Guide to EN ISO 13849-1

Safety Performance Levels Transition from EN 954-1 to EN ISO 13849-1

This free publication is intended to shed some light on the recent and upcoming changes in the legislation and standards that apply to the safety of machinery. It is focused on the EU requirements but, due to the increasing globalisation of machinery safety standards, much of the content is relevant worldwide.

Machinery and processes continue to become faster, more flexible and more powerful. In order to offer the continued safety of operators and technicians, protective measures have, in turn, evolved to keep pace with the increasing complexity of automation. What is required for safer functionality increasingly depends on what the machine is doing or what mode it is in. This means that "safety" has, in some way, to communicate with the "normal" control system. That means that we need to reconsider how we achieve the independence and integrity of the safety system. One of the most significant manifestations of this is a new generation of standards commonly referred to as Functional Safety Standards. In this publication we will consider one of the most significant of them: EN ISO 13849-1. In addition to this, there is a new Machinery Directive in the EU that looks to keep the legislative landscape relevant to the contemporary industrial environment.

For anyone supplying machines, or using them, it is important to keep informed of the relevant standards and regulatory requirements. This publication is intended to assist in that task, especially with regard to control system aspects. It is not a substitute for a detailed study of the specific provisions detailed in the standards and legislation. It is intended to give an overview and hopefully it will help to give some clarity on what is required.

Safebook 3

This free booklet offers guidance on the principles of machine safety, relevant standards and methods of safety implementation. It is a handy A5 size document that gives an overview of:

• International and regional regulations
• Relevant standards for machinery safety
• Safety strategy
• Risk Assessment
• Protective Measures and Complimentary Equipment
• Safety Distance Calculation
• Prevention of Unexpected Power-up
• Structure of Safety Related Control Systems
• Functional Safety of Control Systems
• System Design According to IEC/EN 62061
• System design according to EN ISO 13849-1:2008

Safety Solutions Seminars

Safety standards are changing. We'll tell you how. We'll clarify what the new EU Directive means and how you can protect your personnel and machinery from everyday risk without adversely affecting productivity.

Keeping abreast of changes in safety standards can be a challenge.

Which is why you’ll find this seminar so valuable - it’s designed to get you up to speed on changes in relevant EU Directives and legislation, quickly and efficiently. During the space of just a few hours, you’ll find out what’s new and what’s coming.

You’ll learn, for example, why the concept of Functional Safety will change the behaviour of users and designers of automation systems, and why there is growing interest in SILs (Safety Integrity Levels) and PL (Performance Levels).

But that's far from all. Other key topics covered will include:

• How you can use PLCs in safety applications
• Safety Standards - What's new, what's coming and which ones do I need to know about?
• What does a CE mark mean for Safety?
• What should you be asking of your suppliers?
• What is risk, how do we assess it and how does it impact existing risk assessments?
• How safe is safe enough?

There will also be time for open discussions relating to your specific needs (where time allows).

Training

To help you comply with current and emerging standards, Rockwell Automation offer a range of training and consulting services. Training is based on proven classes but can also be tailored where required. Available training and services may include:

• Risk Assessment
• Hazard Assessment
• Machine Safety Training
• Safety Circuit Analysis
• Machine Stop Time Services
• Safety System Design
• Safety System Validation
• LOTO Services (Lockout and Tagout)
• Conformance Audits
• CCE Conformance
• Turnkey Safety Systems

SISTEMA

Performance Level Calculator software

For many years, the most common way of classifying safety related systems on machinery has been to use the Categories of the standard EN 954-1 “Safety related parts of control systems”. This standard will be withdrawn and can no longer be used to provide a presumption of conformity with the European Machinery Directive. A new standard to replace EN 954-1 has already been published and is available for use: EN ISO 13849-1:2008, or “Safety of machinery - Safety related parts of control systems”. It provides a transition path from the previous five “Categories” (B, 1, 2, 3, 4) to the new classification of five “Performance Levels” (a, b, c, d, e).

In some circumstances it may be possible to use alternative standards such as EN (IEC) 62061. However, the majority of designers will likely turn to EN ISO 13849-1 because the standard has been specifically drafted to provide a transition path for those who design systems to Categories per EN 954-1. It covers all control system technologies (electrical, mechanical, pneumatic and hydraulic) and can be used either for a complete system or for a subsystem. For the next few years EN ISO 13849-1 is likely to become the most commonly used standard for machine safety systems.

What is the SISTEMA Tool?

The SISTEMA tool, developed by Germany’s BGIA organization, automates calculation of the attained Performance Level (PL) of the safety related parts of a machine’s control system in the context of EN ISO 13849-1. SISTEMA is available in English and German language versions and may be downloaded free of charge.
Click here to download the SISTEMA Tool

How is Rockwell Automation Supporting SISTEMA?

Data for Rockwell Automation machinery safety products is now available in the form of a library file (download located on the left navigation) to be used with the SISTEMA calculation tool based on EN ISO 13849-1.

The availability of this data library is evidence of the recognition by Rockwell Automation of the impact of EN ISO 13849-1 and other functional safety standards on industry. It is one of a number of activities and tools launched to provide help and guidance on how to deal with changes in legislation and standards in an ever more competitive environment.

The combination of the SISTEMA tool and the Rockwell Automation SISTEMA library will provide machinery and system designers with comprehensive support in the evaluation of safety in the context of EN ISO 13849-1. Users are spared time consuming consultation of tables and calculation of formulae since these tasks are performed by the software. The final results can be printed out in the form of a multiple page report.