I/O expansion for safety controller

An industrial safety controller configured to evaluate functional safety of a safety program to verify a target output is operating in a safe state, the industrial safety controller comprising:

• a connector configured to communicatively couple the industrial safety controller to an expansion module;
• a first processing unit operative to execute at least one safety function, wherein the at least one safety function:
• generates a safety output signal responsive to receiving at least one input signal;
• provides the safety output signal to an output terminal of the expansion module via the connector;
• receives a feedback signal from at least one load actuated by the safety output signal;
• and
• verifies a target output is operating in a safe state when the safety output signal corresponds to the feedback signal.

A method for controlling safety and non-safety functions of a controlled process using an industrial safety controller, the method comprising the steps of:

• executing at least one safety function with a first processing unit in the industrial safety controller;
• generating a safety output signal with the at least one safety function responsive to receiving at least one input signal;
• communicatively coupling an expansion module with the industrial safety controller via a connector;
• providing the safety output signal from the first processing unit to an output terminal of the expansion module;
• receiving a feedback signal from at least one load actuated by the safety output signal;
• and
• verifying that the controlled process is in a safe state of operation when the safety output signal corresponds to the feedback signal.