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Functional Safety of Machinery

Rockwell Automation - TÜV Rheinland

This is a 5 day training with limited participation to 12 persons.

The new standards regarding Functional Safety as well as the new European Machinery Directive demand that persons and organizations performing responsible (accountable) tasks during the life cycle phase of a machine have to acquire and prove their competencies in Machine Safety.

Within this training the requirements for the design as well as the proof of Functional Safety for Machinery applilcations are described and discussed in detail based on the relevant current standards. The selection of protective devices for Machinery in order to achieve the required risk reduction is shown. Examples of safety functions are explained. The main requirements of ISO 13849 and IEC 62061 for the design of safety related parts of machine control systems are presented and appliction examples illustrating the quantitative assessment of safety functions are discussed.

Target Group

Application engineers and system integrators with some experience in Functional Safety; also designers and safety specialists working in Machinery applications.


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Day 1

  • Introduction „TÜV Rheinland Functional SafetyTraining Program“
  • Guidelines and Standards Machine Directive, A, B and C standards,
    • Standards and status of standards regarding Functional Safety in Machine safeguarding,
    • Importance (meaning) of harmonized and non-harmonized standards
    • Machines and safety components listed in the appendix IV of the Machinery Directive.
  • Risk Analysis Methods for determination of necessary measures for the reduction of risks at machines (ISIO 12100);
    • Direct, indirect and indicative safety;
    • Procedure acc. to ISO 13849 and EN 62061,
    • Examples;
  • Comparison of safety classifications.
  • Introduction to ISO 13849
    • Importance (meaning) of safety categories;
    • Principle information regarding deterministic fault consideration, faults and fault exclusions acc. to ISO 13849-2;
  • Safety Devices
    • Systematic of safety devices, advantages and disadvantages, installation requirements, configuration of safety devices;
  • Guards, interlocking devices:
    • Types, examples regarding application, installation requirements acc. to different safety categories
    • Faults, fault exclusions
    • Normative requirements
  • Other safety devices:
    • Type, installation requirements, advantages and disadvantages;
    • Calculation of safety distances

Day 2

  • Safety functions of machines
    • Start/re-start interlock, start functions, Emergency off, emergency switching off, stop categories muting etc. ,
    • Realization acc. to the different safety categories
    • Circuits, schematics, examples
  • Connection of safety devices to controls, interface circuits
    • Realization acc. to the different safety categories,
    • Examples for correct and incorrect typical circuits.
  • New standards regarding safety of machinery
  • Importance (meaning) of these standards regarding quality management, documentation and safety related availability.

Day 3

  • ISO 13849
    • - Contents of ISO 13849-1, application area, restrictions regarding applicability,
    • Documentation requirements and quality management,
    • Requirements regarding SW,
    • Use of standard components in safety functions,
    • Proof of safety, verification and validation of safety functions,
    • Examples.
  • Validation
    • Validation acc. to ISO 13849-2. IEC 62061
  • Content of IEC 62061, application area,
    • Documentation requirements and quality management, life cycle model,
    • Meaning of terms SIL, SIL CL, HFT, SFF and their context,
    • Requirements regarding safety relevant application software,
    • Proof of safety, verification and validation of safety functions,
  • Examples.

Day 4

Examples for proof of Functional Safety acc. to IEC 62061, Examples for proof of Functional Safety acc. to ISO 13849-1 Questions and answers, discussion


This training is designed to provide benefit for engineers with some experience in Functional Safety. It is highly recommended that participants either have experience in Safety of Machinery applications or have attended an introduction course on Functional Safety.


Day 5 of the training: Start: 9 am End: 12 pm Exam duration: 3 hours The exam consists of 70 multiple choice questions and 12 open questions. The standards EN ISO 13849 part 1 and 2 and EN 62061 are essential working material for the exam. Additionally a calculator should be brought along for the quantitative assessment.


The standards ISO 13849 part 1 and part 2 and IEC 62061 are required working material for this training and need to be brought along by the participants.


€ 2.600 + VAT. Includes: exam, training proceedings, lunch and refreshments € 2.300 zzgl. MwSt. Without exam and TÜV FS Engineer certificate