Introduction

• Three-day classroom training, tailored to the requirements of technicians
• Well thought-out combination of theory and practice with a high degree of interaction
• Training offered worldwide
• Globally recognised certificate from SGS-TÜV Saar and SICK

Who should enroll

• Technicians, service technicians, machine operators, safety officers, engineers with a need for knowledge on safety of machinery
• Suited to end users, system integrators and OEMs at the industrial automation area

Prerequisites

• At least 2 years of work experience with industrial machinery
• Basic knowledge in automation technology and familiarity with the requirements of electrical safety

Duration                                                    Pricing (excl.GST) per person

Sign up for the training

Your benefits

• Experience training conducted by experts with extensive technical know-how, years of experience in machine safety and knowledge of local safety requirements
• Acquire the ability to evaluate protective measures on your machines and thus make a decisive contribution to operational safety in your company
• Benefit from structured, practical knowledge transfer and helpful training material for your daily work
• Use the “Certified Functional Safety Application Technician” title on your business card

Objectives

• Inspection of the installation of protective devices
• Identification of hazards
• Identification of safety relevant impairments for machine operators
• Application of measures to maintain operational safety
• Support when purchasing machines with safety-related requirements

Participants learn

• that fundamental standards and regulations for safe machinery are relevant (e.g., ISO 12100/ AS/NZS 4024.1201, ISO 13849-1 / AS/NZS 4024.1503, and EU Machinery Directive, EU Work Equipment Directive, ANSI B11.19, NR12)
• how and where to find related standards and regulations
• what has to be observed in general for the installation of selected protective equipment and the reliable usage thereof

Participants will understand

• the need for and the procedure of risk assessment and identification of hazards
• the differences between the various protective devices regarding functionality, application and relevant parameters (excluding hydraulics and pneumatics)
• the importance of correct installation of the protective equipment
• the need of regular verification of protective measures
• basic terms of machine safety and the definition of a safety function
• the relevance of modifications to a machine with respect to safety of machinery
• the necessity of legally compliant documentation

Participants will be able to

• understand and document protective devices and their mode of operation using an example application
• derive necessary activities to check the protective measures
• identify defeating of protective equipment and suggest countermeasures
• perform and document verifications according to a specified test plan

After the training, participants are able to fulfill these tasks:

• Check of the correct mechanical and electrical installation of protective devices
• Evaluate and verify protective devices according to a specification
• Identify hazards
• Suggest protective devices
• Support the purchasing department to specify the safety related requirements for machines and production lines
• Propose activities to sustain the safety of machinery
• Recognise safety related impairments for machine operators and shortcomings in machine safety

Agenda

Day 1

• Cooperation TÜV Saar & SICK
• Legal fundamentals
• 6 steps to safe machinery –general proceeding
• Requirements of the EU and the intentions (CE, enabling the EU market)
• The relevance and priority of laws, directives and standards
• Different stakeholders (user, manufacturer) – different directives –similar obligations
• Risk assessment for new machines (manufacturer)
• Risk assessment for hazards caused by the installation (machine end user)
• When a machine user becomes a manufacturer
• Definition of a machine What falls under the machinery directive and what doesn’t?
• The general requirements of the CE mark
• International, regional and national standards
• Differences between type A, type B and type C standards
• Type C standards for specific machine types
• General indications about occurring hazards and possible solutions
• Type C standards always have priority over Type A and type B standards
• Procedure during risk assessment

• Who must perform a risk assessment?
• What is the content of a risk assessment?
• The risk assessment and risk reduction process (3-step method)
• Machine phases of life (machine life cycle)
• Risk assessment continued  by machine user based on residual risk from manufacturer
• Risk assessment methods

• 3-step risk reduction method
• (Safe)Design principles
• Physical/ non-physical guards and a selection tools (ISO 12100 / AS/NZS 4024.1201)
• Different requirements for hazardous point, access and area protection

Day 2

• All aspects –electrical, mechanical (constructive), (micro)ergonomic, light, noise, etc.
• Electro-magnetic compatibility (EMC)
• Incentive for manipulation
• Requirements for safety
• Short circuit, cross-connection, power and device failure
• Counter measures: dual channel, test pulses, forced-to-open contacts, redundancy 

• Types of physical guards
• Monitored access

• Installation requirements (fastening elements)
• No new hazards arise when accessing/ opening physical guards
• Stopping times & calculation for physical guards (S=KxT)
• Heights, distances, body values for upper & lower limbs (ISO 13857 / AS/NZS 4024.1801)
• Unlocking by timing, automated, manual
• Position switches with advanced manipulation protection

• Protection types (hazardous point, access, area protection)
• Stationary machines or mobile platforms
• Functionality of AOPD and AOPDDR
• Appropriate safety distance for respective resolutions (ISO 13855 / AS 4024.2801, S=KxT+C)
• Avoiding reaching over, under, around protective devices
• Different types for different applications (AOPD, AOPDDR, Camera based) 
• PLr depending on the result of risk assessment
• AOPDDR –max PL d 
• Reflection, mirroring and counter measures

• HW requirements: yellow background, red button, manual reset (locally)
• Functional requirements:

• Different types: push buttons, rope switches
• Emergency Stop ‘complementary measure’ does not reduce risk
• Emergency Stop always has priority over all other functions
• No further hazards, when Emergency Stop is actuated
• No restart of machine movements upon reset
• EMO switches off the energy supply

Day 3

• Safety Functions split in subsystems –integrated in machine safety control system
• Input –logic –output = safety function (safety chain)
• Many different safety functions available
• Mostly more than one required to sufficiently realise a protective measure
• Difference requirements for standard and safety components –5 pillars
• The performance level of an SRP/CS is estimated via quantifiable (e.g., category) and qualifying aspects (e.g., safety related software).
• Complete safety chain must meet PLr (a, b, c, d, e acc. ISO 13849-1 / AS/NZS 4024.1503) 

• Signs, instructions, PPE, training –last step in 3-step method
• Pictograms preferred
• Additional measures: audible alarm, light tower, rotating light
• Operating instructions: original language and additional country related language
• Possible hazard signs for existing residual risk
• Required knowledge level for operating personnel (training requirements)

• Occasion related inspections
• Upgrading –state of the art technology

• What shall be checked and why (2009/104/EC)
• Full coverage of the protected area (test equipment)
• Appropriate installation, reaching over, under around, climbing/ stepping on or over
• Closed gaps, safety distances (additional equipment –e.g., 2-hand-control) stopping time, lighting, ergonomics, mirroring, reflection, machine upgrades, manipulation
• Documentation of alterations, modifications & upgrades