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Industry Challenges

Contec continuously updates its engineering practices to align with evolving functional safety standards. With the release of the fourth edition of ISO 13849-1 in July 2023, significant updates have been introduced that affect how safety-related control systems are specified, designed, validated and maintained. We have already begun integrating these changes into our services to support our clients maintain compliance, improve system reliability, and prepare for future regulatory transitions.

What’s New in ISO 13849:2023?

This edition introduces technical and structural improvements that reshape how machine safety is approached in both design and documentation of your process or machines:

ISO 13849:2023

  • Clearer Design Workflow: Safety functions must now be defined in detail through a Safety Requirements Specification (SRS) before design begins.

  • Integration of Validation: Validation requirements previously in Part 2 are now embedded in Part 1, emphasizing their importance in the design process.

  • Subsystem Approach: A clear distinction between SRP/CS (Safety-Related Parts of Control Systems) and subsystems, enabling modular design and integration of SIL-rated components.

  • Enhanced Software Requirements: A dedicated section for safety-related software introduces lifecycle models, classification of programming languages (LVL vs. FVL), and validation strategies.

  • Electromagnetic Interference Immunity: New Annex L provides practical strategies for EMC compliance, including system-level protective measures.

  • Functional Safety Plan: Mandatory planning to prevent systematic failures, documented in Annex G.

  • Updated Performance Level (PL) Determination: Revised risk graph and parameter definitions for PLr calculation, with stricter documentation requirements

How Contec has implemented the 2023 Standard

These changes are already reflected in how Contec scopes, designs, and validates safety-related systems. Our updated workflows incorporate the new requirements across all project phases:

  1. Risk Assessment & Safety Function Specification
    • We use EN ISO 12100 in combination with ISO 13849:2023 Annex A, to define safety functions with precise details: triggering events, response times, operating modes, and PLr requirements.
    • We ensure feasibility checks early in the process to identify potential misuse or the risk of bypassing safety functions, as recommended in section 5.2.3.
  2. Subsystem Design & Integration
    • Our modular design approach combines EN ISO 13849-compliant subsystems with SIL-rated components from IEC 61508/62061.
    • We apply updated category requirements, including fault detection strategies for Category 2 and fault accumulation considerations for Category 4.
  3. Software Development & Validation
    • We follow the V-model for safety-related software, adapting development and validation to the programming language type (LVL or FVL).
    • Validation is planned and executed in accordance with Annex N.
  4. Electromagnetic Compatibility (EMC) Strategy Integration
    • We apply Annex L’s point-based evaluation system for immunity measures, ensuring compliance without unnecessary testing costs.
  5. Validation & Documentation
    • Our validation activities are aligned with Section 10 of the standard, including both functional testing and analytical methods.
    • We provide full technical documentation and user guidance in compliance with Sections 12 and 13, supporting CE marking and audit readiness.
  6. Maintainability & Lifecycle Support
    • We design safety systems with long-term maintainability in mind, including physical accessibility, intuitive diagnostics, and support for ongoing maintenance.
    • Our team continues to assist clients with system updates, technical documentation, and compliance support throughout the machine lifecycle.

    Client Benefits from Early Adoption

    • Regulatory Readiness Compliance: Early adoption of ISO 13849:2023 ensures readiness for upcoming harmonization under the EU Machinery Directive.
    • Improved Safety & Reliability: Enhanced design and validation processes reduce risks of systematic and random failures.
    • Cost Efficiency: Modular subsystem integration and alternative EMC strategies optimize resources without compromising safety.
    • Digital Integration: Advanced software lifecycle management supports Industry 4.0 and remote diagnostics while maintaining safety integrity.

    Conclusion

    The 2023 revision of ISO 13849-1 sets a new benchmark for machine safety. By embedding these principles into our services, Contec reinforces its position as a trusted partner for safe, compliant, and innovative automation solutions.

    For more details or to schedule a compliance review, contact our safety engineering team today.