CLC IEC/TS 63394:2024

Safety of machinery - Guidelines on functional safety of safety-related control system

In the context of the safety of machinery, the sector standard IEC 62061 as well as ISO 13849 1 provide requirements to manufacturers of machines for the design, development and integration of safety-related control systems (SCS) or safety-related parts of control systems (SRP/CS), depending on technology used (mechanical, pneumatic, hydraulic or electrical technologies) to perform safety function(s). This document does not replace ISO 13849-1 and IEC 62061. This document gives additional guidance to the application of IEC 62061 or ISO 13849-1. This document:  gives guidelines and specifies additional requirements for specific safety functions based on the methodology of ISO 12100, which are relevant in machinery and respecting typical boundary conditions of machinery;  considers safety functions which are designed for high demand mode of operation yet are rarely operated, called rarely activated safety functions; NOTE 1 IEC 62061:2021 completely covers high demand. However, other safety functions related to the protection of the machine itself and indirectly of persons are considered more in detail in this document.  gives additional information for the calculation of failure rates using other (non-electronic) technologies based e.g. on Weibull distribution, because all the formula defined in IEC 62061 and ISO 13849-1 are based on exponential distribution. Therefore, the basis for these guidelines and additional requirements is  a typical classification of safety functions;  a consideration of typical architectures used for designing safety functions;  a consideration of modes of operation of safety functions;  the derivation and evaluation of PFH formulas for subsystems considering the used technology. NOTE 2 These guidelines can also be used for application of ISO 13849-1 for the design process of SRP/CS. This document does not address low demand mode of operation according to IEC 61508. This document does not take into account either layer of protection analysis (LOPA) or basic process control system (BPCS), according to IEC 61511 as a risk reduction measure. This document considers all lifecycle phases of the machine regarding functional safety, and SCS or SRP/CS. NOTE 3 The user of the machine needs information from the machine manufacturer for the safe operation of the machine, e.g. useful lifetime of components, maintenance information, testing of safety functions if necessary.

Sicherheit von Maschinen - Leitlinien zur funktionalen Sicherheit sicherheitsbezogener Steuerungssysteme

Sécurité des machines - Lignes directrices sur la sécurité fonctionnelle des systèmes de commande relatifs à la sécurité

Varnost strojev - Smernice za funkcionalno varnost varnostno vodenega sistema

V kontekstu varnosti strojev področna standarda IEC 62061 in ISO 13849-1 podajata zahteve za proizvajalce strojev v zvezi z načrtovanjem, razvojem in integracijo varnostno vodenih sistemov (SCS) ali varnostnih delov nadzornih sistemov (SRP/CS), glede na tehnologijo (mehansko, pnevmatsko, hidravlično ali električno), ki se uporablja za izvajanje varnostnih funkcij. Ta dokument ne nadomešča standardov ISO 13849-1 in IEC 62061. Ta dokument podaja dodatna navodila za uporabo standarda IEC 62061 oziroma ISO 13849-1. Ta dokument:
–   podaja smernice in določa dodatne zahteve za posebne varnostne funkcije na podlagi metodologije standarda ISO 12100, ki so relevantne za stroje, pri čemer se upoštevajo značilni mejni pogoji strojev;
–   obravnava varnostne funkcije, ki so zasnovane za način delovanja z visokimi zahtevami, vendar se redko uporabljajo (imenovane redko aktivirane varnostne funkcije);
OPOMBA 1: Visoke zahteve so v celoti zajete v standardu IEC 62061:2021. V tem dokumentu pa so podrobneje obravnavane druge varnostne funkcije, povezane z zaščito samega stroja in posredno oseb.
–   podaja dodatne informacije za izračun pogostosti okvar z uporabo drugih (neelektronskih) tehnologij, ki temeljijo na primer na Weibullovi porazdelitvi, saj vse formule, opredeljene v standardih IEC 62061 in ISO 13849-1, temeljijo na eksponentni porazdelitvi.
Podlaga za te smernice in dodatne zahteve je naslednja:
–   značilna razvrstitev varnostnih funkcij;
–   upoštevanje značilnih arhitektur, ki se uporabljajo za načrtovanje varnostnih funkcij;
–   upoštevanje načinov delovanja varnostnih funkcij;
–   izpeljava in vrednotenje formul PFH za podsisteme glede na uporabljeno tehnologijo.
OPOMBA 2: Te smernice je mogoče uporabiti tudi v povezavi s standardom ISO 13849-1 pri načrtovanju varnostnih delov nadzornih sistemov.
Ta dokument ne obravnava načina delovanja z nizkimi zahtevami v skladu s standardom IEC 61508.
Ta dokument ne obravnava analize varnostnih plasti (LOPA) ali osnovnega nadzornega sistema za proces (BPCS) kot ukrepa za zmanjšanje tveganja v skladu s standardom IEC 61511.
Ta dokument obravnava vse faze življenjskega cikla stroja v zvezi s funkcionalno varnostjo, vključno z varnostno vodenimi sistemi oziroma varnostnimi deli nadzornih sistemov.
OPOMBA 3: Uporabnik stroja mora od proizvajalca stroja prejeti informacije za njegovo varno delovanje (npr. uporabna življenjska doba sestavnih delov, informacije o vzdrževanju, preskušanje varnostnih funkcij, če je to potrebno).

General Information

• Status: Published
• Publication Date: 01-Feb-2024
• ICS: 13.110 - Safety of machinery
• ICS: 25.040.99 - Other industrial automation systems
• ICS: 29.020 - Electrical engineering in general
• Technical Committee: CLC/TC 44X - Safety of machinery: electrotchnical aspects
• Current Stage: 6060 - Document made available - Publishing
• Start Date: 02-Feb-2024
• Due Date: 18-Feb-2025
• Completion Date: 02-Feb-2024
• Ref Project: SIST-TS CLC IEC/TS 63394:2024 - Safety of machinery - Guidelines on functional safety of safety-related control system

Standards Content (Sample)

SLOVENSKI STANDARD
01-september-2024
Varnost strojev - Smernice za funkcionalno varnost varnostno vodenega sistema
Safety of machinery - Guidelines on functional safety of safety-related control system
Sicherheit von Maschinen - Leitlinien zur funktionalen Sicherheit sicherheitsbezogener
Steuerungssysteme
Sécurité des machines - Lignes directrices sur la sécurité fonctionnelle des systèmes de
commande relatifs à la sécurité
Ta slovenski standard je istoveten z: CLC IEC/TS 63394:2024
ICS:
13.110 Varnost strojev Safety of machinery
25.040.99 Drugi sistemi za Other industrial automation
avtomatizacijo v industriji systems
29.020 Elektrotehnika na splošno Electrical engineering in
general
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

TECHNICAL SPECIFICATION CLC IEC/TS 63394

SPÉCIFICATION TECHNIQUE
TECHNISCHE SPEZIFIKATION February 2024
ICS 13.110; 29.020; 25.040.99
English Version
Safety of machinery - Guidelines on functional safety of safety-
related control system
(IEC/TS 63394:2023)
Sécurité des machines - Lignes directrices sur la sécurité Sicherheit von Maschinen - Leitlinien zur funktionalen
fonctionnelle des systèmes de commande relatifs à la Sicherheit sicherheitsbezogener Steuerungssysteme
sécurité (IEC/TS 63394:2023)
(IEC/TS 63394:2023)
This Technical Specification was approved by CENELEC on 2024-01-22.

CENELEC members are required to announce the existence of this TS in the same way as for an EN and to make the TS available promptly
at national level in an appropriate form. It is permissible to keep conflicting national standards in force.

CENELEC members are the national electrotechnical committees of Austria, Belgium, Bulgaria, Croatia, Cyprus, the Czech Republic,
Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, the
Netherlands, Norway, Poland, Portugal, Republic of North Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland,
Türkiye and the United Kingdom.

European Committee for Electrotechnical Standardization
Comité Européen de Normalisation Electrotechnique
Europäisches Komitee für Elektrotechnische Normung
CEN-CENELEC Management Centre: Rue de la Science 23, B-1040 Brussels
© 2024 CENELEC All rights of exploitation in any form and by any means reserved worldwide for CENELEC Members.
Ref. No. CLC IEC/TS 63394:2024 E

European foreword
This document (CLC IEC/TS 63394:2024) consists of the text of IEC/TS 63394:2023 prepared by
IEC/TC 44 "Safety of machinery - Electrotechnical aspects".
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. CENELEC shall not be held responsible for identifying any or all such patent rights.
Any feedback and questions on this document should be directed to the users’ national committee. A
complete listing of these bodies can be found on the CENELEC website.
Endorsement notice
The text of the International Technical Specification IEC/TS 63394:2023 was approved by CENELEC
as a European Technical Specification/Technical Report without any modification.
In the official version, for Bibliography, the following notes have to be added for the standard indicated:
IEC 60204-1:2016 NOTE Approved as EN 60204-1:2018
IEC 60947-5-3:2013 NOTE Approved as EN 60947-5-3:2013 (not modified)
IEC 60947-5-8:2020 NOTE Approved as EN IEC 60947-5-8:2021 (not modified)
IEC 60947-7-1 NOTE Approved as EN 60947-7-1
IEC 60947-7-2 NOTE Approved as EN 60947-7-2
IEC 61000-6-7 NOTE Approved as EN 61000-6-7
IEC 61025:2006 NOTE Approved as EN 61025:2007 (not modified)
IEC 61496-1 NOTE Approved as EN IEC 61496-1
IEC 61508-1:2010 NOTE Approved as EN 61508-1:2010 (not modified)
IEC 61508-4:2010 NOTE Approved as EN 61508-4:2010 (not modified)
IEC 61508-5:2010 NOTE Approved as EN 61508-5:2010 (not modified)
IEC 61508-6:2010 NOTE Approved as EN 61508-6:2010 (not modified)
IEC 61508-7:2010 NOTE Approved as EN 61508-7:2010 (not modified)
IEC 61800-5-2:2016 NOTE Approved as EN 61800-5-2:2017 (not modified)
IEC 61511 (series) NOTE Approved as EN 61511 (series)
IEC 61649:2008 NOTE Approved as EN 61649:2008 (not modified)
ISO 11161:2007 NOTE Approved as EN ISO 11161:2007 (not modified)
ISO 13855:2010 NOTE Approved as EN ISO 13855:2010 (not modified)

Annex ZA
(normative)
Normative references to international publications
with their corresponding European publications
The following documents are referred to in the text in such a way that some or all of their content
constitutes requirements of this document. For dated references, only the edition cited applies. For
undated references, the latest edition of the referenced document (including any amendments) applies.
NOTE 1  Where an International Publication has been modified by common modifications, indicated by (mod), the
relevant EN/HD applies.
NOTE 2  Up-to-date information on the latest versions of the European Standards listed in this annex is available
here: www.cencenelec.eu.
Publication Year Title EN/HD Year
IEC 62061 2021 Safety of machinery - Functional safety of EN IEC 62061 2021
safety-related control systems
IEC/TR 63074 2019 Safety of machinery - Security aspects related - -
to functional safety of safety-related control
systems
ISO 12100 2010 Safety of machinery - General principles for EN ISO 12100 2010
design - Risk assessment and risk reduction
ISO 13849-1 2015 Safety of machinery - Safety-related parts of - -
control systems - Part 1: General principles for
design
ISO 13850 2015 Safety of machinery - Emergency stop function EN ISO 13850 2015
- Principles for design
ISO 13851 2019 Safety of machinery - Two-hand control devices EN ISO 13851 2019
- Principles for design and selection
ISO 14118 2017 Safety of machinery - Prevention of unexpected EN ISO 14118 2018
start-up
ISO 14119 2013 Safety of machinery - Interlocking devices EN ISO 14119 2013
associated with guards - Principles for design
and selection
IEC TS 63394 ®
Edition 1.0 2023-02
TECHNICAL
SPECIFICATION
colour
inside
Safety of machinery – Guidelines on functional safety of safety-related control

system
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
ICS 13.110; 29.020; 25.040.99 ISBN 978-2-8322-6533-8

– 2 – IEC TS 63394:2023 © IEC 2023
CONTENTS
FOREWORD . 9
INTRODUCTION . 11
1 Scope . 12
2 Normative references . 12
3 Terms and definitions . 13
3.1 Terms and definitions . 13
3.2 Alphabetical list of terms, definitions and abbreviated terms . 26
4 Typical classification of safety functions in safety of machinery . 28
4.1 General . 28
4.1.1 Overview . 28
4.1.2 Risk assessment and risk reduction according to ISO 12100 . 28
4.1.3 Risk reduction and interconnection to SCS and SRP/CS . 29
4.1.4 Basic assumptions for risk reduction in machinery . 29
4.2 Basic safety assumptions for the design and integration of the SCS or
SRP/CS . 29
4.3 Safety functions . 30
4.3.1 General . 30
4.3.2 Risk reduction process by safety functions . 30
4.3.3 Typical classification of safety functions . 31
4.4 Interrelation between ISO 12100 and IEC 62061 or ISO 13849-1 . 32
4.4.1 General . 32
4.4.2 Input information in accordance with IEC 62061 or ISO 13849-1 . 32
4.4.3 Output information from IEC 62061 or ISO 13849-1 . 33
4.5 Safety functions for protection of persons . 34
4.5.1 General . 34
4.5.2 Safety functions for protection of persons based on guards and
protective devices . 34
4.6 Other safety functions to prevent hazardous situations . 35
4.6.1 General . 35
4.6.2 Other safety functions . 35
4.7 Safety functions for protection of the integrity of the machine . 36
4.7.1 General . 36
4.7.2 Safety functions for the protection of integrity of the machine . 36
4.8 Safety functions and Type-C standards . 36
5 Demand mode of operation related to safety functions . 37
5.1 General . 37
5.2 High demand or continuous mode of operation . 37
5.2.1 General . 37
5.2.2 Approach of IEC 62061 and ISO 13849-1 . 38
5.2.3 Rarely activated safety functions . 38
5.3 Low demand mode of operation . 39
5.3.1 General . 39
5.3.2 Approach of IEC 62061 and ISO 13849-1 . 40
6 Design process of safety functions . 40
6.1 General . 40
6.2 Design procedure . 40
6.3 Evaluation of required safety integrity . 41

IEC TS 63394:2023 © IEC 2023 – 3 –
6.4 Decomposition of a safety function . 41
6.5 Subsystem design . 41
6.5.1 Architectural constraints . 41
6.5.2 Fault accumulation and undetected faults . 43
6.5.3 Evaluation of PFH . 43
6.6 Examples of safety functions. 45
7 Verification procedures for safety functions . 45
7.1 General . 45
7.2 Verification of the test interval of a safety function . 45
7.3 Verification procedures . 46
7.4 Initial verification . 46
7.5 Periodic verification . 47
7.5.1 General . 47
7.5.2 Frequency of periodic verification . 48
7.6 Verification reporting . 49
Annex A (informative) Risk assessment and risk reduction according to ISO 12100 . 50
A.1 General . 50
A.2 Ris
...