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PD ISO TR 22100 — Safety of Machinery Relationship with ISO 12100 Technical Reports
Safety of Machinery — Relationship with ISO 12100 (ISO/TR 22100-1/2/3, BSI UK implementation)
🛡️ PD ISO TR 22100 is the UK implementation, published by BSI, of the ISO/TR 22100 series of technical reports, prepared by UK Technical Committee MCE/3 (Safeguarding of machinery) and focused on the relationship between safety of machinery and ISO 12100. The three parts in this batch are: Part 1, how ISO 12100 relates to type-B and type-C standards; Part 2, how ISO 12100 relates to ISO 13849-1 (safety-related parts of control systems); and Part 3, implementation of ergonomic principles in safety standards. Together they clarify the hierarchical relationships and coordination methods of the machinery-safety standards system (types A/B/C), and are an important reference for machine designers, safety engineers, and standards writers in understanding and applying the machinery-safety standards system.
💡 ISO 12100 (Safety of machinery — General principles for design — Risk assessment and risk reduction) is the type-A foundational standard in machinery safety, specifying the general principles of risk assessment and risk reduction. Type-B standards (e.g., ISO 13849-1 control systems) and type-C standards (specific machinery safety requirements) are built upon it, forming a hierarchical, coordinated safety standards system.
1. Series Overview 📌
The machinery-safety standards system is organised into types A, B, and C: Type A (basic safety standards, e.g., ISO 12100) gives the fundamental concepts and design principles applicable to all machinery; Type B (group safety standards) addresses a class of safety characteristics (e.g., ISO 13849-1 control-system safety, ISO 13850 emergency stop), subdivided into B1 and B2; and Type C (machinery safety standards) addresses specific machinery (e.g., presses, injection moulding, woodworking machines). The ISO/TR 22100 series clarifies the coordination among these classes and guides correct referencing and implementation. BSI adopts them as “PD ISO/TR 22100-xxx”.
In this batch, Part 1 clarifies the relationship between ISO 12100 and type-B/C standards, Part 2 clarifies the relationship between ISO 12100 and ISO 13849-1, and Part 3 addresses the implementation of ergonomic principles in safety standards.
2. Series Structure and Part Highlights 📋
| Part | Document Title | ISO Edition | Core Content |
|---|---|---|---|
| Part 1 | How ISO 12100 relates to type-B and type-C standards | ISO/TR 22100-1:2015 (Ed. 1.0) | Position of ISO 12100 in the safety standards system, coordination and referencing with type-B/C standards |
| Part 2 | How ISO 12100 relates to ISO 13849-1 | ISO/TR 22100-2:2013 (Ed. 1.0) | Strategy and relationship for using ISO 13849-1 control systems in risk assessment and risk reduction |
| Part 3 | Implementation of ergonomic principles in safety standards | ISO/TR 22100-3:2016 (Ed. 1.0) | Ergonomic risk assessment and reduction strategy, significant ergonomic hazards, and potential consequences |
All three parts are classified under ICS 13.110 (Safety of machinery) and handled by the same UK technical committee MCE/3, progressing from “system relationship” to “control safety” to “ergonomics”.
⚠️ This series comprises technical reports (TR) that clarify inter-standard relationships and implementation methods; they are not mandatory requirements. Specific machinery should comply with the applicable type-C standard; if none exists, risk assessment and risk reduction per type-A/B standards apply.
3. Key Technical Requirements 🔧
1. ISO 12100 Relationship with Type-B/C Standards (Part 1)
Part 1 clarifies the structure and coordination of the machinery-safety standards system, mainly including:
- Position of ISO 12100: its foundational role as a type-A basic standard in the system;
- Relationship with type-B standards: the linkage between ISO 12100 and type-B standards (e.g., emergency stop, guards, control safety);
- Relationship with type-C standards: how type-C standards define specific machinery safety requirements based on ISO 12100;
- Referencing and coordination: how to correctly reference and coordinate various standards in design, avoiding conflicts and omissions.
2. ISO 12100 Relationship with ISO 13849-1 (Part 2)
ISO 13849-1 specifies the design and evaluation of safety-related parts of control systems (performance level PL, categories). Part 2 clarifies the relationship, mainly including:
- Risk assessment and risk reduction strategy: how to use the control-system safety requirements of ISO 13849-1 during risk assessment and risk reduction;
- Safety-related parts of control systems: the role of ISO 13849-1 in machinery safety design and its linkage with ISO 12100;
- Practical guidance: methods for translating ISO 13849-1 safety-function requirements into the risk-reduction process.
3. Implementation of Ergonomic Principles (Part 3)
Ergonomics (operating force, reachability, posture, vision) is an important dimension of risk assessment. Part 3 explains the implementation of ergonomic principles in safety standards:
- Risk assessment and reduction strategy: risk assessment and risk reduction strategy for ergonomic hazards;
- Significant ergonomic hazards: identifying significant ergonomic hazards within the ISO 12100 framework;
- Potential consequences: assessing the potential consequences of ergonomic hazards (e.g., musculoskeletal disorders, fatigue, mis-operation).
🚨 If ergonomics is ignored in machinery safety design, operators may be subjected to uncomfortable postures or excessive operating forces, leading to fatigue, mis-operation, and musculoskeletal disorders — increasing accident risk. Risk assessment must systematically incorporate the ergonomic dimension.
4. Engineering Practice Applications 🛠️
- 🔍 Standard selection: when designing machinery, first confirm the applicable type-C standard; if none, perform risk assessment per ISO 12100 and reference appropriate type-B standards to ensure adequate risk reduction.
- ⚙️ Control-safety design: for safety functions (e.g., emergency stop, guard interlock), determine the performance level (PL) and category per ISO 13849-1, linked with the ISO 12100 risk-assessment process.
- 👷 Ergonomic optimisation: when designing operator interfaces, maintenance access, and material handling, incorporate ergonomic assessment per Part 3 to reduce operator burden and mis-operation risk.
- 📋 Safety assessment and CE: in machinery safety assessment and CE certification, use this series as a guide to build a harmonised-standard reference matrix, forming complete risk assessment and validation documentation.
5. Frequently Asked Questions ❓
❓ Q: What is the difference between type-A, B, and C machinery-safety standards?
A: Type-A (e.g., ISO 12100) gives general safety design principles for all machinery; type-B addresses a class of safety characteristics (e.g., control safety, guards); type-C gives safety requirements for specific machinery. Type-C takes precedence; where no type-C exists, perform risk assessment per type-A/B.
A: Type-A (e.g., ISO 12100) gives general safety design principles for all machinery; type-B addresses a class of safety characteristics (e.g., control safety, guards); type-C gives safety requirements for specific machinery. Type-C takes precedence; where no type-C exists, perform risk assessment per type-A/B.
❓ Q: What is the performance level (PL) in ISO 13849-1?
A: PL (Performance Level) is the metric in ISO 13849-1 for evaluating the performance of safety-related parts of control systems, graded a–e, related to the severity of harm, exposure frequency, and avoidability, used to determine the required control performance of a safety function.
A: PL (Performance Level) is the metric in ISO 13849-1 for evaluating the performance of safety-related parts of control systems, graded a–e, related to the severity of harm, exposure frequency, and avoidability, used to determine the required control performance of a safety function.
❓ Q: Why does machinery safety emphasise ergonomics?
A: Poor ergonomics causes operator fatigue, discomfort, and mis-operation, increasing accident risk. Incorporating ergonomics into risk assessment and risk reduction is key to safeguarding operator safety and health and improving human-machine interaction reliability.
A: Poor ergonomics causes operator fatigue, discomfort, and mis-operation, increasing accident risk. Incorporating ergonomics into risk assessment and risk reduction is key to safeguarding operator safety and health and improving human-machine interaction reliability.
🔍 Q: Is this series mandatory?
A: No. They are technical reports (TR) clarifying inter-standard relationships and implementation methods. Actual machinery safety should comply with the applicable type-C standard or risk assessment per type-A/B standards, and meet relevant regulatory requirements (e.g., the Machinery Directive).
A: No. They are technical reports (TR) clarifying inter-standard relationships and implementation methods. Actual machinery safety should comply with the applicable type-C standard or risk assessment per type-A/B standards, and meet relevant regulatory requirements (e.g., the Machinery Directive).