Complete Guide to EN ISO 13849-1: Functional Safety for Modern Machinery

Ensuring the safety of automated machinery is a core requirement in today's industrial environments. EN ISO 13849-1 is one of the most widely applied international standards for functional safety, providing a systematic framework for designing, evaluating, and validating safety-related control systems.

This guide explains the key principles of the standard, how Performance Levels are determined, and why compliance is essential for manufacturers, integrators, and end users.

What Is EN ISO 13849-1?

EN ISO 13849-1 is an internationally recognised standard that defines requirements for the design and assessment of safety-related parts of control systems. It applies to machinery across different industries, ensuring that safety functions are capable of reducing risks to acceptable levels.

The standard covers:

· The structure of safety-related control systems

· Hardware quality, diagnostics, and reliability

· Software design requirements

· Determining Performance Levels (PL)

· Validation of safety functions

Unlike older prescriptive standards, EN ISO 13849-1 takes a risk-based approach, allowing engineers to tailor safety solutions to the unique hazards of each machine.

The Role of Safety Functions

A safety function is any control action that helps prevent or mitigate a hazardous situation. Examples include:

· Emergency stop functions

· Guard monitoring on doors and fences

· Presence detection using safety light curtains or scanners

· Two-hand control units

· Safe speed or safe motion monitoring

Each function must be designed so that failures do not lead to unacceptable risk. EN ISO 13849-1 provides a structured method for evaluating the reliability of each function individually.

Understanding Performance Levels (PL)

Performance levels are used to specify the ability of safety-related parts of a control system to perform safety functions under foreseeable conditions.

Performance Level (PL) is a measure defined in the ISO 13849-1 standard. It indicates the ability of a machine's safety control system to perform its safety functions under foreseeable conditions.

In simple terms, PL quantifies how well a safety system can reduce risk — the higher the PL, the lower the probability that a dangerous failure will occur.

PL is categorized into five levels: PLa, PLb, PLc, PLd, and PLe.

· PLa represents the lowest safety performance (basic protection).

· PLe represents the highest level, used for high-risk applications such as heavy presses, robotics, or automated production lines.

Determining the Required Performance Level (PLr) is a fundamental step in ensuring functional safety and reducing machine-related risks to an acceptable level. The process, as defined by ISO 13849-1, should be conducted early in the machine design phase, when safety functions are being specified and risk mitigation strategies are developed.

To identify the required PLr, engineers evaluate three key parameters using the standard risk graph:

Severity of Injury (S): Determines how serious the potential harm could be. Minor or reversible injuries correspond to S1, while severe or irreversible injuries (including fatal accidents) correspond to S2.

Frequency and Duration of Exposure (F): Refers to how often and how long an operator is exposed to a hazard. Occasional access is classified as F1, whereas frequent or constant exposure is F2.

Possibility of Avoiding the Hazard (P): Evaluates whether the operator can reasonably avoid or limit harm once the hazard occurs. If avoidance is feasible, it is rated P1; if avoidance is nearly impossible, it is P2.

By combining these three parameters, the required Performance Level can be determined. For instance, a scenario involving minor injury potential (S1), frequent exposure (F2), and low avoidance possibility (P2) would lead to a Required Performance Level of PLr = C. In this case, the safety-related control system must meet PL C or higher (PL C–PL E) to ensure adequate protection.

This systematic approach ensures that each safety function is designed with the appropriate reliability, aligning both with regulatory compliance and the operational safety goals of the machine.

Performance Level (PL) is a measure defined in the ISO 13849-1 standard. It indicates the ability of a machine's safety control system to perform its safety functions under foreseeable conditions.

In simple terms, PL quantifies how well a safety system can reduce risk — the higher the PL, the lower the probability that a dangerous failure will occur.

PL is categorized into five levels: PLa, PLb, PLc, PLd, and PLe.

· PLa represents the lowest safety performance (basic protection).

· PLe represents the highest level, used for high-risk applications such as heavy presses, robotics, or automated production lines.

PL vs. SIL: Understanding the Difference

Both Performance Level (PL) and Safety Integrity Level (SIL) define how reliably a safety control system performs its protective function — yet they come from different standards and apply to other types of systems.

PL, from ISO 13849-1, is mainly used in machine control systems that include mechanical, pneumatic, hydraulic, or electronic components.

SIL, from IEC 62061 (and IEC 61508), focuses on electrical and programmable electronic systems.

While both measure the probability of a dangerous failure, their methods differ:

· PL evaluates system reliability using categories (B–4), MTTFd, diagnostic coverage (DC), and common cause failure (CCF), defining levels from PLa to PLe.

· SIL uses a quantitative probability model (PFHd) to classify systems from SIL 1 to SIL 4.

Although approximate correlations exist, PL and SIL are not interchangeable. Each should be applied according to the relevant standard, depending on the control architecture and the scope of the application.

Why Performance Levels Matter

Performance Levels are not just technical classifications — they represent the measurable reliability of a machine’s safety system. Establishing the correct PL ensures that safety-related components consistently perform their intended protective functions, even in the event of a fault or system stress.

A properly defined and validated PL brings several key advantages:

· Enhanced Safety Assurance: The system maintains a predictable and dependable safety response, minimizing the risk of injury or equipment damage.

· Regulatory Compliance: Meeting the appropriate PL fulfills international safety requirements, supporting conformity with ISO 13849-1 and global market standards.

· Operational Efficiency: Well-designed safety architectures reduce unnecessary interruptions, enabling continuous, safe, and efficient production.

· Long-Term Reliability: Verified PL levels help ensure the system’s safety performance remains stable over its entire lifecycle.

In essence, Performance Levels bridge the gap between functional safety and industrial productivity. They provide engineers with a quantifiable benchmark for system integrity and give organizations the confidence that their automation processes meet the highest safety expectations.

Our Perspective: Building Safer and Smarter Systems with High-Performance Safety Sensors

At Dadisick, we are committed to developing advanced safety sensing solutions that meet international safety standards and support high-performance Level (PL) requirements. Our technologies empower engineers and system integrators to design machine safety systems that safeguard personnel while maintaining optimal production efficiency. By combining precision detection, fast response times, and proven reliability, Dadisick safety sensors help manufacturers achieve the required Performance Level (PLr) with confidence — ensuring every system operates safely, intelligently, and efficiently in demanding industrial environments.

Conclusion: Performance Levels — The Core of Safe and Reliable Automation

Understanding and applying Performance Levels (PL) is the foundation of every safe and compliant automation system.

By aligning machine design practices with ISO 13849-1 and integrating reliable safety components, companies can ensure not only regulatory compliance but also long-term operational excellence.

A clearly defined Performance Level represents more than just a safety metric — it reflects a company’s commitment to protection, reliability, and trust across every stage of the production process.