Reer Mosaic MI8 Installation And Use Manual
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Reer Mosaic MI8 Installation And Use Manual

Modular safety controller
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MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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8540780 • 23/03/2017 • Rev.31

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Summary of Contents for Reer Mosaic MI8

  • Page 1 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 8540780 • 23/03/2017 • Rev.31...

  • Page 2: Table Of Contents

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC CONTENTS INTRODUCTION ............................7 Contents of this handbook ................7 Important safety instructions ................7 Abbreviations and symbols ................8 Applicable standards ..................8 OVERVIEW ..............................9 PRODUCT COMPOSITION ........................11 INSTALLATION ............................12 Mechanical fastening ..................12 Calculation of safety distance of an ESPE connected to MOSAIC .......
  • Page 3 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC OSSD (MO4LHCS8) ..................30 SAFETY RELAYS (MR2, MR4, MOR4, MOR4S8) ..........31 Characteristics of the output circuit............. 31 MR2/MR4 internal contacts diagram ............31 Example of MR2 module connection with static OSSD outputs of a module M1 ........................
  • Page 4 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Installing the software ..................65 PC HARDWARE requirements ............... 65 PC SOFTWARE requirements ................ 65 How to install MSD ..................65 Fundamentals ..................... 66 Standard tool bar ..................67 Textual tool bar ..................68 Create a new project (configure the MOSAIC system) ........68 EDIT CONFIGURATION (composition of the various modules) .......
  • Page 5 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC ENABLING GRIP SWITCH ................101 TESTABLE SAFETY DEVICE ............... 102 SOLID STATE DEVICE ................103 FIELDBUS INPUT ..................104 LL0-LL1 ....................104 COMMENTS .................... 105 TITLE ..................... 105 SPEED CONTROL TYPE FUNCTION BLOCKS ............. 106 Warning concerning safety ..............
  • Page 6 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC .................... 145 MUTING OVERRIDE (max number = 4) ............ 146 MISCELLANEOUS FUNCTION BLOCKS ............. 148 SERIAL OUTPUT (max number = 4) ............148 NETWORK (max number = 1)..............149 Example of application in Category 2 according to ISO 13849-1: .... 152 Logical block diagram of a safety function using the network ....

  • Page 7: Introduction

    Always test the complete system whenever new safety components are added (see the "TESTING the system" section, page 80).  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 8: Abbreviations And Symbols

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Abbreviations and symbols MCM = MOSAIC Configuration Memory: memory chip for MOSAIC M1 (accessory) MOSAIC Safety Communication: proprietary bus for expansion units MSC = MSD = MOSAIC Safety Designer: MOSAIC configuration SW running in Windows OSSD = Output Signal Switching Device: solid state safety output MTTF...

  • Page 9: Overview

    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 10 The MCT1 and MCT2 Mosaic units are used to connect the 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 11: Product Composition

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC PRODUCT COMPOSITION 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 12: 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 13: 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 14: 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 15: Usb Input

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC USB input The MOSAIC master M1 includes a USB 2.0 connector for connection to Personal Computer where the MSD (MOSAIC Safety Designer) configuration SW resides. A USB cable of the correct size is available as an accessory (CSU). Figure 2 - USB 2.0 front panel connector MOSAIC Configuration Memory (MCM) TECHNICAL DATA LABEL...

  • Page 16: Module Mi8O2

    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 42) ...

  • Page 17: Module Mi8

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Module MI8 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 18: Module Mi16

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Module MI16 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 19: Module Mo2

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Module 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 20: 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 21: 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 22: 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 23: Module Mos8

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Module MOS8 SIGNAL TYPE DESCRIPTION OPERATION 24VDC 24VDC power supply NODE_SEL0 Input Input ("type B" according to EN 61131-2) Node selection Input ("type B" according to EN 61131-2) NODE_SEL1 Input 0VDC 0VDC power supply 24VDC power supply 24VDC STATUS 1-8 OUTPUT STATUS 1...

  • Page 24: Module Mo4Lhcs8

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Module MO4LHCS8 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 Input (according EN 61131-2)

  • Page 25: 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 diagram to M1 Configuration check (including complete system TEST at page 54) on M1 OK? End of connection...

  • Page 26: Signals

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 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 27: Proximity Input For Speed Controller Mv

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC PROXIMITY INPUT FOR SPEED CONTROLLER MV Configuration With Interleaved Proximity (Figure 5) 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 28: 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 29: Outputs

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC OUTPUTS 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 30: Modular Safety Integrated Controller Mosaic

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 250ms < t1< 5s t = 250ms t2 = 250ms OSSD (MO4LHCS8) MO4LHCS8 provides 4 High Current Safety Outputs (2A max per channel). Two different output configurations (configurable with MSD configuration software) can be set: Four single channels (1 Safety Output per channel with its relative feedback input).

  • Page 31: 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 32: 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 33: Technical Features

    24,7 ÷ 52,5 + T Input_filter M1 + 13 Slaves 25,8 ÷ 54,6 + T Input_filter M1 + 14 Slaves M1> module connection ReeR proprietary 5-pole bus (MSC) Connection cable cross-section 0,5 ÷ 2,5 mm / AWG 12÷30 (solid/stranded) Max length of connections...

  • Page 34: Enclosure

    400mA@24VDC max 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) 5.68E-9 Rated voltage 24VDC  20% Dissipated power 3W max Digital INPUTS (No./description)

  • Page 35: 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 via MSC 5-way ReeR proprietary bus MI12T8 module PFH d (IEC 61508:2010) 5.56E-9 Rated voltage 24VDC  20%...

  • Page 36: Mr2 - Mr4 Modules

    Manual operation with RESTART button 8 / Programmable output Digital OUTPUT (No./description) PNP active high Response time 12ms Mechanical life of contacts > 40 x 10 Connection to M1 via MSC 5-way ReeR proprietary bus 8540780 • 23/03/2017 • Rev.31...

  • Page 37: Mo4Lhcs8 Module

    8 / Programmable output / PNP active high Response time 12ms 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 38: Mechanical Dimensions

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MECHANICAL DIMENSIONS 99 mm 22.5 mm 108 mm Figure 10 8540780 • 23/03/2017 • Rev.31...

  • Page 39: Signals

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC SIGNALS Master M1 (Figure 11) 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) FAIL Writing/loading/ diagram to/from MCM card flashes flashes...

  • Page 40: Mi8O2 (Figure 12)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MI8O2 (Figure 12) MEANING IN FAIL EXT FAIL IN1÷8 OSSD1/2 CLEAR1/2 STATUS1/2 GREEN ORANGE YELLOW RED/GREEN YELLOW YELLOW Power on - initial TEST FAIL Table 21 - Opening Screen MEANING IN FAIL EXT FAIL IN1÷8 OSSD1/2 CLEAR1/2 STATUS1/2...

  • Page 41: Mi8 (Figure 13)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MI8 (Figure 13) MEANING IN FAIL EXT FAIL IN1÷8 GREEN ORANGE YELLOW Power on - initial TEST FAIL Table 23 - Opening Screen MEANING IN FAIL EXT FAIL IN1÷8 GREEN ORANGE YELLOW if the unit is waiting for the first INPUT condition communication from the MASTER FLASHES...

  • Page 42: Mi12T8 (Figure 15)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MI12T8 (Figure 15) MEANING IN FAIL EXT FAIL IN1÷12 GREEN ORANGE YELLOW Power on - initial TEST Table 25 - Opening Screen MEANING IN FAIL EXT FAIL IN1÷12 GREEN ORANGE YELLOW if the unit is waiting for the first INPUT condition communication from the MASTER FLASHES...

  • Page 43: Mi16 (Figure 15)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MI16 (Figure 15) MEANING IN FAIL EXT FAIL IN1÷16 GREEN ORANGE YELLOW Power on - initial TEST FAIL Table 27 - Opening Screen MEANING IN FAIL EXT FAIL IN1÷16 GREEN ORANGE YELLOW if the unit is waiting for the first INPUT condition communication from the MASTER FLASHES...

  • Page 44: Mo2 (Figure 16)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MO2 (Figure 16) MEANING IN FAIL EXT FAIL OSDD1/2 CLEAR1/2 STATUS1/2 GREEN ORANGE RED/GREEN YELLOW YELLOW Power on - initial TEST FAIL Table 29 - Opening screen MEANING IN FAIL EXT FAIL OSSD1/2 CLEAR1/2 STATUS1/2 GREEN ORANGE RED/GREEN...

  • Page 45: Mo4 (Figure 17)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MO4 (Figure 17) MEANING IN FAIL EXT FAIL OSDD1/4 CLEAR1/4 STATUS1/4 GREEN ORANGE RED/GREEN YELLOW YELLOW Power on - initial TEST FAIL Table 31 - Opening screen MEANING IN FAIL EXT FAIL OSDD1/4 CLEAR1/4 STATUS1/4 GREEN ORANGE RED/GREEN...

  • Page 46: Mor4 (Figure 18)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MOR4 (Figure 18) IN FAIL EXT FAIL SEL 0/1 RELAY 1/4 CLEAR1/4 MEANING GREEN ORANGE GREEN YELLOW Power on - initial TEST Table 33 - Opening screen MEANING IN FAIL EXT FAIL SEL 0/1 RELAY 1/4 CLEAR1/4 GREEN ORANGE...

  • Page 47: Mor4S8 (Figure 19)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MOR4S8 ( Figure IN FAIL EXT FAIL SEL 0/1 RELAY 1/4 CLEAR1/4 STATUS1/8 MEANING GREEN ORANGE GREEN YELLOW YELLOW Power on - initial TEST Table 35 - Opening screen MEANING IN FAIL EXT FAIL SEL 0/1 RELAY 1/4 CLEAR1/4 STATUS1/8...

  • Page 48: Mos8 (Figure 20)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MOS8 ( Figure IN FAIL EXT FAIL SEL 0/1 STATUS1/8 MEANING GREEN ORANGE YELLOW Power on - initial TEST Table 37 - Opening screen MEANING IN FAIL EXT FAIL SEL 0/1 STATUS1/8 GREEN ORANGE YELLOW if the unit is waiting for the first communication from...

  • Page 49: Mos16 (Figure 21)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MOS16 ( Figure IN FAIL EXT FAIL SEL 0/1 STATUS1/16 MEANING GREEN ORANGE YELLOW Power on - initial TEST Table 39 - 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...

  • Page 50: Mv1, Mv2 (Figure 22)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MV1, MV2 ( Figure 22 ENC* PROX IN FAIL EXT FAIL MEANING GREEN ORANGE YELLOW YELLOW YELLOW Power on - initial TEST Table 41 - Opening screen ENC* PROX IN FAIL EXT FAIL MEANING GREEN ORANGE YELLOW YELLOW...

  • Page 51: Mr2 (Figure 23) / Mr4 (Figure 24)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MR2 (Figure 23) / MR4 (Figure 24) MEANING OSSD1 GREEN NORMAL OPERATION ON with output activated Table 43 - MR2 - Dynamic screen OSSD1 OSSD2 MEANING GREEN GREEN NORMAL OPERATION ON with output activated Table 44 - MR4 - Dynamic screen OSSD OSSD Figure...

  • Page 52: Mo4Lhcs8 (Figure 25)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MO4LHCS8 ( Figure IN FAIL EXT FAIL SEL 0/1 OSSD 1/4 CLEAR1/4 STATUS1/8 MEANING GREEN ORANGE GREEN YELLOW YELLOW Power on - initial TEST Table 45 - Opening screen MEANING IN FAIL EXT FAIL SEL 0/1 OSSD 1/4 CLEAR1/4 STATUS1/8...

  • Page 53: Troubleshooting

    OSSD output (only the LED • If the problem error flashes corresponding to the persists return output in FAIL mode) the M1 to ReeR to be repaired • Restart the system. Error in • If the problem communication flashes persists return...

  • Page 54: Mi8O2 (Figure 27)

    FAIL • Firmware version not compatible with M1, Compatibility error 5 flashes flashes flashes flashes flashes return to ReeR for FW upgrade. • Check OSSD1/2 4 flashes connections (only the LED • If the problem OSSD output error flashes corresponding to the...

  • Page 55: Mi8 (Figure 28)

    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 56: Mi12T8 (Figure 29)

    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 50 - Troubleshooting MI12T8 Figure MI12T8 8540780 • 23/03/2017 • Rev.31...

  • Page 57: Mi16 (Figure 30 - Mi16)

    REMEDY ORANGE GREEN YELLOW FAIL 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 58: Mo2 / Mo4 (Figure 31)

    STATUS1/4 REMEDY GREEN ORANGE RED/GREEN YELLOW YELLOW 2 or 3 Return the unit to Internal fault flashes ReeR to be repaired • Firmware version not compatible Compatibility error with M1, return to FAIL FAIL flashes flashes flashes flashes ReeR for FW upgrade.

  • Page 59: Mor4 (Figure 32)

    EXT FAIL SEL 0/1 RELAY 1/4 CLEAR1/4 MEANING REMEDY 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 60: Mor4S8 (Figure 33)

    ReeR to be repaired • Firmware version not compatible with M1, Compatibility error flashes flashes flashes flashes return to ReeR for FW upgrade. 4 flashes • If the problem (only the LED persists, return the Relais output error flashes corresponding to the...

  • Page 61: Mos8 (Figure 34)

    MEANING REMEDY IN FAIL EXT FAIL SEL 0/1 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 62: Mos16 (Figure 35)

    REMEDY IN FAIL EXT FAIL SEL 0/1 STATUS1/8 STATUS9/16 YELLOW 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 flashes return to ReeR for FW upgrade.

  • Page 63: Mv0, Mv1, Mv2 (Figure 33)

    • Firmware version not address compatible with M1, Compatibility error of the unit flashes flashes flashes flashes return to ReeR for FW upgrade. • Change the encoder Encoder INTERNAL • Return the unit to error flashes flashes ReeR to be repaired •...

  • Page 64: Mo4Lhcs8 (Figure 37)

    SEL 0/1 OSSD 1/4 CLEAR1/4 STATUS1/8 REMEDY GREEN ORANGE GREEN YELLOW YELLOW 2 / 3 • Return the unit to ReeR to Internal fault Rosso flashes be repaired • Firmware version not compatible with M1, Compatibility error flashes flashes flashes...

  • Page 65: Mosaic Safety Designer Software

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MOSAIC SAFETY DESIGNER SOFTWARE The "MOSAIC SAFETY DESIGNER" 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 66: 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 38 You are now ready to create your project. 8540780 •...

  • Page 67: Standard Tool Bar

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Standard tool bar The standard tool bar is shown in Figure 39. The meanings of the icons are listed below: Figure 39 1 -> CREATE A NEW PROJECT 2 -> CHANGE CONFIGURATION (composition of different modules) 3 ->...

  • Page 68: Textual Tool Bar

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Textual tool bar Optionally the textual tool bar shown below is also available (drop down). Figure 40 Create a new project (configure the MOSAIC system) Select icon CREATE (Figure 39) from the standard tool bar to start a new project. The user authentication window is displayed (Figure 41).

  • Page 69: Edit Configuration (Composition Of The Various Modules)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC EDIT CONFIGURATION (composition of the various modules) The change of the system composition is obtained with the icon The configuration window is showed again (Figure 39). Change user parameters The change of user parameters is obtained with the icon The dialog user identification request appears (Figure 43).

  • Page 70: 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 44): Figure 44 1 > OBJECT TOOL WINDOW This contains the various function blocks that will make up your project; these blocks are divided into 3 different types: - physical - inputs...

  • Page 71: 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 72 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC ON CONNECTION (WIRES)  Delete  Display full path of the connection (network) OBJECT PROPERTIES WINDOW Connection start point DESIGN AREA Figure 45 8540780 • 23/03/2017 • Rev.31...

  • Page 73: Example Of A Project

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Example of a project Figure 46 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 74: Project Report

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Project report 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 75: Connect To Mosaic

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Connect to 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").  If a remote connection (via internet) is needed M1 can connect to the appropriate devices through its USB port.

  • Page 76: System Composition

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Figure 48 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 77: 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 use the icon . (Password Required: level 1). A pop-up window will appear (in real time) with: - Status of the inputs (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 78 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Figure 52 - graphic monitor 8540780 • 23/03/2017 • Rev.31...

  • Page 79: 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 80: 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 81: Object Function Blocks

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC OBJECT FUNCTION BLOCKS OUTPUT OBJECTS OSSD (safety outputs) 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). ...

  • Page 82: Single Ossd (Safety Output)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC SINGLE OSSD (safety output) SINGLE OSSD safety output uses semiconductor technology and do not require maintenance, Output1 supplies 24Vdc if the In is 1 (TRUE) and vice versa 0Vdc if the In is 0 (FALSE). ...
  • Page 83 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Here below you can find the explanation of the four MO4LHCS8 Single OSSDs configuration. Configuration with 2 dual channel Configuration with 4 single outputs outputs (safety category 4) (safety category 4) Manual Reset: If selected this enables the request to reset each time the input signal falls. Otherwise, output enabling directly follows In input conditions.

  • Page 84: Status (Signal 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: 3.

  • Page 85: Relay

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC RELAY The Output relay is a N.O. relay output. Relay outputs 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 86: 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 55 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 87 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 88: 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 89: 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 90: 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 91: 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 92: Enable (Enable Key)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 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. 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.

  • Page 93: 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 94: 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 95 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 96: 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 97: 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 98: 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. NETWORK_IN This functional block implements a Network connection input interface;...

  • Page 99: 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 100: 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 101: Enabling Grip Switch

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 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). Test at start-up: If selected this enables the test at start-up of the switch. This test is performed by opening and closing the switch contact to run a complete function test and enable the output.

  • Page 102: Testable Safety Device

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC POSITION 1: enabling grip fully released POSITION 2: enabling grip pressed to middle position POSITION 3: enabling grip fully pressed Position Input (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 Position...

  • Page 103: Solid State Device

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC * Simultaneity error = the maximum time between switching of the single contacts has been exceeded. Parameters Manual Reset: If selected, enables the reset request after each activation of the device. Otherwise, enabling of the output follows directly the conditions of the inputs. Reset may be of two types: Manual and Monitored.

  • Page 104: Fieldbus Input

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC conditions of the inputs. Reset may be of two types: Manual and Monitored. Selecting the Manual option, only transition of the signal from 0 to 1 is checked. If Monitored is selected, double transition from 0 to 1 and return to 0 is checked. t1 >...

  • Page 105: Comments

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC  IMPORTANT: LL0 and LL1 cannot be used to disable the logical ports in the diagram. COMMENTS This allows a description to be entered and placed in any point of the diagram. TITLE Automatically adds the name of the manufacturer, the designer, the project name and the CRC.

  • Page 106: 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 ( ) of the function block.

  • Page 107: 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. In the case in which the speed is below the predetermined threshold the output will be 1 (TRUE).
  • Page 108 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Proximity choice: 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 109: Window Speed Control

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC WINDOW SPEED CONTROL The Window Speed Control function block monitors the speed of a device, generating the Zero to 1 (TRUE) output when the speed is within a prefixed range. Parameters Axis type: 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 110 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 111: Stand Still

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC STAND STILL The StandStill 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 Axis type: 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 112 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 113: 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, 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 114 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Proximity choice: 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 115: 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 116: 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 117: 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...

  • Page 118: Multiplexer

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Select Logic 1, 2, 3: enables the selection of one of the following types of operator: AND, NAND, OR, NOR, XOR, XNOR. Enable (OUT1, OUT2) If selected, activates an output with the result of the first two operators. MULTIPLEXER Logical MULTIPLEXER forwards the signal of the inputs to the output according to the Sel...

  • Page 119: 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) The D FLIP FLOP operator saves the previously set status on output Q according to the following truth table.

  • Page 120: User Restart Manual (Max Number = 16 With Other Restart Operators)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC USER RESTART MANUAL (max number = 16 with other RESTART operators) The USER RESTART MANUAL operator saves the restart signal according to the following truth table. Clear Restart 1 Keep memory Rising edge Falling edge 1 Keep memory Parameters Clear enable: If selected enables the saving process to be reset.

  • Page 121: Macro Restart Monitored (Max Number = 16 With Other Restart Operators)

    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 122: Guard Lock Operators (Max Number = 4)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC GUARD LOCK OPERATORS (max number = 4) GUARD LOCK operator is designed to control locking/unlocking of an ELECTROMECHANICAL GUARD LOCK in a variety of operating contexts. Description of "GUARD LOCK" operator inputs/outputs “Lock_fbk” input unlocks/locks the guard lock. Electromechanical guard locks are unlocked/locked via an electric control that energises/de-energises electromagnet.
  • Page 123 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC “Gate” input connected to the guard lock. The status of the door/gate (GATE) is detected using specific contacts. For example, the status of the door/gate may be indicated by a normally open contact that is closed when Figure 58 the door/gate is closed, as in the case in Figure 58 - Example of feedback of the status of a door/gate connected to the guard lock.
  • Page 124 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 125 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Example of operation in the “no Gate” mode switch 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. Lock_fbk Output1 LockOut Figure 59 –...
  • Page 126 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Figure 60 - 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 89) that verifies the status of device)
  • Page 127 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 128 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Figure 62 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 command is sen switches from LL0 to LL1.
  • Page 129 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Operation in the “Mandatory Gate Opening” mode In this case, the user must NOT sele "Mandatory Gate opening" parameter. The Gate input must always be connected to an see the E-GATE (safety gate section on page 89) that verifies the status device) of the door/gate.
  • Page 130 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Example of operation in the “Mandatory Gate Opening” mode switch. Th The status of the safety gate is monitored by the "Gate" input via the "FBK_GATE" input block, the "Mandatory Gate opening" parameter is selected. The guard lock used in the example continues to be locked when the electromagnet is not energised.
  • Page 131 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC (7) At this time the electromagnet is actually deactivated, approx. 95ms after the command was sent due to the technical characteristics of the device. The guard lock is now locked. Figure 64 - 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.
  • Page 132 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Figure 65 – 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. Parameters Manual Reset: There are two types of reset: Manual and Monitored.
  • Page 133 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Unlock Time (s): The time that must pass between the UnLock_cmd input reaching and the real guard unlock (Lockout output). 0ms ÷ 1 s Step 100 ms 1.5 s ÷ 10 s Step 0.5 s 15 s ÷...

  • Page 134: 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. COUNTER (max number = 16) The operator COUNTER is a pulse counter. There are 3 operationg modes: 1) AUTOMATIC 2) MANUAL...
  • Page 135 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 136: 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. CLOCKING The CLOCKING operator generates a clock signal output with the set period if the IN input is 1 (TRUE).

  • Page 137: Monostable

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 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. Parameters Time: The delay can be set to between 10 ms and 1098.3 s.

  • Page 138: 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 139: 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 140: Delay Line

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 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 141 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 142: 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 143 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 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).

  • Page 144: Sequential" Muting

    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 145 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 Input Muting Muting...

  • Page 146: Muting Override (Max Number = 4)

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Parameters Timeout (sec): Sets the time, between 10 secs and unlimited, within which the Muting cycle must end. If the cycle is not complete at the end of this time, Muting is immediately discontinued. Enable: If selected it enables the possibility of enabling or not enabling the Muting function.
  • Page 147 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC  Otherwise, a Warning is displayed in the compilation phase and in the report.  The user must adopt additional safety measures during the Override phase. Conditions to be checked for activation of Override light "With sensors sensor Override...

  • Page 148: Miscellaneous Function Blocks

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MISCELLANEOUS FUNCTION BLOCKS SERIAL OUTPUT (max number = 4) 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 149: 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 150 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC  Perform a local reset of the module which caused the network shutdown, to restore its safety output. Response Time The max response time of the network starting from emergency stop is given by the formula: = [(212 ms x n°Master)-260ms] ...
  • Page 151 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Figure 66 - NETWORK function block scheme example (Category 2) Figure 67 - NETWORK function block scheme example (Category 4) 8540780 • 23/03/2017 • Rev.31...

  • Page 152: Example Of Application In Category 2 According To Iso 13849-1

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Example of application in Category 2 according to ISO 13849-1: Network data flow Figure 68 Network parameters for the PL calculation Architecture: Cat.2 Diagnostic coverage: DC = 90% Reliability of Module M1: MTTF = 437 (years) Logical block diagram of a safety function using the network INPUT M1 n°1...

  • Page 153: Logical Block Diagram Of A Safety Function Using The Network

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Network data flow Figure 69 Network parameters for the PL calculation Architecture: Cat.4 Diagnostic coverage: DC = 99% PFH Module M1: PFHd = 6,86E-09 (hour Logical block diagram of a safety function using the network INPUT M1 n°1 M1 n°2...

  • Page 154: Reset M1

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 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. t < 5s  If > 5s, RESET is not generated. ...

  • Page 155: 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 70 - Two outputs with one delayed (in MANUAL mode) 8540780 •...

  • Page 156: 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 157: 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 158: How To Use Graphic Simulation

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC (Speed selection) (LL0) (LL0) Figure 73 – 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 How to use graphic simulation Click on the...
  • Page 159 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Click the "X" key (top right) to exit the graphic simulation environment. Figure 74 – Example of a result of the graphic simulation.  It shows the traces and the three keys in the bottom right corner for selecting the traces, saving and printing.
  • Page 160 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Figure 75 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. Figure 76 This file will contain the names of the signals as shown in the diagram, you may use a text editor to enter the status of the input signals at a given moment in Figure 77 time as well as the duration of the simulation and the time step to be used,...
  • Page 161 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Traces visibility: used to select the traces (signal waveforms) to be displayed in the Figure 78 graph. When you press this key, it opens a pop-up window as shown in from which you can add or remove traces to or from the graph. Figure 78 - Traces visibility.

  • Page 162: 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 163 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.  when 3000 ms have which indicates the request to start sent by the operator ...

  • Page 164: Mosaic Fail Codes

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MOSAIC FAIL CODES In case of malfunction the Mosaic system transmits to the MSD software a code corresponding to the error detected by the master M1. To read the code, proceed as follows: connect the Master M1 (indicating FAIL by led) to the PC using the USB cable; launch the software MSD;...
  • Page 165 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 166: 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 MI8O2 MOSAIC I/O expansion unit (8 inputs / 2 double OSSD) 1100010 MOSAIC input expansion unit (8 inputs) 1100020 MI16 MOSAIC input expansion unit (16 inputs)

  • Page 167: Warranty

    MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC WARRANTY 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 169 Dichiarazione CE di conformità EC declaration of conformity Torino, 28/06/2016 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 170 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC ReeR S.p.A. 32 via Carcano 10153 Torino Italia Tel. +39/0112482215 r.a. Fax +39/011859867 Internet: www.reer.it e-mail: info@reer.it 8540780 • 23/03/2017 • Rev.31...

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