Stage 4: Installation and Validation Requirements

The Functional Safety Lifecycle and YOU!

Stage 4: Installation and Validation Requirements

By Tyler Knutson, Automation Specialist, Safety

Machine safety has become more recognized than ever before. Employers and equipment manufacturers are tasked with providing equipment that is free from recognized hazards yet remain efficient, productive, & competitively priced. Revere Electric Supply, in partnership with Rockwell Automation, provides the tools needed to improve compliance, simplify development, reduce design time, and reduce costs.

In Stages 1 -3: You learned the importance of having a proven method of providing documentation showing a machine is safe to operate, mitigation techniques required, developing the functional safety requirements for your newly assessed machine, and using the tools needed to properly design & verify your safety system.

For Stage 4, we will focus on ensuring that your system was installed properly and to your specifications.

Some Questions to ask While Installing & Validating Your Safety System

1. Installation

  • Do the safety components meet the functional specifications?
  • Have the wiring methods been verified and proper grounding procedures met?
  • Has the correct signage and labeling been used?
  • Has wiring been installed per the electrical schematics?

2. Validation

  • Are the instructions on proper validation developed for each safety function?
  • Normal operation test: Safety input » Logic » Output
  • Abnormal operation test: Induce faults, short wires, break connections, remove wires, etc.

3. Have ISO 13849-2 Standards been followed during this process?

It’s important to make sure the system you’ve installed follows the documentation laid out in Stages 1-3. Validation of those systems ensures you or your customers that you are still current and meet the correct safety standards.

Note that Revere Electric is here to help you move forward with the validation process to meet the requirements set by your risk assessment and design process

What Items Should be Included in a Validation Checklist?

  1. General Machine Information (Machine name/ Model, Serial, Customer Information, Tester Information, BOM)
  2. Step by Step Verification Process
    • List out step number with description of verification action
    • Pass / fail
    • Indicate any changes / modifications made during the process
  3. focus on specific operations
    • Normal Operation: The Safety System responds properly to all normal Start, Stop, and Reset commands
    • Abnormal Operation: The Safety System responds properly to all forseeable faults with corresponding diagnostics
      • Safety input tests, safety output tests
      • Communication between relay tests, Configured settings tests

Rockwell Automation has assembled numerous Machinery Safety Functions that provide detailed validation documentation relating to your application. Along with a similar bill of material, you can mix / match different validation documentation to build a common process for your documentation. If you are working on current project, please use these as reference to help you move from your Risk Assessment (Stage 1) to Installation and Validation (Stage 4).

For more information into providing the appropriate products to meet your risk assessment and functional safety specifications, please review the following:

Rockwell Automation Machinery Safebook 5

Rockwell Automation Pre-Engineered Safety Functions

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