Reer MOSAIC Master M1 Guide

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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MODULAR SAFETY INTEGRATED CONTROLLER
Installation and use
(Copy of the original instructions)

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MODULAR SAFETY INTEGRATED CONTROLLER
TABLE OF CONTENTS
INTRODUCTION ................................................................................................................ 9
Contents of this handbook ................................................................................9
Important safety instructions.............................................................................9
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 .........................................................................................14
MSD software..................................................................................................15
PRODUCT COMPOSITION............................................................................................16
INSTALLATION ................................................................................................................17
MOSAIC M1, MOSAIC M1S, Expansion Modules mechanical fastening ...............17
MOSAIC M1S COM Mechanical fastening ..........................................................18
Calculation of safety distance of an ESPE connected to MOSAIC........................19
Electrical connections......................................................................................19
Instructions concerning connection cables .....................................................20
Master Module MOSAIC M1 ............................................................................20
Master Modules MOSAIC M1S / MOSAIC M1S COM..........................................21
USB interface .................................................................................................22
LAN interface (RJ45).......................................................................................22
MOSAIC Configuration Memory (MCM) ...........................................................22
MULTIPLE LOAD function ....................................................................................... 22
RESTORE function.................................................................................................. 23
Compatibility between MCM memory and Master modules: ................................... 23
New MCM features with f.w. 2.0.0 ......................................................................... 23
Module MI8O2 ...............................................................................................24
Module MI8O4 ...............................................................................................25
Module MI8 ...................................................................................................26
Module MI12T8 .............................................................................................26
Module MI16 .................................................................................................27
Module MO2..................................................................................................27
Module MO4..................................................................................................28
Module MO4L ................................................................................................28
Module MR2 ..................................................................................................29
Module MR4 ..................................................................................................29
Module MR8 ..................................................................................................30
Modules MV0 - MV1 - MV2 .............................................................................31
Encoder connections with RJ45 connector (MV1, MV2) ........................................... 31
Module MOR4................................................................................................33
Module MOR4S8 ............................................................................................33

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Module MOS8 ................................................................................................34
Module MOS16 ..............................................................................................34
Module MO4LHCS8 ........................................................................................35
Modulo MA2 ..................................................................................................35
Modulo MA4 ..................................................................................................36
MA2 / MA4 Analog sensor connections ................................................................. 37
Example of connection of Mosaic to the machine control system ....................38
Checklist after installation...............................................................................38
OPERATING DIAGRAM..................................................................................................39
SIGNALS..............................................................................................................................40
INPUTS............................................................................................................40
MASTER ENABLE.............................................................................................40
NODE SEL ......................................................................................................40
PROXIMITY INPUT FOR SPEED CONTROLLER MV ..............................................40
Configuration With Interleaved Proximity............................................................... 41
RESTART_FBK.................................................................................................41
OUTPUTS ........................................................................................................42
OUT STATUS (SIL 1/PL c) ................................................................................42
OUT TEST ......................................................................................................42
OSSD SAFETY OUTPUTS ...................................................................................43
Important note concerning OSSD Safety Outputs ................................................... 43
OSSD (MOSAIC M1, MI8O2, MO2, MO4) ..........................................................43
OSSD (MOSAIC M1S, MOSAIC M1S COM, MI8O4, MO4L) ..................................43
OSSD (MO4LHCS8) .........................................................................................45
OSSD OUTPUTS CONFIGURATION ...................................................................46
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..............................................................50
Safety level parameters.......................................................................................... 50
General data.......................................................................................................... 50
Enclosure .............................................................................................................. 51
MOSAIC M1 module............................................................................................... 52
MOSAIC M1S module ............................................................................................. 52
MOSAIC M1S COM module..................................................................................... 53
MI8O2 module ...................................................................................................... 53
MI8O4 module ...................................................................................................... 54
MI8 - MI16 modules............................................................................................... 54
MI12T8 module ..................................................................................................... 54
MO2 - MO4 modules.............................................................................................. 55
MO4L module........................................................................................................ 55
MOS8 –MOS16 modules........................................................................................ 55
MR2 - MR4 –MR8 modules .................................................................................... 56
MOR4 –MOR4S8 module ....................................................................................... 56
MO4LHCS8 module................................................................................................ 57
MV0 - MV1 - MV2 modules..................................................................................... 57
MA2, MA4 module................................................................................................. 58
MECHANICAL DIMENSIONS ..............................................................................59

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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....................................................................................................... 63
LED state explanation............................................................................................ 63
EtherNET/IP LEDs................................................................................................... 64
LED state explanation............................................................................................ 65
Modbus/TCP LEDs ................................................................................................. 65
LED state explanation............................................................................................ 65
PROFINET LEDs...................................................................................................... 66
LED state explanation............................................................................................ 66
MI8O2 (Figure 23)..........................................................................................67
MI8O4 (Figure 23)..........................................................................................68
MI8 (Figure 25) ..............................................................................................69
MI12T8 (Figure 27) ........................................................................................70
MI16 (Figure 27) ............................................................................................71
MO2 (Figure 28).............................................................................................72
MO4 (Figure 29).............................................................................................73
MO4L (Figure 23)...........................................................................................74
MOR4 (Figure 31)...........................................................................................75
MOR4S8 (Figure 32) .......................................................................................76
MOS8 (Figure 33)...........................................................................................77
MOS16 (Figure 34).........................................................................................78
MV0, MV1, MV2 (Figure 35)............................................................................79
MR2, MR4, MR8 (Figure 36)............................................................................80
MO4LHCS8 (Figure 37)...................................................................................81
MA2, MA4 (Figure 38) ....................................................................................82
LED INDICATORS (Troubleshooting) .................................................................83
Master MOSAIC M1 (Figure 39).......................................................................83
Master MOSAIC M1S / MOSAIC M1S COM (Figure 40) ......................................84
MI8O2 (Figure 41)..........................................................................................85
MI8O4 (Figure 42)..........................................................................................86
MI8 (Figure 43) ..............................................................................................87
MI12T8 (Figure 44) ........................................................................................88
MI16 (Figure 45) ............................................................................................89
MO2 / MO4 (Figure 46)..................................................................................90
MO4L (Figure 47)...........................................................................................91
MOR4 (Figure 48)...........................................................................................92
MOR4S8 (Figure 49) .......................................................................................93
MOS8 (Figure 50)...........................................................................................94
MOS16 (Figure 51).........................................................................................95
MV0, MV1, MV2 (Figure 52)............................................................................96
MO4LHCS8 (Figure 53)...................................................................................97
MA2, MA4 (Figure 54) ....................................................................................98
MOSAIC SAFETY DESIGNER SOFTWARE ............................................................. 100
Installing the software...................................................................................100
PC HARDWARE requirements........................................................................100
PC SOFTWARE requirements.........................................................................100
Installation of MSD software.........................................................................100

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Fundamentals..............................................................................................101
Standard toolbar..........................................................................................102
Textual toolbar............................................................................................103
Create a new project (configure the MOSAIC system) .....................................103
Pages configuration / management..............................................................104
Fieldbus with dynamic input order....................................................................... 106
Create a new project: MOSAIC M1S COM fieldbus parameters configuration..106
ModBus TCP parameters...................................................................................... 106
EtherNet/IP parameters ....................................................................................... 107
Profinet RT parameters........................................................................................ 107
EtherCat parameters............................................................................................ 108
Edit Configuration (composition of the various modules) ..............................109
Change user parameters ..............................................................................109
Objects - Operator - Configuration toolbars..................................................110
Creating the diagram ...................................................................................111
Use of mouse right button................................................................................... 112
Example of a project....................................................................................113
Project validation................................................................................................. 113
Resources Allocation ........................................................................................... 114
Project report ...................................................................................................... 115
Connect MSD to Mosaic Master......................................................................117
Communication channel selection................................................................117
USB connection.................................................................................................... 117
Network Connection (MOSAIC M1S COM only) ..................................................... 117
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)............................. 123
Download project to MOSAIC (from PC) ............................................................... 124
Upload an existing project to PC (from MOSAIC) .................................................. 125
Configurations LOG ............................................................................................. 125
System composition ............................................................................................ 125
Errors Log ........................................................................................................... 126
Disconnecting System ......................................................................................... 126
Monitor functions ........................................................................................126
Monitor (I/O status in real time - textual)............................................................. 126
Monitor (I/O status in real time - textual - graphic) .............................................. 127
Monitor (I/O with Diagnostic) .............................................................................. 127
Fieldbus Monitor (Only for MOSAIC M1S COM) ..................................................... 128
Password protection ....................................................................................129
Level 1 password................................................................................................. 129
Level 2 password................................................................................................. 130
Maintenance Password (MOSAIC M1S, MOSAIC M1S COM).................................... 130
Password Change ................................................................................................ 130
Testing the system ......................................................................................131
OBJECT FUNCTION BLOCKS............................................................................132
OUTPUT OBJECTS .........................................................................................132
OSSD (safety outputs).......................................................................................... 132
SINGLE-DOUBLE OSSD (safety output)................................................................... 133
STATUS (SIL 1/PL c output) .................................................................................. 136
FIELDBUS PROBE .................................................................................................. 137

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RELAY.................................................................................................................. 138
Use with RESTART: Automatic (A) or Manual (B) (Category 2)................................ 139
INPUT OBJECTS ............................................................................................141
E-STOP (emergency stop) ..................................................................................... 141
E-GATE (safety gate device).................................................................................. 142
SINGLE E-GATE (safety gate device) ...................................................................... 143
LOCK FEEDBACK .................................................................................................. 144
ENABLE (enable key) ............................................................................................ 145
ESPE (optoelectronic safety light curtain / laser scanner)...................................... 146
FOOTSWITCH (safety pedal) ................................................................................. 147
MOD-SEL (safety selector) .................................................................................... 149
PHOTOCELL (safety photocell) ............................................................................. 149
TWO-HAND (bimanual control)............................................................................. 150
NETWORK_IN ....................................................................................................... 151
SENSOR ............................................................................................................... 151
S-MAT (safety mat) .............................................................................................. 152
SWITCH ............................................................................................................... 153
ENABLING GRIP SWITCH ....................................................................................... 154
TESTABLE SAFETY DEVICE .................................................................................... 155
RFID (RFID safety sensor)..................................................................................... 157
SOLID STATE DEVICE ........................................................................................... 158
RESTART INPUT ................................................................................................... 159
FIELDBUS INPUT................................................................................................... 159
LL0-LL1 ............................................................................................................... 160
COMMENTS ......................................................................................................... 160
TITLE................................................................................................................... 160
SPEED CONTROL TYPE FUNCTION BLOCKS .....................................................161
Warning concerning safety .................................................................................. 161
Note concerning Speed Control Function Blocks .................................................. 161
SPEED CONTROL.................................................................................................. 162
WINDOW SPEED CONTROL ................................................................................... 165
STAND STILL........................................................................................................ 167
STAND STILL AND SPEED CONTROL ..................................................................... 169
SPEED EQUALITY CHECK ...................................................................................... 172
ANALOG INPUT TYPE FUNCTION BLOCKS .......................................................173
ANALOG INPUT (4 inputs each MA4 module, 2 inputs each MA2 module) ............ 173
ANALOG DIVISION (4 inputs each MA4 module, 2 inputs each MA2 module) ........ 184
OPERATOR FUNCTION BLOCKS.......................................................................197
LOGICAL OPERATORS...................................................................................197
AND .................................................................................................................... 197
NAND.................................................................................................................. 197
NOT .................................................................................................................... 198
OR....................................................................................................................... 198
NOR .................................................................................................................... 198
XOR..................................................................................................................... 199
XNOR .................................................................................................................. 199
LOGICAL MACRO ................................................................................................. 199
MULTIPLEXER....................................................................................................... 200
DIGITAL COMPARATOR (MOSAIC M1S, MOSAIC M1S COM only)............................ 200
MEMORY OPERATORS...................................................................................203
D FLIP FLOP (max number = 16)........................................................................... 203
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

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USER RESTART MONITORED (max number = 16 with MOSAIC M1, 32 with
MOSAIC M1S, MOSAIC M1S COM with other RESTART operators).......................... 205
MACRO RESTART MANUAL (max number = 16 with MOSAIC M1, 32 with MOSAIC M1S,
MOSAIC M1S COM with other RESTART operators) ............................................... 205
MACRO RESTART MONITORED (max number = 16 with MOSAIC M1, 32 with
MOSAIC M1S, MOSAIC M1S COM with other RESTART operators).......................... 206
PRE-RESET (MOSAIC M1S, MOSAIC M1S COM only) (max number = 32 with other
RESTART operators)............................................................................................. 207
GUARD LOCK OPERATOR (max number = 4 with MOSAIC M1, 8 with
MOSAIC M1S, MOSAIC M1S COM) .................................................................208
GUARD LOCK....................................................................................................... 208
COUNTER OPERATORS .................................................................................220
COUNTER (max number = 16).............................................................................. 220
COUNTER COMPARATOR ..................................................................................... 221
TIMER OPERATORS (max number = 32 with MOSAIC M1, 48 with MOSAIC M1S,
MOSAIC M1S COM) ......................................................................................222
MONOSTABLE ...................................................................................................... 222
MONOSTABLE_B................................................................................................... 223
PASSING MAKE CONTACT .................................................................................... 224
DELAY ................................................................................................................. 225
LONG DELAY ....................................................................................................... 226
DELAY COMPARATOR .......................................................................................... 227
DELAY LINE.......................................................................................................... 227
LONG DELAY LINE .............................................................................................. 228
CLOCKING ........................................................................................................... 229
MUTING FUNCTION......................................................................................230
MUTING OPERATORS (max number=4 with MOSAIC M1, 8 with
MOSAIC M1S/MOSAIC M1S COM) ....................................................................230
"Concurrent" MUTING .......................................................................................... 230
MUTING “L”.......................................................................................................... 231
"Sequential" MUTING ........................................................................................... 232
MUTING “T” ......................................................................................................... 233
MUTING OVERRIDE (max number = 4).................................................................. 234
ANALOG OPERATORS (MOSAIC M1S/MOSAIC M1S COM)................................236
ANALOG COMPARATOR ....................................................................................... 236
MATH (max number = 16)............................................................................238
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: ......................... 246
Logical block diagram of a safety function using the network .............................. 247
Example of application in Category 4 according to ISO 13849-1: ......................... 247
Logical block diagram of a safety function using the network .............................. 248
RESET MOSAIC M1 ............................................................................................... 248
OSSD EDM (MOSAIC M1S / MOSAIC M1S COM, max number = 32) ....................... 248
INTERPAGE IN / INTERPAGE OUT.......................................................................... 250
INTFBK_IN/INTFBK_OUT (MOSAIC M1S/MOSAIC M1S COM only, max number=8).. 251
TERMINATOR....................................................................................................... 251
Special Applications.....................................................................................252
Output delay with manual.................................................................................... 252
Simulator.....................................................................................................253
Schematic Simulation...................................................................................254

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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............................................................. 265

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INTRODUCTION
Contents of this handbook
This handbook describes how to use the MOSAIC programmable safety module and its
expansion units ("SLAVES");
it includes:
•a description of the system
•method of installation
•connections
•signals
•troubleshooting
•use of the configuration SW
Important safety instructions
This safety alert symbol indicates a potential personal safety hazard. Failure to comply with
instructions bearing this symbol could pose a very serious risk to personnel.
➔This symbol indicates an important instruction.
The MOSAIC is built to the following safety levels: SIL 3, SILCL 3, PL e, Cat. 4, Type 4 in accordance
with the applicable standards. However, the definitive SIL and PL of the application will depend on
the number of safety components, their parameters and the connections that are made, as per
the risk analysis.
Read the "Applicable Standards" section carefully.
Perform an in-depth risk analysis to determine the appropriate safety level for your specific
application, on the basis of all the applicable standards.
Programming/configuration of the Mosaic is the sole responsibility of the installer or user.
The device must be programmed/configured in accordance with the application-specific risk
analysis and all the applicable standards.
Once you have programmed/configured and installed the Mosaic and all the relative devices, run
a complete application safety test (see the "TESTING the system" section, page 131).
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.
The ambient temperature in the place where the system is installed must be compatible with the
operating temperature parameters stated on the product label and in the specifications.
For all matters concerning safety, if necessary, contact your country's competent safety
authorities or the competent trade association.

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Abbreviations and symbols
AES = Advanced Encryption Standard
CIP = Common Industrial Protocol
DHCP = Dynamic Host Control Protocol
DNS = Domain Name Server
FW = Firmware
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
LL0, LL1 = Logic Level 0, Logic Level 1
OMB = Open Modbus/TCP
OSSD = Output Signal Switching Device: solid state safety output
MTTFd= Mean Time to Dangerous Failure
PL = Performance Level
PFHd= Probability of a dangerous failure per Hour
SIL = Safety Integrity Level
SILCL = Safety Integrity Level Claim Limit
SW = Software
TCP/IP = Transmission Control Protocol / Internet Protocol

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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:
CEI EN 61131-2
Programmable controllers, part 2:
Equipment requirements and tests
EN ISO 13489-1
Safety of machinery:
Safety related parts of control systems. General principles for design
EN 61496-1
Safety of machinery: Electro-sensitive protective equipment. Part 1: General
requirements and tests.
EN 61508-1
Functional safety of electrical/electronic/programmable electronic safety-
related systems: General requirements.
EN 61508-2
Functional safety of electrical/electronic/programmable electronic safety-
related systems: Requirements for electrical/electronic/programmable
electronic safety-related systems.
EN 61508-3
Functional safety of electrical/electronic/programmable electronic safety-
related systems: Software requirements.
EN 61508-4
Functional safety of electrical/electronic programmable electronic safety
related systems: Definitions and abbreviations.
EN 62061
Safety of machinery. Functional safety of safety-related electrical, electronic
and programmable electronic control systems
EN 81-20
Safety rules for the construction and installation of lifts. Lifts for the
transport of persons and goods. Passenger and goods passenger lifts
EN 81-50
Safety rules for the construction and installation of lifts. Examinations and
tests. Design rules, calculations, examinations and tests of lift components
Table 1

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OVERVIEW
MOSAIC is a modular safety controller. It consists of a master unit (MOSAIC M1,
MOSAIC M1S or MOSAIC M1S COM), which can be configured using the MSD
graphic interface, and a number of expansion units connected to the main unit via
the proprietary MSC bus.
The MOSAIC M1, MOSAIC M1S, MOSAIC M1S COM can also be used as a stand-alone
device and they are equipped with:
•MOSAIC M1: 8 safety inputs, 2 independent programmable dual channel
safety outputs (OSSD) and 2 SIL 1/PL c outputs
•MOSAIC M1S: 8 safety inputs, 4 independent programmable single channel
safety outputs (OSSD) and up to 4 SIL 1/PL c outputs
•MOSAIC M1S COM: 8 safety inputs, 4 independent programmable single
channel safety outputs (OSSD), up to 4 SIL 1 / PL c outputs and enhanced
communications features (see "MOSAIC M1S COM key features").
➔The following expansions are available: I/O expansions (MI8O2 and MI8O4 (MI8O4 with
MOSAIC M1S, MOSAIC M1S COM only)), input expansions (MI8, MI12T8, MI16), output
expansions (MO2, MO4 and MO4LHCS8 and MO4L (MO4L for MOSAIC M1S, MOSAIC M1S COM
only)), SIL 1/PL c output expansions (MOS8 and MOS16), guided contact safety relay output
modules (MR2, MR4, MR8, MOR4 and MOR4S8), encoder and proximity input expansions (MV2,
MV, MV0), modules with analog inputs (MA2, MA4 only for MOSAIC M1S, MOSAIC M1S COM)
and diagnostic connections to the main fieldbuses: MBP (PROFIBUS), MBC (CanOpen), MBD
(DeviceNet), MBEI (ETHERNET/IP), MBEP (Profinet), MBEC (ETHERCAT), MBMR (Modbus RTU),
MBEM (Modbus/TCP) MBCCL (CC-link).
MOSAIC is capable of monitoring the following safety sensors and commands:
optoelectronic sensors (safety light curtains, scanners, safety photocells),
mechanical switches, safety mats, emergency stops, two-hand controls, all
managed by a single flexible and expandable device.
Master MOSAIC M1 / MOSAIC M1S / MOSAIC M1S COM
The system must consist of just one Master MOSAIC M1, MOSAIC M1S, MOSAIC M1S
COM and a number of electronic expansions that can range from 0 to a maximum
of 14, not more than 4 of which of the same type. There is no limit to the number
of relay modules 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.
MASTER and its SLAVE units communicate via the 5-way MSC bus (ReeR proprietary
bus), physically arranged on the rear panel of each unit.
Furthermore, by means of MBx Fieldbus interfaces or MOSAIC M1S COM or both,
are available:
•All inputs states (with diagnostics)
•All safety outputs states (with diagnostics)

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•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.
•16 probe outputs with MOSAIC M1 or 32 probe outputs with MOSAIC M1S,
MOSAIC M1S COM (MBx firmware version ≥ 2.0). These probe outputs can be
connected everywhere in the schematic by means of MSD software.
MOSAIC M1S COM key features
The new MOSAIC M1S COM is equipped with LAN connectivity. It performs the same
functions as MOSAIC M1S and thus even USB connectivity, furthermore it allows the
user to share process data over a specific Fieldbus and to configure itself through
remote connection via TCP/IP networks.
The user can select and configure a Fieldbus between 4 choices:
•EtherNet/IP
•MODBUS/TCP
•PROFINET
•EtherCAT
From a fieldbus point of view MOSAIC M1S COM is always considered as a slave
device. The Process Data Mapping document 8547780 is available at:
https://www.reersafety.com/ in the manuals download area.
Process Data Map come into two versions:
1. Process Data Map without analog data
2. Process Data Map with analog data
The user can choose if send or not analog data as process data. If the user choose
to include analog data into process map then he must be sure that:
1. At least one MA4 or MA2 analog input module is present into the MOSAIC
configuration
2. The process data map supports analog data.
Following the main characteristic supported by each Fieldbus protocol.
Fieldbus
DHCP support
DNS support
TCP/IP connectivity
EtherNet/IP
Yes
Yes
Yes
MODBUS/TCP
Yes
No
Yes
PROFINET
No
No
Yes
EtherCAT
No
No
Yes*
* Only if EoE option is properly enabled and configured.
When TCP/IP network is available the user can configure MOSAIC M1S COM and
perform Monitor through remote connection with MSD software.
The data exchanged with MSD (when TCP/IP network connection is used) are
protected against malicious sniffing with an AES 128 bit encryption.

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The AES key is exchanged during the initial phase of connection process with an
RSA process with a 1024 bit key.
➔The MOSAIC system is certified to the maximum safety level envisaged by the applicable
industrial safety standards (SIL 3, SILCL 3, PL e, Cat. 4).
MOSAIC M1S COM and MBx in the same project: Fieldbus management
➔If your project is configured with both MOSAIC M1S COM and MBx module then the Fieldbus
management is perfomed exclusively by MBx module.
Expansion modules
With the MI8, MI16 and MI12T8 Mosaic expansion units, the number of inputs in
the system can be increased to allow more external devices to be connected. The
MI12T8 also provides 8 OUT_TEST outputs.
The MO2 and MO4 Mosaic expansion units provide the system, respectively, with
2 and 4 OSSD (Output Signal Switching Device) pairs for controlling devices
connected downstream of the MOSAIC. These modules provides also 2 (MO2) or
4 (MO4) SIL 1/PL c outputs.
The MO4LHCS8 is a safety module with 4 single channel High Current Safety
Outputs (2A/channel usable also in pairs) and 4 relative inputs for external
feedback contacts (EDM).
The module provides 8 SIL 1/PL c outputs.
The MI802 expansion unit provides 8 inputs, 2 pairs of OSSD outputs and 2
programmable SIL 1/PL c outputs.
The MI8O4 expansion unit provides 8 inputs, 4 single channel OSSD outputs
(usable also in pairs) and up to 4 programmable SIL 1/PL c outputs or up to 4
relative inputs for external feedback contacts (EDM).
The MO4L expansion unit provides 4 single channel OSSD outputs (usable also in
pairs) and up to 4 programmable SIL 1/PL c outputs or up to 4 relative inputs for
external feedback contacts (EDM).
The MR2, MR4 and MR8Mosaic expansion units provide the system with 2, 4
and 8 N.O. guided contact safety relay outputs, respectively, with the related
external relay feedback (N.C. contact).
The expansion units in the MB series permit connection to the most commonly used
industrial fieldbus systems for diagnostics and data transmission like Profibus
(MBP), Canopen (MBC), Devicenet (MBD), CClink (MBCCL), Profinet (MBEP),
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). 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).

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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The MV0, MV1 and MV2 Mosaic expansion units can be used to control the
following (up to PLe):
•Zero speed, Max. speed, Speed range;
•Direction of movement, rotation/translation;
Up to 4 speed thresholds can be set for each logic input (axis).
Each unit incorporates two logic inputs that can be configured using the MSD
software and is thus capable of controlling up to two independent axes.
The MOR4 and MOR4S8 are safety expansion units provided with 4 independent
safety relay outputs and the corresponding 4 inputs for the external feedback
contacts (EDM).
There are two possible output settings (configured using the MSD configuration
software).
•Two pairs of connection contacts (2 N.O. contacts per output with 2
corresponding feedback inputs).
•Four independent single connection contacts (1 N.O. contact per output with
4 corresponding feedback inputs).
The MOR4S8 unit has 8 programmable SIL 1/PL c outputs.
The MOS8 and MOS16 have 8 and 16 SIL 1/PL c outputs.
The MA2provides 2 independent safety analog inputs usable also in pairs.
The MA4 provides 4 independent safety analog inputs usable also in pairs.
MSD software
The MSD software is capable of creating complex logics, using logical operators
and safety functions such as muting, timer, counters, etc.
All this is performed through an easy and intuitive graphic interface.
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). By MCM the configuration can therefore quickly be copied
to another master unit.

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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English
PRODUCT COMPOSITION
The MOSAIC M1, MOSAIC M1S, MOSAIC M1S COM are supplied with:
•Multi-language installation sheet.
➔NB: the rear panel MSC connector and MCM memory can be ordered separately as accessories.
The expansion units are supplied with:
•Multilingual Installation sheet.
•Rear panel MSC connector (not present in the MR2 and MR4 which are connected
via terminal blocks only).
➔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.

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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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.
2. Fix the train of connectors thus obtained to the Omega DIN 35mm (EN 5022)
rail (hooking them at the top first).
3. Fasten the units to the rail, arranging the contacts on the base of the unit on
the respective connector. Press the unit gently until you feel it snap into place.
4. To remove a unit, use a screwdriver to pull down the locking latch on the
back of the unit; then lift the unit upwards and pull.
1 2a
2b 3 4
Figure 1

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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English
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. Fix to the Omega DIN 35mm (EN 5022) the same number of "MSC" 5-pole
rear panel connectors as the number of units to be installed (hooking them
at the top first).
2. Connect between them the connectors just mounted.
3. Fasten the units to the rail, arranging the contacts on the base of the unit
on the respective connector. Press the unit gently until you feel it snap
into place.
4. To remove a unit, use a screwdriver to pull down the locking latch on the
back of the unit; then lift the unit upwards and pull.
Figure 2

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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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 Sso that the
dangerous point can be reached only after stopping the dangerous movement of the
machine.
The european standard:
- ISO 13855:2010- (EN 999:2008) Safety of machinery - Positioning of safeguards with respect to
the approach speeds of parts of the human body.
1
provides the elements to calculate the proper
safety distance.
Carefully read the installation manual of each device for specific information on the correct
positioning.
Remember that the total response time depends on:
MOSAIC response time + ESPE response time + response time of the machine (i.e. the time taken
by the machine to stop the dangerous movement from the moment in which the stop signal is
transmitted).
Electrical connections
Figure 3
The MOSAIC system units are provided with terminal
blocks for the electrical connections. Each unit can
have 8, 16 or 24 terminals.
Each unit also has a rear panel plug-in connector (for
communication with the master and with the other
expansion units).
The MR2, MR4 and MR8 are connected via terminal
blocks only.
➔Terminal tightening torque: 5÷7lb-in (0,6÷0,7 Nm).
Install safety units in an enclosure with a protection class of at least IP54.
Connect the module when it is not powered.
The supply voltage to the units must be 24Vdc 20% (PELV, in compliance with the standard EN
60204-1 (Chapter 6.4)).
Do not use the MOSAIC to supply external devices.
The same ground connection (0VDC) must be used for all system components.
1
"Describe the methods that designers can use to calculate the minimum safety distance from a specific dangerous point for
the safety devices, particularly Electro-sensitive devices (eg. light curtains), safety-mats or pressure sensitive floors and
bimanual control. It contains a rule to determine the placement of safety devices based on approach speed and the stopping
time of the machine, which can reasonably be extrapolated so that it also includes the interlocking guards without guard
locking."

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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.
➔Cables used for connections of longer than 50m must have a cross-section of at least 1mm2
(AWG16).
Connections of each single MOSAIC system unit are listed in the table below:
Master Module MOSAIC M1
TERMINAL
SIGNAL
TYPE
DESCRIPTION
OPERATION
1
24VDC
-
24VDC power supply
-
2
MASTER_ENABLE1
Input
Master Enable 1
Input ("type B" according to
EN 61131-2 )
3
MASTER_ENABLE2
Input
Master Enable 2
Input ("type B" according to
EN 61131-2 )
4
0VDC
-
0VDC power supply
-
5
OSSD1_A
Output
Static output 1
PNP active high
6
OSSD1_B
Output
PNP active high
7
RESTART_FBK1
Input
Feedback/Restart 1
Input according to EN 61131-2
8
OUT_STATUS1
Output
SIL 1/PL c output
PNP active high
9
OSSD2_A
Output
Static output 2
PNP active high
10
OSSD2_B
Output
PNP active high
11
RESTART_FBK2
Input
Feedback/Restart 2
Input according to EN 61131-2
12
OUT_STATUS2
Output
SIL 1/PL c output
PNP active high
13
OUT_TEST1
Output
Short circuit detection output
PNP active high
14
OUT_TEST2
Output
Short circuit detection output
PNP active high
15
OUT_TEST3
Output
Short circuit detection output
PNP active high
16
OUT_TEST4
Output
Short circuit detection output
PNP active high
17
INPUT1
Input
Digital input 1
Input according to EN 61131-2
18
INPUT2
Input
Digital input 2
Input according to EN 61131-2
19
INPUT3
Input
Digital input 3
Input according to EN 61131-2
20
INPUT4
Input
Digital input 4
Input according to EN 61131-2
21
INPUT5
Input
Digital input 5
Input according to EN 61131-2
22
INPUT6
Input
Digital input 6
Input according to EN 61131-2
23
INPUT7
Input
Digital input 7
Input according to EN 61131-2
24
INPUT8
Input
Digital input 8
Input according to EN 61131-2
Table 2