVP-ES2 / EX2 / SS2 (compact entry), DVP-SX2 / SA2 / SV2 (motion + analogue), DVP-SE (Ethernet). This guide uses Function Blocks terminology from the supplied guide dataset, but controller capabilities and language support can change by model, firmware, software edition, and license.

Verify Before You Start:

The selected controller supports the required Function Blocks constructs

The project version matches the installed WPLSoft / ISPSoft / DIADesigner-AX release

Required communications, motion, safety, and simulation options are licensed

Firmware and device-description files are compatible with the project

The vendor manuals used for the design match the exact hardware revision

Application Planning:

For a Safety Systems exercise, map the required inputs and outputs before writing logic. The example considers 5 sensor types, including Safety light curtains, Emergency stop buttons, Safety door switches, and 4 actuator types.

Control Equipment for Safety Systems:

Safety PLCs (fail-safe controllers)

Safety relays (configurable or fixed)

Safety I/O modules with diagnostics

Safety network protocols (PROFIsafe, CIP Safety)

Controller-family references used in this guide include:

DVP-ES2 / EX2 / SS2 (compact entry): Confirm CPU, I/O, memory, communications, and Function Blocks support in the current selection guide

DVP-SX2 / SA2 / SV2 (motion + analogue): Confirm CPU, I/O, memory, communications, and Function Blocks support in the current selection guide

DVP-SE (Ethernet): Confirm CPU, I/O, memory, communications, and Function Blocks support in the current selection guide

DVP-EH3 (legacy high-end): Confirm CPU, I/O, memory, communications, and Function Blocks support in the current selection guide

Hardware Selection Checklist:

Count local and remote I/O, including planned expansion

Measure the required task and communications update rates

Identify memory, data-retention, diagnostics, and cybersecurity requirements

Treat safety functions as a separate, standards-led design activity

Confirm lifecycle status, regional availability, licensing, and support

Source and Validation Note:

This page does not represent a vendor certification or a hardware acceptance test. Use current Delta manuals, release notes, and safety documentation as the authority for product-specific behavior. Validate adapted logic in a simulator or isolated test setup before connecting it to equipment.

Investment Considerations:

For Safety Systems projects, compare hardware, software licensing, training, engineering, test equipment, commissioning, spares, and ongoing support. Obtain current pricing and lifecycle information directly from the vendor or an authorized regional supplier.

Understanding Function Blocks for Safety Systems

Function Block Diagram (FBD) is a graphical programming language where functions and function blocks are represented as boxes connected by signal lines. Data flows from left to right through the network.

Execution Model:

Blocks execute based on data dependencies - a block executes only when all its inputs are available. Networks execute top to bottom when dependencies allow.

Core Advantages for Safety Systems:

Visual representation of signal flow: Critical for Safety Systems when handling advanced control logic

Good for modular programming: Critical for Safety Systems when handling advanced control logic

Reusable components: Critical for Safety Systems when handling advanced control logic

Excellent for process control: Critical for Safety Systems when handling advanced control logic

Good for continuous operations: Critical for Safety Systems when handling advanced control logic

Why Function Blocks Fits Safety Systems:

Safety Systems systems in Universal typically involve:

Sensors: Emergency stop buttons (Category 0 or 1 stop), Safety light curtains (Type 2 or Type 4), Safety laser scanners for zone detection

Actuators: Safety contactors (mirror contact type), Safe torque off (STO) drives, Safety brake modules

Complexity: Advanced with challenges including Achieving required safety level with practical architecture

Programming Fundamentals in Function Blocks:

StandardBlocks:
- logic: AND, OR, XOR, NOT - Boolean logic operations
- comparison: EQ, NE, LT, GT, LE, GE - Compare values
- math: ADD, SUB, MUL, DIV, MOD - Arithmetic operations

TimersCounters:
- ton: Timer On-Delay - Output turns ON after preset time
- tof: Timer Off-Delay - Output turns OFF after preset time
- tp: Pulse Timer - Output pulses for preset time

Connections:
- wires: Connect output pins to input pins to pass data
- branches: One output can connect to multiple inputs
- feedback: Outputs can feed back to inputs for state machines

Best Practices for Function Blocks:

Arrange blocks for clear left-to-right data flow

Use consistent spacing and alignment for readability

Label all inputs and outputs with meaningful names

Create custom FBs for frequently repeated logic patterns

Minimize wire crossings by careful block placement

Common Mistakes to Avoid:

Creating feedback loops without proper initialization

Connecting incompatible data types

Not considering execution order dependencies

Overcrowding networks making them hard to read

Typical Applications:

1. HVAC control: Directly applicable to Safety Systems
2. Temperature control: Related control patterns
3. Flow control: Related control patterns
4. Batch processing: Related control patterns

Understanding these fundamentals prepares you to implement effective Function Blocks solutions for Safety Systems using Delta WPLSoft / ISPSoft / DIADesigner-AX.

Implementing Safety Systems with Function Blocks

Safety system control uses safety-rated PLCs and components to protect personnel and equipment from hazardous conditions. These systems implement safety functions per IEC 62443 and ISO 13849 standards with redundancy and diagnostics.

This walkthrough demonstrates practical implementation using Delta WPLSoft / ISPSoft / DIADesigner-AX and Function Blocks programming.

System Requirements:

A typical Safety Systems implementation includes:

Input Devices (Sensors):
1. Emergency stop buttons (Category 0 or 1 stop): Critical for monitoring system state
2. Safety light curtains (Type 2 or Type 4): Critical for monitoring system state
3. Safety laser scanners for zone detection: Critical for monitoring system state
4. Safety interlock switches (tongue, hinged, trapped key): Critical for monitoring system state
5. Safety mats and edges: Critical for monitoring system state

Output Devices (Actuators):
1. Safety contactors (mirror contact type): Primary control output
2. Safe torque off (STO) drives: Supporting control function
3. Safety brake modules: Supporting control function
4. Lock-out valve manifolds: Supporting control function
5. Safety relay outputs: Supporting control function

Control Equipment:

Safety PLCs (fail-safe controllers)

Safety relays (configurable or fixed)

Safety I/O modules with diagnostics

Safety network protocols (PROFIsafe, CIP Safety)

Control Strategies for Safety Systems:

1. Primary Control: Safety-rated PLC programming for personnel protection, emergency stops, and safety interlocks per IEC 61508/61511.
2. Safety Interlocks: Preventing Safety integrity level (SIL) compliance
3. Error Recovery: Handling Redundancy requirements

Implementation Steps:

Step 1: Perform hazard analysis and risk assessment

In WPLSoft / ISPSoft / DIADesigner-AX, perform hazard analysis and risk assessment.

Step 2: Determine required safety level (SIL/PL) for each function

In WPLSoft / ISPSoft / DIADesigner-AX, determine required safety level (sil/pl) for each function.

Step 3: Select certified safety components meeting requirements

In WPLSoft / ISPSoft / DIADesigner-AX, select certified safety components meeting requirements.

Step 4: Design safety circuit architecture per category requirements

In WPLSoft / ISPSoft / DIADesigner-AX, design safety circuit architecture per category requirements.

Step 5: Implement safety logic in certified safety PLC/relay

In WPLSoft / ISPSoft / DIADesigner-AX, implement safety logic in certified safety plc/relay.

Step 6: Add diagnostics and proof test provisions

In WPLSoft / ISPSoft / DIADesigner-AX, add diagnostics and proof test provisions.

Delta Function Design:

WPLSoft P-labels are the primary reuse mechanism on DVP. ISPSoft instance-based function blocks enable proper IEC-style reuse on AH / AS, with library import / export. Delta-supplied motion, communication, and PID FBs ship with the IDE.

Common Challenges and Solutions:

1. Achieving required safety level with practical architecture

Solution: Function Blocks addresses this through Visual representation of signal flow.

2. Managing nuisance trips while maintaining safety

Solution: Function Blocks addresses this through Good for modular programming.

3. Integrating safety with production efficiency

Solution: Function Blocks addresses this through Reusable components.

4. Documenting compliance with multiple standards

Solution: Function Blocks addresses this through Excellent for process control.

Safety Considerations:

Use only certified safety components and PLCs

Implement dual-channel monitoring per category requirements

Add diagnostic coverage to detect latent faults

Design for fail-safe operation (de-energize to trip)

Provide regular proof testing of safety functions

Performance Metrics:

Task and I/O timing: Record minimum, average, and maximum values under a defined test load

Accuracy: Define an acceptable tolerance and compare it with calibrated reference measurements

Throughput: Count completed cycles over a fixed interval and record rejected or incomplete cycles

Fault response: Measure detection, safe-state, alarm, and recovery behavior for each test case

Resource use: Record memory, communications load, and diagnostic-buffer behavior

Delta Diagnostic Tools:

WPLSoft / ISPSoft online monitor with rung-state colour,Soft-element watch table and tag watch lists,Built-in offline simulator (WPLSoft and ISPSoft),Modbus RTU / TCP communication wizard with diagnostic counters,DIADesigner-AX integrated diagnostics for AX motion projects,M1000-range system flags for CPU and comms diagnostics,Delta distributor support and loaner CPUs in major markets,Delta IA forum and DeltaPLC community for application questions

Use the monitoring and diagnostic functions available in your WPLSoft / ISPSoft / DIADesigner-AX version, and record the software, firmware, hardware, workload, and test procedure with every result.

Delta Function Blocks Example for Safety Systems

Illustrative Function Blocks example for Safety Systems using Delta terminology. Adapt the syntax to your WPLSoft / ISPSoft / DIADesigner-AX release, compile it, and verify it in an isolated test environment before use on equipment.

(* Delta WPLSoft / ISPSoft / DIADesigner-AX - Safety Systems Control *)
(* Reusable Function Blocks Implementation *)
(* WPLSoft P-labels are the primary reuse mechanism on DVP. ISP *)

FUNCTION_BLOCK FB_SAFETY_SYSTEMS_Controller

VAR_INPUT
    bEnable : BOOL;                  (* Enable control *)
    bReset : BOOL;                   (* Fault reset *)
    rProcessValue : REAL;            (* Emergency stop buttons (Category 0 or 1 stop) *)
    rSetpoint : REAL := 100.0;  (* Illustrative value; replace with a reviewed requirement *)
    bEmergencyStop : BOOL;           (* Safety input *)
END_VAR

VAR_OUTPUT
    rControlOutput : REAL;           (* Safety contactors (mirror contact type) *)
    bRunning : BOOL;                 (* Process active *)
    bComplete : BOOL;                (* Cycle complete *)
    bFault : BOOL;                   (* Fault status *)
    nFaultCode : INT;                (* Diagnostic code *)
END_VAR

VAR
    (* Internal Function Blocks *)
    fbSafety : FB_SafetyMonitor;     (* Safety logic *)
    fbRamp : FB_RampGenerator;       (* Soft start/stop *)
    fbPID : FB_PIDController;        (* Process control *)
    fbDiag : FB_Diagnostics;         (* M-flag banks latched on fault detection on DVP; ISPSoft on AH / AS allows alarm structures and HMI alarm-banner integration via Delta DOPSoft or third-party HMIs over Modbus TCP. *)

    (* Internal State *)
    eInternalState : E_ControlState;
    tonWatchdog : TON;
END_VAR

(* Safety Monitor - Use only certified safety components and PLCs *)
fbSafety(
    Enable := bEnable,
    EmergencyStop := bEmergencyStop,
    ProcessValue := rProcessValue,
    HighLimit := rSetpoint * 1.2,
    LowLimit := rSetpoint * 0.1
);

(* Main Control Logic *)
IF fbSafety.SafeToRun THEN
    (* Ramp Generator - Prevents startup surge *)
    fbRamp(
        Enable := bEnable,
        TargetValue := rSetpoint,
        RampRate := 20.0,  (* Illustrative value; tune and verify for the process *)
        CurrentValue => rSetpoint
    );

    (* PID Controller - Process regulation *)
    fbPID(
        Enable := fbRamp.InPosition,
        ProcessValue := rProcessValue,
        Setpoint := fbRamp.CurrentValue,
        Kp := 1.0,
        Ki := 0.1,
        Kd := 0.05,
        OutputMin := 0.0,
        OutputMax := 100.0
    );

    rControlOutput := fbPID.Output;
    bRunning := TRUE;
    bFault := FALSE;
    nFaultCode := 0;

ELSE
    (* Safe State - Implement dual-channel monitoring per category requirements *)
    rControlOutput := 0.0;
    bRunning := FALSE;
    bFault := NOT bEnable;  (* Only fault if not intentional stop *)
    nFaultCode := fbSafety.FaultCode;
END_IF;

(* Diagnostics - PLC-tier logging is uncommon on DVP — logging happens at the HMI tier (DOPSoft, Delta DIAView SCADA) or via Modbus pull from a higher-level historian. AH / AS supports SD-card data logging and on-board CSV export. *)
fbDiag(
    ProcessRunning := bRunning,
    FaultActive := bFault,
    ProcessValue := rProcessValue,
    ControlOutput := rControlOutput
);

(* Watchdog - Detects frozen control *)
tonWatchdog(IN := bRunning AND NOT fbPID.OutputChanging, PT := T#10S);
IF tonWatchdog.Q THEN
    bFault := TRUE;
    nFaultCode := 99;  (* Watchdog fault *)
END_IF;

(* Reset Logic *)
IF bReset AND NOT bEmergencyStop THEN
    bFault := FALSE;
    nFaultCode := 0;
    fbDiag.ClearAlarms();
END_IF;

END_FUNCTION_BLOCK

Code Explanation:

1.Encapsulated function block follows WPLSoft P-labels are the primary reuse m - reusable across Universal projects
2.FB_SafetyMonitor illustrates status checks and high/low limits; it is not a certified safety function
3.FB_RampGenerator prevents startup issues common in Safety Systems systems
4.FB_PIDController tuned for Universal: Kp=1.0, Ki=0.1
5.Watchdog timer illustrates one way to flag an unchanged output for diagnosis
6.Diagnostic function block enables PLC-tier logging is uncommon on DVP — logging happens at the HMI tier (DOPSoft, Delta DIAView SCADA) or via Modbus pull from a higher-level historian. AH / AS supports SD-card data logging and on-board CSV export. and M-flag banks latched on fault detection on DVP; ISPSoft on AH / AS allows alarm structures and HMI alarm-banner integration via Delta DOPSoft or third-party HMIs over Modbus TCP.

Best Practices

✓Follow Delta naming conventions: WPLSoft / DVP work is dominated by raw soft-element addressing (X0, Y0, M100, D1
✓Delta function design: WPLSoft P-labels are the primary reuse mechanism on DVP. ISPSoft instance-based
✓Data organization: DVP has no structured data blocks — D / register banks are documented by range.
✓Function Blocks: Arrange blocks for clear left-to-right data flow
✓Function Blocks: Use consistent spacing and alignment for readability
✓Function Blocks: Label all inputs and outputs with meaningful names
✓Safety Systems: Keep safety logic simple and auditable
✓Safety Systems: Use certified function blocks from safety PLC vendor
✓Safety Systems: Implement cross-monitoring between channels
✓Debug with WPLSoft / ISPSoft / DIADesigner-AX: Run the offline simulator with forced inputs before live download
✓Safety: Use only certified safety components and PLCs
✓Use a compatible simulator or isolated test rig to test Safety Systems logic before deployment

Common Pitfalls to Avoid

⚠Function Blocks: Creating feedback loops without proper initialization
⚠Function Blocks: Connecting incompatible data types
⚠Function Blocks: Not considering execution order dependencies
⚠Delta common error: Battery-low alarm on legacy DVP-EH causing D-range data loss
⚠Safety Systems: Achieving required safety level with practical architecture
⚠Safety Systems: Managing nuisance trips while maintaining safety
⚠Neglecting to validate Emergency stop buttons (Category 0 or 1 stop) leads to control errors
⚠Insufficient comments make Function Blocks programs unmaintainable over time

Related Certifications

🏆Delta IA Academy distributor-led engineer training

🏆WPLSoft / ISPSoft course completions

🏆DIADesigner-AX motion specialist tracks for AX-series engineers

🏆Advanced Delta Programming Certification

Applying Function Blocks to Safety Systems using Delta WPLSoft / ISPSoft / DIADesigner-AX requires understanding the platform, the process, and the project's acceptance criteria. This guide has covered implementation structure, an illustrative code example, verification practices, and common pitfalls for a advanced Safety Systems exercise.

Use the practices outlined here to create a design that can be reviewed and tested. Define performance targets in the project requirements and confirm them with repeatable measurements.

Next Steps:

1. Check Sources: Read the current WPLSoft / ISPSoft / DIADesigner-AX help, controller manual, release notes, and relevant standards
2. Practice Safely: Adapt the example in a simulator or isolated training setup
3. Review: Have the I/O map, state behavior, faults, and recovery steps reviewed
4. Test: Record normal, boundary, fault, restart, and communications test results

Function Blocks Foundation:

Function Block Diagram (FBD) is a graphical programming language where functions and function blocks are represented as boxes connected by signal line...

Project duration depends on scope, reviews, hardware availability, software and firmware versions, testing, commissioning, and site constraints. Remember: Keep safety logic simple and auditable

For further learning, explore related topics including Temperature control, Emergency stop systems, and Delta platform-specific features for Safety Systems optimization.