Training Objective
The objective of this training is to familiarize participants with the safe programming of PLCs according to the requirements of Regulation 2023/1230 on machinery and the harmonized standard EN ISO 13849-1. During the training, participants will learn about the concepts of control system reliability, Performance Level (PL), and Safety Integrity Level (SIL), as well as safety system parameters such as Category, Diagnostic Coverage (DC), Common Cause Failure (CCF), and Mean Time to Dangerous Failure (MTTFd). Participants will learn how to implement safety functions in Siemens PLCs using Safety Advanced tools to meet the safety level requirements according to PN EN ISO 13849-1 (PL) and IEC 62061 (SIL).
Target Audience
This training is dedicated to manufacturers or users of machines where engineers and designers are involved in designing safety-related control systems, programming safety-related PLCs, and testing safety systems based on PLCs. Participants should primarily include automation engineers, programming engineers, electrical system designers, and managers from automation and machine design departments.
Topics Covered During the Training
- Introduction to machinery technical safety
- Legal requirements for the design and construction of machinery
- Risk assessment and safety-related control systems
- Risk reduction measures related to safety systems
- Basic parameters of safety systems according to EN ISO 13849-1
- Performance Level (PL)
- Safety Integrity Level (SIL)
- Diagnostic Coverage (DC)
- Common Cause Failure (CCF)
- Mean Time to Dangerous Failure (MTTFd)
- Introduction to safety PLCs (CPU F, safe I/O modules, Safety sections)
- Safety functions of the PLC
- Emergency Stop (F_EmergencyStop) – PL e / SIL 3
- Guard Locking (F_GuardLocking) – PL d-e
- Light Curtain (F_LightCurtain) – PL e
- Two-Hand Control (F_TwoHandControl) – PL d
- Speed Monitoring (F_SpeedMonitor) – PL c-e
- Safety Function Acknowledgment (F_Acknowledge)
- Diagnostics and testing of safety programs in PLC
- Implementation of periodic tests
- Logs and alarms in CPU F
- Error detection in the Safety system
- Programming and best practices
- Dual-channel inputs, fail-safe
- Periodic testing of inputs/outputs
- Use of certified safety blocks
- Access protection and safety locks
- Documentation and validation
- Safety function list and required levels
- Validation of PL using SISTEMA
- Requirements matrix vs implementation in PLC
- Conclusions, discussion, summary
The training is based on the requirements of the following legal provisions and harmonized standards:
- Machinery Regulation (EU) 2023/1230 – essential requirements for machinery
- EN ISO 12100 – Safety of machinery — General principles for design — Risk assessment and reduction
- EN ISO 13857 – Safety of machinery — Safety distances to prevent reaching hazardous areas with upper and lower limbs
- EN ISO 13855 – Safety of machinery — Location of protective equipment relative to the approach speeds of parts of the human body
- EN 60204-1 – Safety of machinery — Electrical equipment of machines — Part 1: General requirements
- EN ISO 13849-1 – Safety of machinery — Safety-related parts of control systems — Part 1: General principles for design
- EN ISO 13849-2 – Safety of machinery — Safety-related parts of control systems — Part 2: Validation
- EN ISO 14119 – Safety of machinery — Interlocking devices associated with guards — Principles for design and selection
- EN ISO 14120 – Safety of machinery — Guards — General requirements for the design and construction of fixed and movable guards
- EN IEC 62061 – Safety of machinery — Functional safety of safety-related control systems
- EN 61508-1 – Functional safety of electrical/electronic/programmable electronic safety-related systems — Part 1: General requirements
Contact for Training
Zbigniew Zapała, tel. +48 538 337 206, email: training@proestima.pl