Training Objective
The aim of the training is to familiarize participants with the safe programming of PLC controllers in accordance with the requirements of the EU Machinery Regulation 2023/1230 and the harmonized standard PN 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 key safety system parameters such as Category, Diagnostic Coverage (DC), Common Cause Failure (CCF), and Mean Time to Dangerous Failure (MTTFd). The course will also teach participants how to implement safety functions in Siemens PLCs using Safety Advanced tools, ensuring they meet the safety level requirements stipulated in EN ISO 13849-1 (PL) and IEC 62061 (SIL).
Target Group
This training is intended for machine manufacturers or users, where engineers and designers are involved in the design of control systems related to safety, programming safety-related PLCs, and testing safety systems based on PLCs. The primary audience includes automation engineers, programming engineers, electrical system design engineers, and managers of automation and machine design departments.
Training Topics
- Introduction to technical machine safety
- Legal requirements for the design and construction of machines
- Risk assessment in relation to safety-related control systems
- Risk reduction measures associated with safety systems
- Basic parameters of safety systems according to PN 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, safety I/O modules, Safety section)
- 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 Reset Function (F_Acknowledge)
- Diagnostics and testing of safety programs in PLCs:
- Implementation of periodic tests
- CPU F logs and alarms
- Fault detection in the Safety system
- Programming and best practices:
- Dual-channel inputs, fail-safe configurations
- Cyclic input/output tests
- Use of certified F-blocks
- Access protection and safety locking
- Documentation and validation:
- List of safety functions and required safety levels
- PL validation using SISTEMA
- Requirement matrix vs. PLC implementation
- Conclusions, discussion, summary
The training is based on the requirements of the following legal regulations and harmonized standards:
- EU Machinery Regulation 2023/1230 – Essential health and safety requirements for machinery
- EN ISO 12100 – Safety of machinery—General principles for design—Risk assessment and risk reduction
- EN ISO 13857 – Safety of machinery—Safety distances to prevent hazard zones being reached by upper and lower limbs
- EN ISO 13855 – Safety of machinery—Positioning of safeguards with respect 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
- PN-EN 61508-1 – Functional safety of electrical/electronic/ programmable electronic safety-related systems—Part 1: General requirements
Contact for the training:
Zbigniew Zapała, tel. +48 538 337 206