Page 1 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC DULAR FETY NTEGRATED ONTROLLER Installation and use 8540780 • 25/01/2023 • Rev.43...
Page 2: Table Of Contents
Abbreviations and symbols................10 Applicable standards ..................11 OVERVIEW .......................... 12 Master MOSAIC M1 / MOSAIC M1S / MOSAIC M1S COM ........12 MOSAIC M1S COM key features ..............13 MOSAIC M1S COM and MBx in the same project: Fieldbus management ..14 Expansion modules ..................
Page 3 SAFETY RELAYS (MR2, MR4, MR8, MOR4, MOR4S8) ......... 47 Characteristics of the output circuit ............... 47 MR2/MR4/MR8 internal contacts diagram ............47 Example of MR2 module connection with static OSSD of a module MOSAIC M1 ..48 Switching operation timing diagram............... 49 TECHNICAL FEATURES ....................50 GENERAL SYSTEM CHARACTERISTICS ..............
Page 4 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LED INDICATORS (Normal Operation) ............... 60 Master MOSAIC M1 (Figure 20) ............... 60 Master MOSAIC M1S (Figure 20) ..............61 Master MOSAIC M1S COM (Figure 20) ............. 62 MOSAIC M1S COM specific Fieldbus LED indicators ......... 63 EtherCAT LEDs.......................
Page 5 Connected Master parameters visualization ..........121 MOSAIC M1S COM connected via LAN ..............121 MOSAIC M1S COM connected via USB ..............121 MOSAIC M1/MOSAIC M1S connected via USB ............122 Operations available with master connected (MOSAIC M1S COM) ....123 Visualization network parameters ................ 123 Visualization/setting network parameters (MOSAIC M1S COM)......
Page 6 T FLIP FLOP (max number = 16) ................203 SR FLIP FLOP ......................203 USER RESTART MANUAL (max number = 16 with MOSAIC M1, 32 with MOSAIC M1S, MOSAIC M1S COM with other RESTART operators) ..........204 8540780 • 25/01/2023 • Rev.43...
Page 7 EQUALITY CHECK (max number = 16) ..............239 SPEED COMPARATOR ................... 239 MISCELLANEOUS FUNCTION BLOCKS .............. 242 SERIAL OUTPUT (max number = 4 with MOSAIC M1, 8 with MOSAIC M1S, MOSAIC M1S COM) ........................... 242 NETWORK (max number=1) ................. 243 Example of application in Category 2 according to ISO 13849-1: ......
Page 8 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC How to use graphic simulation ..............255 Application example of graphic simulation ............259 Mosaic Fail Codes ..................261 Errors Log ......................261 ACCESSORIES AND SPARE PARTS ................. 262 WARRANTY ........................263 EC DECLARATION OF CONFORMITY ..............264 UKCA DECLARATION OF CONFORMITY .............
Page 9: Introduction
Always test the complete system whenever new safety components are added (see the "TESTING the system" page 131).  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 10: Abbreviations And Symbols
LAN = Local Area Network MCM = MOSAIC Configuration Memory: memory chip for MOSAIC M1, MOSAIC M1S, MOSAIC M1S COM (accessory) MSC = MOSAIC Safety Communication: proprietary bus for expansion units MSD = MOSAIC Safety Designer: MOSAIC configuration SW running in Windows...
Page 11: Applicable Standards
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Applicable standards MOSAIC complies with the following European Directives: • 2006/42/EC "Machinery Directive" • 2014/30/EU "Electromagnetic Compatibility Directive" • 2014/35/EU "Low Voltage Directive" • 2011/65/EU "Restriction on the use of certain hazardous substances in electrical and electronic equipment" and is built to the following standards: Programmable controllers, part 2: CEI EN 61131-2...
Page 12: Overview
MR2 e MR4 that can be installed. With 14 expansions, the system can have up to: • with MOSAIC M1: 128 inputs, 16 safety outputs and 32 SIL 1/ PL c outputs. • with MOSAIC M1S, MOSAIC M1S COM: 128 inputs, 32 safety outputs and 48 SIL 1/ PL c outputs.
Page 13: Mosaic M1S Com Key Features
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC • 8 fieldbus inputs with MOSAIC M1 or 32 fieldbus inputs with MOSAIC M1S, MOSAIC M1S COM (MBx firmware version ≥ 2.0). These fieldbus inputs can act in the schematic as physical inputs, but are not safety inputs and they can’t be used in safety related applications.
Page 14: Mosaic M1S Com And Mbx In The Same Project: Fieldbus Management
EthernetIP (MBEI), Ethercat (MBEC), Modbus RTU (MBEM). MBU expansion unit permits connection to devices with a USB port. The MCT1 and MCT2 expansion units are used to connect the MOSAIC M1, MOSAIC M1S, MOSAIC M1S COM to other slave units installed at a distance (< 50 m).
Page 15: Msd Software
The configuration performed on the PC is sent to the master unit via USB or LAN (if MOSAIC M1S COM is used) connection; the file resides in the MOSAIC M1, MOSAIC M1S, MOSAIC M1S COM and can also be saved on the proprietary MCM memory card (accessory).
Page 16: Product Composition
➔ NB: to install an expansion unit (excluding relays) you will need the MSC connector supplied with the unit plus another MSC for the connection to the MOSAIC M1, MOSAIC M1S or MOSAIC M1S COM. This can be ordered separately as an accessory.
Page 17: Installation
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC INSTALLATION MOSAIC M1, MOSAIC M1S, Expansion Modules mechanical fastening  Do not apply power supply before carry out the following operations. 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.
Page 18: Mosaic M1S Com Mechanical Fastening
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MOSAIC M1S COM Mechanical fastening  Do not apply power supply before carry out the following operations.  The off-centre position of the rear connector housing only allows MOSAIC M1S COM to be housed on the right side of any other MOSAIC expansion module. Fix the MOSAIC system units to a 35mm DIN rail as follows: 1.
Page 19: 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 20: Instructions Concerning Connection Cables
➔ Cables used for connections of longer than 50m must have a cross-section of at least 1mm 2 (AWG16). Connections of each single MOSAIC system unit are listed in the table below: Master Module MOSAIC M1 TERMINAL SIGNAL TYPE DESCRIPTION...
Page 21: Master Modules Mosaic M1S / Mosaic M1S Com
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Master Modules MOSAIC M1S / MOSAIC M1S COM TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 24VDC power supply 24VDC 0VDC power supply 0VDC OSSD1 Output Solid State Safety Output 1 PNP active high OSSD2 Output Solid State Safety Output 2 PNP active high Feedback/Restart 1 Input according to EN 61131-2...
Page 22: Usb Interface
MOSAIC M1S COM and used to save the SW configuration parameters. The MCM is written each time a new project is sent from the PC to the MOSAIC M1. ➔ Always switch the MOSAIC M1, MOSAIC M1S, MOSAIC M1S COM off before logging on to/logging off from the MCM.
Page 23: Restore Function
If the Master unit is damaged, you can replace it with a new one; having already saved all the configurations on the MCM, all you need to do is insert the MCM in the new MOSAIC M1, MOSAIC M1S, MOSAIC M1S COM and switch on the MOSAIC system, that will immediately load the backup configuration.
Page 24: Module Mi8O2
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Module MI8O2 TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 24VDC 24VDC power supply Input Input NODE_SEL0 ("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 25: Module Mi8O4
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Module MI8O4 TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 24VDC 24VDC power supply NODE_SEL0 Input ("type B" according to EN 61131-2 ) Node selection NODE_SEL1 Input ("type B" according to EN 61131-2 ) 0VDC 0VDC power supply OSSD1 Output Solid State Safety Output 1...
Page 26: 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 power supply 0VDC Input Digital input 1...
Page 27: 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 28: Module Mo4
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Module MO4 TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 24VDC power supply 24VDC 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 29: Module Mr2
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC ➔ The STATUS SIL 1/PL c signal outputs are shared with the FEEDBACK/RESTART inputs of the OSSDs. To use them, the corresponding OSSD must be used with automatic reset without external feedback monitoring. Module MR2 TERMINAL SIGNAL TYPE...
Page 30: Module Mr8
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Module MR8 TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 24VDC 24VDC power supply 0VDC power supply Input OSSD1_A Control ZONE 1 PNP active high OSSD1_B Input FBK_K1_K2_1_1 Output Feedback K1K2 ZONE 1 Normally closed EDM FBK_K1_K2_1_2 Output A_NC1 Output NC contact ZONE 1...
Page 31: Modules Mv0 - Mv1 - Mv2
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Modules MV0 - MV1 - MV2 TERMINAL SIGNAL TYPE DESCRIPTION OPERATION 24VDC 24VDC power supply Input ("type B" according NODE_SEL0 Input to EN 61131-2) Node selection Input ("type B" according NODE_SEL1 Input to EN 61131-2) 0VDC 0VDC power supply Output...
Page 32 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC POWER SUPPLY POWER SUPPLY 5VDC/ EXT_0V 5VDC 24VDC EXT_0V ENCODER TTL ENCODER TTLB BROWN BROWN +5VDC +5VDC 5VDC/24VDC WHITE WHITE EXT_0V EXT_0V EXT_0V EXT_0V N.C. N.C. N.C. N.C. GREEN GREEN YELLOW YELLOW N.C. N.C. N.C. N.C.
Page 33: 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 34: Module Mos8
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Module MOS8 SIGNAL TYPE DESCRIPTION OPERATION 24VDC power supply 24VDC 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 24VDC 24VDC power supply STATUS 1-8 OUT_STATUS 1-8...
Page 35: 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 36: Modulo Ma4
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Modulo MA4 SIGNAL TYPE DESCRIPTION OPERATION 24 VDC 24VDC power supply NODE_SEL0 Input Input ("type B" according to EN 61131-2) Node selection Input Input ("type B" according to EN 61131-2) NODE_SEL1 0 VDC 0VDC power supply Isolated 24VDC power supply for sensor Output 24VDC_S1...
Page 37: Ma2 / Ma4 Analog Sensor Connections
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MA2 / MA4 Analog sensor connections The MA2/MA4 modules are suitable for: • 4/20mA current output sensors with 2/3/4 wires • 0/20mA current output sensors with 2/3/4 wires • 0/10V voltage output sensors with 3 wires Following are shown some connections example: Figure 8 ...
Page 38: 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 9 Checklist after installation The MOSAIC system is able to detect the faults that occurs in each own module. Anyway to have the system perfect operation perform the following checks at start up and at least every one year: Operate a complete system TEST (see "TESTING the system") Verify that all the cables are correctly inserted and the terminal blocks well screwed.
Page 39: Operating Diagram
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC OPERATING DIAGRAM 8540780 • 25/01/2023 • Rev.43...
Page 40: Signals
SIGNALS INPUTS MASTER ENABLE The MOSAIC M1 master has two inputs: MASTER_ENABLE1 and MASTER_ENABLE2. ➔ These signals must both be permanently set to logic level 1 (24VDC) for the MOSAIC to operate. If the user needs to disable the MOSAIC simply lower these inputs to logic level 0 (0VDC).
Page 41: Configuration With Interleaved Proximity
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Configuration With Interleaved Proximity 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 42: Outputs
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MODE OF RESTART_FBK OPERATION ext_Restart_fbk With K1_K2 control AUTOMATIC Without K1_K2 control ext_Restart_fbk With K1_K2 control MANUAL Without K1_K2 control Table 24 OUTPUTS OUT STATUS (SIL 1/PL c) The OUT STATUS signal is a Programmable SIL 1 /PL c output that can indicate the status of: •...
Page 43: Ossd Safety Outputs
(e.g. two OSSD outputs shorted together). The test method chosen to perform this safety check is the “voltage dip” test: periodically (every: MOSAIC M1: 20 ms; MOSAIC M1S and MOSAIC M1S COM: 600 ms) and for a very short time (< 120 µs) each OSSD output is forced to 0VDC and if the test results are not consistent the system goes in fail and into a safe state.
Page 44 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Different output configurations (configurable with configuration software) can be set: • 4 single channels (1 Safety Output per channel with its relative feedback input). • 2 dual channels (2 Safety Outputs per channel with their relative feedback input). •...
Page 45: Ossd (Mo4Lhcs8)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC OSSD (MO4LHCS8) MO4LHCS8 provides 4 independent High Current Safety Outputs OSSD (2A max per channel). These outputs are short circuit protected, cross circuit monitored and supply: In the ON condition: (Uv-0,6V)...Uv (24VDC ± 20%) • In the OFF condition: 0V...2V r.m.s.
Page 46: Ossd Outputs Configuration
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Configuration with 2 dual channel Configuration with 4 single outputs outputs (safety category SIL3/Pl e) (safety category SIL3/Pl e) OSSD OUTPUTS CONFIGURATION Each OSSD output can be configured as shown in Table 25: The output is activated according to le configurations set by the MSD SW only if the Automatic corresponding RESTART_FBK input is conected to 24VDC.
Page 47: Safety Relays (Mr2, Mr4, Mr8, Mor4, Mor4S8)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC SAFETY RELAYS (MR2, MR4, MR8, MOR4, MOR4S8) Characteristics of the output circuit The MR2/MR4/MR8 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, the MR4 uses four and the MR8 uses eight.
Page 48: Example Of Mr2 Module Connection With Static Ossd Of A Module Mosaic M1
MOSAIC MR8 ZONE 3/4 INTERNAL DIAGRAM Figura 15 Example of MR2 module connection with static OSSD of a module MOSAIC M1 Figure 16 If a relay module is connected, the response time of the OSSD linked, must be increased of 12ms.
Page 49: Switching Operation Timing Diagram
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Switching operation timing diagram. Figure 17 8540780 • 25/01/2023 • Rev.43...
Page 50: Technical Features
Pollution degree General data Max number of inputs Max number of OSSD outputs 16 (MOSAIC M1); 32 (MOSAIC M1S, MOSAIC M1S COM) Max number of signalling outputs 32 (MOSAIC M1); 48 (MOSAIC M1S, MOSAIC M1S COM) Max number of slave units...
Page 51: Enclosure
MOSAIC M1S COM + 13 Slaves Encoder/Proximity interface where is 2s 29,07...68,24 + T Input_filter MOSAIC M1S COM + 14 Slaves MOSAIC M1, MOSAIC M1S, MOSAIC M1S COM, -> ReeR proprietary 5-pole bus (MSC) module connection Connection cable cross-section 0,5...2,5 mm / AWG 12÷30 (solid/stranded)
Page 52: Mosaic M1 Module
400mA@24VDC max - Interface type C class 3 (ZVEI CB24I) SLOT for MCM card Available Connection to PC USB 2.0 (Hi Speed) - Max cable length: 3m Connection to slave units via MSC 5-way ReeR proprietary bus MOSAIC M1S module (IEC 61508:2010) 1,44E-08 99,7% Rated voltage 24VDC ...
Page 53: Mosaic M1S Com Module
Ethernet connection max length of 100 m connection cables Supported fieldbus protocol EtherNet/IP - MODBUS/TCP - PROFINET - EtherCAT Connection to slave units via MSC 5-way ReeR proprietary bus MI8O2 module (IEC 61508:2010) 5.67E-9 99,8% 24VDC  20% Rated voltage...
Page 54: Mi8O4 Module
4 single / solid state safety outputs: PNP active high – 400mA@24VDC max OSSD (No./description) Interface type C class 3 (ZVEI CB24I) Connection to MOSAIC M1S, via MSC 5-way ReeR proprietary bus MOSAIC M1S COM MI8 - MI16 modules Model MI16 (IEC 61508:2010) 4.46E-9...
Page 55: Mo2 - Mo4 Modules
99,6% Rated voltage 24VDC  20% Dissipated power 3W max SIL 1/PL c OUTPUTS (No./description) programmable - PNP active high Connection to MOSAIC M1 and MOSAIC M1S, through 5-way MSC proprietary bus MOSAIC M1S COM 8540780 • 25/01/2023 • Rev.43...
Page 56: Mr2 - Mr4 - Mr8 Modules
8 / Programmable output SIL 1/PL c OUTPUTS (No./description) PNP active high Mechanical life of contacts > 40 x 10 MOSAIC M1 connections and via MSC 5-way ReeR proprietary bus MOSAIC M1S, MOSAIC M1S COM 8540780 • 25/01/2023 • Rev.43...
Page 57: Mo4Lhcs8 Module
SIL 1/PL c 8 / Programmable output / PNP active high Response time 12ms MOSAIC M1 connections and via MSC 5-way ReeR proprietary bus MOSAIC M1S, MOSAIC M1S COM ➔ Using MO4LHCS8 with current output >500mA, separate it from adjacent modules by interposing an MSC connector.
Page 58: Ma2, Ma4 Module
1 second and then again activated to check if the input overvoltage/overcurrent condition still exist in an endless loop until the anomaly disappear. Disconnected cable detection Overthreshold / Underthreshold detection Connection to MOSAIC M1S, via MSC 5-way ReeR proprietary bus MOSAIC M1S COM 8540780 • 25/01/2023 • Rev.43...
Page 59: Mechanical Dimensions
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MECHANICAL DIMENSIONS Figure 18 - MOSAIC M1, MOSAIC M1S and Slave Modules Figure 19 - MOSAIC M1S COM and MR8 8540780 • 25/01/2023 • Rev.43...
Page 60: Led Indicators (Normal Operation)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LED INDICATORS (Normal Operation) Master MOSAIC M1 (Figure 20) 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)
Page 61: Master Mosaic M1S (Figure 20)
Flashes quickly not correct) (ref. System composition) MSD requesting connection: (slave module missing or not ready) Flashes quickly Flashes quickly (ref. System composition) MSD connected MOSAIC M1 stopped Table 29 - Opening Screen MEANING IN FAIL EXT FAIL IN1...8 OSSD1...4 STATUS/RST/FBK 1...4...
Page 62: Master Mosaic M1S Com (Figure 20)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Master MOSAIC M1S COM (Figure 20) MEANING IN FAIL EXT FAIL IN1...8 OSSD1...4 STATUS/RST/FBK 1...4 GREEN ORANGE BLUE YELLOW RED/GREEN/YELLOW YELLOW Power on - initial TEST MCM recognised (max 1s) (max 1s) Writing/loading/ diagram to/from MCM card flashes flashes MSD requesting connection:...
Page 63: Mosaic M1S Com Specific Fieldbus Led Indicators
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MOSAIC M1S COM specific Fieldbus LED indicators EtherCAT LEDs COLOR STATE MEANING OFF  INIT: The device is in INIT state GREEN  MS (Red/Green) Blinking (2.5 hz) PRE-OPERATIONAL: The device is in PRE-OPERATIONAL state RUN STATUS GREEN ...
Page 64: Ethernet/Ip Leds
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC EtherNET/IP LEDs COLOR STATE MEANING GREEN ⚫ DEVICE OPERATIONAL: The device is operating correctly GREEN  Flashing (1 Hz) STANDBY: The device has not been configured. SELF-TEST: The device is performing its power-up testing. The module status indicator test sequence occurs before the network status indicator test sequence, according to the following sequence: •...
Page 65: Led State Explanation
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LED state explanation STATE MEANING Flashing (1 Hz) The indicator turns on and off with a frequency of 1 Hz: "ON" for 500 ms, followed by "OFF' for 500 ms. Flashing green/red/green The MS LED indicator turns on green on for 250 ms, then red on for 250 ms, then green on (until the test is completed). Flashing green/red/OFF The NS LED indicator turns on green on for 250 ms, then red on for 250 ms, then off (until the test is completed).
Page 66: Profinet Leds
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC PROFINET LEDs COLOR STATE MEANING OFF  NO ERROR Flashing RED  MS (Red/Green) DCP signal service is initiated via the bus (1 Hz, 3 s) SYSTEM FAILURE WATCHDOG TIMEOUT: channel, generic or extended diagnosis present; RED ⚫...
Page 67: Mi8O2 (Figure 23)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MI8O2 (Figure 23) MEANING IN FAIL EXT FAIL SEL0/1 IN1...8 OSSD1/2 CLEAR1/2 STATUS1/2 GREEN ORANGE YELLOW RED/GREEN YELLOW YELLOW Power on - initial TEST Table 33 - Opening Screen MEANING IN FAIL EXT FAIL IN1...8 SEL0/1 OSSD1/2 CLEAR1/2...
Page 68: Mi8O4 (Figure 23)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MI8O4 (Figure 23) MEANING IN FAIL EXT FAIL SEL0/1 IN1...8 OSSD1...4 STATUS/RST/FBK 1...4 GREEN ORANGE YELLOW RED/GREEN/YELLOW YELLOW Power on - initial TEST Table 35 - Opening Screen MEANING IN FAIL EXT FAIL IN1...8 SEL0/1 OSSD1...4 STATUS/RST/FBK 1...4 GREEN...
Page 69: Mi8 (Figure 25)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MI8 (Figure 25) MEANING IN FAIL EXT FAIL SEL0/1 IN1...8 GREEN ORANGE YELLOW Power on - initial TEST Table 37 - Opening Screen MEANING IN FAIL EXT FAIL SEL0/1 IN1...8 GREEN ORANGE YELLOW if the unit is waiting for the first INPUT condition communication from the MASTER FLASHES...
Page 70: Mi12T8 (Figure 27)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MI12T8 (Figure 27) MEANING IN FAIL EXT FAIL SEL0/1 IN1...12 GREEN ORANGE YELLOW Power on - initial TEST Table 39 - Opening Screen MEANING IN FAIL EXT FAIL SEL0/1 IN1...12 GREEN ORANGE YELLOW if the unit is waiting for the first INPUT condition communication from the MASTER FLASHES...
Page 71: Mi16 (Figure 27)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MI16 (Figure 27) MEANING IN FAIL EXT FAIL SEL0/1 IN1...16 GREEN ORANGE YELLOW Power on - initial TEST Table 41 - Opening Screen MEANING IN FAIL EXT FAIL SEL0/1 IN1...16 GREEN ORANGE YELLOW if the unit is waiting for the first INPUT condition communication from the MASTER FLASHES...
Page 72: Mo2 (Figure 28)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MO2 (Figure 28) MEANING IN FAIL EXT FAIL SEL0/1 OSDD1/2 CLEAR1/2 STATUS1/2 GREEN ORANGE RED/GREEN YELLOW YELLOW Power on - initial TEST Table 43 - Opening screen MEANING IN FAIL EXT FAIL SEL0/1 OSSD1/2 CLEAR1/2 STATUS1/2 GREEN ORANGE...
Page 73: Mo4 (Figure 29)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MO4 (Figure 29) MEANING IN FAIL EXT FAIL SEL0/1 OSSD1...4 CLEAR1...4 STATUS1...4 GREEN ORANGE RED/GREEN YELLOW YELLOW Power on - initial TEST Table 45 - Opening screen MEANING IN FAIL EXT FAIL SEL0/1 OSSD1...4 CLEAR1...4 STATUS1...4 GREEN ORANGE...
Page 74: Mo4L (Figure 23)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MO4L (Figure 23) MEANING IN FAIL EXT FAIL SEL0/1 OSSD1...4 STATUS/RST/FBK 1...4 GREEN ORANGE RED/GREEN/YELLOW YELLOW Power on - initial TEST Table 47 - Opening Screen MEANING IN FAIL EXT FAIL SEL0/1 OSSD1...4 STATUS/RST/FBK 1...4 GREEN ORANGE RED/GREEN/YELLOW...
Page 75: Mor4 (Figure 31)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MOR4 (Figure 31) IN FAIL EXT FAIL SEL0/1 RELAY1...4 CLEAR1...4 MEANING GREEN ORANGE GREEN YELLOW Power on - initial TEST Table 49 - Opening screen MEANING IN FAIL EXT FAIL SEL0/1 RELAY1...4 CLEAR1...4 GREEN ORANGE GREEN YELLOW if the unit is waiting...
Page 76: Mor4S8 (Figure 32)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MOR4S8 (Figure 32) IN FAIL EXT FAIL SEL0/1 RELAY1...4 CLEAR1...4 STATUS1...8 MEANING GREEN ORANGE GREEN YELLOW YELLOW Power on - initial TEST Table 51 - Opening screen MEANING IN FAIL EXT FAIL SEL0/1 RELAY1...4 CLEAR1...4 STATUS1...8 GREEN ORANGE...
Page 77: Mos8 (Figure 33)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MOS8 (Figure 33) IN FAIL EXT FAIL SEL0/1 STATUS1...8 MEANING GREEN ORANGE YELLOW Power on - initial TEST Table 53 - Opening screen MEANING IN FAIL EXT FAIL SEL0/1 STATUS1...8 GREEN ORANGE YELLOW if the unit is waiting for the first communication from the MASTER...
Page 78: Mos16 (Figure 34)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MOS16 (Figure 34) IN FAIL EXT FAIL SEL0/1 STATUS1/16 MEANING GREEN ORANGE YELLOW Power on - initial TEST Table 55 - Opening screen IN FAIL EXT FAIL SEL 0/1 STATUS1/16 MEANING GREEN ORANGE YELLOW if the unit is waiting for the first communication from the MASTER...
Page 79: Mv0, Mv1, Mv2 (Figure 35)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MV0, MV1, MV2 (Figure 35) ENC* PROX IN FAIL EXT FAIL SEL0/1 MEANING GREEN ORANGE YELLOW YELLOW YELLOW Power on - initial TEST Table 57 - Opening screen ENC* PROX IN FAIL EXT FAIL SEL0/1 MEANING GREEN ORANGE...
Page 80: Mr2, Mr4, Mr8 (Figure 36)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MR2, MR4, MR8 (Figure 36) OSSD1 MEANING GREEN NORMAL OPERATION ON with output activated Table 59 - MR2 - Dynamic screen OSSD1 OSSD2 MEANING GREEN GREEN NORMAL OPERATION ON with output activated Table 60 - MR4 - Dynamic screen OSSD1 OSSD2 OSSD3...
Page 81: Mo4Lhcs8 (Figure 37)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MO4LHCS8 (Figure 37) IN FAIL EXT FAIL SEL0/1 OSSD1...4 CLEAR1...4 STATUS1...8 MEANING GREEN ORANGE GREEN YELLOW YELLOW Power on - initial TEST Table 62 - Opening screen MEANING IN FAIL EXT FAIL SEL0/1 OSSD1...4 CLEAR1...4 STATUS1...8 GREEN ORANGE...
Page 82: Ma2, Ma4 (Figure 38)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MA2, MA4 ( Figure 38 MEANING IN FAIL EXT FAIL SEL0/1 CHAN 1...4 GREEN ORANGE RED/GREEN Power on - initial TEST RED ON Table 64 – Initial operation LEDs state SEL0/1 IN FAIL EXT FAIL CHAN 1...4 MEANING GREEN...
Page 83: Led Indicators (Troubleshooting)
ReeR to be repaired • Restart the system Slave unit • Check which unit error is in FAIL mode MCM error Replace the MCM flashes flashes Table 66 - Troubleshooting MOSAIC M1 Figure 39 - MOSAIC M1 8540780 • 25/01/2023 • Rev.43...
Page 84: Master Mosaic M1S / Mosaic M1S Com (Figure 40)
OSSD output (only the LED • If the problem error flashes corresponding to the persists return output in FAIL mode) the MOSAIC M1 to ReeR to be repaired • Restart the system. Error in • If the problem communication persists return...
Page 85: Mi8O2 (Figure 41)
IN1...8 OSSD1/2 CLEAR1/2 STATUS1/2 REMEDY GREEN ORANGE YELLOW RED/GREEN YELLOW YELLOW 2 or 3 • Return the unit to ReeR Internal fault flashes to be repaired • Firmware version not compatible with Compatibility error 5 flashes flashes flashes flashes flashes MOSAIC M1, return to ReeR for FW upgrade.
Page 86: Mi8O4 (Figure 42)
• If the problem OSSD output error flashes corresponding to the persists, return the Shows the output in FAIL mode) unit to ReeR to be physical repaired address of the unit • Restart the system Error in • If the problem...
Page 87: Mi8 (Figure 43)
MOSAIC M1, return to 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 88: Mi12T8 (Figure 44)
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 71 - Troubleshooting MI12T8 Figure - MI12T8 8540780 • 25/01/2023 • Rev.43...
Page 89: Mi16 (Figure 45)
IN1...16 REMEDY GREEN ORANGE YELLOW Internal fault 2 or 3 flashes • Return the unit to ReeR to be repaired • Firmware version not compatible with Compatibility error flashes flashes MOSAIC M1, return to ReeR for FW upgrade. Shows the •...
Page 90: Mo2 / Mo4 (Figure 46)
(only the LED • If the problem OSSD output error corresponding to flashes persists, return the the output in FAIL unit to ReeR to be mode) repaired Shows the • Restart the system physical • If the problem Error in communication...
Page 91: Mo4L (Figure 47)
EXT FAIL SEL0/1 OSSD1...4 STATUS/RST/FBK 1...4 REMEDY GREEN ORANGE RED/GREEN/YELLOW YELLOW 2 or 3 • Return the unit to ReeR to Internal fault flashes be repaired • Firmware version not compatible with Compatibility error flashes flashes flashes MOSAIC M1, return to ReeR for FW upgrade.
Page 92: Mor4 (Figure 48)
IN FAIL EXT FAIL SEL 0/1 RELAY 1...4 CLEAR1...4 REMEDY GREEN ORANGE GREEN YELLOW • Return the unit to ReeR Internal fault 2 / 3 flashes Rosso to be repaired • Firmware version not compatible with Compatibility error flashes flashes...
Page 93: Mor4S8 (Figure 49)
2 / 3 • Return the unit to Internal fault Rosso flashes ReeR to be repaired • Firmware version not compatible with Compatibility error MOSAIC M1, return to flashes flashes flashes flashes ReeR for FW upgrade. 4 flashes • If the problem...
Page 94: Mos8 (Figure 50)
MEANING IN FAIL EXT FAIL SEL0/1 REMEDY STATUS1...8 YELLOW GREEN ORANGE • Return the unit to ReeR Internal fault 2 / 3 flashes to be repaired • Firmware version not compatible with Compatibility error flashes flashes MOSAIC M1, return to ReeR for FW upgrade.
Page 95: Mos16 (Figure 51)
REMEDY IN FAIL EXT FAIL SEL0/1 STATUS1...8 STATUS9...16 GREEN ORANGE YELLOW YELLOW • Return the unit to ReeR Internal fault 2 / 3 flashes to be repaired • Firmware version not compatible with Compatibility error flashes flashes flashes MOSAIC M1, return to ReeR for FW upgrade.
Page 96: Mv0, Mv1, Mv2 (Figure 52)
ReeR to be repaired • Firmware version not compatible with Compatibility error flashes flashes flashes flashes MOSAIC M1, return to Shows the ReeR for FW upgrade. physical address • Change the encoder Encoder INTERNAL of the unit • Return the unit to...
Page 97: Mo4Lhcs8 (Figure 53)
SEL 0/1 OSSD 1...4 CLEAR1...4 STATUS1...8 REMEDY GREEN ORANGE GREEN YELLOW YELLOW 2 / 3 • Return the unit to ReeR Internal fault Rosso flashes to be repaired • Firmware version not compatible with Compatibility error flashes flashes flashes flashes MOSAIC M1, return to ReeR for FW upgrade.
Page 98: Ma2, Ma4 (Figure 54)
ReeR in order to update the firmware. Communication • Reboot the system Shows the error with MASTER flashes • If reboot does not work return the unit to ReeR physical Error on other • Restart the system address of the slave or MASTER •...
Page 99 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Channel configured as Redundant (Pair of sensors connected), conditions: Sensor supply overload. Input channel overload. Read value over threshold. Read value under threshold. Disconnected sensor: When one of these diagnosis is detected the RED led relative to the channel with the problem will flash. The RED led of the other channel remains ON (no flash).
Page 100: Mosaic Safety Designer Software
• Windows 7 with Service Pack 1 installed (or higher OS). • Microsoft Framework 4.8 (or higher). Installation of MSD software • Download the last available version from the Download section of the ReeR website: https://www.reersafety.com/it/en/download/configuration-software • Run the “SetupDesigner.exe” file.
Page 101: 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 55 You are now ready to create your project. 8540780 •...
Page 102: Standard Toolbar
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Standard toolbar The standard toolbar is shown in Figure 56. The meanings of the icons are listed below: Figure 56 1 -> CREATE A NEW PROJECT 2 -> CHANGE CONFIGURATION (composition of different modules) 3 -> CHANGE USER PARAMETERS (name, company, etc) 4 ->...
Page 103: Textual Toolbar
The user authentication window is displayed (Figure 58). Figure 58 Next the MSD displays a window showing the MOSAIC M1S only. It is possible to select the MOSAIC M1, MOSAIC M1S COM modules acting on the drop-down menu under the master module choosing version.
Page 104: Pages Configuration / Management
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Pages configuration / management In the Options menu there is a choice to configure the grid size, the page size, and its orientation. Figure 59 Pages are managed either through a Page Navigation menu or through the Page1/Page2/Page3 tabs located at the topside that display the names of the pages currently open.
Page 105 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Figure 62 - MOSAIC M1 / MOSAIC M1S project configuration MOSAIC M1S COM Firmware version (> 8.0.0) and Fieldbus to be connected Fieldbus Network parameters / Analog data presence Dynamic input order Figure 63 - MOSAIC M1S COM project configuration...
Page 106: Fieldbus With Dynamic Input Order
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Fieldbus with dynamic input order If enabled, input mapping on Fieldbus (Process Data Mapping) enumerates the input modules as ordered in user configuration (Figure 63) rather with their hierarchical order; the following table shows the differences. PROCESS DATA MAPPING INPUT ORDER Hierarchical order of I/O modules (Default) Dynamic I/O Module Ordering...
Page 107: Ethernet/Ip Parameters
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC EtherNet/IP parameters When MOSAIC M1S COM has to be connected with EtherNet/IP fieldbus you can choose if the stack automatically set the LAN parameters (DHCP active) or (selecting "Manual") directly complete the necessary network parameters: IP Addres, Subnet Mask, Default Gateway, DNS1, DNS2, Station Name (optional).
Page 108: Ethercat Parameters
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Pressing the "Network Parameters" button the user can choose the network configuration Figure 66 Configuration in Profinet RT developing environment ➔ To integrate MOSAIC M1S COM in Profinet RT developing environment, the configuration of the modules must follow the order of the following table.
Page 109: Edit Configuration (Composition Of The Various Modules)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Figure 67 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 56). Change user parameters The change of user parameters is obtained with the icon The dialog user identification request appears (Figure 68).
Page 110: Objects - Operator - Configuration Toolbars
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Objects - Operator - Configuration toolbars Four large tool windows are displayed to the left and right of the main window (shown in Figure 69): Figure 69 1 > OBJECT TOOL WINDOW This section contains the various function blocks that will make up your project; these blocks are divided into five different types: - Inputs - Speed Control...
Page 111: 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 112: Use Of Mouse Right Button
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Use of mouse right button Block Input / Output • Copy / Paste • Delete • Delete all the assigned pins • Alignment with other functional blocks (multiple selection) • On-line Help • Monitor Mode: Show / Hide Properties window •...
Page 113: Example Of A Project
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Example of a project Figure 71 shows an example of a project in which the MOSAIC M1S unit only is connected to two safety blocks (E-GATE and E-STOP). The MOSAIC M1S inputs (1,2,3) for connecting the contacts of the safety components are shown on the left, in yellow.
Page 114: Resources Allocation
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Resources Allocation To activate the RESOURCES ALLOCATION function use the icon Executing this command, all the used elements among Inputs, Outputs, Status, Fieldbus input and Probe are visible, see the example in figure. Figure 72 8540780 •...
Page 115: Project Report
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Project report Print of the System composition with properties of each block. (Icon on the standard toolbar). Figure 73 8540780 • 25/01/2023 • Rev.43...
Page 116 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Figure 74  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 117: Connect Msd To Mosaic Master
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Connect MSD to Mosaic Master Communication channel selection The icon allow user to choose which type of connection activate with MSD: USB or LAN. A pop-up window will appear on MSD with 2 parameters to be set. USB connection Selecting "USB"...
Page 118 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC HOST: Type in this field the IP address of the MOSAIC M1S COM module to be connected. ➔ HOST: MSD will show the last 10 IP addresses entered by the user. Figure 77 - Host selection DEVICE SCANNING: By clicking on the word "Device Scanning"...
Page 119 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC ➔ The following figure shows the scanning phase in progress and the detection of devices with their IP and MAC addresses. Figure 79 - Scanning phase TEST: Clicking on the word "Test" the presence of the host (MOSAIC M1S COM) on the network is verified.
Page 120 Figure 81 - Test failed ➔ After clicking on icon MSD start the connection with MOSAIC M1/MOSAIC M1S module (only through USB) or with MOSAIC M1S COM (through USB or LAN). A window appears to request the password. Enter the password (see "Password protection").
Page 121: Connected Master Parameters Visualization
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Connected Master parameters visualization MOSAIC M1S COM connected via LAN ➔ When MOSAIC M1S COM is connected via LAN in the “Module connected” textbox are displayed these parameters: - MOSAIC M1S COM: firmware version - Ethernet Release: current ZIP container stored - IP: MOSAIC M1S COM IP address - MAC: MOSAIC M1S COM MAC address * - Protocol choice: the currently running Fieldbus together with its version...
Page 122: Mosaic M1/Mosaic M1S Connected Via Usb
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Figure 85 MOSAIC M1/MOSAIC M1S connected via USB ➔ When MOSAIC M1/MOSAIC M1S COM is connected via USB in the “Module connected” textbox are displayed these parameters: - MOSAIC M1/MOSAIC M1S: firmware version - S/N: module serial number Figure 86 8540780 •...
Page 123: Operations Available With Master Connected (Mosaic M1S Com)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Operations available with master connected (MOSAIC M1S COM) Visualization network parameters With the Level 1 password, the user is only allowed to view the connection parameters (refer to Password protection). Select the icon to read the Fieldbus parameters. Figure 87 Visualization/setting network parameters (MOSAIC M1S COM) With the Level 2 password, the user is enabled to view and edit the connection...
Page 124: Download Project To Mosaic (From Pc)
"Enable Fieldbus speed data" are selected, a process map with analog data must be used). Download project to MOSAIC (from PC) To send the saved configuration from a PC to MOSAIC M1, MOSAIC M1S, MOSAIC M1S COM use the icon on the standard toolbar and wait the execution. MOSAIC M1, MOSAIC M1S, MOSAIC M1S COM will save the project in its internal memory and (if present) in MCM memory.
Page 125: Upload An Existing Project To Pc (From Mosaic)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Upload an existing project to PC (from MOSAIC) To upload a project from MOSAIC M1, MOSAIC M1S, MOSAIC M1S COM to MSD use the icon on the Standard toolbar. MSD will display the project residing in MOSAIC M1, MOSAIC M1S, MOSAIC M1S COM .
Page 126: Errors Log
Please refer to the paragraph " at page 261. Disconnecting System To disconnect the PC from MOSAIC M1, MOSAIC M1S, MOSAIC M1S COM use the icon ; when the system is disconnected it is resetted and it starts with the sent project.
Page 127: Monitor (I/O Status In Real Time - Textual - Graphic)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Figure 95 - Textual monitor Monitor (I/O status in real time - textual - graphic) To activate/deactivate the monitor use the icon . (Password Required: level 1). The color of links (Figure 33) allows you to view the diagnostics (in real time) with: RED = OFF GREEN = ON DASHED ORANGE = Connection Error...
Page 128: Fieldbus Monitor (Only For Mosaic M1S Com)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Figure 98 - Monitor - Output diagnostic (graphic) Figure 99 - Monitor - Output diagnostic (textual) Fieldbus Monitor (Only for MOSAIC M1S COM) Operating with MOSAIC M1S COM module connected to an external fieldbus, select the icon in the figure to activate the Fieldbus monitor.
Page 129: Password Protection
Mosaic (level 1 password) is not visible. Level 1 password All operators using the MOSAIC M1, MOSAIC M1S, MOSAIC M1S COM system must have a Level 1 PASSWORD. This password allows only to view the configuration and error LOGs, composition of the system and MONITOR in real time and upload operations.
Page 130: Level 2 Password
When a new project is UPLOADED the level 2 password could be changed. ➔ Should you forget either of these passwords, please contact ReeR which will provide an unlock file (when the unlock file is saved in the right directory the icon will appear on the toolbar).
Page 131: Testing The System
Testing the system  After validating and uploading the project to the MOSAIC M1, MOSAIC M1S, MOSAIC M1S COM 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 132: Object Function Blocks
(according to following output conditions). OUTPUT ERROR MOSAIC M1, MOSAIC M1S, MOSAIC M1S COM CLEAR LED Flashing With high level (TRUE) OUTPUT, the FBK signal must be at low level (FALSE) within the set time.
Page 133: Single-Double Ossd (Safety Output)
The Error Out signal is reset in case of one of the following events: 1. Switching on and switching off of system. 2. Activation of the RESET MOSAIC M1 operator. Example of OSSD with correct Feedback Example of OSSD with incorrect Feedback signal...
Page 134 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Parameters Output Type: There is a choice of 2 different output type: • Single Output Type • Double Output Type Using MOSAIC M1S, MOSAIC M1S COM, MI8O4, MO4L, MO4LHCS8 modules, the operator can choose between different configurations: 1.
Page 135 With high level (TRUE) OUTPUT, the FBK signal must be at low level (FALSE) within the set time. Otherwise, OUTPUT is set to low level (FALSE) and the error is indicated on the master MOSAIC M1 by the flashing CLEAR LED corresponding to the OSSD in error.
Page 136: Status (Sil 1/Pl C Output)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC No test pulses: if selected disables the “voltage dip” test on the OSSD safety outputs (refer to Important note concerning OSSD Safety “ Outputs ”, page 43).  Selecting “no test pulse” causes the loss of the safety function of the Single-Double OSSD (function block grey colored).
Page 137: Fieldbus Probe
MOSAIC M1S/MOSAIC M1S COM and MBx fw >= 2.0, 32 probes with MOSAIC M1S COM and 16 with MOSAIC M1 or MBx fw < 2.0. (For more detailed information, consult the fieldbus manual available in the ReeR website).  WARNING: the PROBE output is NOT a safety output.
Page 138: Relay
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC RELAY The Output RELAY Consists in a N.O. (Normally Open) contact relay. Relay contacts are closed when the input IN is equal to 1 (TRUE), otherwise they are open (FALSE). Parameters Category There is a choice of 3 different relay output categories: Category 1.
Page 139: 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 105 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: •...
Page 140 (TRUE) when an external FBK error is detected. The Error Out signal is reset in case of one of the following events: 1. Switching on and switching off of system. 2. Activation of the RESET MOSAIC M1 operator. RELAY Example of RELAY with incorrect Feedback signal...
Page 141: 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 142: E-Gate (Safety Gate Device)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Filter (ms): This is used to filter the signals coming from the emergency stop. The filter can be configured to between 3 and 250 ms and eliminates any bouncing on the contacts. The length of the filter affects the calculation of the unit's total response time. With Simultaneity (only with Double_NC Input type): If selected this activates the test to verify concurrent switching of the signals coming from the emergency stop.
Page 143: 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.
Page 144: 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 145: Enable (Enable Key)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Simultaneity (ms) (only with Double_NC or Double NC/NO Input type): This is only active if the previous parameter is enabled. It defines the maximum time (in ms) between the switching of two different signals from the external contacts. Enable Error Out: If selected reports a fault detected by the function block.
Page 146: Espe (Optoelectronic Safety Light Curtain / Laser Scanner)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC between the lines. To enable this control, the test output signals must be configured (amongst those available). Test at start-up: If selected this enables the test at start-up of the external component. This test is performed by opening and activating the enable key to run a complete function test and enable the output.
Page 147: Footswitch (Safety Pedal)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC OUT TEST signals cannot be used in case of safety static output ESPE because the control is carried out from the ESPE. Test at start-up: If selected this enables the test at start-up of the safety light curtain. This test is performed by occupying and clearing the area protected by the safety light curtain to run a complete function test and enable the output.
Page 148 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 functional 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 149: 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 150: Two-Hand (Bimanual Control)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC ➔ An output test signal is mandatory and can be selected from the 4 possible Test Output 1...4. ➔ If the Manual Reset is active, a consecutive Input have to be used. Example: Input 1 is used for the functional block, then Input 2 have to be used for the Reset Input.
Page 151: Network_In
This filter can be set to between 3 and 250ms. The length of the filter affects the calculation of the unit's total response time. ➔ This input can only be allocated on MOSAIC M1, MOSAIC M1S, MOSAIC M1S COM and can’t be used on expansion modules ➔...
Page 152: 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 functional 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 153: Switch
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Output test: This is used to select which test output signals are to be sent to the s-mat contact. 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 154: Enabling Grip Switch
(position 2), the OUTPUT will be 1 (TRUE). Refer to truth tables at the bottom of the page. ➔ The ENABLING GRIP functional block requires that the assigned module has a minimum Firmware version as Table below: MOSAIC M1 MI8O2 MI16 MI12T8 Parameters Type of inputs: Double NO –...
Page 155: Testable Safety Device
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Table mode 1 (device 2NO + 1NC) POSITION 1: enabling grip fully released POSITION 2: enabling grip pressed to middle position POSITION 3: enabling grip fully pressed Position Input 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 156 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 157: Rfid (Rfid Safety Sensor)
Enable line: The RFID has the possibility of being used with other identical ones in cascade (maximum 16 in series). Only ReeR R-Safe RFID can be used in cascade; in this case the name of the block will change into “R-Safe RFID”.
Page 158: Solid State Device
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Figure 106 - Example of RFID line monitoring 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.
Page 159: Restart Input
On the fieldbus the states are represented with 4 bytes with MOSAIC M1S, MOSAIC M1S COM and 1 byte with MOSAIC M1. (For more detailed information, consult the fieldbus manual available in ReeR website).  WARNING: the FIELDBUS INPUT is NOT a safety input.
Page 160: Ll0-Ll1
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LL0-LL1 These allow a predefined logical level to be entered on a component’s input. LL0 -> logical level 0 LL1 -> logical level 1  IMPORTANT: LL0 and LL1 cannot be used to disable the logical ports in the diagram. COMMENTS This item allows a description to be entered and placed in any point of the diagram.
Page 161: Speed Control Type Function Blocks
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC SPEED CONTROL TYPE FUNCTION BLOCKS Warning concerning safety  An external error or malfunction deriving from encoder/proximity or its wiring, does not necessarily involve a change of safety status of the normal output (i.e. “Zero”) of the function block. 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 (“Enable Error Out”).
Page 162: Speed Control
Speed 4 can be entered from: 1 to 8 with MOSAIC M1 fw >= 4.0, MOSAIC M1S fw >=5.1 and MVx fw >= 2.0, with MOSAIC M1S COM and MVx fw >= 2.0 8540780 • 25/01/2023 • Rev.43...
Page 163 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 1 to 4 with MOSAIC M1 fw <4.0 or MOSAIC M1S< 5.1 or MVx fw < 2.0. In the case of thresholds greater than 1, the input pins for the selection of the specific threshold will appear in the lower part of the function block.
Page 164 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Frequency: It shows the frequencies values calculated starting from the speed thresholds fM and fm (fm is the fM threshold frequency decreased by the hysteresis set). If the displayed value is GREEN, the calculation of frequency gave a positive Proximity choice: result.
Page 165: Window Speed Control
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC WINDOW SPEED CONTROL The Window Speed Control function block monitors the speed of a device, causing a transition from 0 (FALSE) to 1 (TRUE) of the WINDOWS output when the speed is within a prefixed range. Parameters Axis type: It defines the type of axis controlled by the device.
Page 166 1 (TRUE). The maximum speed value could be entered with the decimal point provided that MOSAIC M1 fw >= 4.0 or MOSAIC M1S fw >= 5.1 or MOSAIC M1S COM and MVx fw >= 2.0 were used.
Page 167: Stand Still
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC STAND STILL The StandStill function block monitors the speed of a device, causing a transition from 0 (FALSE) to 1 (TRUE) of the ZERO output when the speed is lower than a selected value. Parameters Axis type: It defines the type of axis controlled by the device.
Page 168 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Measurement: Enter in this field the number of pulses/revolution (in the case of rotational sensor) or µm/pulse (linear sensor) relating to the sensor used Verification: Enter in this field the number of pulses/revolution (in the case of rotational sensor) or µm/pulse (linear sensor) relating to the second sensor used.
Page 169: Stand Still And Speed Control
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC STAND STILL AND SPEED CONTROL The StandStill and Speed Control function block monitors the speed of a device, causing the transition from 0 (FALSE) to 1 (TRUE) of the ZERO output when the speed is lower than a selected output.
Page 170 (OVER) will be 0 (FALSE). If the measured speed is less than the set value, the function block output (OVER) will be 1 (TRUE). The speed value could be entered with the decimal point provided that MOSAIC M1 fw >= 4.0 or MOSAIC M1S fw >= 5.1 or MOSAIC M1S COM and MVx fw >= 2.0 were used.
Page 171 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Frequency zero speed/Frequency1/ Frequency2: It shows the maximum calculated frequency values fM and fm (fm is the fM threshold frequency decreased by the hysteresis set). If the displayed value is GREEN, the calculation of frequency gave a positive result.
Page 172: Speed Equality Check
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC SPEED EQUALITY CHECK The Speed Equality Check function block monitors the input frequency values (Axis1, Axis2) from two encoders and checks whether they have deviation. The operator can set the resolutions of the two encoders, the max deviation threshold (in percent) and the timeout of threshold.
Page 173: Analog Input Type Function Blocks
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC ANALOG INPUT TYPE FUNCTION BLOCKS ANALOG INPUT (4 inputs each MA4 module, 2 inputs each MA2 module) The functional block “Analog Input” allows the selection of which types of analog sensor that will be used (0...20mA; 4...20mA; 0...10V) together with the parameters that will set the acquisition. It allows also the configuration of two simple threshold comparators or one window comparator.
Page 174 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Detailed description Input type It defines the inputs type of the MA2/MA4 module channels described below. Single A single sensor is connected to one channel from 1 to 4. Redundant A pair of sensors is connected to two adjacent channels (1-2 or 3-4). The sensor pair readings are processed by a single analog block.
Page 175 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC In case of Input Type -> Redundant, three further options will be enabled: 1. Sensors coherence 2. Incoherence calculation mode 3. Consolidation Sensors coherence The measurement results of the two channels in redundant configuration are unlikely to be exactly the same (even with equal sensors) due to the tolerances in the signal chain.
Page 176 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Incoherence calculation mode: equal sensors Select Equal sensors if the sensors to be used are identical i.e. they have the same scale. No additional configuration is required. The following parameter is provided to define whether the sensors are the same or different.
Page 177 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Incoherence calculation mode: different sensors The two sensors used in the redundant configuration must provide the same reading in units but they can have different scaling factors. The following parameter is provided to define whether the sensors are the same or different.
Page 178 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Input Type Redundant: Consolidation If you select Redundant as Input type, you must configure the Consolidation parameter which specifies the measurement value to be used. Select the measurement values to be used by MA2/MA4 comparators sent analog data...
Page 179 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Input type: 0÷10V -> 0÷10V Input selected Reading analysis: Window comparator If you activate the option Window comparator, the output Out1 is added to the graphical representation of the function block and a number of additional parameters are displayed.
Page 180 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC The following figure and table exemplify the states of the Window comparator: Figure 108 – Example of window comparator behavior Current state of window Next state of window Measurement value (A) comparator comparator (A) < Low threshold value + hysteresis OUT OF WINDOW OUT OF WINDOW (A) >...
Page 181 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Reading analysis: Enable threshold1 / threshold2 If you activate the options Enable threshold1 and/or Enable threshold2, the output Out1 and/or Out2 are added to the graphical representation of the function block and a number of additional parameters are displayed. The following parameters are provided to define the behavior of the Threshold comparator: •...
Page 182 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Samples per second Let the user to choose the number of sampling per second of the Analog to Digital Sigma Delta converter. A low value would have better performance in terms of noise while an high value would have better performance in terms of response speed. The value 50 and 60 enhance line filter rejection.
Page 183 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Voltage sensors: voltage limits The user can set the range of valid measurement values by set a maximum voltage. If the measurement values are over the maximum value a diagnosis is set. The allowable maximum voltage values range from 10,05 V to 11,5 V. The following table summarize MA2/MA4 module behaviour as a function of measurement values.
Page 184: Analog Division (4 Inputs Each Ma4 Module, 2 Inputs Each Ma2 Module)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Enable Error Out When this flag is checked the a digital signal is available to indicate an error when an anomaly on a sensor is detected. This is highlighted on input block by a dark green square near the label “Error”.
Page 185 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Parameters • Input type o Single o Redundant Sensors coherence ▪ Incoherence ▪ calculation mode Consolidation ▪ • Measurement unit • Scale: minimum value • Scale: maximum value • 0...20 mA Input • 0...10 V Input •...
Page 186 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Single The measurement values of two single channels are divided. Redundant The measurement values of two pairs of sensors configured as redundant are divided. The following illustration shows this configuration (the suffix R identifies the redundant input channel). The following table summarizes the possible divisions: Channel 1 / Channel 2 Division...
Page 187 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Sensors coherence The measurement results of the two channels in redundant configuration are unlikely to be exactly the same (even with equal sensors) due to the tolerances in the signal chain. The tolerable difference between the channels can be set-up in the option Sensors Coherence.
Page 188 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Incoherence calculation mode: equal sensors Select Equal sensors if the sensors to be used are identical i.e. they have the same scale. No additional configuration is required. The following parameter is provided to define whether the sensors are the same or different.
Page 189 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Incoherence calculation mode: different sensors The two sensors used in the redundant configuration must provide the same reading in units but they can have different scaling factors. The following parameter is provided to define whether the sensors are the same or different.
Page 190 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Input Type Redundant: Consolidation If you select Redundant as Input type, you must configure the Consolidation parameter which specifies the measurement value to be used. Select the measurement values to be used by MA2/MA4 comparators sent analog data...
Page 191 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Input type: 0÷10V -> 0÷10V Input selected Division analysis: Window comparator If you activate the option Window comparator, the output Out1 is added to the graphical representation of the function block and a number of additional parameters are displayed.
Page 192 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Current state of window Next state of window Division value (A) comparator comparator (A) < Low threshold value + hysteresis OUT OF WINDOW OUT OF WINDOW (A) > High threshold OUT OF WINDOW OUT OF WINDOW (A) >= High threshold value - hysteresis OUT OF WINDOW OUT OF WINDOW...
Page 193 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Current state of Next state of threshold DIVISION VALUES (A) threshold comparator comparator (A) < Threshold value - hysteresis UNDER THRESHOLD UNDER THRESHOLD (A) <= Threshold value UNDER THRESHOLD UNDER THRESHOLD (A) > Threshold value UNDER THRESHOLD OVER THRESHOLD (A) <...
Page 194 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Current state of threshold comparator Next state of threshold comparator Division values (A) (A) < Threshold value UNDER THRESHOLD UNDER THRESHOLD (A) <= Threshold value + hysteresis UNDER THRESHOLD UNDER THRESHOLD (A) > Threshold value + hysteresis UNDER THRESHOLD OVER THRESHOLD (A) >...
Page 195 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Current sensors: current limits With the following parameters you can limit the measurement range by setting a minimum and a maximum permissible current: Minimum current: The range for the minimum permissible current is 2,5 to 3,9 mA. ⚫...
Page 196 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Analog Output If this option is selected, the raw values of the measurements are available within MSD by using the Graphical Monitor. This is graphically represented on the function block by a light green square and the label Analog.
Page 197: Operator Function Blocks
A little circle will be showed on the inverted input. To cancel the inversion, simply click another time on the same input pin. ➔ The maximum number of functional blocks is 64 with MOSAIC M1 or 128 with MOSAIC M1S, MOSAIC M1S COM. LOGICAL OPERATORS Logical AND returns an output of 1 (TRUE) if all the inputs are 1 (TRUE).
Page 198: 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 199: Xor
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Logical XOR returns an output 0 (FALSE) if the input's number at 1 (TRUE) is even or the inputs are all 0 (FALSE). Parameters Number of inputs: this is used to set between 2 and 8 inputs. XNOR Logical XNOR returns an output 1 (TRUE) if the input's number at 1 (TRUE) is even or the inputs...
Page 200: Multiplexer
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Logic inputs 1, 2: enables the selection of the number of logic inputs (from 1 to 7). Select Logic 1, 2, 3: enables the selection of one of the following types of operator: If one of the Logic Inputs equals "1", the corresponding logic is disabled and the input is directly connected to the end logic (e.g.
Page 201 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC input In8 (or less if the number of inputs selected is less than 8) is the MSB (most significant bit). Example of operator with 8 inputs: Example of operator with 5 inputs: In1 → 0 In1 →...
Page 202 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Signal comparison Signal comparison: Selecting this item will allow the DIGITAL COMPARATOR operator compare first four inputs (In1_A...In4_A) with the second four B inputs (In1_B...In4_B). Depending on the value of the inputs and the operation selected, the following results will be obtained: •...
Page 203: 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 204: User Restart Manual (Max Number = 16 With Mosaic M1, 32 With Mosaic M1S, Mosaic M1S Com With Other Restart Operators)
USER RESTART MANUAL (max number = 16 with MOSAIC M1, 32 with MOSAIC M1S, MOSAIC M1S COM with other RESTART operators) The USER RESTART MANUAL operator saves the restart signal (coming from a RESTART command device) according to the following truth table.
Page 205: User Restart Monitored (Max Number = 16 With Mosaic M1, 32 With Mosaic M1S, Mosaic M1S Com With Other Restart Operators)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC USER RESTART MONITORED (max number = 16 with MOSAIC M1, 32 with MOSAIC M1S, MOSAIC M1S COM with other RESTART operators) The USER RESTART MONITORED operator is used to save the restart signal (coming from a RESTART command device) according to the following truth table.
Page 206: Macro Restart Monitored (Max Number = 16 With Mosaic M1, 32 With Mosaic M1S, Mosaic M1S Com With Other Restart Operators)
Restart. The behaviour is represented in the truth table. MACRO RESTART MONITORED (max number = 16 with MOSAIC M1, 32 with MOSAIC M1S, MOSAIC M1S COM with other RESTART operators) The MACRO RESTART MONITORED operator is used to combine a logic gate chosen by the user with the Restart Manual functional block ("USER RESTART...
Page 207: Pre-Reset (Mosaic M1S, Mosaic M1S Com Only) (Max Number = 32 With Other Restart Operators)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Restart request: If selected, it enables an output that can be used to signal the possibility of performing the Restart. The behaviour is represented in the truth table. PRE-RESET (MOSAIC M1S, MOSAIC M1S COM only) (max number = 32 with other RESTART operators) The PRE-RESET operator can be used when there is no possibility of having a single reset...
Page 208: Guard Lock Operator (Max Number = 4 With Mosaic M1, 8 With Mosaic M1S, Mosaic M1S Com)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC GUARD LOCK OPERATOR (max number = 4 with MOSAIC M1, 8 with MOSAIC M1S, MOSAIC M1S COM) GUARD LOCK The “GUARD LOCK” operator is designed to control locking/unlocking of an ELECTROMECHANICAL GUARD LOCK in a variety of operating contexts.
Page 209 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Enable error out: This can be selected to enable a signal (Error Out) to indicate a lock malfunction. When Error Out = 1 (TRUE) there is a fault in the lock. (e.g. open door with guard lock locked, Feedback Time exceeding the maximum allowed, etc.).
Page 210 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Figure 112 - Example of feedback of the status of a door/gate connected to the guard lock. The signal received by the module is processed by the "Guard Lock" operator. “Unlock_cmd” input The “Unlock_cmd” input detects the command sent by the user to lock or unlock the guard lock.
Page 211 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 212 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Example of operation in the “no Gate” mode The guard lock used in the example continues to be locked when the electromagnet is not energised. Therefore the "Interlock spring " option must be selected. The user unlocks the guard lock with the “SWITCH” block. The “LockOut” signal controls a “STATUS”...
Page 213 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Figure 114 - 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 select the “Gate not present” parameter. The Gate input must always be connected to an “E-GATE”...
Page 214 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 215 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Figure 116 shows the traces relative to the operation. These are described in detail below: (1) At this time the user requests to unlock the guard lock. The “COMMAND” signal switches from LL0 to LL1, and the “OUTPUT1” signal switches from LL1 to LL0. (2) At this time the electromagnet is activated with a delay of "Unlock Time", after the command is sent.
Page 216 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Operation in the “Mandatory Gate Opening” mode In this case, the user must NOT select the “Gate not present” parameter and must select the "Mandatory Gate opening" parameter. The Gate input must always be connected to an “E-GATE”...
Page 217 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Example of operation in the “Mandatory Gate Opening” mode In this example the user unlocks the guard lock with the “SWITCH” block. The “LockOut” signal controls a “STATUS” SIL 1/PL c output that controls the guard lock electromagnet, the status of which is detected by the “LOCK FEEDBACK”...
Page 218 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC (8) As soon as the “Guard Lock” operator detects that the guard lock is locked and the gate is closed, the “Output1” signal switches to LL1. Figure 118 - Traces relative to “Guard Lock” block operation in the “Mandatory gate opening mode”.
Page 219 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Figure 119 – Example of possible error condition in "Mandatory gate opening" mode. In this case the error condition is generated because the gate has not been opened, even though a request has been sent to unlock/lock the guard lock. 8540780 •...
Page 220: Counter Operators
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC COUNTER OPERATORS COUNTER (max number = 16) COUNTER operator is a pulse counter that sets output Q to 1 (TRUE) as soon as the desired count is reached. There are 3 operating modes: 1) AUTOMATIC 2) MANUAL 3) AUTOMATIC + MANUAL Following are illustrated 3 examples for each...
Page 221: Counter Comparator
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC The counter generates a pulse duration equal to the system MANUAL/AUTOMATIC: response time as soon as the set count is reached. If the CLEAR signal is activated, the internal count goes back to 0. Parameters Enable Clear: If selected enables the signal CLEAR in order to restart the counter setting output Q to 0 (FALSE).
Page 222: Timer Operators (Max Number = 32 With Mosaic M1, 48 With Mosaic M1S, Mosaic M1S Com)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC TIMER OPERATORS (max number = 32 with MOSAIC M1, 48 with MOSAIC M1S, MOSAIC M1S COM) TIMER operators allow you to generate a signal (TRUE or FALSE) for a user-definable period. MONOSTABLE The MONOSTABILE operator generates a level 1 (TRUE) output activated by the rising edge of the input and remains in this condition for the set time.
Page 223: 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 224: 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 225: Delay
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC DELAY DELAY operator applies a delay to a signal by setting the output to 1 (TRUE) after the set time, against a change in the level of the input signal. Parameters Time: The delay can be set to between 10 ms and 1098,3 s Scale: The user can choose two different scales for the time T to be set.
Page 226: Long Delay
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC LONG DELAY The LONG DELAY operator allows to apply a delay (up to more than 15 hours) to a signal bringing to 1 (TRUE) the Out output after the set time, in case of a level variation of the signal on the In input.
Page 227: Delay Comparator
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC DELAY COMPARATOR This operator compares the timer value outputted by a LONG DELAY timer and connected to the DELAY COMPARATOR “Timer” input with the set threshold value. The OUT output will be 0 (FALSE) as long as the timer value is lower than the threshold value.
Page 228: Long Delay Line
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC ➔ Unlike the DELAY operator, the DELAY LINE operator does not filter any interruptions in the IN input which are shorter than the set time. ➔ This operator is recommended when using delayed OSSD (the OSSD must be programmed with RESTART MANUAL).
Page 229: Clocking
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC CLOCKING The CLOCKING operator generates a square wave output which period is set by the user. The output is enabled if the “En” input is set to 1 (TRUE). Clocking has up to 7 inputs to control output Duty Cycle. Parameters Time: The period can be set to between 100 ms and 1098,3 s.
Page 230: Muting Function
(in a potentially dangerous situation), it is enabled to bypass the safety device temporarily, allowing the material to pass through the guarded opening. MUTING OPERATORS (max number=4 with MOSAIC M1, 8 with MOSAIC M1S/MOSAIC M1S COM) "Concurrent" MUTING The activation of the Muting function occurs...
Page 231: Muting "L
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Select CURTAIN Input Muting Muting active Select SENSOR Input Muting Muting active Blind Time: Only with Muting Close=Curtain, blind time is enabled when it is known that after a complete transition of the pallet (muting cycle close) some protruding objects could still occupy the light curtain and send the input to 0 (FALSE).
Page 232: Sequential" Muting
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Enable Type: There are two Enable modes: Enable/Disable and Enable Only. • If “Enable/Disable” is selected the Muting cycle cannot start if Enable is stucked at 1 (TRUE) or 0 (FALSE). It is only activated with a rising edge of the signal. On the other hand the falling edge disables Muting regardless of the current condition.
Page 233: Muting "T
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Direction: This let the user to choose the order in which the sensors are occupied. If set to BIDIR they can be occupied in both directions, from S1 to S4 and from S4 to S1, if set to UP they can be occupied from S1 to S4 and if set to DOWN from S4 to S1.
Page 234: Muting Override (Max Number = 4)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC With Enable: When checked let the user the possibility of enabling or not enabling the Muting function. Otherwise the Muting function is always enabled. Enable Type: There are two Enable modes: Enable/Disable and Enable Only. •...
Page 235 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Light "With occupied Occupied Override Override curtain Input sensors" selected sensor request output occupied Timeout (sec): Used to set the time, between 10 sec and infinity, by which the Override function must end. Override mode: Used to configure the type of Override (pulsed or maintained action). With OverOut: Used to activate an Override active Signaling output (active when high).
Page 236: Analog Operators (Mosaic M1S/Mosaic M1S Com)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC ANALOG OPERATORS (MOSAIC M1S/MOSAIC M1S COM) ANALOG COMPARATOR This operator works as a comparator of an analog signal connected. The threshold value to be entered will be in engineering units (eg Kg, °C) and must respect the limits defined by the functional block connected ot the “Analog”...
Page 237 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Example of window comparator behavior When the window comparator is not enabled, the output state of the threshold comparator depends on the value of the measurement and on its current state. There are two possible states: ➔...
Page 238: Math (Max Number = 16)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC In the following figure is given an example of the behavior of the threshold comparator. Example of threshold comparator behavior MATH (max number = 16) The Math operator performs the sum (or the difference) between analog signals coming from an ANALOG INPUT blocks.
Page 239: Equality Check (Max Number = 16)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC EQUALITY CHECK (max number = 16) This operator checks if two analog inputs are equal within a selectable value. The signals must have the same physical unit and must be generated by sensors of the same type (4/20mA, 0/20mA or 0/10V) but they can have different scales.
Page 240 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC If the speed values are over “High threshold” value or under “Low threshold – Hysteresis” value then the state of the window comparator is “OUT OF WINDOW”. If the state of the window comparator is “IN WINDOW” and speed values are under “High threshold”...
Page 241 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC If the measurement values are over “Threshold” value then the state of the threshold comparator is “OVER THRESHOLD” until the measurements stay over “Threshold- Hysteresis” value. If the measurement values are under “Threshold-Hysteresis” value then the state of the threshold comparator is “UNDER THRESHOLD”...
Page 242: Miscellaneous Function Blocks
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC MISCELLANEOUS FUNCTION BLOCKS SERIAL OUTPUT (max number = 4 with MOSAIC M1, 8 with MOSAIC M1S, MOSAIC M1S COM) The Serial Output operator outputs the status of up to 8 inputs, serialising the information. Operating principles.
Page 243: Network (Max Number=1)
The RESET command must be installed outside the zone of operation in a position where the zone of operation and the entire work area concerned are clearly visible. ➔ Network can be realized only with masters of the same type: only MOSAIC M1 or only MOSAIC M1S / MOSAIC M1S_COM. ➔...
Page 244 Response Time ➔ Network can be realized only with masters of the same type: only MOSAIC M1 or only MOSAIC M1S / MOSAIC M1S_COM. The max response time of the network starting from emergency stop is given by the formula: (Master MOSAIC M1) t = 11.3 ms + [175.3 ms x (number of controllers –...
Page 245 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Master MOSAIC M1 signals with Network operative NETWORK FUNCTIONAL BLOCK SIGNALS Network out Network in Network out (OSSD) Reset in (STATUS) FAIL EXT OSSD STATUS STOP CLEAR BLINKING RED/GREEN (BLINKING) BLINKING BLINKING STATUS GREEN FAIL...
Page 246: Example Of Application In Category 2 According To Iso 13849-1
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Figure 121 - NETWORK function block scheme example (Category 4) Example of application in Category 2 according to ISO 13849-1: Network data flow Figure 122 8540780 • 25/01/2023 • Rev.43...
Page 247: Logical Block Diagram Of A Safety Function Using The Network
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Network parameters for the PL calculation Architecture: Cat.2 Diagnostic coverage: DC = 90% Reliability of Module MOSAIC M1: MTTF = 437 (years) Logical block diagram of a safety function using the network INPUT MOSAIC M1 n°1 MOSAIC M1 n°2...
Page 248: Logical Block Diagram Of A Safety Function Using The Network
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Logical block diagram of a safety function using the network INPUT MOSAIC M1 n°1 MOSAIC M1 n°2 MOSAIC M1 n°3 MOSAIC M1 n°4 OUTPUT LOGIC (NETWORK) RESET MOSAIC M1 This operator generates a system Reset when there...
Page 249 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Parameters External K delay: allows the operator to set the time window within which the external feedback signal (Fbk_K) is to be monitored (according to output conditions). Enable Clear: if checked enables input Clear. With this input at 1 it is possible to clear the error when the fault has been repaired. Using this input it is no longer necessary to reset MOSAIC M1S/MOSAIC M1S COM or turn off the system.
Page 250: Interpage In / Interpage Out
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC INTERPAGE IN / INTERPAGE OUT First case (1 page scheme) If the scheme is very complicated and requires a connection between two elements very far, use the "Interpage" component. INTERPAGE OUT INTERPAGE IN The element "Interpage out" must have a name which, invoked by the corresponding "Interpage in", allows the desired link.
Page 251: Intfbk_In/Intfbk_Out (Mosaic M1S/Mosaic M1S Com Only, Max Number=8)
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC INTFBK_IN/INTFBK_OUT (MOSAIC M1S/MOSAIC M1S COM only, max number=8) This operator can be used to create logical loops or to connect the output of a function block to the input of another function block. IntFbk consist of IntFbk_In and IntFbk_Out; after one MOSAIC M1S/MOSAIC M1S COM logical cycle delay, every IntFbk_In assumes the same logical value of the corresponding IntFbk_Out.
Page 252: 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 126 - Two outputs with one delayed (in MANUAL mode) 8540780 •...
Page 253: Simulator
 Mosaic configuration safety parameters are provided in the MSD software report. The top toolbar features two new green icons (with firmware MOSAIC M1 version 3.0 or higher): Figure 127 – Simulator icons These icons refer to the new Simulator function.
Page 254: 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 255: How To Use Graphic Simulation
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC (Speed selection) (LL0) (LL0) Figure 129 – MV frequency/rpm input ➔ The keys for enabling block outputs are shown at the top, an example of a pop-up window for entering, in this case, frequency and rpm in a "speed control" block is shown at the bottom How to use graphic simulation Click on the icon to start the graphic simulation.
Page 256 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Click the "X" key (top right) to exit the graphic simulation environment. Figure 130 – 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 257 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Template Stimuli: used to save the template file with the desired name and disk location. Figure 132 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 time Figure 133 as well as the duration of the simulation and the time step to be used, Figure 132 –...
Page 258 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Figure 134 - Traces visibility. ➔ The traces that can be added to the graph are shown in the box on the left. The traces currently displayed and which can be removed from the graph are shown in the box on the right. 8540780 •...
Page 259: 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 260 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC Result of the simulation The graph shows the signals relating to the simulation, in this case: • when 2000 ms have elapsed the “Safety area" signal rises to logic level 1, which indicates closing of the gate. •...
Page 261: 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 MOSAIC M1, MOSAIC M1S, MOSAIC M1S COM. To read the code, proceed as follows: connect the Master MOSAIC M1, MOSAIC M1S, MOSAIC M1S COM (indicating FAIL by led) to the PC using the USB cable;...
Page 262: Accessories And Spare Parts
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC ACCESSORIES AND SPARE PARTS MODEL DESCRIPTION CODE MOSAIC M1 MOSAIC main unit (8 inputs / 2 double OSSD ) 1100000 MOSAIC main unit (8 inputs / 4 single OSSD ) 1100003 MOSAIC M1S MOSAIC M1S COM...
Page 263: Warranty
Characteristics are subject to change without prior notice. No part of this document may be reproduced unless authorised by ReeR. 8540780 • 25/01/2023 • Rev.43...
Page 264: Ec Declaration Of Conformity
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC EC DECLARATION OF CONFORMITY 8540780 • 25/01/2023 • Rev.43...
Page 265: Ukca Declaration Of Conformity
MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC UKCA DECLARATION OF CONFORMITY ReeR declares that integrated controller MOSAIC complies with following UK legislation: • S.I. 2008 No. 1597 - The Supply of Machinery (Safety) Regulations • S.I. 2016 No. 1101 - Electrical Equipment (Safety) Regulations •...
Page 266 MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC 8540780 • 25/01/2023 • Rev.43...

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