ISO 13849 & IEC 62061: Functional Safety for Machinery Sector

The program targets:

• Design Engineers, Software Engineers, and Control System Integrators.
• Maintenance Engineers and Safety Managers.
• Machinery Manufacturers and Importers.
• Health & Safety (EHS) Professionals and Consultants.
• Highly recommended for Health & Safety (EHS) professionals, consultants, and machinery importers who must ensure that the equipment they handle meets international safety requirements and performance standards.

The course is delivered over three days and covers the following eight specialized modules:

1. Module 1: Risk Estimation and Evaluation (ISO 12100)
2. Module 2: Risk Reduction Methods and Safeguarding
3. Module 3: Introduction to Functional Safety Frameworks
4. Module 4: ISO 13849-1: Safety-Related Parts of Control Systems
5. Module 5: Software Development according to ISO 13849-1
6. Module 6: Software Development & Validation (IEC 62061 & IEC 61508)
7. Module 7: Validation & Verification (V&V) according to ISO 13849-2
8. Module 8: IEC 62061: Design and Integration of Safety-Related Control Systems

Examination on day 4:

The examination will be of three (3) hrs where the use of only the training content provided is permissible.

Details of course contents:

Module 1: Risk Estimation and Evaluation (ISO 12100)

This module focuses on the foundational phase of the safety lifecycle: identifying hazards and evaluating risks. Participants will learn to use the Hazard Rating Number (HRN) methodology to quantify risk severity. A key focus is placed on defining machine limits and differentiating between 'Intended Use' and 'Reasonably Foreseeable Misuse'. Practical exercises involve analyzing complex industrial machinery to ensure no operational hazards are overlooked during the assessment phase.

Module 2: Risk Reduction Methods and Safeguarding

Once risks are identified, they must be mitigated. This module covers the selection andimplementation of protective measures according to the 3-step hierarchy. Participants will study the effectiveness of inherently safe design features, technical safeguarding measures such as light curtains and interlocks, and the role of 'Information for Use'. The module includes a systematic approach to calculating the actual risk reduction achieved through these various interventions.

Module 3: Introduction to Functional Safety Frameworks

This module provides an overview of the global safety standards landscape. It covers the hierarchy of standards(Type A, B, and C) and how they relate to the over arching goal of functionalsafety. Specific attention is given to the relationship between ISO 12100, ISO 13849-1, and IEC 62061. The module also discusses the regulatory requirements in different regions, including the new EU Machinery Regulations and relevant US standards.

Module 4: ISO 13849-1 – Safety-Related Parts of Control Systems

As the primary standard for machinery control safety, this module is a technical deep-dive into architectural design. Participants will learn how to build safety circuits for Categories B, 1, 2, 3, and 4. The curriculum covers the quantification of Performance Levels (PL a-e) and requires participants to perform manual calculations for MTTFd, Diagnostic Coverage (DC), and Common Cause Failures (CCF). The module introduces SISTEMA as a tool for modeling these circuits.

Module 5: Software Development (ISO 13849-1)

Software reliability is critical to modern machinery safety. This module focuses on the lifecycle requirements for Limited Variability Language (LVL) software. Participants learn to apply the V- Model for software development, which includes defining requirements specifications, module design, and rigorous testing. The goal is to ensure that the safety logic is robust, verifiable, and free from systematic errors that could lead to dangerous failures.

Module 6: Software Development & Validation (IEC 62061 & IEC 61508)

This module expands on software safety for complex electronic systems. It provides a simplified version of the software development process according to IEC 61508 and discusses the validation requirements for high-integrity systems. The module also addresses the differences between LVL and Full Variability Language (FVL), ensuring that developers use the correct methodology for their specific control system complexity.

Module 7: Validation and Verification (V&V) – ISO 13849-2

Validation proves that the designed safety system actually meets the target Performance Levels. This module details the process for verifying safety specifications. Participants will work through practical, reworked examples of validation plans and testing procedures. The focus is on creating a comprehensive safety technical file that demonstrates full compliance with ISO 13849-2 through systematic analysis and functional testing.

Module 8: IEC 62061 – Design and Integration

The final module provides a practical walkthrough of the design and integration process for safety- related electrical, electronic, and programmable electronic control systems. It covers the determination of Safety Integrity Levels (SIL) and demonstrates the use of safety design tools, such as ABB’sFSDT-01, to automate calculations and ensure that integrated subsystems function reliably and safely.

Note: Activities, assignments, group discussions, and case studies will be spread across all days.

Today’s industry needs cross-disciplinary knowledge to achieve the maximum quality, reliability and safety. Constantly changing functions in mobile and stationary systems require companies to reach high levels of expertise, particularly with regard to safety, in order to master this complexity. Safety regulations insist that persons with responsibilities in these environments must possess adequate specialist knowledge.

The Functional Safety Engineer – Machinery certification is an intensive three and a half day technical program providing comprehensive knowledge of the machinery safety lifecycle. From initial risk assessment according to ISO 12100 to the rigorous design and validation of safety-related control systems using ISO 13849 and IEC 62061, this course delivers the expertise needed to quantify safety performance using Performance Levels (PL) and Safety Integrity Levels (SIL).

This program includes the following standards with an exam on the final day:

ISO 12100: Risk assessment according to international standard 12100

ISO 13849-1: Safety of machinery — Safety-related parts of control systems

IEC 62061: Safety of machinery: Functional safety of electrical, electronic and programmable electronic control systems

Successful completion of the course exam is required as part of the Functional Safety Certification Program in order to be qualified as Functional Safety Engineer and earn a TÜV SÜD Academy certificate.

The aim of this course is to train delegates in the fundamental principles of functional safety and to gain competency in the application of functional safety standards certified by TÜV SÜD.

• Globally recognized TÜV SÜD certificate upon successful completion of the exam.
• Deeper insights into ISO 12100, ISO 13849-1/-2, and IEC 62061.
• Practical skills in risk estimation, defining safety functions, and using tools like SISTEMA.
• Understanding mandatory documentation andlifecycle requirements for safety-related application software (SRASW).
• Networking opportunities with industry experts and functional safety professionals.

Industry Relevance

This certification is globally recognized and serves as a benchmark for competency in the machinery sector. It is particularly relevant given the recent updates to the EU Machinery Regulations. The course is taught by functional safety experts who are active in international standards committees, ensuring that the material is not only technically accurate but also reflective of current industry best practices and regulatory shifts.

Earning an ISO 13849 and IEC 62061 Functional Safety for Machinery Sector Engineer-level certificate serves several important purposes:

1. Demonstrates Competence in Functional Safety

These standards define how to design and validate safety-related control systems for machinery. Certification shows you have the knowledge to:

• Assess risks and hazards in machinery.
• Design safety functions that meet required Performance Levels (PL) or Safety Integrity Levels (SIL).
• Apply systematic approaches to reduce risks to acceptable levels.
  
  

2. Compliance with International Standards

Many industries (automotive, manufacturing, robotics, etc.) require compliance with ISO 13849 and IEC 62061 for legal and regulatory reasons. Certification ensure:

• You understand the standards deeply.
• You can help your organization achieve compliance and avoid liability.
  
  

3. Career Advancement & Credibility

Being certified at the engineer level:

• Positions you as a subject matter expert in functional safety.
• Opens opportunities for roles in safety engineering, risk assessment, and system design.
• Adds credibility when working with clients or auditors.
  
  

4. Improves Safety and Reduces Risk

Functional safety is about preventing accidents caused by control system failures. Certification equips you to:

• Implement robust safety architectures.
• Validate safety functions correctly.
• Reduce the likelihood of catastrophic failures.
  
  

5. Strategic Value for Organizations

Companies benefit because:

• Certified engineers help avoid costly accidents and downtime.
• They ensure machinery meets global safety requirements, enabling international trade.

Instructor-led training in a virtual classroom. This means the course is Live Online. Participants will learn through online teaching. Lectures, case studies, group exercises, discussions, problem solving, examples with explanation, assignments and/or quizzes happen in the virtual classroom training. Participants need to connect to the class from any internet accessible location. Each module is delivered live using webinar technology, creating a virtual classroom learning environment. Live sessions provide you with direct access to the trainer so you can ask questions, understand complex concepts and share ideas with peers. Webcam and microphone are REQUIRED to interact with the instructor and/or other participants.

The training program culminates in an online proctored exam in which you will need your webcam on.

The course content and structure are designed by the domain experts from TÜV SÜD. With immense experience and knowledge in the relevant standards, our team of product specialists and technical experts at TÜV SÜD, developed the course content based on current business landscape and market requirements.

Participants are assessed via a proctored examination at the end of the 3-day session.

• Certificate of Successful Completion: Awarded to those who pass the examination.
• Certificate of Attendance: Awarded to participants who meet attendance requirements but do not pass the exam.

Certification Exam Information

Participants who successfully pass the exam will receive the TÜV SÜD Functional Safety Engineer (FSeng) for the Machinery Sector certificate.

Exam Details

• Schedule: The exam takes place on Day 4 of the training program.
• Duration: 150 minutes (2 hours 30 minutes)
• Format: Single-choice exam (one correct answer per question)
• Number of Questions: 85
• Scoring:
  • Each correct answer is worth 1 point
  • Incorrect or unanswered questions receive 0 points
  • Maximum achievable score: 85 points

Passing Requirements
To pass the examination, participants must achieve a score of 50% or higher, which corresponds to a minimum of 43 points.

Retake Policy: One retake is permitted within 12 months for unsuccessful candidates.

Learners must obtain copies of the ISO standards to be referenced during the course. The standards may be purchased through the American National Standards Institute (ANSI) (www.ansi.org) and/or American Society for Quality (ASQ) (www.asq.org).

To maximize the benefits of this course, participants should have a background in engineering or machine design. A basic knowledge of machinery safety principles and an understanding of control system components, such as sensors, logic solvers, and actuators, is strongly recommended. This foundational knowledge allows participants to engage more deeply with the advanced technical calculations and design concepts presented in the curriculum.

1. What is the Functional Safety Engineer for ISO 13849 & IEC 62061 Training Course?

The Functional Safety Engineer for ISO 13849 & IEC 62061 training course is a 3.5 day programme that teaches engineers, technicians, and managers how to design and manage safety-related control systems in machinery. It covers key standards, including ISO 13849 and IEC 62061, with a focus on SIL, performance levels, diagnostics, and compliance. Participants can earn a TÜV SÜD certificate and apply for engineer-level registration in the Functional Safety Certification Program.

2. What is Functional Safety?

Functional safety is, simply put, “protecting a user from technology”. It also protects technology from users. However, more technically the definition of functional safety is: “Systems that lead to the freedom from unacceptable risk of injury or damage to the health of people by the proper implementation of one or more automatic protection functions (often called safety functions). A safety system consists of one or more safety functions.

3. What is functional safety, and why is it important in machinery systems?

Functional safety is a part of the overall safety of a system or equipment, which depends on the correct functioning of safety-related systems. It involves ensuring that machinery behaves as intended in response to inputs, avoiding hazardous events or controlling them effectively when failures or malfunctions occur.

In machinery systems, functional safety is crucial because it helps prevent accidents that could result in injury, damage, or fatalities. By implementing safety-related control systems (eg sensors, actuators, and logic controllers), functional safety ensures that risks associated with machinery operation are reduced to acceptable levels. This includes protecting operators, preventing equipment failure, and safeguarding the surrounding environment.

4. What are the key differences between ISO 13849 and IEC 62061?

ISO 13849 and IEC 62061 are both standards used to assess and implement functional safety in machinery, but they differ in their approaches and areas of application:

Scope:

• ISO 13849: Focuses on safety-related parts of control systems (SRP/CS) for machinery, including mechanical, hydraulic, pneumatic, and electrical components.
• IEC 62061: Applies specifically to electrical, electronic, and programmable electronic (E/E/PE) systems used in machinery.

Performance Metrics:

• ISO 13849: Uses Performance Level (PL) to quantify the reliability of safety functions, which is based on parameters such as MTTFd (Mean Time to Dangerous Failure), diagnostic coverage, and system architecture.
• IEC 62061: Uses Safety Integrity Level (SIL), which is part of a more detailed assessment based on Probability of Dangerous Failure per Hour (PFH), Safe Failure Fraction (SFF), and PFD (Probability of Failure on Demand).

Complexity:

• ISO 13849: Simpler to apply and is generally used for less complex machinery systems with simpler safety requirements.
• IEC 62061: More complex and suited to machinery with higher-risk applications, especially when using programmable electronics and complex control systems.

5. How do ISO 13849 and IEC 62061 relate to other machinery safety standards like IEC 61508?

IEC 61508 is a general standard for functional safety across all sectors, including machinery, process industries, and automotive, which provides a framework for the safety lifecycle of electrical, electronic, and programmable electronic systems (E/E/PE).

ISO 13849 and IEC 62061 are sector-specific derivatives of IEC 61508 tailored for machinery safety:

ISO 13849 deals with safety-related parts of control systems and is broader in terms of technology (mechanical, hydraulic, etc.), while IEC 62061 focuses on the electrical and programmable aspects.

Both standards use performance metrics (PL for ISO 13849 and SIL for IEC 62061) that align with the broader SIL concept found in IEC 61508, but adapted for the needs of machinery safety.

In summary, IEC 61508 is the overarching framework, while ISO 13849 and IEC 62061 are machinery-specific standards that apply its principles to ensure functional safety.

6. What is the purpose of ISO 13849 and IEC 62061, and when should each be applied?

ISO 13849 aims to ensure the functional safety of safety-related parts of control systems (SRP/CS), covering a broad range of technologies (electrical, mechanical, hydraulic, etc.). It is applied when dealing with less complex machinery where the control system is not primarily electronic or programmable. This standard is best for applications with simpler safety functions, often in smaller machines or equipment with straightforward safety needs.

IEC 62061 focuses on safety-related electrical, electronic, and programmable electronic control systems (SRECS) in machinery. It should be applied when the safety functions of the machinery are primarily electronic, especially in complex machinery or equipment involving programmable logic controllers (PLCs) and software-based safety controls.


TÜV SÜD additionally offers the opportunity to deliver this training as a dedicated in-house course, delivered solely to your organisation to meet your needs and requirements. To receive a quote and find out more information, please contact us at [email protected].