Machine Safety Function Register Worksheet
Every safety function on a machine should be listed once with the performance level it needs, the performance level it reaches and the proof that it works. This register is that list, ready to feed the technical file.
| SF # | Safety function | Hazard addressed | Required PL (PLr) | Achieved PL | Category | Main devices | Validation | Calculation / test ref | |
|---|---|---|---|---|---|---|---|---|---|
Flag any row where achieved PL is lower than the required PL. The register supports, but does not replace, the risk assessment and the verification calculations required by ISO 13849-1 and ISO 13849-2.
Organize technical file data
Optional review of keeping safety and compliance records linked to machine serial numbers.
Optional. The tool and every export work without this. No spam.
How to use the register
Start from the risk assessment. For each hazard that needs a control measure, create a safety function row and name it by the action it performs, such as stop the robot when the guard opens. Enter the required performance level from your risk graph, then the achieved level from your calculation. Fill in the category, the main devices and the reference to the calculation or test record. Update the validation column as tests are completed and export the sheet for the technical file.
- Name the function by action, not by device
- PLr comes from the risk assessment, not from guesswork
- Achieved PL must be equal to or higher than PLr
- Link each row to a calculation and a test record
Performance level and category
ISO 13849-1 expresses the reliability of a safety function as a performance level from a to e. The achieved level depends on the architecture category (B, 1, 2, 3, 4), the mean time to dangerous failure of components, diagnostic coverage and common cause failure measures. Tools such as manufacturer calculators or SISTEMA can compute it. This worksheet stores the results, it does not calculate them. In the example, SF4 has an achieved PL of c against a required d, which flags a design gap that must be closed before the machine ships.
Validation and the technical file
Calculation is not validation. ISO 13849-2 expects tests that show each function actually performs, including fault conditions where practical. Record the test reference and the result on each row. When a row fails, link it to a punch item or corrective action. For machines placed on the EU market, this register is a convenient index for the technical file, alongside the risk assessment, circuit diagrams and the declaration of conformity.
Common mistakes
Common errors are listing devices instead of functions, copying PLr values from a similar machine, and skipping validation of the less obvious functions such as safe speed during setup. Another mistake is changing a guard or program late in the project without revisiting the register. Treat any change to a safety function as a trigger to update the row and repeat the affected test.
Frequently Asked Questions
What is PLr?
PLr is the required performance level for a safety function, determined from the risk assessment using factors such as severity of injury, frequency of exposure and possibility of avoiding the hazard. It sets the minimum reliability the safety function must achieve.
Does this worksheet calculate performance level?
No. It records the results from a proper calculation tool and your validation tests. Use manufacturer data and a recognized calculation method to determine the achieved level.
Is this register enough for CE marking?
No. It is one part of the technical file. You also need the risk assessment, drawings, instructions, applicable standards list and the declaration of conformity or incorporation.
How often should it be updated?
Whenever a safety function is added, changed or retested, and at the end of each project phase. Review it before FAT and again before shipment so no row is left unvalidated.
If you manage machine documentation across several projects, Netray can help organize it with your ERP and PLM data. Ask for a short review.
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