SGS-TUV Saar CFSAT Functional Safety Training

Event Information

Would you like to contribute to the operational safety and legal certainty of your company? In conjunction with SICK, Aventum are offering the CFSAT functional safety course with TÜV certification. This comprehensive course is conducted by SICK experts in machine safety and provides a well-thought-out combination of theory and practice with a high degree of interaction.

What are the learning outcomes?

Estimate the effectiveness of the installed protective devices
Check protective devices according to a specification
Identify hazards
Advice on the use of protective devices
Support the purchasing department in defining the safety related requirements on machines and production lines
Propose measures to maintain the safety of machines
Recognize safety-related impairments for machine operators and lack of machine safety
Take the Certified Functional Safety Application Technician exam

What does the course cover?

Fundamental standards and regulations for safe machinery, including ISO 12100, ISO 13849, IEC 60204, ISO 13855, ISO 13857, ISO 14120 and EU Machinery Directive, EU Work Equipment Directive from the perspective of the machine operator.
Thorough checking of protective devices
Identify hazards
Identification of safety-related impairments for machine operators
Application of measures to maintain the safety of machine operators
Support when purchasing machines with safety-related requirements.

Who should attend?

The CFSAT course is aimed at service and maintenance personnel for machines and systems, safety officers, system integrators, and designers with a basic knowledge of machine safety.

Prerequisites for certification

To complete the course with a certificate, you will require:

At least 2 years of work experience with industrial machinery
Basic knowledge of automation engineering and familiarity with electrical safety requirements
Basic knowledge of functional safety and machine safety standards and regulations
A pass in the CFSAT exam

$ 2,973

+ GST

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

$ 561

+ GST

Optional Exam
SGS-TÜV Saar Certification

Training Agenda

Day 1

Introduction

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

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

Risk reduction

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

Safe design

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

Physical guards

Types of physical guards
Monitored access

Interlocking w/ w/o locking systems – selection tool (ISO 12100 1 AS/NZS 4024.1201)

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

Non-physical guards (AOPD/AOPDDR)

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

Emergency STOP ≠ Emergency OFF

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

Latchable, stop categories, visibility, accessibility,

machine assignment, must be functional at all times

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

Functional Safety

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)

Administrative measures

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)

EU requirements acc. work equipment directive

Occasion related inspections
Upgrading –state of the art technology

Inspections based upon the work equipment directive

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

Where & When