Reer MOSAIC Master M1 Installation And Use Manual
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Reer MOSAIC Master M1 Installation And Use Manual

Modular safety integrated controller
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MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
1
8540780 • 30/03/2016 • Rev.26

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Summary of Contents for Reer MOSAIC Master M1

  • Page 1 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 8540780 • 30/03/2016 • Rev.26...

  • Page 2: Table Of Contents

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Contents of this handbook ................6 Important safety instructions ................6 Abbreviations and symbols ................7 Applicable standards ..................7 Mechanical fastening ..................11 Calculation of safety distance of an ESPE connected to MOSAIC ....... 12 Electrical connections ..................
  • Page 3 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MO2 - MO4 modules ................33 MOS8 – MOS16 modules ................33 MR2 - MR4 modules ................. 34 MOR4 – MOR4S8 module ................34 MV0 - MV1 - MV2 modules ............... 35 MECHANICAL DIMENSIONS................36 SIGNALS ......................
  • Page 4 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Download a configuration file (project) from Mosaic M1 ......71 Configuration LOG ................... 71 System composition ................. 72 Disconnecting System ................72 MONITOR (I/O status in real time - textual) ..........72 MONITOR (I/O status in real time - textual - graphic)......... 73 Password protection ..................
  • Page 5 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC NOR ....................... 108 XOR ....................... 109 XNOR ..................... 109 LOGICAL MACRO ..................110 MULTIPLEXER ..................110 MEMORY OPERATORS ................111 D FLIP FLOP (max number = 16) ............. 111 T FLIP FLOP (max number = 16) .............. 111 SR FLIP FLOP (max number = 16) ............

  • Page 6: Contents Of This Handbook

    Always test the complete system whenever new safety components are added (see the "TESTING the system" section, page 75).  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 7: Abbreviations And Symbols

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MOSAIC Configuration Memory: memory chip for MOSAIC M1 (accessory) MOSAIC Safety Communication: proprietary bus for expansion units MOSAIC Safety Designer: MOSAIC configuration SW running in Windows Output Signal Switching Device: solid state safety output Mean Time to Dangerous Failure Performance Level Probability of a dangerous failure per Hour Safety Integrity Level...
  • Page 8 With 14 expansions, the system can have up to 128 inputs, 16 dual channel safety outputs and 16 status outputs. The 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 9 M1 to other slave units installed at a distance (< 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 10 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC The MOSAIC M1 is supplied with: • CD-ROM containing the free MSD SW, this 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 11: Mechanical Fastening

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 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 12: Calculation Of Safety Distance Of An Espe Connected To Mosaic

    MODULAR SAFETY INTEGRATED CONTROLLER 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 so that the dangerous point can be reached only after stopping the dangerous movement of the machine.

  • Page 13: 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 14: Usb Input

    Figure 2 - USB 2.0 front panel connector MOSAIC Configuration Memory (MCM) TECHNICAL DATA LABEL A backup memory, called (optional) can be installed in the MOSAIC master M1 and used to save the SW configuration MCM LABEL parameters. The MCM is written a new project is sent from the PC to the M1.
  • Page 15 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC switch on the MOSAIC system, that will immediately load the backup configuration. In this way, the work interruptions will be minimized.  The LOAD and RESTORE functions can be disabled via SW. (see Figure 40) ...
  • Page 16 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 24VDC power supply Input Input according to EN 61131-2 ) Node selection Input Input according to EN 61131-2 ) 0VDC power supply Input Digital input 1 Input according to EN 61131-2 Input Digital input 2 Input according to EN 61131-2 Input Digital input 3...
  • Page 17 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 24VDC power supply Input Input according to EN 61131-2 ) Node selection Input Input according to EN 61131-2 ) 0VDC power supply Input Digital input 1 Input according to EN 61131-2 Input Digital input 2 Input according to EN 61131-2 Input Digital input 3...
  • Page 18 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 24VDC power supply Input Input according to EN 61131-2 ) Node selection Input Input according to EN 61131-2 ) 0VDC power supply Output PNP active high Static output 1 Output PNP active high Input Feedback/Restart 1 Input according to EN 61131-2 Output Programmable signal output PNP active high...
  • Page 19 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 24VDC power supply 0VDC power supply Input Control PNP active high Input Feedback K1K2 Output Output NC contact Output Output NO1 contact Output Output NO2 contact Output Table 9 24VDC power supply Input ( according to Input EN 61131-2) Node selection...

  • Page 20: 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 21 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 24VDC power supply Input Input ( according to EN 61131-2) Node selection Input Input ( according to EN 61131-2) 0VDC power supply Input Feedback/Restart 1 Input (secondo EN 61131-2) Input Feedback/Restart 2 Input (secondo EN 61131-2) Input Feedback/Restart 3 Input (secondo EN 61131-2)
  • Page 22 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 24VDC power supply Input Input ("type B" according to EN 61131-2) Node selection Input Input ("type B" according to EN 61131-2) 0VDC power supply 24VDC power supply OUTPUT STATUS 1 Output Programmable signal output 1 PNP active high Output Programmable signal output 2...

  • Page 23: 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 4 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 24 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC between the Mosaic modules and with the external sensors Validation sw OK ? via USB with PSW diagram to M1 (including complete system TEST at page 54) on M1 OK? End of connection via USB 8540780 •...

  • Page 25: Inputs

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 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 26: Proximity Input For Speed Controller Mv

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC PROXIMITY INPUT FOR SPEED CONTROLLER MV When an axis of the MV modules is configured for a measurement with two proximity switches, these can be configured in interleaved mode. Under the conditions listed below the system reaches a Performance Level = PLe: ...

  • Page 27: 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 16). ...

  • Page 28: Outputs

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC OUT STATUS The OUT STATUS signal is a Programmable signal 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 6).

  • Page 29: Safety Relays (Mr2, Mr4, Mor4, Mor4S8)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 250ms < t1< 5s t = 250ms t2 = 250ms SAFETY RELAYS (MR2, MR4, MOR4, MOR4S8) Characteristics of the output circuit. The MR2/MR4 units use guided contact safety relays, each of which provides The MR2 unit uses two safety relays and the MR4 uses four. The MOR4/MOR4S8 units use four guided-contact safety relays.

  • Page 30: Example Of Mr2 Module Connection With Static Ossd Outputs Of A Module M1

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Example of MR2 module connection with static OSSD outputs of a module M1 Figure 8 Switching operation timing diagram. Figure 9 If a relay module is connected, the response time of the OSSD linked, must be increased of 12ms. 8540780 •...

  • Page 31: General System Characteristics

    Encoder/Proximity interface where is 2s 24,7 ÷ 52,5 + T Input_filter M1 + 13 Slaves 25,8 ÷ 54,6 + T Input_filter M1 + 14 Slaves ReeR proprietary 5-pole bus (MSC) 0,5 ÷ 2,5 mm / AWG 12÷30 (solid/stranded) 100m -10 ÷ 55°C 55°C (UL)

  • Page 32: Enclosure

    2 pairs / solid state safety outputs PNP active high 400mA@24VDC max Available USB 2.0 (Hi Speed) - Max cable length: 3m via MSC 5-way ReeR proprietary bus 5.68E-9 24VDC  20% 3W max 8 / PNP active high according to EN 61131-2...

  • Page 33: Mi8 - Mi16 Modules

    4.94E-9 24VDC  20% 3W max PNP active high according to EN 61131-2 4 / to check for short-circuits - overloads via MSC 5-way ReeR proprietary bus 5.56E-9 24VDC  20% 3W max PNP active high according to EN 61131-2...

  • Page 34: Mr2 - Mr4 Modules

    6A max 4 / EDM control / possible Automatic or Manual operation with RESTART button 8 / Programmable output PNP active high 12ms > 40 x 10 Terminal blocks via MSC 5-way ReeR proprietary bus 8540780 • 30/03/2016 • Rev.26...

  • Page 35: Mv0 - Mv1 - Mv2 Modules

    Rated insulation voltage 250V Overvoltage category II Rated impulse withstand voltage 4.00 kV 500KHz (HTL: 300KHz) 1Hz ÷ 450KHz PNP/NPN - 3/4 wires Terminal blocks 1Hz ÷ 4KHz 5KHz >10Hz > 5% via MSC 5-way ReeR proprietary bus 8540780 • 30/03/2016 • Rev.26...

  • Page 36: Mechanical Dimensions

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 99 mm 22.5 mm 108 mm Figure 10 8540780 • 30/03/2016 • Rev.26...

  • Page 37: Signals

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Master M1 (Figure 11) (max 1s) (max 1s) FAIL flashes flashes Flashes slowly Flashes quickly Flashes quickly Flashes quickly Table 19 - Opening Screen OSSD CLEAR = M1 STATUS connected to INPUT condition op. OK with MASTER_ENABLE1 waiting for...

  • Page 38: Mi8O2 (Figure 12)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MI8O2 (Figure 12) FAIL Table 21 - Opening Screen if the unit is waiting for the first communication INPUT condition from the MASTER with output waiting for Shows the RESTART if no INPUT or OUTPUT OUTPUT NODE_SEL0/1 requested by the...

  • Page 39: Mi8 (Figure 13)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MI8 (Figure 13) FAIL Table 23 - Opening Screen if the unit is waiting for the first INPUT condition communication from the MASTER if no INPUT or OUTPUT requested by the configuration only the number of the INPUT incorrect external with the incorrect connection if INPUT or OUTPUT requested by the...

  • Page 40: Mi12T8 (Figure 15)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MI12T8 (Figure 15) Table 25 - Opening Screen if the unit is waiting for the first INPUT condition communication from the MASTER if no INPUT or OUTPUT requested by the configuration only the number of the INPUT with the incorrect connection incorrect external if INPUT or OUTPUT requested by the...

  • Page 41: Mi16 (Figure 15)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MI16 (Figure 15) FAIL Table 27 - Opening Screen if the unit is waiting for the first INPUT condition communication from the MASTER if no INPUT or OUTPUT requested by the configuration only the number of the INPUT incorrect external with the incorrect connection if INPUT or OUTPUT requested by the...

  • Page 42: Mo2 (Figure 16)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MO2 (Figure 16) FAIL Table 29 - Opening screen if the unit is waiting for the first with output waiting for communication from the MASTER RESTART Shows the OUTPUT if no INPUT or OUTPUT requested by NODE_SEL0/1 signal op.

  • Page 43: Mo4 (Figure 17)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MO4 (Figure 17) FAIL Table 31 - Opening screen OSSD CLEAR if the unit is waiting for the first with output waiting for communication from the MASTER RESTART STATUS Shows the OUTPUT if no INPUT or OUTPUT requested by NODE_SEL0/1 signal op.

  • Page 44: Mor4 (Figure 18)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MOR4 (Figure 18) Table 33 - Opening screen if the unit is waiting waiting for with contact for the first opened RESTART communication from the MASTER Shows the if no INPUT or NODE_SEL0/1 operation OK operation OK signal table OUTPUT requested by...

  • Page 45: Mor4S8 (Figure 19)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MOR4S8 ( Figure Table 35 - Opening screen if the unit is waiting for the waiting for first with contact opened RESTART communication from the MASTER Shows the if no INPUT or OUTPUT NODE_SEL0/1 OUTPUT requested operation OK operation OK condition...

  • Page 46: Mos8 (Figure 20)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MOS8 ( Figure Table 37 - Opening screen if the unit is waiting for the first communication from the MASTER Shows the OUTPUT if no INPUT or OUTPUT NODE_SEL0/1 signal operation OK operation OK condition table requested by the configuration...

  • Page 47: Mos16 (Figure 21)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MOS16 ( Figure Table 39 - Opening screen if the unit is waiting for the first communication from the MASTER Shows the OUTPUT if no INPUT or OUTPUT NODE_SEL0/1 signal operation OK operation OK condition table requested by the configuration...

  • Page 48: Mv1, Mv2 (Figure 22)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MV1, MV2 ( Figure 22 Table 41 - Opening screen if the unit is waiting for the first Axis in normal communication speed range from the MASTER Shows the Encoder Proximity if no INPUT or NODE_SEL0/1 connected and connected and...

  • Page 49: Mr2 (Figure 23) / Mr4 (Figure 24)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MR2 (Figure 23) / MR4 (Figure 24) with output activated Table 43 - MR2 - Dynamic screen with output activated Table 44 - MR4 - Dynamic screen OSSD OSSD Figure - MR2 Figure - MR4 8540780 •...

  • Page 50: Troubleshooting

    Return the unit to ReeR to be repaired • Check the OSSD1/2 connections • If the problem persists return the M1 to ReeR to be repaired • Restart the system. • If the problem persists return the M1 to ReeR to be repaired OSSD •...

  • Page 51: Mi8O2 (Figure 26)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MI8O2 (Figure 26) • Return the unit to ReeR to be repaired FAIL • Firmware version not compatible with M1, return to ReeR for FW upgrade. • Check OSSD1/2 connections • If the problem persists, return the Shows the...

  • Page 52: Mi8 (Figure 27)

    • Firmware version not compatible with M1, return to ReeR for FW upgrade. Shows the • Restart the system physical • If the problem persists, return the MI8 to ReeR address of to be repaired the unit • Restart the system •...

  • Page 53: Mi12T8 (Figure 28)

    ReeR to be repaired • Restart the system • Check which unit is in FAIL mode • Change the unit's address (see • Return the unit to ReeR to be repaired Table 48 - Troubleshooting MI12T8 Figure MI12T8 8540780 • 30/03/2016 • Rev.26...

  • Page 54: Mi16 (Figure 29 - Mi16)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MI16 (Figure 29 - MI16) FAIL • Return the unit to ReeR to be repaired • Firmware version not compatible with M1, return to ReeR for FW upgrade. Shows the • Restart the system physical •...

  • Page 55: Mo2 / Mo4 (Figure 30)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MO2 / MO4 (Figure 30) Return the unit to ReeR to be repaired • Firmware version not compatible with M1, return to FAIL FAIL ReeR for FW upgrade. • Check OSSD1/2 connections • If the problem...

  • Page 56: Mor4 (Figure 31)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MOR4 (Figure 31) • Return the unit to ReeR to be repaired • Firmware version not compatible with M1, return to ReeR for FW upgrade. • If the problem persists, return the module to ReeR to be repaired Shows the •...

  • Page 57: Mor4S8 (Figure 32)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MOR4S8 (Figure 32) • Return the unit to ReeR to be repaired • Firmware version not compatible with M1, return to ReeR for FW upgrade. • If the problem persists, return the module to ReeR to be repaired Shows the •...

  • Page 58: Mos8 (Figure 33)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MOS8 ( Figure 33 • Return the unit to ReeR to be repaired • Firmware version not compatible with M1, return to ReeR for FW upgrade. • Restart the system Shows the physical • If the problem persists,...

  • Page 59: Mos16 (Figure 34)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MOS16 ( Figure • Return the unit to ReeR to be repaired • Firmware version not compatible with M1, return to ReeR for FW upgrade. Shows the • Restart the system physical • If the problem persists,...

  • Page 60: Mv0, Mv1, Mv2 (Figure 32)

    Shows the physical • Firmware version not address compatible with M1, of the unit return to ReeR for FW upgrade. • Change the encoder • Return the unit to ReeR to be repaired • Change the proximity • Return the unit to ReeR to be repaired •...

  • Page 61: Installing The Software

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC application software can be used to configure a logic diagram of the connections between the MOSAIC (Master + expansions) and the components of the system being developed. The MOSAIC and its SLAVE units will thus monitor and control the connected safety components.

  • Page 62: 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 36 You are now ready to create your project. 8540780 •...

  • Page 63: Standard Tool Bar

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Standard tool bar The standard tool bar is shown in Figure 37. The meanings of the icons are listed below: Figure 37 (composition of different modules) (name, company, etc) (Real time I/O status - (Real time I/O status - 8540780 •...

  • Page 64: Textual Tool Bar

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Textual tool bar Optionally the textual tool bar shown below is also available (drop down). Figure 38 Create a new project (configure the MOSAIC system) Select icon CREATE (Figure 37) from the standard tool bar to start a new project. The user authentication window is displayed (Figure 39).

  • Page 65: Edit Configuration (Composition Of The Various Modules)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC EDIT CONFIGURATION (composition of the various modules) The configuration window is showed again (Figure 37). Change user parameters The dialog user identification request appears (Figure 41). To accomplish this operation is not necessary to Log out from Mosaic. Generally it serves when a new user must create a new project (even using a previously created).

  • Page 66: 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 42): Figure 42 8540780 • 30/03/2016 • Rev.26...

  • Page 67: 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 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 68 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC ON CONNECTION (WIRES)  Delete  Display full path of the connection (network) Figure 43 8540780 • 30/03/2016 • Rev.26...

  • Page 69: Example Of A Project

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Example of a project Figure 44 shows an example of a project in which the M1 unit only is connected to two safety blocks (E-GATE and E-STOP). The M1 inputs (1,2,3) for connecting the contacts of the safety components are shown on the left, in yellow.

  • Page 70: Project Report

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Print of the System composition with properties of each block. (Icon on the standard toolbar).  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 71: Connect To Mosaic

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC After connecting M1 to the PC via CSU cable (USB) use the icon for the connection. A window appears to request the password. Enter the password (see "Password protection"). Figure 45 To send the saved configuration from a PC to M1 use the icon on the standard toolbar and wait the execution.

  • Page 72: System Composition

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 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 73: Monitor (I/O Status In Real Time - Textual - Graphic)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Figure 49 - textual monitor To activate/deactivate the monitor use the icon . (Password Required: level 1). The color of links (Figure 33) allows you to view the diagnostics with: = OFF = ON = Connection Error = Pending enable (for example RESTART) Placing the mouse pointer over the link, you can display the diagnostics.

  • Page 74: Password Protection

    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 75: Testing The System

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC TESTING the system  After validating and uploading the project to the M1 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 76: Object Function Blocks

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC OUTPUT OBJECTS OSSD safety outputs which use semiconductor technology do not require maintenance, Output1 and Output2 supply 24Vdc if the In is 1 (TRUE) and vice versa 0Vdc if the In is 0 (FALSE).  Each pair of OSSD outputs has a relative RESTART_FBK input.

  • Page 77: Status (Signal Output)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC STATUS output (NOT SAFETY OUTPUT) makes it possible to monitor any point on the diagram by connecting it to the input. The output returns 24Vdc if the input is 1 (TRUE), or 0Vdc if the input is 0 (FALSE). ...

  • Page 78: Use With Restart: Automatic (A) Or Manual (B) (Category 2)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Outputs with single Category 2 relay with OTE outputs. Each MOR4/S8 unit can have up to 4 of these outputs. Features: • Internal relays are always monitored. • Monitored EDM feedback. • The output can be configured to Manual or Automatic restart.
  • Page 79 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC External K delay (ms): Select the Maximum delay the external contactors are allowed to introduce. This value can be used to check the maximum delay between switching of the internal relays and switching of the external contactors (during both activation and deactivation).

  • Page 80: Input Objects

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC INPUT OBJECTS 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 81: 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: If selected this activates the test to verify concurrent switching of the signals coming from the emergency stop.

  • Page 82: Single E-Gate (Safety Gate Device)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC  WARNING: If the Manual Reset is active, a consecutive Input have to be used. Example : Input 1 and Input 2 are used for the fuctional block, then Input 3 have to be used for the Reset Input. Output test: This is used to select which test output signals are to be sent to the component contacts.

  • Page 83: Lock Feedback

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC  WARNING: If the Manual Reset is active, a consecutive Input have to be used. Example : Input 1 and Input 2 are used for the fuctional block, then Input 3 have to be used for the Reset Input. Output test: This is used to select which test output signals are to be sent to the component contacts.

  • Page 84: Enable (Enable Key)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC With Simultaneity: If selected this activates the test to verify concurrent switching of the signals coming from the external contacts. Simultaneity (ms): This is only active if the previous parameter is enabled. It defines the maximum time (in msecs) between the switching of two different signals from the external contacts.

  • Page 85: Espe (Optoelectronic Safety Light Curtain / Laser Scanner)

    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 86: Footswitch (Safety Pedal)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC  WARNING: If the Manual Reset is active, a consecutive Input have to be used. Example : Input 1 and Input 2 are used for the fuctional block, then Input 3 have to be used for the Reset Input. OUT TEST signals cannot be used in case of safety static output ESPE because the control is carried out from the ESPE.
  • Page 87 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 88: Mod-Sel (Safety Selector)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 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 89: Two-Hand (Bimanual Control)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC  The response time of the photocell must be >2ms and <20ms. Output test: This is used to select which test output are to be sent to the photocell test input. This additional control permits detection and management of any short-circuits between the lines.

  • Page 90: Network_In

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Enable Error Out: If selected reports a fault detected by the function block. Item description: This allows a description of the component's function to be entered. The text is displayed in the top part of the symbol. This functional block implements a Network connection input interface;...

  • Page 91: S-Mat (Safety Mat)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC  WARNING: If the Manual Reset is active, a consecutive Input have to be used. Example : Input 1 is used for the fuctional block, then Input 2 have to be used for the Reset Input. Output test: This is used to select which test output signals are to be sent to the sensor.

  • Page 92: Switch

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC  Two output test signals are mandatory. Each output OUT TEST can be connected to only one input S-MAT (it is not allowed parallel connection of 2 inputs).  The function block S-MAT can not be used with 2-wire components and termination resistance.

  • Page 93: Enabling Grip Switch

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Output test: This is used to select which test output signals are to be sent to the switch. 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 94 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 (only with 2NO+1NC) 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...

  • Page 95: Testable Safety Device

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC The TESTABLE SAFETY DEVICE functional block checks the status of the Inx inputs of a single or double safety sensor, both NO and NC. Refer to the tables below to check type of sensor and behaviour. (single NC) (single NO) (double NC)

  • Page 96: Solid State Device

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Power-on test: If selected, enables the power-on test of the device. This test requires activation and de-activation of the device in order to run a complete functional check and enable the Output terminal. This test is required only at machine start-up (power-on of the module).

  • Page 97: Fieldbus Input

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Filter (ms): Permits filtering of signals from the safety device. This filter can be set to between 3 and 250 ms and eliminates any rebounds on the contacts. The duration of the filter affects calculation of module total response time. Simultaneity (ms): always active.

  • Page 98: Speed Control Type Function Blocks

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC  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 the function block. Failures or malfunctions of encoder/proximity switch or its wiring are then recognized by the module, managed and specified via the diagnostic bit on every function block ...

  • Page 99: Speed Control

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC function block monitors the speed of a device generating an output 0 (FALSE) when the measured speed exceeds a predetermined threshold. In the case in which the speed is below the predetermined threshold the output will be 1 (TRUE).
  • Page 100 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC It allows you to choose the type of proximity sensor from PNP, NPN, Normally Open (NA) and Normally Closed (NC), with 3 or 4 wires. (In order to ensure a Performance Level = PLe use a proximity switch type PNP NO: ref.

  • Page 101: Window Speed Control

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC function block monitors the speed of a device, generating the Zero to 1 (TRUE) output when the speed is within a prefixed range. Parameters It defines the type of axis controlled by the device. It will be Linear in the case of a translation and will be Rotary in the case of motion around an axis.
  • Page 102 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 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 103: Stand Still

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC function block monitors the speed of a device, generating the Zero to 1 (TRUE) output when the speed is lower than a selected value. Parameters It defines the type of axis controlled by the device. It will be Linear in the case of a translation and will be Rotary in the case of motion around an axis.
  • Page 104 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 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). It shows the maximum calculated frequency values fM and fm (decreased by the hysteresis set).

  • Page 105: Stand Still And Speed Control

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC function block monitors the speed of a device, generating the Zero to 1 (TRUE) output when the speed is lower than a selected value. In addition, it generates the Over = 0 (FALSE) output if the measured speed exceeds a predetermined threshold.
  • Page 106 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC It allows you to choose the type of proximity sensor from PNP, NPN, Normally Open (NA) and Normally Closed (NC), with 3 or 4 wires. (In order to ensure a Performance Level = PLe use a proximity switch type PNP NO: ref.

  • Page 107: Operator Function Blocks

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 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 108: 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 109: Xnor

    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. Logical XNOR returns an output 1 (TRUE) if the input's number at 1 (TRUE) is even or the inputs are all 0 (FALSE).

  • Page 110: Multiplexer

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 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 111: 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. The D FLIP FLOP operator saves the previously set status on output Q according to the following truth table.
  • Page 112 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC The USER RESTART MANUAL operator saves the restart signal according to the following truth table. 1 Keep memory Rising edge Falling edge 1 Keep memory Parameters Clear enable: If selected enables the saving process to be reset. The USER RESTART MONITORED operator is used to save the restart signal according to the following truth table.
  • Page 113 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Parameters Logic Inputs: enables the selection of the number of logic inputs (from 1 to 7). Select Logic: enables the selection of one of the following types of operator: AND, NAND, OR, NOR, XOR, XNOR. Enable Clear: If selected enables the saving process to be reset.

  • Page 114: Guard Lock Operators (Max Number = 4)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC GUARD LOCK OPERATORS (max number = 4) GUARD LOCK operator controls locking/unlocking analysing consistency between Lock command and the status of an E-GATE and a FEEDBACK. The main ouput is 1 (TRUE) when the guard lock is closed and locked. 1) The input must always be connected to a (feedback coil lock) input...
  • Page 115 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Parameters 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. If Monitored is selected the double transition from 0 to 1 and then back to 0 is verified. t1 >...

  • Page 116: Counter Operators

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC COUNTER OPERATORS COUNTER operator is a pulse counter that sets output Q to 1 (TRUE) as soon as the desired count is reached. The operator COUNTER is a pulse counter. There are 3 operationg modes: 1) AUTOMATIC 2) MANUAL 3) AUTOMATIC + MANUAL...
  • Page 117 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 3) The counter generates a pulse duration equal to the system response time as soon as the set count is reached. If the CLEAR signal is activated, the internal count goes back to 0. Parameters Clear Enable: If selected this enables the request to clear in order to restart the counter setting output Q to 0 (FALSE).

  • Page 118: Timer Operators (Max Number = 32)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC TIMER OPERATORS (max number = 32) TIMER operators allow you to generate a signal (TRUE or FALSE) for a user-definable period. The CLOCKING operator generates a clock signal output with the set period if the IN input is 1 (TRUE).
  • Page 119 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 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. Parameters Time: The delay can be set to between 10 ms and 1098.3 s.

  • Page 120: Monostable

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 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 121: Passing Make Contact

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 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 122: Delay

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 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 Rising edge: If selected, the delay starts on the input signal's rising edge at the end of which the output changes to 1 (TRUE) if the input is 1 (TRUE) where it remains for as long as the input stays at 1 (TRUE).

  • Page 123: Delay Line

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC This operator applies a delay to a signal by setting the OUT output to 0 after the set time, set at a falling edge of the IN signal. If IN returns to 1 before the end of the set time, the OUT output still generates...

  • Page 124: Muting Function

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MUTING FUNCTION The Muting function generates a temporary, automatic interruption of safety device 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 125 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Blind Time: , blind time is enabled if you know that after the complete transition of the pallet (muting cycle close) some protruding objects could still occupy the light curtain and send the input to 0 (FALSE). During blind time the input remains 1 (TRUE).
  • Page 126 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC There are two Enable modes: Enable/Disable and Enable Only. If Enable/Disable is selected the Muting cycle cannot start if Enable is fixed at 1 (TRUE) or 0 (FALSE) but is only activated with a rising edge. To disable muting, set Enable to 0 (FALSE). In this mode the falling edge disables Muting regardless of the condition.
  • Page 127 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Muting Close: There are two types, CURTAIN and SENSOR. If you select CURTAIN muting closes when the input signal rises, if you select SENSOR it closes when the third sensor has been cleared. Select CURTAIN Select SENSOR Blind Time: , blind time is enabled if you know that...
  • Page 128 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 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 129 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 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 130 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC With OverOut: Used to activate an Override active Signaling output (active when high). With Request: Used to activate a Signaling output (active when high) indicating that the Override function can be activated. Manual Reset:  Should the INPUT be active (TRUE), the reset enables the output of the function block.
  • Page 131 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC operator outputs the status of up to 8 inputs, serialising the information. This operator outputs the status of all the connected inputs in two different ways: 1) The status of the line in the idle condition is 1 (TRUE); 2) The start data transmission signal is 1 bit = (FASLE);...

  • Page 132: Network

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC operator is used to distribute Stop and Reset commands via a simple local network. Use to exchange START, STOP and RUN signals between the different nodes. This operator allows stop and reset commands to be distributed simply in a local Mosaic network.
  • Page 133 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Response Time The max response time of the network starting from emergency stop is given by the formula: = [(212 ms x n°Master)-260ms]  The max number of connected Master must be 10. MASTER n°1 MASTER n°2 MASTER n°3 MASTER n°4...
  • Page 134 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Figure 55 - NETWORK function block scheme example (Category 2) Figure 56 - NETWORK function block scheme example (Category 4) 8540780 • 30/03/2016 • Rev.26...
  • Page 135 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Network data flow Figure 57 Cat.2 DC = 90% MTTF = 437 (years) INPUT M1 n°1 M1 n°2 M1 n°3 M1 n°4 OUTPUT LOGIC (NETWORK) 8540780 • 30/03/2016 • Rev.26...
  • Page 136 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Network data flow Figure 58 Cat.4 DC = 99% PFHd = 6,86E-09 (hour INPUT M1 n°1 M1 n°2 M1 n°3 M1 n°4 OUTPUT LOGIC (NETWORK) 8540780 • 30/03/2016 • Rev.26...
  • Page 137 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 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.  If > 5s, RESET is not generated.  It can be used to reset faults without disconnecting system power. If the scheme is very complicated and requires a connection between two elements very far, use the "Interpage"...

  • Page 138: Special Applications

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC SPECIAL APPLICATIONS If you need to have two OSSD output with one of them delayed (in MANUAL mode) use the following scheme: Figure 59 - Two outputs with one delayed (in MANUAL mode) 8540780 • 30/03/2016 • Rev.26...

  • Page 139: Mosaic Fail Codes

    CHECK THE OSSD3 CONNECTIONS RELATIVE TO THE MODULE IN Errors solid state output OSSD3 ERROR Microcontroller Error TRY TO RESTART SYSTEM. IF ERROR PERSISTS, SEND UNIT TO REER Mainboard error LABORATORY FOR REPAIR. Communication error between units MCM memory card error...
  • Page 140 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MOSAIC main unit (8 inputs / 2 double OSSD ) 1100000 MOSAIC I/O expansion unit (8 inputs / 2 double OSSD) 1100010 MOSAIC input expansion unit (8 inputs) 1100020 MOSAIC input expansion unit (16 inputs) 1100021 MOSAIC input expansion unit (12 input, 8 test output) 1100022...
  • Page 141 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC ReeR warrants that all of its MOSAIC units shall be free from defects in material or workmanship for a period of 12 (twelve) months from the date of shipment. This warranty applies to the products under normal conditions of use.
  • Page 142 Dichiarazione CE di conformità EC declaration of conformity Torino, 14/03/2016 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 143 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 300 Roundhill Drive Rockaway, NJ 07866 Tel: 973-586-2500 www.norstat.com 8540780 • 30/03/2016 • Rev.26...

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