Lifecycle Stage 09

Pre-Commissioning and Calibration

1. Purpose of This Stage

This stage is the systematic verification that the installed system is correctly wired, configured, calibrated, and functionally operational before the process or machine is started with actual production conditions. It is the bridge between installation (Stage 8) and full commissioning (Stage 10).

The distinction between pre-commissioning and commissioning is critical:

• Pre-commissioning (this stage): Verifies the system is built and installed correctly — wiring, configuration, calibration, and basic functional response. Performed without the process running, without material in the machine, and without production conditions. The goal is to find and fix construction and installation errors before they become dangerous under actual operating conditions.
• Commissioning (Stage 10): Verifies the system performs correctly under actual or simulated production conditions — response times measured with actual machine dynamics, safety functions tested with actual safeguarding devices and actual hazard zone conditions, V&V report completed.

Pre-commissioning catches the errors that should never reach commissioning: wired-to-wrong-terminal, reversed polarity, miscalibrated sensor, incorrect safety PLC configuration, motor running backward, e-stop wired to wrong channel. Discovering these errors during commissioning — with the process running and people in the area — is more expensive, more disruptive, and potentially dangerous.

This stage also establishes baseline measurements that become the reference for the entire operational life of the machine — initial calibration values, initial proof test response measurements, and initial safety function verification records. These baselines are used during Stage 11 (Maintenance) to detect degradation over time.

This stage answers: Is every circuit, device, instrument, and safety function verified to be correctly installed and basically functional before we start the machine with the process?

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2. Entry Criteria

This stage begins when Stage 8 (Installation) exit criteria are met.

Required Inputs

Input	Source (Stage)	Why It Matters
Installation record (completed)	Stage 8	Confirms all physical installation is complete, field wiring verified, grounding verified, power supply verified, safety distances measured
Pre-commissioning checklist	Stage 6 (commissioning package)	The structured checklist created by the designer — defines what must be verified and in what order
Safety function verification plan	Stage 5 / Stage 6	Defines test procedures and acceptance criteria for each safety function — pre-commissioning executes the preliminary tests; Stage 10 executes the full tests
Safety function register (finalized)	Stage 3 / Stage 4	Master reference for all safety functions with PLr/SIL targets, safe states, response times, reset behavior
Cause and effect matrix	Stage 6	Reference for verifying that every input produces the correct output response
As-built schematics	Stage 7 / Stage 8	Current revision reflecting all build and field changes — the reference for all wiring verification
As-built interconnection diagrams	Stage 7 / Stage 8	Reference for field wiring verification
I/O assignment table	Stage 5	Reference for I/O verification — maps every physical I/O point to its PLC address and function
Safety PLC program (approved version with CRC/signature)	Stage 7	Reference for verifying that the loaded program matches the approved version
Drive parameter list (approved)	Stage 7	Reference for verifying drive configuration including safety-related parameters
Component-specific commissioning procedures	Manufacturer data	Commissioning procedures for specific safety devices (light curtain alignment, laser scanner zone verification, safety PLC diagnostic checks)
Calibration specifications	Stage 5 / manufacturer data	Calibration range, accuracy, and acceptance criteria for each instrument
Response time analysis	Stage 4	Reference for preliminary response time checks (full measurement in Stage 10)
Build records (from Stage 7)	Stage 7	In-panel functional test results — pre-commissioning builds on these, not repeats them
Available fault current documentation	Stage 8	Confirms SCCR is not exceeded — verified before any energization
Customer site safety requirements	Customer	Permit requirements, LOTO procedures, hot work permits, site-specific PPE, observer/witness requirements

Pre-Commissioning Readiness Verification

Before pre-commissioning activities begin:

Check	Action	Responsible
Installation record complete and signed	Confirm all Stage 8 exit criteria are met	Project engineer
All installation open items resolved or dispositioned	No open items that affect pre-commissioning scope	Project engineer
All as-built documentation is current revision	Schematics, interconnection diagrams, I/O table, cable schedule reflect actual installation	Project engineer / controls designer
All safety devices physically installed and wired	No temporary jumpers or bypasses on safety circuits (unless formally documented and controlled)	Safety engineer / installer
All guards installed	Physical guards in place — pre-commissioning tests require guards to be operated	Mechanical / project engineer
Machine is in a safe state for testing	No material in the machine, no production conditions, hazard zones clear of personnel (except test personnel with controlled access)	Site supervisor / safety engineer
Test equipment available and calibrated	Multimeters, Megger, loop calibrators, stopwatches/timers, phase rotation meter, vibration meter (if applicable) — all with current calibration certificates	Commissioning engineer
Site LOTO and safety procedures in effect	LOTO procedures for controlled energization and de-energization; personnel trained on emergency procedures	Site safety / commissioning engineer
Customer witness requirements identified	If customer requires witness of specific tests, schedule is coordinated	Project manager

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3. Standards Influence

Standard	Role at This Stage	Key Requirements
ISO 13849-1:2023 Annex K	Provides a systematic verification checklist for safety-related parts of control systems — the primary tool for pre-commissioning verification of machinery safety functions	Annex K (informative but widely used as the de facto checklist); §8.2 (validation — testing)
ISO 13849-2:2012	Provides fault lists and validation methods for specific technologies (electrical, pneumatic, hydraulic, mechanical) — used to define what faults to test during pre-commissioning	All tables (fault lists by technology)
IEC 62061:2021 §6.6	Verification requirements for SRECS — systematic verification that the hardware and software implementation matches the safety requirements specification	§6.6 (verification), §6.9 (validation)
IEC 61511-1:2016 §15	Pre-startup safety review (PSSR) requirements for SIS — formal review confirming that the SIS is installed, configured, tested, and ready for operation	§15 (SIS installation, commissioning, and validation), §16 (SIS safety validation)
IEC 60204-1:2016 §18	Verification and testing requirements for machine electrical equipment — PE continuity, insulation resistance, voltage withstand, functional tests	§18.1 (general), §18.2 (continuity of PE), §18.3 (insulation resistance), §18.4 (voltage withstand), §18.5 (protection against residual voltage), §18.6 (functional tests)
NFPA 79:2024 §19	Testing requirements for machine electrical equipment — similar to IEC 60204-1 §18	§19.4 (testing)
ISA 84.00.01 / IEC 61511	Pre-startup acceptance test (PSAT) requirements for SIS	Clause 15
IEC 61508-2:2010 §7.9	Hardware integration testing requirements	§7.9
IEC 61326-1:2020	EMC requirements — if EMC testing is required at the installation site (typically for CE marking or if EMC issues are suspected)	All clauses
ISO 13855:2010	Safety distance verification — pre-commissioning confirms that the installed safety distances meet the calculations	All clauses
IEC 62046:2018	Verification of muting functions — specific test requirements for muting, blanking, and reduced resolution	All applicable clauses
Manufacturer commissioning procedures	Each safety device manufacturer provides commissioning and verification procedures specific to their product — these are normative for the device’s PL/SIL certification	Per device

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4. Engineering Activities

4.1 Pre-Commissioning Sequence

The recommended sequence ensures that basic electrical integrity is confirmed before functional testing, and non-safety functions are verified before safety functions (so that the machine can be controlled during safety testing):

Phase 1: ELECTRICAL VERIFICATION (No power applied)
    │
    ├── Step 1: Visual inspection
    ├── Step 2: PE continuity verification (field wiring)
    ├── Step 3: Insulation resistance test (field wiring)
    ├── Step 4: Point-to-point spot check (field wiring)
    │   ★ GATE: Electrical verification complete — safe to energize ★
    │
    ▼
Phase 2: INITIAL ENERGIZATION (Controlled power-up)
    │
    ├── Step 5: Controlled power-up sequence
    ├── Step 6: Voltage verification at all distribution points
    ├── Step 7: Control power verification (24VDC, 120VAC)
    ├── Step 8: PLC and safety controller boot verification
    │   ★ GATE: System energized and stable ★
    │
    ▼
Phase 3: I/O VERIFICATION AND LOOP CHECKS
    │
    ├── Step 9: Standard (non-safety) I/O verification
    ├── Step 10: Safety I/O verification
    ├── Step 11: Analog loop checks and calibration
    ├── Step 12: Communication link verification
    │   ★ GATE: All I/O verified ★
    │
    ▼
Phase 4: MOTOR AND ACTUATOR CHECKS
    │
    ├── Step 13: Motor rotation check (bump test)
    ├── Step 14: Motor protection verification
    ├── Step 15: Actuator stroke and position verification
    ├── Step 16: Pneumatic/hydraulic system verification
    │   ★ GATE: All drives and actuators verified ★
    │
    ▼
Phase 5: SAFETY FUNCTION VERIFICATION (DRY RUN)
    │
    ├── Step 17: Safety controller configuration verification
    ├── Step 18: Safety function dry-run testing (each SF)
    ├── Step 19: ISO 13849-1 Annex K checklist execution
    ├── Step 20: Muting function verification (if applicable)
    ├── Step 21: Mode-dependent safety behavior verification
    ├── Step 22: Diagnostic function verification
    │   ★ GATE: All safety functions verified (dry run) ★
    │
    ▼
Phase 6: INSTRUMENT CALIBRATION
    │
    ├── Step 23: Transmitter calibration / verification
    ├── Step 24: Safety-rated instrument calibration
    ├── Step 25: Alarm setpoint verification
    │   ★ GATE: All instruments calibrated ★
    │
    ▼
Phase 7: BASELINE DOCUMENTATION
    │
    ├── Step 26: Record baseline measurements
    ├── Step 27: Complete pre-commissioning checklist
    ├── Step 28: Pre-commissioning review and sign-off
    │   ★ GATE: Pre-commissioning complete — ready for Stage 10 ★

4.2 Phase 1: Electrical Verification (No Power)

Step 1: Visual Inspection

Check Item	What to Look For
Field wiring	No visible damage, no loose connections, no missing labels, no wires pinched in enclosure doors or cable glands
Safety devices	All safety devices installed and undamaged — light curtains, guard switches, e-stops, safety sensors, laser scanners
Guards	All physical guards installed, secure, no gaps
Enclosures	All covers closed, all glands sealed, no foreign objects inside panels
Labels and nameplates	All wire labels, component labels, and panel nameplates present and legible
Cable routing	Safety circuit cables separated from power cables per design; dual-channel separation maintained in field routing
Junction boxes	All covers installed and secured; terminal connections tight; wire identification present

Step 2: PE Continuity Verification (Field Wiring)

Requirement	Method	Acceptance Criteria
PE continuity from every exposed conductive part of the machine to the main PE terminal	Low-resistance ohmmeter (≥ 200mA test current per IEC 60204-1, or ≥ 10A for formal testing)	≤ 0.1Ω
Includes: machine frame, remote enclosures, door-mounted components, safety device enclosures, conduit system	Point-by-point measurement	Document each measurement point and value

Note: If PE continuity was measured during installation (Stage 8), pre-commissioning verifies that the measurements are still valid and extends to any points not measured during installation.

Step 3: Insulation Resistance Test (Field Wiring)

Requirement	Method	Acceptance Criteria
Insulation resistance between all power conductors and PE	Megger test at 500VDC (for circuits ≤ 500V)	≥ 1 MΩ
Disconnect all electronic devices before testing	Remove PLC modules, disconnect VFDs, disconnect safety controllers, disconnect power supplies — Megger voltage can damage electronics	Document which devices were disconnected
Test between phases (L1-L2, L1-L3, L2-L3) and each phase to PE	Megger at each point	≥ 1 MΩ per test

If insulation resistance is below 1 MΩ, investigate and correct before energizing. Low insulation resistance indicates damaged insulation, moisture ingress, or contamination.

Step 4: Point-to-Point Spot Check (Field Wiring)

Requirement	Method	Scope
Spot-check field wiring against interconnection diagrams	Continuity check with multimeter	If 100% P2P was performed at Stage 8: spot-check 10-20% of field connections plus 100% of any connections made after Stage 8 P2P check. If 100% P2P was NOT performed at Stage 8: perform 100% P2P now.
100% check of all safety circuit field wiring	Continuity and correct terminal landing verification	Every safety circuit field wire verified — no exceptions
Verify no shorts between channels	Insulation check between Channel A and Channel B conductors of dual-channel safety circuits	No continuity between channels when devices are disconnected

★ GATE: Electrical Verification Complete ★ All Phase 1 checks must pass before power is applied. Any failure must be investigated and corrected.

4.3 Phase 2: Initial Energization

Step 5: Controlled Power-Up Sequence

Step	Action	Verification
1	Ensure all output devices are in safe state (motor disconnects open, pneumatics vented, hydraulics depressurized)	Physical verification
2	All personnel clear of machine hazard zones	Verbal confirmation; visual check
3	Close main disconnect	No trips, no arcing, no abnormal sounds
4	Measure voltage at main bus	Correct voltage, correct phase rotation
5	Energize control transformer / 24VDC power supply	Measure output voltage — within specification
6	Verify PLC boots correctly	RUN indicators, no fault LEDs, correct mode
7	Verify safety controller boots correctly	Status LEDs per manufacturer documentation; safety controller enters expected startup state
8	Verify HMI boots correctly	Home screen displays; communication with PLC established

Step 6-8: Voltage and System Verification

Check	Method	Acceptance Criteria
Voltage at every power distribution point	Multimeter measurement	Within ±10% of nominal (or per component specification)
24VDC at safety I/O power rail	Multimeter measurement	24VDC ±10% (typical 21.6–26.4VDC) — some safety controllers require tighter range
24VDC at remote I/O cabinets	Multimeter measurement at the furthest point	Within specification after cable voltage drop
Safety controller status	LED indicators, diagnostic screen	No faults; correct configuration loaded; correct firmware version
Safety PLC program CRC/signature	Read from safety controller	Matches approved CRC/signature from Stage 7

★ GATE: System Energized and Stable ★

4.4 Phase 3: I/O Verification and Loop Checks

Step 9: Standard (Non-Safety) Digital I/O Verification

Activity	Method	Documentation
Verify each digital input	Activate each input device (push button, limit switch, proximity sensor, etc.); observe PLC input status (via PLC programming software or HMI diagnostic screen)	Record: I/O address, device tag, activated state (ON/OFF), correct response (yes/no)
Verify each digital output	Command each output from PLC (via force or test routine — with appropriate safety precautions); verify physical output device activates	Record: I/O address, device tag, commanded state, physical response confirmed
Verify correct mapping	Input device tag matches I/O assignment table; output device tag matches I/O assignment table	Any mismatch → wiring error or programming error — investigate and correct

Step 10: Safety I/O Verification

Safety I/O verification requires additional rigor because errors in safety I/O can directly affect safety function integrity.

Activity	Method	Documentation
Verify each safety input (Channel A and Channel B independently)	Activate safety device; verify safety controller registers correct state on both channels; verify discrepancy detection works (activate one channel only — controller should detect mismatch)	Record: SF-ID, I/O address (CH A and CH B), device tag, activated state, both channels respond correctly, discrepancy detection confirmed
Verify each safety output	Command safety output from safety controller; verify physical output device (contactor, valve) activates and deactivates correctly	Record: SF-ID, I/O address, device tag, commanded state, physical response confirmed
Verify EDM feedback	With safety output energized: verify feedback input reads “healthy.” Simulate contactor welding (manually hold contactor in — if safe to do so — or disconnect feedback wire): verify safety controller detects fault	Record: SF-ID, feedback I/O address, healthy state confirmed, fault detection confirmed
Verify dual-channel input independence	Disconnect one channel at a time; verify safety controller detects single-channel loss and responds correctly (fault state or safe state per design)	Record: SF-ID, CH A disconnected — response, CH B disconnected — response
Verify safe state on loss of power	Remove 24VDC from safety I/O; verify all safety outputs go to safe state (contactors drop out, valves close/vent)	Record: Safe state confirmed for all safety outputs

Step 11: Analog Loop Checks and Calibration

Activity	Method	Documentation
Loop check each analog input	Apply known signal (4mA, 12mA, 20mA for 4-20mA loops; or known process value from calibrator) at the field device; verify PLC reads correct value	Record: Loop tag, applied signal, PLC reading, error (within specification?)
Loop check each analog output	Command known output value from PLC; measure actual signal at the output terminal or at the field device	Record: Loop tag, commanded value, measured signal, error
Verify scaling	Apply 0%, 50%, 100% signals; verify PLC engineering units read correctly	Record: Raw signal vs engineering unit at each point
Identify and correct zero/span errors	If readings are out of tolerance, adjust at the transmitter, at the PLC scaling, or both	Record: Before adjustment values, adjustment made, after adjustment values

Step 12: Communication Link Verification

Activity	Method	Documentation
PLC to safety controller	Verify safety data exchange; verify correct addressing; verify failsafe behavior on communication loss (disconnect cable — verify safe state)	Record: Link status, data exchange confirmed, failsafe behavior confirmed
PLC to HMI	Verify all HMI data points updating correctly; verify alarm communication	Record: Link status, data exchange confirmed
PLC to drives (fieldbus)	Verify drive communication; verify correct drive addressing; verify failsafe behavior on communication loss	Record: Link status, drive response confirmed, failsafe confirmed
Safety network (PROFIsafe, CIP Safety, FSoE, etc.)	Verify safety network communication; verify correct addressing and configuration; verify failsafe behavior on communication loss	Record: Safety network status, all nodes online, failsafe behavior confirmed
Remote I/O	Verify all remote I/O modules communicating; verify correct addressing	Record: Module status, data exchange confirmed

★ GATE: All I/O Verified ★

4.5 Phase 4: Motor and Actuator Checks

Step 13: Motor Rotation Check (Bump Test)

Activity	Method	Precautions
Verify motor rotation direction	Briefly energize each motor (“bump”) and observe rotation direction; compare to required direction per mechanical design	Motor disconnects closed one at a time; area clear of personnel; observer positioned to see rotation safely; ready to stop immediately
Correct reversed rotation	If rotation is incorrect: de-energize, LOTO, swap two phase conductors at the motor terminal box (for 3-phase) or at the starter	Do NOT swap phases at the panel — this may affect other circuits

Step 14: Motor Protection Verification

Activity	Method	Documentation
Verify overload relay settings	Compare overload relay trip setting to motor nameplate FLA	Record: Motor tag, nameplate FLA, overload setting, correct (yes/no)
Verify VFD motor parameters	Compare VFD motor parameters (voltage, frequency, FLA, power) to motor nameplate	Record: Drive tag, motor nameplate data, drive parameter values, correct (yes/no)
Verify VFD safety function parameters	Compare STO, SS1, SS2, SLS, SOS parameters to approved parameter list from Stage 7	Record: Drive tag, parameter name, approved value, actual value, correct (yes/no)
Motor insulation test (if required)	Megger test on motor windings — disconnect from VFD/starter before testing	≥ 1 MΩ (or per motor manufacturer specification)

Step 15: Actuator Stroke and Position Verification

Activity	Method	Documentation
Verify valve stroke (pneumatic/hydraulic)	Command valve open and closed; verify full stroke; verify position feedback matches actual position	Record: Valve tag, full open confirmed, full close confirmed, feedback correct
Verify cylinder operation	Command cylinder extend and retract; verify full travel; verify position switches (if any) activate at correct positions	Record: Cylinder tag, full extend confirmed, full retract confirmed, position switches correct
Verify safety-rated actuators	Safety valves, safety-rated cylinders — verify safe state position on loss of control signal or loss of supply pressure/power	Record: Actuator tag, safe state position confirmed on signal loss, safe state position confirmed on supply loss

Step 16: Pneumatic/Hydraulic System Verification

Activity	Method	Documentation
Verify supply pressure	Measure actual supply pressure; compare to design specification	Record: Actual pressure vs specified pressure
Verify pressure regulation	Verify pressure regulators set correctly; verify safety pressure switches (if any) activate at correct setpoints	Record: Regulator settings, pressure switch setpoints
Verify exhaust/dump function	For safety circuits with energy isolation (dump valves, exhaust valves): verify that the safety function correctly vents/dumps pressure when activated	Record: Dump valve response confirmed; pressure drops to safe level within specified time
Leak test	Pressurize system; verify no leaks at connections, fittings, cylinders, valves	Record: System leak-free (or leaks identified and corrected)

★ GATE: All Drives and Actuators Verified ★

4.6 Phase 5: Safety Function Verification (Dry Run)

This is the most important phase of pre-commissioning. Each safety function is tested individually under controlled conditions — without the process running — to verify basic correct operation before full commissioning testing in Stage 10.

Step 17: Safety Controller Configuration Verification

Check	Method	Acceptance Criteria
Safety PLC program matches approved version	Read CRC/signature from safety controller; compare to approved CRC/signature from Stage 7	Exact match
Safety controller configuration parameters match approved values	Download configuration; compare parameter-by-parameter to approved configuration list	All parameters match
Safety controller firmware version is correct	Read firmware version; compare to version used in Stage 4 PL/SIL calculation and Stage 7 verification	Correct version — firmware version can affect PFHd and PL/SIL rating
Safety controller diagnostic status is clear	Check diagnostic buffer/log for any errors or warnings	No unresolved errors or warnings
No forced I/O states	Verify zero forced inputs or outputs in the safety program	Zero forces
No bypassed safety functions	Verify no safety functions are in bypass/override state (unless formally documented for pre-commissioning purposes with controlled removal procedure)	Zero bypasses (or all documented and controlled)

Step 18: Safety Function Dry-Run Testing

For each safety function in the register, perform a dry-run test:

Test Element	What to Verify	Method
Triggering	Safety function activates when the triggering condition occurs	Physically activate the safety device (open guard door, press e-stop, interrupt light curtain, etc.)
Safe state	Machine reaches the correct safe state	Verify output devices de-energize (contactors drop out, valves close/vent, drives disable); verify machine motion stops (or would stop — motors may not be loaded during dry run)
Response	Safety controller processes the demand and commands the safe state	Verify safety controller output status changes; verify safety controller diagnostic shows the demand was recognized
Indication	Safety status is correctly displayed to the operator	Verify HMI shows safety function tripped; verify any safety status pilot lights activate; verify muting lamp (if applicable) is OFF when not muting
Reset	Safety function resets only through the correct procedure	Release/clear the triggering condition; verify machine does NOT restart automatically (unless automatic restart is explicitly designed and justified); press reset button; verify machine can now be restarted
Lockout	Safety function cannot be defeated by the operator	Attempt to restart machine with safety device still in tripped state — verify restart is prevented
Cross-channel	Both channels of dual-channel safety functions operate correctly	Test with both channels active; then test with each channel individually disabled (if safe to do so) — verify safety controller detects single-channel fault

Safety Function Dry-Run Test Record Template

SF-ID	Safety Function	Test Date	Triggering Device Activated	Safe State Achieved?	Correct Outputs De-Energized?	HMI Indication Correct?	Reset Procedure Correct?	Auto-Restart Prevented?	Cross-Channel Test?	Discrepancy Detection?	EDM Test?	Result	Tested By	Witnessed By
SF-01	Guard interlock — operator door		Door opened	Y/N	K1, K2 de-energized	Y/N	Manual reset required, confirmed	Y/N	CH A tested, CH B tested	Discrepancy detected	Simulated K1 weld — detected	PASS/FAIL
SF-02	E-stop — operator station 1		E-stop pressed	Y/N	All safety outputs de-energized	Y/N	E-stop released + reset button required, confirmed	Y/N	CH A tested, CH B tested	Discrepancy detected	Simulated K1 weld — detected	PASS/FAIL
SF-03	Light curtain — infeed		LC beam interrupted	Y/N	K1, K2 de-energized	Y/N	Beam clear + reset (or auto-restart per design)	Y/N	N/A (integral dual-channel)	N/A	Simulated K1 weld — detected	PASS/FAIL

Step 19: ISO 13849-1 Annex K Checklist Execution

Annex K of ISO 13849-1 provides a structured verification checklist. The following is an expanded, practical version:

Section A: General Safety Function Verification

#	Check Item	Method	Acceptance Criteria	SF-ID	Result
A1	Safety function achieves the defined safe state	Functional test	Machine reaches defined safe state per safety function register
A2	Safety function responds to all defined triggering events	Functional test	Each triggering event produces the correct response
A3	Safety function does not produce unintended hazardous conditions when activated	Observation during test	No unexpected motion, no energy release, no hazardous condition created by the safety function itself
A4	Restart after safety function activation requires the defined reset procedure	Functional test	Machine does not restart without the specified reset action
A5	Safety function operates correctly in all defined operating modes	Test in each mode	Correct behavior in automatic, manual, setup, maintenance modes as specified

Section B: Input Device Verification

#	Check Item	Method	Acceptance Criteria	SF-ID	Result
B1	Input device is correct type and model per BOM	Visual inspection	Matches BOM part number
B2	Input device is installed per manufacturer instructions	Visual inspection	Mounting, orientation, alignment per manufacturer guide
B3	Input device NC contacts used (where specified)	Schematic comparison + functional test	Wire break / disconnection detected as safety demand
B4	Dual-channel inputs both functional	Individual channel test	Both channels respond; discrepancy detection works
B5	Input device environmental suitability	Visual assessment	Device rated for actual conditions (temperature, dust, moisture, vibration)

Section C: Logic Solver Verification

#	Check Item	Method	Acceptance Criteria	SF-ID	Result
C1	Safety controller is correct type and model per BOM	Visual inspection	Matches BOM part number
C2	Safety controller firmware version is correct	Read from controller	Matches approved version
C3	Safety program CRC/signature matches approved version	Read from controller	Exact match
C4	Safety controller configuration parameters are correct	Parameter comparison	All parameters match approved values
C5	No forced I/O or bypassed functions	Status check	Zero forces, zero bypasses
C6	Diagnostic function detects channel discrepancy	Simulate single-channel fault	Controller enters fault state or safe state within discrepancy time
C7	Watchdog / self-monitoring is functional	Observe status LEDs; check diagnostic log	No watchdog errors; self-test passes

Section D: Output Device Verification

#	Check Item	Method	Acceptance Criteria	SF-ID	Result
D1	Output devices are correct type and model per BOM	Visual inspection	Match BOM part numbers
D2	Output devices achieve safe state when de-energized	Remove control signal; observe	Contactors open, valves close/vent, drives disable
D3	EDM (External Device Monitoring) detects output device failure	Simulate output device failure (disconnect feedback wire or hold contactor in)	Safety controller detects fault; prevents restart
D4	Redundant output devices (both contactors / both valves) are functional	Test each independently (if possible without creating hazard)	Both devices respond correctly
D5	Output device utilization category is correct for the application	Verify component rating vs actual load	Rating ≥ actual load; correct AC category

Section E: Wiring and Installation Verification

#	Check Item	Method	Acceptance Criteria	SF-ID	Result
E1	Dual-channel wiring is physically separated (panel and field)	Visual inspection	Separate wire ducts in panel; separate conduits in field; per CCF requirements
E2	Safety circuit wiring is correctly identified (color, labels)	Visual inspection	Correct color; labels at both ends; consistent with wire schedule
E3	No safety circuit wiring passes through non-safety terminal blocks	Trace wiring path	Safety circuits terminate on dedicated safety terminals
E4	Cable/wire integrity	Visual and test	No visible damage; insulation resistance acceptable
E5	Safety distances are correct	Physical measurement	Measured distance ≥ calculated minimum per ISO 13855

Section F: Environmental and CCF Verification

#	Check Item	Method	Acceptance Criteria	SF-ID	Result
F1	CCF measures from Stage 4 are implemented	Inspection against CCF scoring worksheet	All scored measures are physically present and functional
F2	Environmental conditions are within component ratings	Measurement (temperature, humidity) and observation (dust, vibration, chemical exposure)	All conditions within rated range
F3	EMC environment is acceptable for safety devices	Observation; EMC testing if concerns exist	No interference observed on safety device operation; safety devices function correctly near VFDs, motors, and other EMI sources

Step 20: Muting Function Verification (If Applicable)

Test	Method	Acceptance Criteria
Muting activates only under correct conditions	Present the correct muting sensor sequence; verify muting enables	Muting engages only with correct sensor pattern; safety device is temporarily bypassed
Muting lamp activates during muting	Observe muting indication lamp	Lamp ON during muting, OFF at all other times
Muting times out if conditions not cleared	Activate muting; do not clear the muting condition; verify timeout	Muting disengages after timeout; safety device returns to active protection
Safety function remains active if muting conditions are not met	Attempt to trigger muting with incorrect sensor sequence (wrong order, single sensor, etc.)	Muting does NOT engage; safety device remains active
Safety function activates if person enters during muting	During active muting: interrupt the safety device (light curtain beam break by person, not by product)	Safety function activates — muting does not override person detection
Override/bypass indicators	If override is used for maintenance: verify override indicator is visible and cannot be ignored	Override lamp/indicator ON when override is active; HMI displays override status

Per IEC 62046 requirements.

Step 21: Mode-Dependent Safety Behavior Verification

Test	Method	Acceptance Criteria
Safety functions in automatic mode	Test all safety functions while machine is in automatic mode	All safety functions active as specified for automatic mode
Safety functions in manual/jog mode	Switch to manual mode; test all safety functions	Safety functions active as specified for manual mode; any additional safeguards for manual mode are functional (e.g., reduced speed, hold-to-run)
Safety functions in setup/teach mode	Switch to setup mode; test all safety functions	Safety functions active as specified for setup mode; enabling device (if used) is functional; speed limiting is active
Safety functions in maintenance mode	Switch to maintenance mode (if defined); test all safety functions	Safety functions active as specified; LOTO requirements are communicated
Mode transition behavior	Switch between modes; verify safety system responds correctly to each transition	No loss of safety function during mode transition; safety controller re-evaluates safety state on mode change
Mode selection authority	Verify that mode selection requires the correct authorization (key switch, password, access level)	Unauthorized mode change is prevented

Step 22: Diagnostic Function Verification

Test	Method	Acceptance Criteria
Single-channel fault detection	Disconnect one channel of each dual-channel safety function; verify detection	Safety controller detects fault within specified discrepancy time
EDM fault detection	Simulate contactor/valve welding; verify detection	Safety controller detects fault; prevents restart
Ground fault detection (if implemented)	Introduce ground fault on safety circuit (if safe to do so); verify detection	Safety controller detects ground fault
Wire break detection	Disconnect a safety input wire; verify detection	Safety controller detects loss of signal and enters safe state
Communication loss detection	Disconnect safety network cable; verify detection	Safety controller detects communication loss and enters safe state within specified time
Power supply fault detection	Reduce 24VDC voltage below minimum threshold (if safe to do so); verify detection	Safety controller detects undervoltage and responds per design
Diagnostic logging	Verify safety controller diagnostic buffer records all detected faults	Fault events logged with timestamp and fault type

★ GATE: All Safety Functions Verified (Dry Run) ★

4.7 Phase 6: Instrument Calibration

Step 23: Standard Instrument Calibration / Verification

Activity	Method	Documentation
Calibrate or verify each transmitter (pressure, temperature, level, flow)	Apply known input (calibrator, reference standard); compare transmitter output to expected output at 0%, 25%, 50%, 75%, 100% of range	Calibration certificate or record: Tag, range, applied input, measured output, error, tolerance, pass/fail, date, calibrator serial number, technician
Verify transmitter configuration	Range, engineering units, damping, output type (4-20mA, HART, fieldbus) match specification	Record: Configuration parameters vs specification
Verify alarm setpoints	Command or simulate process values at alarm setpoints; verify alarm activates at correct value	Record: Alarm tag, setpoint, actual activation point, error, tolerance

Step 24: Safety-Rated Instrument Calibration

Safety-rated instruments (SIL-rated transmitters, safety-rated pressure switches, etc.) require additional calibration rigor:

Additional Requirement	Detail
Calibration against traceable reference	Reference standard must have traceable calibration certificate
As-found and as-left values recorded	Record the “as-found” reading (before any adjustment) and the “as-left” reading (after calibration) — the as-found value becomes the baseline for future proof tests
Trip point verification	For safety instruments with trip points (pressure switches, temperature switches): verify trip point and reset point
Response time measurement (if specified)	Some safety instruments have response time requirements — measure and record
Calibration interval established	Document the required calibration interval for each safety instrument — this feeds into Stage 11 maintenance plan
Calibration procedure documented	Procedure must be documented so it can be repeated identically at each calibration interval

Step 25: Alarm Setpoint Verification

Activity	Method	Documentation
Verify all safety-related alarm setpoints	Simulate or apply process values at each alarm setpoint	Record: Alarm tag, type (high, low, high-high, etc.), setpoint value, actual activation value, correct (yes/no)
Verify alarm priority and response	Confirm alarm displays on HMI with correct priority level and message	Record: Alarm tag, HMI display confirmed, priority correct
Verify alarm-initiated actions	If alarm triggers an automatic action (shutdown, interlock), verify the action occurs	Record: Alarm tag, expected action, actual action confirmed

★ GATE: All Instruments Calibrated ★

4.8 Phase 7: Baseline Documentation

Step 26: Record Baseline Measurements

These baselines become the reference for the life of the machine — used during proof testing (Stage 11) to detect degradation:

Baseline Measurement	Method	Why It Matters
Safety function response time (preliminary)	Stopwatch or timer measurement of time from safety device activation to output device de-energization (contactor dropout, valve closure)	Baseline for comparison during proof testing; preliminary check against response time requirement (formal measurement with calibrated instruments in Stage 10)
Safety device alignment readings	Light curtain alignment indicators, laser scanner diagnostic readings	Baseline for detecting misalignment during operation
Motor current (no-load and loaded if possible)	Clamp ammeter measurement	Baseline for detecting bearing wear, coupling misalignment, or load changes
Vibration levels (if specified)	Vibration meter at motor/bearing locations	Baseline for predictive maintenance
Instrument as-left calibration values	From calibration records	Baseline for detecting transmitter drift at next calibration
Valve stroke times (safety valves)	Timed measurement of open-to-close and close-to-open	Baseline for detecting valve degradation (increasing stroke time indicates wear or buildup)
Safety controller diagnostic status	Download diagnostic buffer/log	Clean baseline — any future diagnostics can be compared to this initial state
Contactor operation count (if available)	Read from safety controller or contactor counter	Starting count for B10d life calculation
Supply voltage at safety devices	Multimeter measurement at the furthest safety device	Baseline for detecting voltage degradation (connector corrosion, cable degradation)

Step 27: Complete Pre-Commissioning Checklist

Compile all records from Phases 1–6 into the pre-commissioning checklist document:

Section	Content	Status
Electrical verification	PE continuity, insulation resistance, P2P check records	Complete / open items
I/O verification	Standard I/O, safety I/O, analog loops, communications	Complete / open items
Motor and actuator checks	Rotation, protection settings, actuator operation	Complete / open items
Safety function dry-run tests	Individual SF test records per template	Complete / open items
Annex K checklist	Completed checklist sections A–F	Complete / open items
Muting verification (if applicable)	Muting test records	Complete / open items / N/A
Mode-dependent behavior	Mode test records	Complete / open items
Diagnostic verification	Diagnostic test records	Complete / open items
Instrument calibration	Calibration records	Complete / open items
Baseline measurements	Baseline measurement records	Complete / open items

Step 28: Pre-Commissioning Review and Sign-Off

Activity	Detail
Pre-commissioning review meeting	Project engineer, safety engineer, commissioning engineer (and customer if required) review all pre-commissioning records; identify any open items; assess readiness for Stage 10
Open item disposition	All open items classified: (1) must be closed before Stage 10, (2) can be closed during Stage 10, or (3) deferred to post-commissioning with justification and risk acceptance
Sign-off	Pre-commissioning checklist signed by commissioning engineer, safety engineer, and project engineer (and customer if required)

★ GATE: Pre-Commissioning Complete — Ready for Stage 10 ★

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5. Pre-Startup Safety Review (PSSR) — Process Safety Applications

For process safety applications governed by IEC 61511, a formal Pre-Startup Safety Review (PSSR) is required before the process is started. The PSSR is broader than pre-commissioning — it verifies organizational and procedural readiness in addition to technical readiness.

5.1 PSSR Checklist

#	PSSR Item	Verification	Status
1	Construction and equipment are in accordance with design specifications	Installation record, as-built documentation
2	Safety, operating, maintenance, and emergency procedures are in place	Documentation package review
3	Process hazard analysis (PHA) recommendations have been resolved	PHA action item tracker
4	Training of operating and maintenance personnel has been completed	Training records
5	SIS has been inspected, tested, and is operational	Pre-commissioning records (this stage)
6	All safety instrumented functions (SIFs) have been validated	SIF validation records (Stage 10 will complete this)
7	Management of change requirements have been met (if applicable)	MOC records
8	Adequate process safety information is available	PSI documentation review
9	All pre-startup action items from the PSSR are resolved	PSSR action item tracker
10	PSSR team sign-off	PSSR team signatures

5.2 PSSR Team

Role	Responsibility
Process engineer	Confirms process design and operating procedures are correct
Safety / SIS engineer	Confirms SIS installation, configuration, and testing are complete
Operations representative	Confirms operating procedures are in place and operators are trained
Maintenance representative	Confirms maintenance procedures are in place and maintainers are trained
HSE representative	Confirms safety procedures, emergency procedures, and regulatory requirements are met

PSSR must be completed and signed before the process is started. This is a regulatory requirement under OSHA PSM (29 CFR 1910.119) and IEC 61511.

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6. Key Deliverables

#	Deliverable	Description
1	Pre-commissioning checklist (completed)	Master checklist with all phases completed, all sections signed off, all open items dispositioned
2	Electrical verification records	PE continuity measurements, insulation resistance results, P2P spot check records
3	I/O verification records	Standard I/O, safety I/O (both channels), analog loops, communication links — all verified and documented
4	Safety function dry-run test records	Individual test record for each safety function per the template in Section 4.6
5	ISO 13849-1 Annex K checklist (completed)	All sections A–F completed for each safety function
6	Muting function test records	If applicable — complete muting verification per IEC 62046
7	Mode-dependent behavior test records	Safety function behavior verified in each operating mode
8	Diagnostic function test records	All diagnostic functions verified — single-channel fault, EDM, wire break, communication loss, ground fault
9	Motor and actuator check records	Rotation verified, protection settings verified, actuator operation confirmed, safety-rated actuators safe-state confirmed
10	Calibration records	Standard and safety-rated instrument calibration — as-found and as-left values, calibrator reference, pass/fail
11	Baseline measurement records	All baseline measurements per Section 4.8 Step 26
12	Safety controller configuration verification record	CRC/signature match, parameter verification, firmware version confirmation, zero forces/bypasses confirmed
13	Drive safety parameter verification record	Safety-related drive parameters verified against approved list
14	PSSR checklist (if process safety application)	Completed PSSR per Section 5
15	Open item list	Any items not resolved during pre-commissioning — with classification, owner, target date, and impact on Stage 10
16	Pre-commissioning photographs	Photographs of safety device installations, alignment verification, test setups — evidence of pre-commissioning activities
17	Updated as-built documentation	Any additional as-built changes discovered during pre-commissioning incorporated into documentation
18	Test equipment calibration records	Calibration certificates for all test instruments used during pre-commissioning

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7. Exit Criteria — Gate Review

This stage is complete when all of the following are true:

#	Criterion	Evidence
1	PE continuity verified ≤ 0.1Ω at all field measurement points	Electrical verification records
2	Insulation resistance ≥ 1 MΩ on all field wiring circuits	Electrical verification records
3	100% of safety circuit field wiring verified point-to-point	P2P check records
4	All standard I/O verified functional with correct addressing	I/O verification records
5	All safety I/O verified functional — both channels, discrepancy detection confirmed, EDM confirmed	Safety I/O verification records
6	All analog loops checked and instruments calibrated within tolerance	Calibration records
7	All communication links verified including failsafe behavior on communication loss	Communication verification records
8	All motors verified for correct rotation and protection settings	Motor check records
9	All actuators verified for correct operation and safe-state behavior	Actuator check records
10	Safety PLC program CRC/signature matches approved version; zero forces/bypasses confirmed	Configuration verification record
11	All drive safety parameters verified against approved list	Drive parameter verification record
12	Every safety function dry-run tested with triggering, safe state, reset, lockout, cross-channel, and EDM verified	Safety function dry-run test records — all PASS
13	ISO 13849-1 Annex K checklist completed for all safety functions	Completed Annex K checklist — all items PASS
14	Muting functions verified per IEC 62046 (if applicable)	Muting test records — all PASS
15	Mode-dependent safety behavior verified in all operating modes	Mode test records — all PASS
16	All diagnostic functions verified (single-channel fault, EDM, wire break, communication loss)	Diagnostic test records — all PASS
17	Baseline measurements recorded	Baseline measurement records
18	PSSR completed and signed (if process safety application)	Completed PSSR checklist
19	All open items dispositioned — items that must close before Stage 10 are closed; items deferred to Stage 10 are documented and accepted	Open item list reviewed and signed
20	Pre-commissioning checklist completed and signed by commissioning engineer, safety engineer, and project engineer	Signed pre-commissioning checklist
21	Test equipment calibration records on file	Calibration certificates

If any safety function fails its dry-run test, the failure must be investigated and corrected before Stage 10. Do not proceed to commissioning with known safety function failures — they will not resolve themselves under production conditions.

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8. Roles and Responsibilities at This Stage

Role	Responsibility
Commissioning Engineer	Owns this stage — executes pre-commissioning checklist, performs I/O verification, motor checks, safety function dry-run tests, compiles records, signs off on checklist
Safety / Controls Engineer	Verifies safety controller configuration (CRC match, parameters, zero forces); reviews and approves safety function test results; verifies Annex K checklist; assesses any deviations or failures for safety impact
Instrument Technician	Performs instrument calibration, loop checks, and alarm setpoint verification; produces calibration records
Electrical / Controls Designer	Supports pre-commissioning with design clarification; updates as-built documentation for any changes discovered
PLC Programmer	Supports I/O verification and functional testing; resolves any programming issues discovered during testing; verifies safety PLC program integrity
Mechanical / Process Engineer	Supports motor rotation verification, actuator checks, pneumatic/hydraulic system verification; provides process context for instrument calibration ranges and alarm setpoints
Project Engineer	Coordinates pre-commissioning schedule; manages open items; coordinates with customer for witness requirements
Customer Representative	Witnesses pre-commissioning activities (if contractually required); participates in PSSR (if process safety); accepts pre-commissioning results
Customer Operations / Maintenance	May observe or participate in pre-commissioning to gain familiarity with the system before taking ownership at handover

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9. Common Mistakes at This Stage

Mistake	Consequence	How to Avoid
Skipping pre-commissioning and going straight to commissioning	Wiring errors, miscalibrated instruments, and incorrect configurations discovered under production conditions — more dangerous, more expensive, more disruptive to fix	Mandatory pre-commissioning gate before Stage 10; project schedule must allocate time for this stage
Testing safety functions with jumpers or bypasses instead of actual safety devices	Verifies the logic but not the physical input device, wiring, and channel integrity; jumpers may be left in place	Test with actual safety devices; if jumpers are absolutely necessary for a specific test, formally document them and have a mandatory removal verification step
Not verifying both channels of dual-channel safety inputs independently	One channel may be wired incorrectly but the dual-channel test passes because the other channel works	Test each channel independently — disconnect one at a time and verify the safety controller detects the single-channel loss
Not verifying EDM (contactor feedback)	Contactor welding goes undetected during operation; PL/SIL is lower than calculated	Simulate contactor welding for each monitored output; verify safety controller detects the fault and prevents restart
Not verifying diagnostic discrepancy time	Safety controller may detect a channel discrepancy but take longer than the specified time — potentially allowing a dangerous condition to persist	Measure discrepancy detection time; compare to specification
Calibrating instruments without recording as-found values	Cannot determine if the instrument drifted since factory calibration or since last calibration; proof test effectiveness cannot be assessed	Always record as-found values before making any adjustments
Not verifying safety function behavior during mode transitions	Safety function may work correctly in automatic mode but fail to activate (or fail to deactivate) when switching to manual or setup mode	Test every mode transition; verify safety system re-evaluates safety state on mode change
Not verifying communication loss failsafe behavior	Safety network cable failure during operation could leave the machine in an uncontrolled state if failsafe is not properly configured	Disconnect safety network cable during testing; verify safe state is achieved within specified time
Not verifying safe state on loss of 24VDC power	Power supply failure could leave safety outputs in an indeterminate state	Remove 24VDC; verify all safety outputs go to safe state
Pre-commissioning records are incomplete or unsigned	Commissioning team cannot confirm what was tested; auditors find gaps in the verification chain; liability exposure	Complete every field in the checklist; sign every section; document every result — even if the result is “not applicable”
Not recording baseline measurements	No reference point for future proof testing; degradation cannot be detected	Mandatory baseline measurement step before closing pre-commissioning
Using uncalibrated test equipment	Measurements may be inaccurate; calibration records and pre-commissioning results are invalid	Verify all test equipment has current calibration certificates before use; record calibration certificate numbers
Not testing e-stops at every station	E-stop at one station may work but e-stop at another station may be wired incorrectly	Test every e-stop device at every station individually
Not verifying alarm setpoints for safety-related alarms	Alarm may not activate at the correct process value; operator may not receive warning in time	Simulate process values at each alarm setpoint; verify alarm activates at the correct value

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10. Relationship to Adjacent Stages

┌──────────────────────────────────────┐
│  STAGE 8: INSTALLATION                │
│                                      │
│  Provides:                           │
│  • Installed system                  │
│  • Installation record               │
│  • Field wiring verification         │
│  • Grounding verification            │
│  • Safety distance measurements      │
│  • Available fault current doc       │
└──────────────────┬───────────────────┘
                   │
                   ▼
┌──────────────────────────────────────┐
│  STAGE 9: PRE-COMMISSIONING          │  ◄── You are here
│                                      │
│  Produces:                           │
│  • Pre-commissioning checklist       │
│    (completed)                       │
│  • Safety function dry-run test      │
│    records (all PASS)                │
│  • Annex K checklist (completed)     │
│  • I/O verification records          │
│  • Calibration records               │
│  • Baseline measurements             │
│  • PSSR (if process safety)          │
│                                      │
│  Confirms:                           │
│  • System is correctly wired         │
│  • System is correctly configured    │
│  • System is correctly calibrated    │
│  • Safety functions basically work   │
│  • System is ready for full          │
│    commissioning under production    │
│    conditions                        │
└──────────────────┬───────────────────┘
                   │
                   ▼
┌──────────────────────────────────────┐
│  STAGE 10: COMMISSIONING              │
│                                      │
│  Builds on pre-commissioning:        │
│  • Repeats safety function tests     │
│    under actual production           │
│    conditions (not dry run)          │
│  • Measures actual response times    │
│    with calibrated instruments       │
│  • Verifies safety distances with    │
│    actual machine dynamics           │
│  • Executes FAT/SAT procedures       │
│  • Completes V&V report              │
│  • Provides final PL/SIL            │
│    verification evidence             │
│                                      │
│  Pre-commissioning results are       │
│  INPUT to Stage 10 — not repeated    │
│  unless changes were made between    │
│  stages                              │
└──────────────────┬───────────────────┘
                   │
                   ▼
┌──────────────────────────────────────┐
│  STAGE 11: MAINTENANCE                │
│                                      │
│  Uses baselines from this stage:     │
│  • Calibration as-left values        │
│    → compared to future proof test   │
│    as-found values to detect drift   │
│  • Safety function response times    │
│    → compared to future measurements │
│    to detect degradation             │
│  • Valve stroke times                │
│    → compared to future measurements │
│  • Contactor operation counts        │
│    → tracked toward B10d limit       │
│  • Safety controller diagnostics     │
│    → future diagnostics compared to  │
│    clean baseline                    │
└──────────────────────────────────────┘

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11. Temporary Bypasses and Overrides During Pre-Commissioning

11.1 Principle

During pre-commissioning, it may be necessary to temporarily bypass or override a safety function to test other parts of the system (e.g., bypassing a guard interlock to test motor rotation with the guard open under controlled conditions). This is permitted only under strict controls.

11.2 Bypass Control Requirements

Requirement	Detail
Documented	Every bypass must be formally documented — which safety function, why, when, who authorized, how long
Authorized	Safety engineer must authorize every bypass
Time-limited	Bypass must have a defined duration; automatic expiration if possible
Compensating measures	Alternative risk control measures must be in place during the bypass (e.g., physical barriers, dedicated observer, reduced speed, restricted access)
Visible indication	Bypass must be visible — warning sign on the machine, HMI indication, physical tag on the bypassed device
Tracked	Bypass log maintained; every active bypass tracked until removed
Verified removal	After the test requiring the bypass is complete, the bypass must be removed and the safety function verified to be fully operational
Final confirmation	Before closing pre-commissioning: verify zero active bypasses; all bypass log entries show “removed and verified”

11.3 Bypass Log Template

Bypass #	SF-ID	Safety Function	Reason for Bypass	Authorized By	Date/Time Applied	Compensating Measures	Expected Duration	Date/Time Removed	Removal Verified By	Safety Function Re-Tested?
BP-001	SF-01	Guard interlock — door	Motor rotation check with guard open	[Safety engineer name]	[Date/time]	Physical barrier across opening; dedicated observer; motor run in jog only	30 minutes	[Date/time]	[Name]	Yes — SF-01 re-tested PASS

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12. Templates and Tools

Resource	Purpose
Pre-commissioning master checklist template	Structured checklist with all phases and steps per Section 4.1
Safety function dry-run test record template	Per Section 4.6 — individual test form per safety function
ISO 13849-1 Annex K checklist template	Expanded checklist per Section 4.6 Step 19 — Sections A–F
I/O verification record template	Standard and safety I/O verification form
Analog loop check / calibration record template	Instrument-by-instrument calibration form with as-found and as-left fields
Communication link verification record template	Link-by-link verification form with failsafe test
Motor check record template	Rotation, protection settings, current measurement form
Actuator check record template	Stroke, position, safe-state verification form
Baseline measurement record template	All baseline measurements per Section 4.8 Step 26
Bypass log template	Per Section 11.3
PSSR checklist template	Per Section 5.1 — for process safety applications
Safety controller configuration verification form	CRC match, parameter comparison, firmware version, force/bypass check
Drive safety parameter verification form	Parameter-by-parameter comparison to approved list
Diagnostic function test record template	Single-channel fault, EDM, wire break, communication loss, ground fault test form
Muting function test record template	Per IEC 62046 requirements
Test equipment calibration log	Record of test instruments used, calibration certificate numbers, and expiration dates
Pre-commissioning review meeting minutes template	Agenda, attendees, open items, readiness decision, sign-off

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Trust Boundary — Engineering Judgment Required

This site is a personal-use paraphrase and navigation reference for industrial automation standards. It is not a substitute for authoritative standards documents, professional engineering judgment, or legal review. All content is sourced from a local RAG corpus and has not been independently verified against current published editions.

Items marked TO VERIFY have limited or unconfirmed local coverage. Items marked NOT IN CORPUS are not covered in the local repository. Do not rely on this site for compliance determinations, safety-critical design decisions, or legal interpretation.