Page 1 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC DULAR FETY NTEGRATED ONTROLLER Installation and use 8540780 • 10/07/2020 • Rev.38...
Page 2: Table Of Contents
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MODULAR SAFETY INTEGRATED CONTROLLER TABLE OF CONTENTS INTRODUCTION ..............................8 Contents of this handbook ................8 Important safety instructions ................8 Abbreviations and symbols ................9 Applicable standards ..................9 OVERVIEW ................................10 PRODUCT COMPOSITION ........................... 13 INSTALLATION ..............................
Page 3 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MASTER ENABLE ....................35 NODE SEL ......................35 PROXIMITY INPUT FOR SPEED CONTROLLER MV ............. 36 Configuration With Interleaved Proximity ..........36 RESTART_FBK ...................... 37 OUTPUTS......................38 OUT STATUS (SIL 1/PL c) ..................38 OUT TEST ......................38 OSSD SAFETY OUTPUTS ..................
Page 4 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MR2, MR4, MR8 (Figure 31) .................. 69 MO4LHCS8 (Figure 32) ..................70 MA2, MA4 (Figure 33) ..................71 LED INDICATORS (Troubleshooting) ..............72 Master M1 (Figure 34) ..................72 Master M1S (Figure 35) ..................73 MI8O2 (Figure 36) ....................
Page 5 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC STATUS (SIL 1/PL c output) ..............111 FIELDBUS PROBE ..................111 RELAY ....................112 Use with RESTART: Automatic (A) or Manual (B) (Category 2) ....113 INPUT OBJECTS ....................115 E-STOP (emergency stop) ............... 115 E-GATE (safety gate device) ..............
Page 6 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC SR FLIP FLOP ..................177 USER RESTART MANUAL (max number = 16 with M1, 32 with M1S with other RESTART operators) ................178 USER RESTART MONITORED (max number = 16 with M1, 32 with M1S with other RESTART operators) ..............
Page 7 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC How to use graphic simulation ................229 Application example of graphic simulation ..........232 MOSAIC FAIL CODES ..................234 ERRORS LOG DOWNLOAD ..............235 ACCESSORIES AND SPARE PARTS ....................... 236 WARRANTY..............................237 8540780 • 10/07/2020 • Rev.38...
Page 8: Introduction
Always test the complete system whenever new safety components are added (see the "TESTING the system" page 106).  ReeR is not responsible for these operations or any risks in connection therewith.  Reference should be made to the handbooks and the relative product and/or application standards to ensure correct use of devices connected to the Mosaic within the specific application.
Page 9: Abbreviations And Symbols
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Abbreviations and symbols MCM = MOSAIC Configuration Memory: memory chip for MOSAIC M1/M1S (accessory) MSC = MOSAIC Safety Communication: proprietary bus for expansion units MSD = MOSAIC Safety Designer: MOSAIC configuration SW running in Windows...
Page 10: Overview
 with M1: 128 inputs, 16 safety outputs and 32 SIL 1/ PL c outputs.  with M1S: 128 inputs, 32 safety outputs and 48 SIL 1/ PL c outputs. MASTER and its SLAVE units communicate via the 5-way MSC bus (ReeR proprietary bus), physically arranged on the rear panel of each unit.
Page 11 (< 50 m). Two MCT units installed at the required distance can be connected using a shielded cable (ReeR MC25, MC50 or other cable with the characteristics set out in the cable data sheet).
Page 12 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC The MOR4 and MOR4S8 are safety expansion units provided with 4 independent safety relay outputs and the corresponding 4 inputs for the external feedback contacts (EDM). There are two possible output settings (configured using the MSD configuration software).
Page 13: Product Composition
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC PRODUCT COMPOSITION The MOSAIC M1 and M1S are supplied with: • CD-ROM containing the free MSD SW, the present PDF multi-language handbook and other product literature. • Multi-language installation sheet.  NB: the rear panel MSC connector and MCM memory can be ordered separately as accessories.
Page 14: Installation
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC INSTALLATION Mechanical fastening Fix the MOSAIC system units to a 35mm DIN rail as follows: 1. Connect the same number of "MSC" 5-pole rear panel connectors as the number of units to be installed. 2. Fix the train of connectors thus obtained to the Omega DIN 35mm (EN 5022) rail (hooking them at the top first).
Page 15: Calculation Of Safety Distance Of An Espe Connected To Mosaic
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Calculation of safety distance of an ESPE connected to MOSAIC Any Electro-sensitive Protective Equipment device connected to MOSAIC, must be positioned at a distance equal to or greater than the minimum safety distance S so that the dangerous point can be reached only after stopping the dangerous movement of the machine.
Page 16: Instructions Concerning Connection Cables
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Instructions concerning connection cables.  Wire size range: AWG 12÷30, (solid/stranded) (UL).  Use 60/75°C copper (Cu) conductor only.  We recommend the use of separate power supplies for the safety module and for other electrical power equipment (electric motors, inverters, frequency converters) or other sources of disturbance.
Page 17: Master Module M1S
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Master Module M1S TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 24VDC 24VDC power supply 0VDC 0VDC power supply OSSD1 Output Solid State Safety Output 1 PNP active high OSSD2 Output Solid State Safety Output 2 PNP active high Feedback/Restart 1 Input according to EN 61131-2 RESTART_FBK1/...
Page 18: Usb Input
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC USB input The MOSAIC master M1 and M1s include a mini USB 2.0 connector for connection to a Personal Computer where the MSD (MOSAIC Safety Designer) configuration SW resides. A USB cable of the correct size is available as an accessory (CSU).
Page 19: Restore Function
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC RESTORE function If the M1 or M1S unit is damaged, you can replace it with a new one; having already saved all the configurations on the MCM, all you need to do is insert the MCM in the new M1/M1S and switch on the MOSAIC system, that will immediately load the backup configuration.
Page 20: Module Mi8O4
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Module MI8O4 TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 24VDC 24VDC power supply Input ("type B" according to EN 61131- NODE_SEL0 Node selection Input ("type B" according to EN 61131- NODE_SEL1 0VDC 0VDC power supply OSSD1 Output Solid State Safety Output 1 PNP active high OSSD2...
Page 21: Module Mi12T8
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Module MI12T8 TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 24VDC 24VDC power supply NODE_SEL0 Input Input ("type B" according to EN 61131-2 ) Node selection NODE_SEL1 Input Input ("type B" according to EN 61131-2 ) 0VDC 0VDC power supply INPUT1 Input Digital input 1...
Page 22: Module Mo2
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Module MO2 TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 24VDC 24VDC power supply NODE_SEL0 Input Input ("type B" according to EN 61131-2 ) Node selection NODE_SEL1 Input Input ("type B" according to EN 61131-2 ) 0VDC 0VDC power supply OSSD1_A Output PNP active high...
Page 23: Module Mo4L
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Module MO4L TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 24VDC 24VDC power supply Input ("type B" according to NODE_SEL0 EN 61131-2 ) Node selection Input ("type B" according to NODE_SEL1 EN 61131-2 ) 0VDC 0VDC power supply OSSD1 Output Solid State Safety Output 1...
Page 24: Module Mr2
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Module MR2 TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 24VDC 24VDC power supply 0VDC 0VDC power supply OSSD1_A Input Control ZONE 1 PNP active high OSSD1_B Input FBK_K1_K2_1 Output Feedback K1K2 ZONE 1 A_NC1 Output NC contact ZONE 1 B_NC1 Output A_NO11...
Page 25: Module Mr8
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Module MR8 TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 24VDC 24VDC power supply 0VDC power supply OSSD1_A Input Control ZONE 1 PNP active high OSSD1_B Input FBK_K1_K2_1_1 Output Feedback K1K2 ZONE 1 Normally closed EDM FBK_K1_K2_1_2 Output A_NC1 Output NC contact ZONE 1...
Page 26: Modules Mv0 - Mv1 - Mv2
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Modules MV0 - MV1 - MV2 TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 24VDC 24VDC power supply Input ("type B" according NODE_SEL0 Input to EN 61131-2) Node selection Input ("type B" according NODE_SEL1 Input to EN 61131-2) 0VDC 0VDC power supply Output...
Page 27: Encoder Connections With Rj45 Connector (Mv1, Mv2)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC ENCODER CONNECTIONS WITH RJ45 CONNECTOR (MV1, MV2) MVTB 5VDC N.C. N.C. N.C. TWISTED * EXT_0V EXT_0V EXT_0V EXT_0V N.C. N.C. N.C. N.C. TWISTED * INPUT Ā Ā Ā Ā N.C. N.C. N.C. N.C. TWISTED * * IN CASE OF UTILIZATION OF TWISTED CABLE POWER SUPPLY POWER SUPPLY...
Page 28: Module Mor4
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Module MOR4 TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 24VDC 24VDC power supply NODE_SEL0 Input Input ("type B" according to EN 61131-2) Node selection NODE_SEL1 Input Input ("type B" according to EN 61131-2) 0VDC 0VDC power supply REST_FBK1 Input Feedback/Restart 1...
Page 29: Module Mos8
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Module MOS8 SIGNAL TYPE DESCRIPTION OPERATION 24VDC 24VDC power supply Input ("type B" according to EN 61131-2) NODE_SEL0 Input Node selection Input ("type B" according to EN 61131-2) NODE_SEL1 Input 0VDC 0VDC power supply 24VDC 24VDC power supply STATUS 1-8 OUT_STATUS 1-8...
Page 30: Module Mo4Lhcs8
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Module MO4LHCS8 SIGNAL TYPE DESCRIPTION OPERATION 24VDC 24VDC power supply Input ("type B" according to EN 61131-2) NODE_SEL0 Input Node selection Input ("type B" according to EN 61131-2) NODE_SEL1 Input 0VDC 0VDC power supply REST_FBK1 Input Feedback/Restart 1 Input (according EN 61131-2)
Page 31: Modulo Ma4
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Modulo MA4 SIGNAL TYPE DESCRIPTION OPERATION 24VDC power supply 24 VDC Input ("type B" according to EN 61131-2) NODE_SEL0 Input Node selection Input ("type B" according to EN 61131-2) NODE_SEL1 Input 0VDC power supply 0 VDC 24VDC_S1 Output Isolated 24VDC power supply for sensor 1...
Page 32: Ma2 / Ma4 Analog Sensor Connections
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MA2 / MA4 Analog sensor connections The MA2/MA4 modules are suitable for:  4/20mA current output sensors with 2/3/4 wires  0/20mA current output sensors with 2/3/4 wires  0/10V voltage output sensors with 3 wires Following are shown some connections example: Figure 5 ...
Page 33: Example Of Connection Of Mosaic To The Machine Control System
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Example of connection of Mosaic to the machine control system Figure 6 CHECKLIST AFTER INSTALLATION The MOSAIC system is able to detect the faults that occurs in each own module. Anyway to have the system perfect operation perform the following checks at start up and at least every one year: Operate a complete system TEST (see "TESTING the system") Verify that all the cables are correctly inserted and the terminal blocks well screwed.
Page 34: Operating Diagram
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC OPERATING DIAGRAM Mechanical fastening Electrical connections between the Mosaic modules and with the external sensors Designing the diagram Validation sw OK ? Connection via USB with PSW Downloading the schematic to M1/M1S Configuration check (including complete system TEST) on M1/M1S OK? End of connection...
Page 35: Signals
SIGNALS INPUTS MASTER ENABLE The MOSAIC M1 master has two inputs: MASTER_ENABLE1 and MASTER_ENABLE2.  These signals must both be permanently set to logic level 1 (24VDC) for the MOSAIC to operate. If the user needs to disable the MOSAIC simply lower these inputs to logic level 0 (0VDC).
Page 36: Proximity Input For Speed Controller Mv
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC PROXIMITY INPUT FOR SPEED CONTROLLER MV  An inadequate mechanical installation of proximity sensors can cause dangerous operation. Pay particular attention to the size of the phonic wheel and to the mechanical fixing of the sensors. ...
Page 37: Restart_Fbk
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC RESTART_FBK The RESTART_FBK signal input allows the MOSAIC to verify an EDM (External Device Monitoring) feedback signal (series of contacts) from the external contactors, and to monitor Manual/Automatic operation (See the list of possible connections in Table 24). ...
Page 38: Outputs
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC OUTPUTS OUT STATUS (SIL 1/PL c) The OUT STATUS signal is a Programmable SIL 1 /PL c output that can indicate the status of: • An input. • An output. • A node of the logic diagram designed using the MSD. OUT TEST The OUT TEST signals must be used to monitor the presence of short-circuits or overloads on the inputs (Figure 8).
Page 39: Ossd (M1, Mi8O2, Mo2, Mo4)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC OSSD (M1, MI8O2, MO2, MO4) The M1, MI8O2, MO2, MO4 modules are equipped with OSSD (static semiconductor safety outputs) dual channel. These outputs are short circuit protected, cross circuit monitored and supply: • In the ON condition: (Uv-0,75V) ÷ Uv (24VDC ± 20%) •...
Page 40 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Configuration with 2 dual channel Configuration with 4 single outputs outputs (safety category SIL3/Pl e) (safety category SIL3/Pl e) 8540780 • 10/07/2020 • Rev.38...
Page 41: Ossd (Mo4Lhcs8)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC OSSD (MO4LHCS8) MO4LHCS8 provides 4 High Current Safety Outputs single channel (2A max per channel). These outputs are short circuit protected, cross circuit monitored and supply: In the ON condition: (Uv-0,6V) ÷ Uv (24VDC ± 20%) •...
Page 42: Ossd Outputs Configuration
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Configuration with 2 dual channel Configuration with 4 single outputs outputs (safety category SIL3/Pl e) (safety category SIL3/Pl e) OSSD OUTPUTS CONFIGURATION Each OSSD output can be configured as shown in Table 25: The output is activated according to le configurations set by the MSD SW only if the Automatic corresponding RESTART_FBK input is conected to 24VDC.
Page 43: Safety Relays (Mr2, Mr4, Mor4, Mor4S8)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC SAFETY RELAYS (MR2, MR4, MOR4, MOR4S8) Characteristics of the output circuit. The MR2/MR4 units use guided contact safety relays, each of which provides two N.O. contacts and one N.C contact in addition to the N.C. feedback contact. The MR2 unit uses two safety relays and the MR4 uses four.
Page 44: Example Of Mr2 Module Connection With Static Ossd Outputs Of A Module M1
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MOSAIC MR8 ZONE 1/2 INTERNAL DIAGRAM MOSAIC MR8 ZONE 3/4 INTERNAL DIAGRAM Figura 12 Example of MR2 module connection with static OSSD outputs of a module M1 Figure 13 If a relay module is connected, the response time of the OSSD linked, must be increased of 12ms. 8540780 •...
Page 45: Switching Operation Timing Diagram
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Switching operation timing diagram. Figure 14 8540780 • 10/07/2020 • Rev.38...
Page 46: Technical Features
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC TECHNICAL FEATURES GENERAL SYSTEM CHARACTERISTICS Safety level parameters Value Standard Parameter PFH d See the technical data tables for each module 1 (only MOS8, MOS16) EN 61508:2010 99,8% Type B Safety standard EN 62061:2005 / A2:2015 SILCL EN 61496-1:2013 Type...
Page 47: Enclosure
400mA@24VDC max - Interface type C class 3 (ZVEI CB24I) SLOT for MCM card Available Connection to PC USB 2.0 (Hi Speed) - Max cable length: 3m Connection to slave units via MSC 5-way ReeR proprietary bus 8540780 • 10/07/2020 • Rev.38...
Page 48: M1S Module
Interface type C class 3 (ZVEI CB24I) SLOT for MCM card Available Connection to PC USB 2.0 (Hi Speed) - Max cable length: 3m Connection to slave units via MSC 5-way ReeR proprietary bus MI8O2 module (IEC 61508:2010) 5.67E-9 Rated voltage 24VDC  20%...
Page 49: Mi8 - Mi16 Modules
Digital INPUTS (No./description) PNP active high according to EN 61131-2 Test OUTPUT (No./description) 4 / to check for short-circuits - overloads Connection to M1 and M1S via MSC 5-way ReeR proprietary bus MI12T8 module PFH d (IEC 61508:2010) 5,60E-09 Rated voltage 24VDC ...
Page 50: Mos8 Mos16 Modules
Manual operation with RESTART button 8 / Programmable output SIL 1/PL c OUTPUTS (No./description) PNP active high Mechanical life of contacts > 40 x 10 Connection to M1 and M1S via MSC 5-way ReeR proprietary bus 8540780 • 10/07/2020 • Rev.38...
Page 51: Mo4Lhcs8 Module
8 / Programmable output / PNP active high Response time 12ms and M1S Connection to M1 via MSC 5-way ReeR proprietary bus  Using MO4LHCS8 with current output >500mA, separate it from adjacent modules by interposing an MSC connector. MV0 - MV1 - MV2 modules...
Page 52: Ma2, Ma4 Module
1 second and then again activated to check if the input overvoltage/overcurrent condition still exist in an endless loop until the anomaly disappear. Disconnected cable detection Overthreshold / Underthreshold detection Connection to M1S via MSC 5-way ReeR proprietary bus 8540780 • 10/07/2020 • Rev.38...
Page 53: Mechanical Dimensions
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MECHANICAL DIMENSIONS 99 mm 22.5 mm 108 mm Figure 15 8540780 • 10/07/2020 • Rev.38...
Page 54: Led Indicators (Normal Operation)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LED INDICATORS (Normal Operation) Master M1 ( Figure 16 MEANING IN FAIL EXT FAIL IN1÷8 OSSD1/2 CLEAR1/2 STATUS1/2 GREEN ORANGE BLUE YELLOW RED/GREEN YELLOW YELLOW Power on - initial TEST MCM recognised (max 1s) (max 1s) Writing/loading/ diagram to/from MCM card flashes...
Page 55: Master M1S (Figure 16)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Master M1S (Figure 16) MEANING IN FAIL EXT FAIL IN1÷8 OSSD1/4 STATUS1/4 GREEN ORANGE BLUE YELLOW RED/GREEN/YELLOW YELLOW Power on - initial TEST MCM recognised (max 1s) (max 1s) Writing/loading/ diagram to/from MCM card flashes flashes MSD requesting connection: Flashes slowly...
Page 56: Mi8O2 (Figure 18)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MI8O2 (Figure 18) MEANING IN FAIL EXT FAIL SEL0/1 IN1÷8 OSSD1/2 CLEAR1/2 STATUS1/2 GREEN ORANGE YELLOW RED/GREEN YELLOW YELLOW Power on - initial TEST Table 31 - Opening Screen MEANING IN FAIL EXT FAIL IN1÷8 SEL0/1 OSSD1/2 CLEAR1/2...
Page 57: Mi8O4 (Figure 18)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MI8O4 (Figure 18) MEANING IN FAIL EXT FAIL SEL0/1 IN1÷8 OSSD1/4 STATUS1/4 GREEN ORANGE YELLOW RED/GREEN/YELLOW YELLOW Power on - initial TEST Table 33 - Opening Screen MEANING IN FAIL EXT FAIL IN1÷8 SEL0/1 OSSD1/4 STATUS1/4 GREEN YELLOW...
Page 58: Mi8 (Figure 20)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC (Figure 20) MEANING IN FAIL EXT FAIL SEL0/1 IN1÷8 GREEN ORANGE YELLOW Power on - initial TEST Table 35 - Opening Screen MEANING IN FAIL EXT FAIL SEL0/1 IN1÷8 GREEN ORANGE YELLOW if the unit is waiting for the first INPUT condition communication from the MASTER FLASHES...
Page 59: Mi12T8 (Figure 22)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MI12T8 (Figure 22) MEANING IN FAIL EXT FAIL SEL0/1 IN1÷12 GREEN ORANGE YELLOW Power on - initial TEST Table 37 - Opening Screen MEANING IN FAIL EXT FAIL SEL0/1 IN1÷12 GREEN ORANGE YELLOW if the unit is waiting for the first INPUT condition communication from the MASTER FLASHES...
Page 60: Mi16 (Figure 22)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MI16 (Figure 22) MEANING IN FAIL EXT FAIL SEL0/1 IN1÷16 GREEN ORANGE YELLOW Power on - initial TEST Table 39 - Opening Screen MEANING IN FAIL EXT FAIL SEL0/1 IN1÷16 GREEN ORANGE YELLOW if the unit is waiting for the first INPUT condition communication from the MASTER FLASHES...
Page 61: Mo2 (Figure 23)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC (Figure 23) MEANING IN FAIL EXT FAIL SEL0/1 OSDD1/2 CLEAR1/2 STATUS1/2 GREEN ORANGE RED/GREEN YELLOW YELLOW Power on - initial TEST Table 41 - Opening screen MEANING IN FAIL EXT FAIL SEL0/1 OSSD1/2 CLEAR1/2 STATUS1/2 GREEN ORANGE RED/GREEN...
Page 62: Mo4 (Figure 24)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC (Figure 24) MEANING IN FAIL EXT FAIL SEL0/1 OSSD1/4 CLEAR1/4 STATUS1/4 GREEN ORANGE RED/GREEN YELLOW YELLOW Power on - initial TEST Table 43 - Opening screen MEANING IN FAIL EXT FAIL SEL0/1 OSSD1/4 CLEAR1/4 STATUS1/4 GREEN ORANGE RED/GREEN...
Page 63: Mo4L (Figure 18)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MO4L (Figure 18) MEANING IN FAIL EXT FAIL SEL0/1 OSSD1/4 STATUS1/4 GREEN ORANGE RED/GREEN/YELLOW YELLOW Power on - initial TEST Table 45 - Opening Screen MEANING IN FAIL EXT FAIL SEL0/1 OSSD1/4 STATUS1/4 GREEN ORANGE RED/GREEN/YELLOW YELLOW if the unit is waiting for the first...
Page 64: Mor4 (Figure 26)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MOR4 (Figure 26) IN FAIL EXT FAIL SEL0/1 RELAY 1/4 CLEAR1/4 MEANING GREEN ORANGE GREEN YELLOW Power on - initial TEST Table 47 - Opening screen MEANING IN FAIL EXT FAIL SEL0/1 RELAY 1/4 CLEAR1/4 GREEN ORANGE GREEN...
Page 65: Mor4S8 (Figure 27)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MOR4S8 (Figure 27) IN FAIL EXT FAIL SEL0/1 RELAY 1/4 CLEAR1/4 STATUS1/8 MEANING GREEN ORANGE GREEN YELLOW YELLOW Power on - initial TEST Table 49 - Opening screen MEANING IN FAIL EXT FAIL SEL0/1 RELAY 1/4 CLEAR1/4 STATUS1/8 GREEN...
Page 66: Mos8 (Figure 28)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MOS8 (Figure 28) IN FAIL EXT FAIL SEL0/1 STATUS1/8 MEANING GREEN ORANGE YELLOW Power on - initial TEST Table 51 - Opening screen MEANING IN FAIL EXT FAIL SEL0/1 STATUS1/8 GREEN ORANGE YELLOW if the unit is waiting for the first communication from the MASTER...
Page 67: Mos16 (Figure 29)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MOS16 (Figure 29) IN FAIL EXT FAIL SEL0/1 STATUS1/16 MEANING GREEN ORANGE YELLOW Power on - initial TEST Table 53 - Opening screen IN FAIL EXT FAIL SEL 0/1 STATUS1/16 MEANING GREEN ORANGE YELLOW if the unit is waiting for the first communication from the MASTER...
Page 68: Mv0, Mv1, Mv2 (Figure 30)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MV0, MV1, MV2 (Figure 30) ENC* PROX IN FAIL EXT FAIL SEL0/1 MEANING GREEN ORANGE YELLOW YELLOW YELLOW Power on - initial TEST Table 55 - Opening screen ENC* PROX IN FAIL EXT FAIL SEL0/1 MEANING GREEN ORANGE...
Page 69: Mr2, Mr4, Mr8 (Figure 31)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MR2, MR4, MR8 (Figure 31) OSSD1 MEANING GREEN NORMAL OPERATION ON with output activated Table 57 - MR2 - Dynamic screen OSSD1 OSSD2 MEANING GREEN GREEN NORMAL OPERATION ON with output activated Table 58 - MR4 - Dynamic screen MEANING OSSD1 OSSD2...
Page 70: Mo4Lhcs8 (Figure 32)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MO4LHCS8 (Figure 32) IN FAIL EXT FAIL SEL0/1 OSSD 1/4 CLEAR1/4 STATUS1/8 MEANING GREEN ORANGE GREEN YELLOW YELLOW Power on - initial TEST Table 60 - Opening screen MEANING IN FAIL EXT FAIL SEL0/1 OSSD 1/4 CLEAR1/4 STATUS1/8 GREEN...
Page 71: Ma2, Ma4 (Figure 33)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Figure 33 MEANING IN FAIL EXT FAIL SEL0/1 CHAN 1/4 GREEN ORANGE RED/GREEN Power on - initial TEST RED ON Table 62 – Initial operation LEDs state SEL0/1 IN FAIL EXT FAIL CHAN 1/4 MEANING GREEN ORANGE if the unit is waiting for the first...
Page 72: Led Indicators (Troubleshooting)
OSSD output corresponding to • If the problem error flashes the output in FAIL persists return the mode) M1 to ReeR to be repaired • Restart the system. Error in • If the problem communication flashes persists return the...
Page 73: Master M1S (Figure 35)
OSSD output (only the LED corresponding • If the problem error flashes to the output in FAIL mode) persists return the M1 to ReeR to be repaired • Restart the system. Error in • If the problem communication flashes...
Page 74: Mi8O2 (Figure 36)
OSSD1/2 CLEAR1/2 STATUS1/2 REMEDY GREEN ORANGE YELLOW RED/GREEN YELLOW YELLOW 2 or 3 • Return the unit to ReeR Internal fault flashes to be repaired • Firmware version not compatible with M1, Compatibility error 5 flashes flashes flashes flashes flashes return to ReeR for FW upgrade.
Page 75: Mi8O4 (Figure 37)
SEL0/1 IN1÷8 OSSD1/4 STATUS1/4 REMEDY GREEN ORANGE YELLOW RED/GREEN/YELLOW YELLOW 2 or 3 • Return the unit to ReeR Internal fault flashes to be repaired • Firmware version not compatible with M1, Compatibility error 5 flashes flashes flashes flashes return to ReeR for FW upgrade.
Page 76: Mi8 (Figure 38)
ReeR for FW upgrade. Shows the • Restart the system Error in communication with physical • If the problem persists, return the unit to ReeR master flashes address of to be repaired the unit Error on other •...
Page 77: Mi12T8 (Figure 39)
NODE SEL • Change the unit's address (see same address detected flashes flashes Node detection circuit error • Return the unit to ReeR to be repaired flashes flashes Table 69 - Troubleshooting MI12T8 Figure - MI12T8 8540780 • 10/07/2020 • Rev.38...
Page 78: Mi16 (Figure 40)
IN1÷16 REMEDY GREEN ORANGE YELLOW Internal fault 2 or 3 flashes • Return the unit to ReeR to be repaired • Firmware version not compatible with M1, Compatibility error flashes flashes return to ReeR for FW upgrade. Shows the • Restart the system...
Page 79: Mo2 / Mo4 (Figure 41)
(only the LED • If the problem OSSD output error corresponding to flashes persists, return the the output in FAIL unit to ReeR to be mode) repaired Shows the • Restart the system physical • If the problem Error in communication...
Page 80: Mo4L (Figure 42)
EXT FAIL SEL0/1 OSSD1/4 STATUS1/4 REMEDY GREEN ORANGE RED/GREEN/YELLOW YELLOW 2 or 3 • Return the unit to ReeR to be Internal fault flashes repaired • Firmware version not Compatibility error compatible with M1, return to flashes flashes flashes ReeR for FW upgrade.
Page 81: Mor4 (Figure 43)
IN FAIL EXT FAIL SEL 0/1 RELAY 1/4 CLEAR1/4 GREEN ORANGE GREEN YELLOW • Return the unit to ReeR Internal fault 2 / 3 flashes Rosso to be repaired • Firmware version not compatible with M1, Compatibility error flashes flashes...
Page 82: Mor4S8 (Figure 44)
GREEN ORANGE GREEN YELLOW YELLOW 2 / 3 • Return the unit to Internal fault Rosso flashes ReeR to be repaired • Firmware version not compatible with M1, Compatibility error flashes flashes flashes flashes return to ReeR for FW upgrade.
Page 83: Mos8 (Figure 45)
MEANING IN FAIL EXT FAIL SEL0/1 REMEDY STATUS1/8 YELLOW GREEN ORANGE • Return the unit to ReeR Internal fault 2 / 3 flashes to be repaired • Firmware version not compatible with M1, Compatibility error flashes flashes return to ReeR for FW upgrade.
Page 84: Mos16 (Figure 46)
REMEDY IN FAIL EXT FAIL SEL0/1 STATUS1/8 STATUS9/16 GREEN ORANGE YELLOW YELLOW • Return the unit to ReeR Internal fault 2 / 3 flashes to be repaired • Firmware version not compatible with M1, Compatibility error flashes flashes flashes return to ReeR for FW upgrade.
Page 85: Mv0, Mv1, Mv2 (Figure 47)
ReeR to be repaired • Firmware version not compatible with M1, Compatibility error flashes flashes flashes flashes return to ReeR for FW Shows the upgrade. physical address • Change the encoder Encoder INTERNAL of the unit • Return the unit to...
Page 86: Mo4Lhcs8 (Figure 48)
EXT FAIL SEL 0/1 OSSD 1/4 CLEAR1/4 STATUS1/8 GREEN ORANGE GREEN YELLOW YELLOW 2 / 3 • Return the unit to ReeR Internal fault Rosso flashes to be repaired • Firmware version not compatible with M1, Compatibility error flashes flashes flashes...
Page 87: Ma2, Ma4 (Figure 49)
ReeR in order to update the firmware. Communication • Reboot the system Shows the error with MASTER flashes • If reboot does not work return the unit to ReeR physical Error on other • Restart the system address of the slave or MASTER •...
Page 88 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Channel configured as Redundant (Pair of sensors connected), conditions: Sensor supply overload. Input channel overload. Read value over threshold. Read value under threshold. Disconnected sensor: When one of these diagnosis is detected the RED led relative to the channel with the problem will flash. The RED led of the other channel remains ON (no flash).
Page 89: Mosaic Safety Designer Software
• Wait for the auto-run installer to request the SW setup program; • Otherwise, run the file located on the root of the installation CD or download the last available version from the Download section of the ReeR website: https://www.reersafety.com/it/en/download/configuration-software. ...
Page 90: Fundamentals
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Fundamentals Once the MSD has been correctly installed it creates an icon on the desktop. To launch the program: double-click on this icon. => The opening screen shown below is displayed: Figure 50 You are now ready to create your project. 8540780 •...
Page 91: Standard Tool Bar
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Standard tool bar The standard tool bar is shown in Figure 51. The meanings of the icons are listed below: Figure 51 1 -> CREATE A NEW PROJECT 2 -> CHANGE CONFIGURATION (composition of different modules) 3 ->...
Page 92: Textual Tool Bar
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Textual tool bar Optionally the textual tool bar shown below is also available (drop down). Figure 52 Create a new project (configure the MOSAIC system) Select icon CREATE (Figure 51) from the standard tool bar to start a new project. The user authentication window is displayed (Figure 53).
Page 93: Edit Configuration (Composition Of The Various Modules)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC SELECT SLAVE (to add to your configuration) Firmware version: NODE SELECTION M1 < 5.0 (from 0 to 3) Necessary for MTBF and SIL Module type selection (MV and MB) Select to disable MCM Figure 54 operations EDIT CONFIGURATION (composition of the various modules) The change of the system composition is obtained with the icon...
Page 94: Objects - Operator - Configuration Tool Bars
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC OBJECTS - OPERATOR - CONFIGURATION tool bars Four large tool windows are displayed to the left and right of the main window (shown in Figure 56): Figure 56 1 > OBJECT TOOL WINDOW This contains the various function blocks that will make up your project; these blocks are divided into 4 different types: - Inputs - Speed Monitoring...
Page 95: Creating The Diagram
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Creating the diagram Once you have selected your system composition, you are ready to configure the project. The logic diagram is created using a DRAG&DROP function: • Select the objects as required from the windows described previously (each single object is described in detail in the following sections) and drag it into the design area.
Page 96: Use Of Mouse Right Button
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC USE OF MOUSE RIGHT BUTTON ON BLOCK INPUT / OUTPUT  Copy / Paste  Delete  Delete all the assigned pins  Alignment with other functional blocks (multiple selection)  On-line Help  Monitor Mode: Show / Hide Properties window ...
Page 97: Example Of A Project
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Example of a project Figure 58 shows an example of a project in which the M1S unit only is connected to two safety blocks (E-GATE and E-STOP). The M1S inputs (1,2,3) for connecting the contacts of the safety components are shown on the left, in yellow.
Page 98: Resources Allocation
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Resources Allocation To activate the RESOURCES ALLOCATION function use the icon Executing this command, all the used elements among Inputs, Outputs, Status, Fieldbus input and Probe are visible, see the example in figure. Figure 59 8540780 •...
Page 99: Project Report
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Project report Print of the System composition with properties of each block. (Icon on the standard toolbar). Figure 60 8540780 • 10/07/2020 • Rev.38...
Page 100 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Figure 61  This definition of PL and of the other related parameters as set forth in ISO 13849-1 only refers to the functions implemented in the Mosaic system by the MSD configuration software, assuming configuration has been performed correctly. ...
Page 101: Connect To Mosaic
 This function is possible only after project validation with OK result. Download a configuration file (project) from Mosaic To download a project from MOSAIC M1 or M1S to MSD use the icon on the Standard toolbar. MSD will display the project residing in M1 or M1S. (Level 1 password is enough).
Page 102: System Composition
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Figure 63 System composition The check of the actual composition of the MOSAIC system is obtained using the icon . (Password Required: level 1). A pop-up window will appear with: - Connected modules; - Firmware version of each module; - Node number (physical address) of each module.
Page 103: Monitor (I/O Status In Real Time - Textual)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MONITOR (I/O status in real time - textual) To activate the MONITOR function use the icon . (Password Required: level 1). A pop-up window will appear with (all in real time): - input s state (when the object has two or more input connections to Mosaic, the MONITOR will show as active only the first), see the example in figure;...
Page 104: Password Protection
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC ged during the monitor. It is possible to display the parameters of a component by clicking on it with the right mouse button, choosing "Show/Hide Properties". Figure 67 - graphical monitor Password protection The MSD requests a password in order to upload and save the project. ...
Page 105: Level 2 Password
When a new project is UPLOADED the level 2 password could be changed.  Should you forget either of these passwords, please contact ReeR which will provide an unlock file (when the unlock file is saved in the right directory the icon will appear on the toolbar).
Page 106: Testing The System
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC TESTING the system  After validating and uploading the project to the M1/M1S and connecting all the safety devices, you must test the system to verify its correct operation. This is done by forcing a change of status for each safety device connected to the MOSAIC to check that the status of the outputs actually changes.
Page 107: Object Function Blocks
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC OBJECT FUNCTION BLOCKS OUTPUT OBJECTS OSSD (safety outputs) OSSD safety outputs use semiconductor technology, if  Each pair of OSSD outputs has a relative RESTART_FBK input. This input must always be connected as indicated in the RESTART_FBK paragraph.
Page 108: Single Double Ossd (Safety Output)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Enable Error Out If selected, enables the ERROR OUT output. This output is set to high level (TRUE) when an external FBK error is detected. The Error Out signal is reset in case of one of the following events: 1.
Page 109 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC  Using single channels OSSD, to maintain Safety Integrity Level (SIL) "3" requirements the OSSD outputs must be independent.  Common cause failures between OSSD outputs must be excluded by observing an appropriate cable installation (i.e. separate cable paths). Example of project 2 single output type function blocks + 1 double output type function blocks Here below you can find the explanation of the M1S, MI8O4, MO4L, MO4LHCS8 SINGLE-OSSD...
Page 110 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC There are two types of reset: Manual and Monitored. In selecting the Manual option only signal transition from 0 to 1 is verified. If the Monitored option is selected, the double transition from 0 to 1 and back to 0 is verified.
Page 111: Status (Sil 1/Pl C Output)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC STATUS (SIL 1/PL c output) STATUS output (SIL 1/PL c output) makes it possible to monitor any point on the diagram by connecting it to the input. The output Is set at 24Vdc if the input is 1 (TRUE), or it is set at 0Vdc if the input is 0 (FALSE).
Page 112: Relay
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC RELAY The Output RELAY Consists in a N.O. (Normally Open) contact relay. Relay contacts are closed when the input IN is equal to 1 (TRUE), otherwise they are open (FALSE). Parameters Category There is a choice of 3 different relay output categories: Category 1.
Page 113: Use With Restart: Automatic (A) Or Manual (B) (Category 2)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Use with RESTART: Automatic (A) or Manual (B) (Category 2) Figure 70 Category 4. Outputs with two Category 4 relays. Each MOR4/S8 unit can have up to 2 of these outputs. With this output the relays are controlled in pairs. Features: 2 double channel outputs.
Page 114 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Manual Reset: When selected, the function requires a reset each time the function block is activated. When not selected, the enabling of the output of the function directly follows the input conditions.  When Manual is selected, the function verifies the reset signal transition from 0 to 1. ...
Page 115: Input Objects
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC INPUT OBJECTS E-STOP (emergency stop) E-STOP function block verifies an emergency stop device inputs status. If the emergency stop button has been pressed the output is 0 (FALSE). If not the output is 1 (TRUE). Parameters Input type: - Single NC...
Page 116: E-Gate (Safety Gate Device)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Filter (ms): This is used to filter the signals coming from the emergency stop. The filter can be configured to between 3 and 250 ms and eliminates any bouncing on the contacts. The length of the filter affects the calculation of the unit's total response time. With Simultaneity (only with Double_NC Input type): If selected this activates the test to verify concurrent switching of the signals coming from the emergency stop.
Page 117: Single E-Gate (Safety Gate Device)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Output test: This is used to select which test output signals are to be sent to the component contacts. This additional control permits detection and management of any short-circuits between the lines. To enable this control, the test output signals must be configured (amongst those available).
Page 118: Lock Feedback
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC between the lines. To enable this control, the test output signals must be configured (amongst those available). Test at start-up: If selected this enables the test at start-up of the external component. This test is performed by opening the mobile guard or safety gate to run a complete function test and enable the output.
Page 119: Enable (Enable Key)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC ENABLE (enable key) ENABLE function block verifies a manual key device Input status. If the key is not turned the output is 0 (FALSE). Otherwise the output is 1 (TRUE). Parameters Input type - Single NO Allows connection of components with one NO contact;...
Page 120: Espe (Optoelectronic Safety Light Curtain / Laser Scanner)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Filter (ms): This is used to filter the signals coming from the external contacts. The filter can be configured to between 3 and 250 ms and eliminates any bouncing on the contacts. The length of the filter affects the calculation of the unit's total response time. With Simultaneity (only with Double NO Input type): If selected this activates the test to verify concurrent switching of the signals coming from the external contacts.
Page 121: Footswitch (Safety Pedal)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Filter (ms): This is used to filter the signals coming from the safety light curtain. The filter can be configured to between 3 and 250 ms and eliminates any bouncing on the contacts. The length of the filter affects the calculation of the unit's total response time. Simultaneity (ms): always active.
Page 122 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Manual reset: If selected this enables the request to reset each time the safety pedal is activated. Otherwise, enabling of the output directly follows the input conditions. There are two types of reset: Manual and Monitored. When Manual is selected the system only verifies the signal's transition from 0 to 1.
Page 123: Mod-Sel (Safety Selector)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MOD-SEL (safety selector) The MOD-SEL function block verifies the status of the inputs from a mode selector (up to 4 inputs): If only one input is 1 (TRUE) the corresponding output is also 1 (TRUE). In all other cases, and thus when all inputs are 0 (FALSE) or more than one input is 1 (TRUE) all the outputs are 0 (FALSE).
Page 124: Photocell (Safety Photocell)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC PHOTOCELL (safety photocell) The PHOTOCELL function block verifies the status of the inputs of an optoelectronic safety photocell. If the beam of the photocell is occupied (photocell output FALSE) the output is 0 (FALSE). Otherwise with the beam clear and an output of 1 (TRUE) the output is 1 (TRUE).
Page 125: Two-Hand (Bimanual Control)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC TWO-HAND (bimanual control) The TWO HAND function block verifies the status of the inputs of a two hand control switch. Only if both the press-buttons are pressed within 500 ms the output is 1 (TRUE). Otherwise the output is 0 (FALSE). Input type: - Double NO Allows connection of two-hand switch...
Page 126: Sensor
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC SENSOR The SENSOR function block verifies the status of the input of a sensor (not a safety sensor). If the beam of the sensor is occupied (sensor output FALSE) the output is 0. Otherwise, with the beam clear and an output of 1 (TRUE) then the output is 1.
Page 127: S-Mat (Safety Mat)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC S-MAT (safety mat) The S-MAT function block verifies the status of the inputs of a safety mat. If a person stands on the mat the output is 0 (FALSE). Otherwise, with the mat clear, the output is 1 (TRUE). Parameters Manual reset: If selected this enables the request to reset each time...
Page 128: Switch
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC SWITCH SWITCH function block verifies the input status of a pushbutton or switch (NOT SAFETY SWITCHES). If the pushbutton is pressed the output is 1 (TRUE). Otherwise, the output is 0 (FALSE). Parameters Manual reset: If selected this enables the request to reset each time the device is activated.
Page 129: Enabling Grip Switch
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC ENABLING GRIP SWITCH The ENABLING GRIP functional block checks the status of the In inputs of an enabling grip. If this is not gripped (position 1) or is gripped completely (position 3), the OUTPUT will be 0 (FALSE). If it is gripped to middle position (position 2), the OUTPUT will be 1 (TRUE).
Page 130: Testable Safety Device
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Table mode 1 (device 2NO + 1NC) POSITION 1: enabling grip fully released POSITION 2: enabling grip pressed to middle position POSITION 3: enabling grip fully pressed Position Input Input Enable Error Out: If selected reports a fault detected by the function block. Item description: Permits insertion of a descriptive text of the function of the component.
Page 131: Solid State Device
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC t1 > 250ms t = 250ms t2 = 250ms  WARNING: if Reset is enabled, the input consecutive to those used by the functional block must be used. For example: If inputs 1 and 2 are used for the functional block, input 3 must be used for Reset.
Page 132: Fieldbus Input
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC t1 > 250ms t = 250ms t2 = 250ms  WARNING: if Reset is enabled, the input consecutive to those used by the functional block must be used. For example: if inputs 1 and 2 are used for the functional block, input 3 must be used for Reset.
Page 133: Ll0-Ll1
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LL0-LL1 input. LL0 -> logical level 0 LL1 -> logical level 1  IMPORTANT: LL0 and LL1 cannot be used to disable the logical ports in the diagram. COMMENTS This item allows a description to be entered and placed in any point of the diagram.
Page 134: Speed Control Type Function Blocks
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC SPEED CONTROL TYPE FUNCTION BLOCKS Warning concerning safety  An external error or malfunction deriving from encoder/proximity or its wiring, does not necessarily involve a change of safety status of the normal output (i.e. “Zero”) of the function block.
Page 135: Speed Control
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC SPEED CONTROL The Speed Control function block monitors the speed of a device generating an output 0 (FALSE) when the measured speed exceeds a predetermined threshold. When the speed is below the predetermined threshold the output will be 1 (TRUE).
Page 136 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Up to 8 threshold settings Threshold no. Speed 1 Speed 2 Speed 3 Speed 4 Speed 5 Speed 6 Speed 7 Speed 8 Pitch: If the Axis Type chosen was linear and rotational, this field allows you to enter the sensor pitch to obtain a conversion between sensor revolutions and distance travelled.
Page 137 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Frequency: It shows the frequencies values calculated starting from the speed thresholds fM and fm (fm is the fM threshold frequency decreased by the hysteresis set). If the displayed value is GREEN, the calculation of frequency gave a positive Proximity choice: result.
Page 138: Window Speed Control
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC WINDOW SPEED CONTROL The Window Speed Control function block monitors the speed of a device, causing a transition from 0 (FALSE) to 1 (TRUE) of the WINDOWS output when the speed is within a prefixed range. Parameters Axis type: It defines the type of axis controlled by the device.
Page 139 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Gear Ratio: This parameter is active if there are two sensors on the selected axis. This parameter allows you to enter the ratio between the two sensors. If both sensors are on the same moving parts, the ratio will be 1 otherwise the number corresponding to the report must be entered.
Page 140: Stand Still
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC STAND STILL The StandStill function block monitors the speed of a device, causing a transition from 0 (FALSE) to 1 (TRUE) of the ZERO output when the speed is lower than a selected value. Parameters Axis type: It defines the type of axis controlled by the device.
Page 141 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Zero speed limit: Enter in this field the maximum speed value above which the output of the function block (ZERO) will be 0 (FALSE). If the measured speed is less than the set value, the output (ZERO) of the function block will be 1 (TRUE).
Page 142: Stand Still And Speed Control
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC STAND STILL AND SPEED CONTROL The StandStill and Speed Control function block monitors the speed of a device, causing the transition from 0 (FALSE) to 1 (TRUE) of the ZERO output when the speed is lower than a selected output.
Page 143 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Up to 8 threshold settings Threshold no. Speed 1 Speed 2 Speed 3 Speed 4 Speed 5 Speed 6 Speed 7 Speed 8 Pitch: If the Axis Type chosen was linear and rotational, this field allows you to enter the sensor pitch to obtain a conversion between sensor revolutions and distance travelled.
Page 144 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Frequency zero speed/Frequency1/ Frequency2: It shows the maximum calculated frequency values fM and fm (fm is the fM threshold frequency decreased by the hysteresis set). If the displayed value is GREEN, the calculation of frequency gave a positive result.
Page 145: Analog Input Type Function Blocks
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC ANALOG INPUT TYPE FUNCTION BLOCKS ANALOG INPUT (4 inputs each MA4 module, 2 inputs each MA2 module) selection of which types of analog sensor that will be used (0...20mA; 4...20mA; 0...10V) together with the parameters that will set the acquisition. It allows also the configuration of two simple threshold comparators or one window comparator.
Page 146 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Detailed description Input type It defines the inputs type of the MA2/MA4 module channels described below. Single A single sensor is connected to one channel from 1 to 4. Redundant A pair of sensors is connected to two adjacent channels (1-2 or 3-4). The sensor pair readings are processed by a single analog block.
Page 147 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC In case of Input Type -> Redundant, three further options will be enabled: 1. Sensors coherence 2. Incoherence calculation mode 3. Consolidation Sensors coherence The measurement results of the two channels in redundant configuration are unlikely to be exactly the same (even with equal sensors) due to the tolerances in the signal chain.
Page 148 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Incoherence calculation mode: equal sensors Select Equal sensors if the sensors to be used are identical i.e. they have the same scale. No additional configuration is required. The following parameter is provided to define whether the sensors are the same or different.
Page 149 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Incoherence calculation mode: different sensors The two sensors used in the redundant configuration must provide the same reading in units but they can have different scaling factors. The following parameter is provided to define whether the sensors are the same or different.
Page 150 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Input Type Redundant: Consolidation If you select Redundant as Input type, you must configure the Consolidation parameter which specifies the measurement value to be used. Select the measurement values to be used by MA2/MA4 comparators and sent as analog data to M1S controller: ...
Page 151 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Measurement unit: Scale and type of input You must specify the unit (e.g. Celsius degree, Bar, kg, m/s) and the scale of the measurement. The MA2/MA4 module will calculate the relationship between these values and the corresponding measured current or voltage values (scaling) based on the condition that the sensor has a linear characteristic.
Page 152 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Reading analysis: Window comparator If you activate the option Window comparator, the output Out1 is added to the graphical representation of the function block and a number of additional parameters are displayed. The following parameters are provided to define the behavior of the Window comparator: High threshold: is the maximum value of the range set for the window.
Page 153 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC The following figure and table exemplify the states of the Window comparator: Figure 72 – Example of window comparator behavior Current state of window Next state of window Measurement value (A) comparator comparator (A) < Low threshold value + hysteresis OUT OF WINDOW OUT OF WINDOW (A) >...
Page 154 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Reading analysis: Enable threshold1 / threshold2 If you activate the options Enable threshold1 and/or Enable threshold2, the output Out1 and/or Out2 are added to the graphical representation of the function block and a number of additional parameters are displayed. The following parameters are provided to define the behavior of the Threshold comparator: ...
Page 155 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Samples per second Let the user to choose the number of sampling per second of the Analog to Digital Sigma Delta converter. A low value would have better performance in terms of noise while an high value would have better performance in terms of response speed. The value 50 and 60 enhance line filter rejection.
Page 156 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Voltage sensors: voltage limits The user can set the range of valid measurement values by set a maximum voltage. If the measurement values are over the maximum value a diagnosis is set. The allowable maximum voltage values range from 10,05 V to 11,5 V. The following table summarize MA2/MA4 module behaviour as a function of measurement values.
Page 157 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Enable Error Out When this flag is checked the a digital signal is available to indicate an error when an anomaly on a sensor is detected. This is highlighted on input block by a dark green square near the label Anomaly Value...
Page 158: Analog Division (4 Inputs Each Ma4 Module, 2 Inputs Each Ma2 Module)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC ANALOG DIVISION (4 inputs each MA4 module, 2 inputs each MA2 module) The function block ANALOG DIVISION allows the arithmetic division of the values of two inputs. The inputs can be single or redundant. ANALOG DIVISION allows also the configuration of one THRESHOLD COMPARATOR (or one WINDOW COMPARATOR) and a WARNING COMPARATOR.
Page 159 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Single The measurement values of two single channels are divided. Redundant The measurement values of two pairs of sensors configured as redundant are divided. The following illustration shows this configuration (the suffix R identifies the redundant input channel). The following table summarizes the possible divisions: Channel 1 / Channel 2 Division...
Page 160 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Sensors coherence The measurement results of the two channels in redundant configuration are unlikely to be exactly the same (even with equal sensors) due to the tolerances in the signal chain. The tolerable difference between the channels can be set-up in the option Sensors Coherence.
Page 161 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Incoherence calculation mode: equal sensors Select Equal sensors if the sensors to be used are identical i.e. they have the same scale. No additional configuration is required. The following parameter is provided to define whether the sensors are the same or different.
Page 162 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Incoherence calculation mode: different sensors The two sensors used in the redundant configuration must provide the same reading in units but they can have different scaling factors. The following parameter is provided to define whether the sensors are the same or different.
Page 163 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Input Type Redundant: Consolidation If you select Redundant as Input type, you must configure the Consolidation parameter which specifies the measurement value to be used. Select the measurement values to be used by MA2/MA4 comparators and sent as analog data to M1S controller: ...
Page 164 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Input type: 0÷10V -> 0÷10V Input selected Division analysis: Window comparator If you activate the option Window comparator, the output Out1 is added to the graphical representation of the function block and a number of additional parameters are displayed.
Page 165 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Current state of window Next state of window Division value (A) comparator comparator (A) < Low threshold value + hysteresis OUT OF WINDOW OUT OF WINDOW (A) > High threshold OUT OF WINDOW OUT OF WINDOW (A) >= High threshold value - hysteresis OUT OF WINDOW OUT OF WINDOW...
Page 166 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Division analysis: Enable threshold If you activate the option Enable threshold, the output Out is added to the graphical representation of the function block and a number of additional parameters are displayed. The following parameters are provided to define the behavior of the Threshold comparator: ...
Page 167 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Division analysis: Warning enable -> warning threshold If you activate the Warning enable, a further output is added to the function block. You can specify a threshold value and a hysteresis. The option "Lower limit" determines the behavior of the comparison. Division analysis: Warning enable ->...
Page 168 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Samples per second Lets you select the number of samples per second of the analog to digital converter. The lower the value, the less the reading is susceptible to noise. The higher the value, the shorter the response time. The Samples per second values 50 and 60 enhance the AC power line filter rejection.
Page 169 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Voltage sensors: voltage limits With the following parameters you can limit the measurement range by setting a minimum and a maximum permissible voltage: Minimum voltage: The value is set to 0 V and cannot be changed. ...
Page 170 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Enable Error Out If selected, provides an output to indicate that an error has been detected by the function block. This is graphically represented on the function block by a dark green square and the label Error. Math Err The output Math Err provides the state of the division: Anomaly...
Page 171: Operator Function Blocks
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC OPERATOR FUNCTION BLOCKS All the input of these operators could be inverted (logical NOT). It could be done clicking with the right mouse key on the input to be inverted. A little circle will be showed on the inverted input.
Page 172: Not
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Logical NOT inverts the logical status of the input. Logical OR returns an output of 1 (TRUE) if at least one of the inputs is 1 (TRUE). Parameters Number of inputs: this is used to set between 2 and 8 inputs. Logical NOR returns an output of 0 (FALSE) if at least one of the inputs is 1 (TRUE).
Page 173: Xor
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Logical XOR returns an output 0 (FALSE) if the input's number at 1 (TRUE) is even or the inputs are all 0 (FALSE). Parameters Number of inputs: this is used to set between 2 and 8 inputs. XNOR Logical XNOR returns an output 1 (TRUE) if the input's number at 1 (TRUE) is even or the inputs...
Page 174: Logical Macro
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LOGICAL MACRO This operator enables the grouping together of two or three logic gates. A maximum of 8 inputs is foreseen. The result of the first two operators converges into a third operator, the result of which is the OUTPUT. Parameters Logic inputs 1, 2: enables the selection of the number of logic inputs (from 1 to 7).
Page 175: Digital Comparator (M1S Only)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC DIGITAL COMPARATOR (M1S only) The digital comparator allows to compare (in binary format) a group of signals with a constant or two groups of signals to each other Comparison with constant In this case the Signal Comparator check must not be activated.
Page 176 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Signal comparison Signal comparison: Selecting this item will allow the DIGITAL COMPARATOR operator compare first four inputs (In1_A...In4_A) with the second four B inputs (In1_B...In4_B). Depending on the value of the inputs and the operation selected, the following results will be obtained: ...
Page 177: Memory Operators
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MEMORY OPERATORS MEMORY operators can be used if you decide to save any data (TRUE or FALSE) from other project components. Status changes are performed according to the truth tables shown for each operator. D FLIP FLOP (max number = 16 with M1, 32 with M1S) The D FLIP FLOP operator saves the previously set status on output Q according to the following truth table.
Page 178: User Restart Manual (Max Number = 16 With M1, 32 With M1S With Other Restart Operators)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Parameters Store output status If selected, it stores the output status of the Flip-flop in non-volatile memory every time it is changed. When the system is turned on, the last stored value is restored. It is possible to have up to 8 Flip-Flops with output status storage that will be distinguishable by an 'M'.
Page 179: User Restart Monitored (Max Number = 16 With M1, 32 With M1S With Other Restart Operators)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC USER RESTART MONITORED (max number = 16 with M1, 32 with M1S with other RESTART operators) The USER RESTART MONITORED operator is used to save the restart signal (coming from a RESTART command device) according to the following truth table.
Page 180: Macro Restart Monitored (Max Number = 16 With M1, 32 With M1S With Other Restart Operators)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Parameters Input Logic: enables the selection of the number of logic inputs (from 1 to 7). Selecting 1 the logic will not be considered. Select Logic: enables the selection of one of the following types of operator: AND, NAND, OR, NOR, XOR, XNOR.
Page 181: Pre-Reset (M1S Only) (Max Number = 32 With Other Restart Operators)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC PRE-RESET (M1S only) (max number = 32 with other RESTART operators) The PRE-RESET operator can be used when there is no possibility of having a single reset button in a position from which a complete visibility of the hazardous area is available.
Page 182: Guard Lock Operators (Max Number = 4 With M1, 8 With M1S)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC GUARD LOCK OPERATORS (max number = 4 with M1, 8 with M1S) GUARD LOCK operator is designed to control locking/unlocking of an ELECTROMECHANICAL GUARD LOCK in a variety of operating contexts. Parameters Manual Reset: There are two types of reset: Manual and Monitored. When Manual is selected the system only verifies the signal's transition from 0 to 1.
Page 183 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Description of "GUARD LOCK" operator inputs/outputs “Lock_fbk” input used to detect the status (feedback) of the electromagnet that unlocks/locks the guard lock. Electromechanical guard locks are unlocked/locked via an electric control that energises/de-energises an electromagnet. Its status (energised/de-energised) is indicated by appropriate contacts.
Page 184 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Figure 76 - Example of feedback of the status of a door/gate connected to the guard lock. The signal received by the module is processed by the "Guard Lock" operator. “Unlock_cmd” input lock. In detail: ...
Page 185 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC “LockOut” output This signal controls the guard lock electromagnet and can assume LL0 and LL1 value. “ErrorOut” output If enabled, when this signal is set to LL1 it indicates an error in the control of the guard lock.
Page 186 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Example of operation in the “no Gate” mode The guard lock used in the example continues to be locked when the electromagnet is not energised. Therefore the "Interlock spring " option must be selected. STATUS SIL 1/PL c output block that controls the guard lock electromagnet, the status of LOCK FEEDBACK indicates the status of the operations.
Page 187 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Figure 78 - Traces relative to “Guard Lock” block operation in the no gate mode. Operation in the “with Gate” mode In this case, the user must NOT The Gate input must always be connected to an E-GATE (safety gate section on page 116) that verifies the status of device)
Page 188 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC When the Unlock_cmd signal is detected, the LockOut signal unlocks the guard lock after the UnLock Time, a parameter that can be defined by the user. The time after which the electromagnet is activated depends entirely on the technical/physical characteristics of the specific device and may therefore vary according to the type of guard lock used.
Page 189 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Figure 80 shows the traces relative to the operation. These are described in detail below: OUTPUT1 (2) At this time the electromagnet is activated with a delay of "Unlock Time", after the switches from LL0 to LL1. (3) At this time the electromagnet is actually activated, 95ms after the command was sent.
Page 190 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Operation in the “Mandatory Gate Opening” mode In this case, the user must NOT "Mandatory Gate opening" parameter. The Gate input must always be connected to an element (see the E-GATE (safety gate section on page 116) that verifies the status device) of the door/gate.
Page 191 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Example of operation in the “Mandatory Gate Opening” mode SWITCH STATUS SIL 1/PL c output that controls the guard lock electromagnet, LOCK FEEDBACK the status of the operations. The status of the safety gate is monitored by the "Gate" input via the "E_GATE" input block, the "Mandatory Gate opening"...
Page 192 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Figure 82 - Traces relative to “Guard Lock” block operation in the “Mandatory gate opening mode”. Mandatory condition if it does not detect that the gate has been opened following a request to unlock the guard lock. This concept is highlighted in the figure below (Figure 83 diagram in Figure 81, so that the error is shown in the graph.
Page 193 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Figure 83 – Example of possible error condition in "Mandatory gate opening" mode. In this case the error condition is generated because the gate has not been opened, even though a request has been sent to unlock/lock the guard lock. 8540780 •...
Page 194: Counter Operators
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC COUNTER OPERATORS COUNTER (max number = 16) COUNTER operator is a pulse counter that sets output Q to 1 (TRUE) as soon as the desired count is reached. There are 3 operating modes: 1) AUTOMATIC 2) MANUAL 3) AUTOMATIC + MANUAL Following are illustrated 3 examples for each...
Page 195: Counter Comparator
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC The counter generates a pulse duration equal to the system MANUAL/AUTOMATIC: response time as soon as the set count is reached. If the CLEAR signal is activated, the internal count goes back to 0. Parameters Enable Clear: If selected enables the signal CLEAR in order to restart the counter setting output Q to 0 (FALSE).
Page 196: Timer Operators (Max Number = 32 With M1, 48 With M1S)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC TIMER OPERATORS (max number = 32 with M1, 48 with M1S) TIMER operators allow you to generate a signal (TRUE or FALSE) for a user-definable period. MONOSTABLE The MONOSTABILE operator generates a level 1 (TRUE) output activated by the rising edge of the input and remains in this condition for the set time.
Page 197: Monostable_B
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MONOSTABLE_B This operator generates a level 1 (TRUE) output activated by the rising/falling edge of the input and remains in this condition for the set time t. Parameters Time: The delay can be set to between 10 ms and 1098,3 s.
Page 198: Passing Make Contact
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC PASSING MAKE CONTACT In the PASSING MAKE CONTACT operator the output follows the signal on the input. However, if this is 1 (TRUE) for longer than the set time, the output changes to 0 (FALSE). When there is an input falling edge, the timer is cleared.
Page 199: Delay
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC DELAY DELAY operator applies a delay to a signal by setting the output to 1 (TRUE) after the set time, against a change in the level of the input signal. Parameters Time: The delay can be set to between 10 ms and 1098,3 s Scale: The user can choose two different scales for the time T to be set.
Page 200: Long Delay
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LONG DELAY The LONG DELAY operator allows to apply a delay (up to more than 15 hours) to a signal bringing to 1 (TRUE) the Out output after the set time, in case of a level variation of the signal on the In input.
Page 201: Delay Comparator
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC DELAY COMPARATOR This operator compares the timer value outputted by a LONG DELAY timer and connected to the DELAY COMPARATOR The OUT output will be 0 (FALSE) as long as the timer value is lower than the threshold value.
Page 202: Long Delay Line
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC  Unlike the DELAY operator, the DELAY LINE operator does not filter any interruptions in the IN input which are shorter than the set time.  This operator is recommended when using delayed OSSD (the OSSD must be programmed with RESTART MANUAL).
Page 203: Clocking
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC CLOCKING The CLOCKING operator generates a square wave output which period is set by the user. The output is enabled if Clocking has up to 7 inputs to control output Duty Cycle. Parameters Time: The period can be set to between 100 ms and 1098,3 s.
Page 204: Muting Function
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MUTING FUNCTION The Muting function generates a temporary, automatic interruption of electro-sensitive protective device (ESPE) operation in order to permit normal transit of material through the guarded opening. In other words, when the system recognizes the material and distinguishes between this and any operator (in a potentially dangerous situation), it is enabled to bypass the safety device temporarily, allowing the material to pass through the guarded opening.
Page 205 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Select CURTAIN Input Muting Muting active Select SENSOR Input Muting Muting active Blind Time: Only with Muting Close=Curtain, blind time is enabled when it is known that after a complete transition of the pallet (muting cycle close) some protruding objects could still occupy the light curtain and send the input to 0 (FALSE).
Page 206: Sequential" Muting
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Enable Type: There are two Enable modes: Enable/Disable and Enable Only.  If “Enable/Disable” is selected the Muting cycle cannot start if Enable is stucked at 1 (TRUE) or 0 (FALSE). It is only activated with a rising edge of the signal. On the other hand the falling edge disables Muting regardless of the current condition.
Page 207 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Direction: This let the user to choose the order in which the sensors are occupied. If set to BIDIR they can be occupied in both directions, from S1 to S4 and from S4 to S1, if set to UP they can be occupied from S1 to S4 and if set to DOWN from S4 to S1.
Page 208 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MUTING “T” The activation of the Muting function occurs following interruption of the sensors S1 and S2 beam (the order does not matter) within a time range from 2s and 5s decided by the operator. The state of the Muting ends after the liberation of at least one of the two sensors.
Page 209: Muting Override (Max Number = 4)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MUTING OVERRIDE (max number = 4) The OVERRIDE function must be used when the machine stops due to incorrect Muting activation sequences with the material obstructing the guarded opening. This function activates the OSSD outputs making it possible to remove the material that is obstructing the guarded opening.
Page 210 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Manual Reset:  Should the INPUT be active (TRUE), the reset enables the output of the function block.  Should the INPUT be not active (FALSE), the output of the function block follows the OVERRIDE request. There are two types of reset: Manual and Monitored.
Page 211: Analog Operators (M1S Only)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC ANALOG OPERATORS (M1S only) Analog Comparator This operator works as a comparator of an analog signal connected. The threshold value to be entered will be in engineering units (eg Kg, °C) and must respect the limits defined by the functional block connected ot the input.
Page 212 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Example of window comparator behavior When the window comparator is not enabled, the output state of the threshold comparator depends on the value of the measurement and on its current state. There are two possible states: ...
Page 213 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC In the following picture is given an example of the behavior of the threshold comparator. Example of threshold comparator behavior 8540780 • 10/07/2020 • Rev.38...
Page 214: Math (Max Number = 16)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Math (max number = 16) The Math operator performs the sum (or the difference) between analog signals coming from an ANALOG INPUT blocks. The signals must have the same physical unit and must be generated by sensors of the same type (4/20mA, 0/20mA or 0/10V) but they can have different scales.
Page 215: Equality Check (Max Number = 16)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Equality check (max number = 16) This operator checks if two analog inputs are equal within a selectable value. The signals must have the same physical unit and must be generated by sensors of the same type (4/20mA, 0/20mA or 0/10V) but they can have different scales.
Page 216: Miscellaneous Function Blocks
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MISCELLANEOUS FUNCTION BLOCKS SERIAL OUTPUT (max number = 4 with M1, 8 with M1S) The Serial Output operator outputs the status of up to 8 inputs, serialising the information. Operating principles. This operator outputs the status of all the connected inputs in two different ways: Asynchronous serialisation: 1) The status of the line in the idle condition is 1 (TRUE);...
Page 217: Network (Max Number = 1)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC NETWORK (max number = 1) The Network operator is used to distribute Stop and Reset commands via a simple local network. Use Network_in and Network_out to exchange START, STOP and RUN signals between the different nodes. Operating principles.
Page 218 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Condition 2: With reference to the Figure 86 and Figure 87, when the emergency stop is pressed in one of the four nodes: The Net_out moves to condition 0 (FALSE); The STOP signal is sent via the Net_out line; The next node receives the stop code and deactivates the output;...
Page 219 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Master M1 signals with Network operative NETWORK FUNCTIONAL BLOCK SIGNALS Network out Network in Network out (OSSD) Reset in (STATUS) FAIL EXT OSSD STATUS STOP CLEAR BLINKING RED/GREEN (BLINKING) BLINKING BLINKING STATUS GREEN FAIL BLINKING Corresponding to the input where is wired Network IN Corresponding to the input where is wired Network OUT Corresponding to the input where is wired Reset IN...
Page 220: Example Of Application In Category 2 According To Iso 13849-1
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Figure 85 - NETWORK function block scheme example (Category 4) Example of application in Category 2 according to ISO 13849-1: Network data flow Figure 86 8540780 • 10/07/2020 • Rev.38...
Page 221: Logical Block Diagram Of A Safety Function Using The Network
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Network parameters for the PL calculation Architecture: Cat.2 Diagnostic coverage: DC = 90% MTTF = 437 (years) Reliability of Module M1: Logical block diagram of a safety function using the network INPUT M1 n°1 M1 n°2 M1 n°3 M1 n°4 OUTPUT...
Page 222: Logical Block Diagram Of A Safety Function Using The Network
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Logical block diagram of a safety function using the network INPUT M1 n°1 M1 n°2 M1 n°3 M1 n°4 OUTPUT LOGIC (NETWORK) RESET M1 This operator generates a system Reset when there is a double OFF-ON-OFF transition on the corresponding input which lasts less than 5 s.
Page 223: Interpage In/Out
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Parameters External K delay: allows the operator to set the time window within which the external feedback signal (Fbk_K) is to be monitored (according to output conditions). Enable Clear: if checked enables input Clear. With this input at 1 it is possible to clear the error when the fault has been repaired. Using this input it is no longer necessary to reset M1S or turn off the system.
Page 224: Intfbk_In / Intfbk_Out (M1S Only, Max Number = 8)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC INTFBK_IN / INTFBK_OUT (M1S only, max number = 8) This operator can be used to create logical loops or to connect the output of a function block to the input of another function block. IntFbk consist of IntFbk_In and IntFbk_Out; after one M1S logical cycle delay, every IntFbk_In assumes the same logical value of the corresponding IntFbk_Out.
Page 225: Special Applications
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC SPECIAL APPLICATIONS Output delay with manual If the operator needs to have two OSSD output with one of them delayed (in MANUAL mode) use the following scheme: Figure 90 - Two outputs with one delayed (in MANUAL mode) 8540780 •...
Page 226: Simulator Feature
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC SIMULATOR FEATURE  This simulator is only designed to assist in the design of safety functions.  The results of the simulation do not constitute validation of the project.  The resulting safety function must always be validated, from the point of view of both hardware and software, under actual usage conditions in accordance with the applicable regulations, such as ISO/EN 13849-2: validation or IEC/EN 62061: Chapter 8 - Validation of the safety-related electrical control system.
Page 227: Schematic Simulation
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Schematic Simulation Click on the icon to start the schematic simulation. Schematic simulation can be used to check/guide the output signals of the various function blocks in real-time, even during the actual simulation. You may choose the block outputs you wish to control and check the response of the various elements of the schematic model according to the colour of the different lines.
Page 228 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC (Speed selection) (LL0) (LL0) Figure 93 – MV frequency input  The keys for enabling block outputs are shown at the top, an example of a pop-up window for entering, in this case, the frequency in a "speed control" block is shown at the bottom 8540780 •...
Page 229: How To Use Graphic Simulation
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC How to use graphic simulation Click on the icon to start the graphic simulation. Graphic simulation can be used to display the signal pattern over time in a graph. First you must define the stimuli in a specific text file: this means defining the trend over time in the waveforms used as inputs (stimuli).
Page 230 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Click on the icon to display the page shown below. Figure 95 – Menu for selecting the graphic simulation mode Figure 95 The functions of each key in the menu shown in will now be described: Template Stimuli: used to save the template file with the desired name and disk location.
Page 231 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Simulation with Stimuli: used to load a template file (suitably completed) and, once loaded, to immediately start the simulation. At the end of the simulation, a graph is displayed with the resulting signals. Load simulation: used to load a previously completed simulation, provided at least one has been saved.
Page 232: Application Example Of Graphic Simulation
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Application example of graphic simulation The following example refers to the use of a press located inside a safety area. The motor of the press can only be started when two conditions are simultaneously true: the safety area gate is closed and the command to start the motor is sent.
Page 233 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Result of the simulation The graph shows the signals relating to the simulation, in this case:  which indicates closing of the gate.  which indicates the request to start sent by the operator  have elapsed logic level 1.
Page 234: Mosaic Fail Codes
239D 240D 241D ERROR 243D 244D 245D 247D 129D MA4 Measures incongruency RETURN THE UNIT TO REER 130D, 134D, 142D MA4 Channel 1 failure RETURN THE UNIT TO REER 131D, 135D, 143D MA4 Channel 2 failure RETURN THE UNIT TO REER...
Page 235: Errors Log Download
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC All other codes are related to errors or an internal malfunction. Please replace the module that gave the error or return to ReeR for repair and/or debugging and inform REER at the time of shipment. CODE...
Page 236: Accessories And Spare Parts
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC ACCESSORIES AND SPARE PARTS MODEL DESCRIPTION CODE MOSAIC main unit (8 inputs / 2 double OSSD ) 1100000 MOSAIC main unit (8 inputs / 4 single OSSD ) 1100003 MI8O2 MOSAIC I/O expansion unit (8 inputs / 2 double OSSD) 1100010 MI8O4 MOSAIC I/O expansion unit (8 inputs / 4 single OSSD)
Page 237: Warranty
Characteristics are subject to change without prior notice. No part of this document may be reproduced unless authorised by ReeR. 8540780 • 10/07/2020 • Rev.38...
Page 238 Dichiarazione CE di conformità / EC declaration of conformity Torino, 01/07/2019 REER SpA - via Carcano 32 10153 – Torino – Italy dichiara che il controllore integrato MOSAIC costituisce un dispositivo di sicurezza realizzato in conformità alle seguenti Direttive Europee: declares that the integrated controller MOSAIC is a safety device complying with the following European Directives: "Direttiva Macchine"...
Page 239 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 8540780 • 10/07/2020 • Rev.38...

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Reer MOSAIC M1 Installation And Use Manual

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