Reer MOSAIC Master M1 Quick start guide

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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.................................................................................................................................................8
Contents of this handbook ...............................................................................8
Important safety instructions............................................................................8
Abbreviations and symbols...............................................................................9
Applicable standards........................................................................................9
OVERVIEW..........................................................................................................................................................10
PRODUCT COMPOSITION...........................................................................................................................13
INSTALLATION................................................................................................................................................14
Mechanical fastening......................................................................................14
Calculation of safety distance of an ESPE connected to MOSAIC.......................15
Electrical connections.....................................................................................15
Instructions concerning connection cables............................................................16
Master Module M1 ...................................................................................16
Master Module M1S..................................................................................17
USB input............................................................................................................ 18
MOSAIC Configuration Memory (MCM).................................................................. 18
MULTIPLE LOAD function..........................................................................18
RESTORE function ....................................................................................19
Module MI8O2 .........................................................................................19
Module MI8O4 .........................................................................................20
Module MI8..............................................................................................20
Module MI12T8........................................................................................21
Module MI16............................................................................................21
Module MO2 ............................................................................................22
Module MO4 ............................................................................................22
Module MO4L ..........................................................................................23
Module MR2.............................................................................................24
Module MR4.............................................................................................24
Module MR8.............................................................................................25
Modules MV0 - MV1 - MV2......................................................................26
ENCODER CONNECTIONS WITH RJ45 CONNECTOR (MV1, MV2)...............................27
Module MOR4 ..........................................................................................28
Module MOR4S8.......................................................................................28
Module MOS8 ..........................................................................................29
Module MOS16.........................................................................................29
Module MO4LHCS8 ..................................................................................30
Modulo MA2 ............................................................................................30
Modulo MA4 ............................................................................................31
MA2 / MA4 Analog sensor connections ................................................................32
Example of connection of Mosaic to the machine control system ........................... 33
CHECKLIST AFTER INSTALLATION....................................................................33
OPERATING DIAGRAM.................................................................................................................................34
SIGNALS..............................................................................................................................................................35
INPUTS...........................................................................................................35

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MASTER ENABLE..................................................................................................35
NODE SEL............................................................................................................35
PROXIMITY INPUT FOR SPEED CONTROLLER MV.....................................................36
Configuration With Interleaved Proximity..................................................36
RESTART_FBK......................................................................................................37
OUTPUTS........................................................................................................38
OUT STATUS (SIL 1/PL c)......................................................................................38
OUT TEST............................................................................................................38
OSSD SAFETY OUTPUTS ..................................................................................38
IMPORTANT NOTE CONCERNING OSSD SAFETY OUTPUTS..........................38
OSSD (M1, MI8O2, MO2, MO4) .............................................................................39
OSSD (M1S, MI8O4, MO4L)...................................................................................39
OSSD (MO4LHCS8)...............................................................................................41
OSSD OUTPUTS CONFIGURATION .........................................................................42
SAFETY RELAYS (MR2, MR4, MOR4, MOR4S8) ........................................................ 43
Characteristics of the output circuit......................................................................43
MR2/MR4/MR8 internal contacts diagram.............................................................43
Example of MR2 module connection with static OSSD outputs of a module M1.......44
Switching operation timing diagram.....................................................................45
TECHNICAL FEATURES ................................................................................................................................46
GENERAL SYSTEM CHARACTERISTICS....................................................................46
Safety level parameters ............................................................................46
General data ............................................................................................46
Enclosure.................................................................................................47
M1 module ..............................................................................................47
M1S module.............................................................................................48
MI8O2 module.........................................................................................48
MI8O4 module.........................................................................................48
MI8 - MI16 modules.................................................................................49
MI12T8 module........................................................................................49
MO2 - MO4 modules ...............................................................................49
MO4L module ..........................................................................................49
MOS8 MOS16 modules ..........................................................................50
MR2 - MR4 MR8 modules ......................................................................50
MOR4 MOR4S8 module..........................................................................50
MO4LHCS8 module ..................................................................................51
MV0 - MV1 - MV2 modules......................................................................51
MA2, MA4 module ...................................................................................52
MECHANICAL DIMENSIONS..............................................................................53
LED INDICATORS (Normal Operation)..............................................................54
Master M1 (Figure 16)..........................................................................................54
Master M1S (Figure 16)........................................................................................55
MI8O2 (Figure 18) ...............................................................................................56
MI8O4 (Figure 18) ...............................................................................................57
MI8 (Figure 20)....................................................................................................58
MI12T8 (Figure 22)..............................................................................................59
MI16 (Figure 22)..................................................................................................60
MO2 (Figure 23)..................................................................................................61
MO4 (Figure 24)..................................................................................................62
MO4L (Figure 18).................................................................................................63
MOR4 (Figure 26) ................................................................................................64
MOR4S8 (Figure 27)............................................................................................. 65
MOS8 (Figure 28) ................................................................................................ 66
MOS16 (Figure 29)............................................................................................... 67
MV0, MV1, MV2 (Figure 30)..................................................................................68

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MR2, MR4, MR8 (Figure 31)..................................................................................69
MO4LHCS8 (Figure 32)......................................................................................... 70
MA2, MA4 (Figure 33)..........................................................................................71
LED INDICATORS (Troubleshooting)................................................................72
Master M1 (Figure 34)..........................................................................................72
Master M1S (Figure 35)........................................................................................73
MI8O2 (Figure 36) ...............................................................................................74
MI8O4 (Figure 37) ...............................................................................................75
MI8 (Figure 38)....................................................................................................76
MI12T8 (Figure 39)..............................................................................................77
MI16 (Figure 40)..................................................................................................78
MO2 / MO4 (Figure 41)........................................................................................79
MO4L (Figure 42)................................................................................................. 80
MOR4 (Figure 43) ................................................................................................81
MOR4S8 (Figure 44)............................................................................................. 82
MOS8 (Figure 45) ................................................................................................83
MOS16 (Figure 46)............................................................................................... 84
MV0, MV1, MV2 (Figure 47)..................................................................................85
MO4LHCS8 (Figure 48)......................................................................................... 86
MA2, MA4 (Figure 49)..........................................................................................87
MOSAIC SAFETY DESIGNER SOFTWARE ..............................................................................................89
Installing the software....................................................................................89
PC HARDWARE requirements................................................................................89
PC SOFTWARE requirements................................................................................. 89
Installation of MSD software.................................................................................89
Fundamentals .....................................................................................................90
Standard tool bar ................................................................................................91
Textual tool bar ..................................................................................................92
Create a new project (configure the MOSAIC system)............................................. 92
EDIT CONFIGURATION (composition of the various modules)................................. 93
Change user parameters...................................................................................... 93
OBJECTS - OPERATOR - CONFIGURATION tool bars...............................................94
Creating the diagram...........................................................................................95
USE OF MOUSE RIGHT BUTTON.................................................................96
Example of a project............................................................................................97
Project validation .....................................................................................97
Resources Allocation................................................................................98
Project report...........................................................................................99
Connect to Mosaic .................................................................................101
Sending the configuration to the MOSAIC ...............................................101
Download a configuration file (project) from Mosaic ...............................101
Configuration LOG.................................................................................101
System composition...............................................................................102
Disconnecting System ............................................................................102
MONITOR (I/O status in real time - textual)............................................103
MONITOR (I/O status in real time - textual - graphic).............................103
Password protection.......................................................................................... 104
Level 1 password ...................................................................................104
Level 2 password ...................................................................................105
Password Change...................................................................................105
TESTING the system........................................................................................... 106
OBJECT FUNCTION BLOCKS...........................................................................107
OUTPUT OBJECTS............................................................................................... 107
OSSD (safety outputs).............................................................................107
SINGLE DOUBLE OSSD (safety output)......................................................108

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STATUS (SIL 1/PL c output).....................................................................111
FIELDBUS PROBE.....................................................................................111
RELAY....................................................................................................112
Use with RESTART: Automatic (A) or Manual (B) (Category 2)...................113
INPUT OBJECTS.................................................................................................. 115
E-STOP (emergency stop).......................................................................115
E-GATE (safety gate device)....................................................................116
SINGLE E-GATE (safety gate device)........................................................117
LOCK FEEDBACK.....................................................................................118
ENABLE (enable key)...............................................................................119
ESPE (optoelectronic safety light curtain / laser scanner).........................120
FOOTSWITCH (safety pedal)....................................................................121
MOD-SEL (safety selector)......................................................................123
PHOTOCELL (safety photocell) ................................................................124
TWO-HAND (bimanual control)...............................................................125
NETWORK_IN..........................................................................................125
SENSOR..................................................................................................126
S-MAT (safety mat) ................................................................................127
SWITCH..................................................................................................128
ENABLING GRIP SWITCH..........................................................................129
TESTABLE SAFETY DEVICE.......................................................................130
SOLID STATE DEVICE..............................................................................131
FIELDBUS INPUT .....................................................................................132
LL0-LL1.................................................................................................133
COMMENTS............................................................................................133
TITLE .....................................................................................................133
SPEED CONTROL TYPE FUNCTION BLOCKS.....................................................134
Warning concerning safety .....................................................................134
Note concerning Speed Control Functional Blocks...................................134
SPEED CONTROL ....................................................................................135
WINDOW SPEED CONTROL......................................................................138
STAND STILL..........................................................................................140
STAND STILL AND SPEED CONTROL ........................................................142
ANALOG INPUT TYPE FUNCTION BLOCKS.......................................................145
ANALOG INPUT (4 inputs each MA4 module, 2 inputs each MA2 module) 145
ANALOG DIVISION (4 inputs each MA4 module, 2 inputs each MA2 module)
.............................................................................................................158
OPERATOR FUNCTION BLOCKS......................................................................171
LOGICAL OPERATORS......................................................................................... 171
AND.......................................................................................................171
NAND ....................................................................................................171
NOT.......................................................................................................172
OR.........................................................................................................172
NOR.......................................................................................................172
XOR.......................................................................................................173
XNOR.....................................................................................................173
LOGICAL MACRO....................................................................................174
MULTIPLEXER .........................................................................................174
DIGITAL COMPARATOR (M1S only)..........................................................175
MEMORY OPERATORS ........................................................................................ 177
D FLIP FLOP (max number = 16 with M1, 32 with M1S) ...........................177
T FLIP FLOP (max number = 16 with M1, 32 with M1S) ...........................177

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SR FLIP FLOP ..........................................................................................177
USER RESTART MANUAL (max number = 16 with M1, 32 with M1S with other
RESTART operators) ...............................................................................178
USER RESTART MONITORED (max number = 16 with M1, 32 with M1S with
other RESTART operators) ......................................................................179
MACRO RESTART MANUAL (max number = 16 with M1, 32 with M1S with
other RESTART operators) ......................................................................179
MACRO RESTART MONITORED (max number = 16 with M1, 32 with M1S with
other RESTART operators) ......................................................................180
PRE-RESET (M1S only) (max number = 32 with other RESTART operators)
.............................................................................................................181
GUARD LOCK OPERATORS (max number = 4 with M1, 8 with M1S)....................... 182
GUARD LOCK .........................................................................................182
COUNTER OPERATORS....................................................................................... 194
COUNTER (max number = 16)................................................................194
COUNTER COMPARATOR........................................................................195
TIMER OPERATORS (max number = 32 with M1, 48 with M1S) ............................. 196
MONOSTABLE.........................................................................................196
MONOSTABLE_B .....................................................................................197
PASSING MAKE CONTACT.......................................................................198
DELAY....................................................................................................199
LONG DELAY..........................................................................................200
DELAY COMPARATOR.............................................................................201
DELAY LINE............................................................................................201
LONG DELAY LINE.................................................................................202
CLOCKING .............................................................................................203
MUTING FUNCTION............................................................................................ 204
MUTING OPERATORS (max number = 4 with M1, 8 with M1S) .............................. 204
"Concurrent" MUTING.............................................................................204
............................................................................................205
"Sequential" MUTING..............................................................................206
............................................................................................208
MUTING OVERRIDE (max number = 4) ....................................................209
ANALOG OPERATORS (M1S only) ........................................................................ 211
Analog Comparator................................................................................211
Math (max number = 16).......................................................................214
Equality check (max number = 16).........................................................215
MISCELLANEOUS FUNCTION BLOCKS.............................................................216
SERIAL OUTPUT (max number = 4 with M1, 8 with M1S) .........................216
NETWORK (max number = 1)..................................................................217
Example of application in Category 2 according to ISO 13849-1:............220
Logical block diagram of a safety function using the network .................221
Example of application in Category 4 according to ISO 13849-1:............221
Logical block diagram of a safety function using the network .................222
RESET M1...............................................................................................222
OSSD EDM (M1S only, max number = 32)...............................................222
INTERPAGE IN/OUT ................................................................................223
INTFBK_IN / INTFBK_OUT (M1S only, max number = 8)...........................224
TERMINATOR .........................................................................................224
SPECIAL APPLICATIONS...................................................................................... 225
Output delay with manual ......................................................................225
SIMULATOR FEATURE......................................................................................... 226
Schematic Simulation......................................................................................... 227

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How to use graphic simulation........................................................................... 229
Application example of graphic simulation.............................................232
MOSAIC FAIL CODES.......................................................................................... 234
ERRORS LOG DOWNLOAD ....................................................................235
ACCESSORIES AND SPARE PARTS .......................................................................................................236
WARRANTY.....................................................................................................................................................237

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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 106).
Always test the complete system whenever new safety components are added (see the
"TESTING the system" page 106).
ReeR is not responsible for these operations or any risks in connection therewith.
Reference should be made to the handbooks and the relative product and/or application
standards to ensure correct use of devices connected to the Mosaic within the specific
application.
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
MCM = MOSAIC Configuration Memory: memory chip for MOSAIC M1/M1S (accessory)
MSC = MOSAIC Safety Communication: proprietary bus for expansion units
MSD = MOSAIC Safety Designer: MOSAIC configuration SW running in Windows
LL0, LL1 = Logic Level 0, Logic Level 1
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
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"
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.
IEC 61784-3
Digital data communication for measurement and control: Functional safety
fieldbuses.
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 (M1 or M1S),
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 M1 or M1S can also be used as a stand-alone device and they are equipped
with:
M1: 8 safety inputs, 2 independent programmable dual channel safety
outputs (OSSD) and 2 SIL 1/PL c outputs
M1S: 8 safety inputs, 4 independent programmable single channel safety
outputs (OSSD) and up to 4 SIL 1/PL c outputs
The following expansions are available: I/O expansions (MI8O2 and MI8O4(with M1S
only)), input expansions (MI8, MI12T8, MI16), output expansions (MO2, MO4 and
MO4LHCS8 and MO4L (only for M1S)), 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 M1S) 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.
The system must consist of just one Master M1 or M1S 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 M1: 128 inputs, 16 safety outputs and 32 SIL 1/ PL c outputs.
with M1S: 128 inputs, 32 safety outputs and 48 SIL 1/ PL c outputs.
MASTER and its SLAVE units communicate via the 5-way MSC bus (ReeR proprietary
bus), physically arranged on the rear panel of each unit.
Furthermore, by means of MBx Fieldbus interfaces, are available:
All inputs states (with diagnostics)
All safety outputs states (with diagnostics)
8 fieldbus inputs with M1 or 32 fieldbus inputs with M1S (MBx firmware
2.0). These fieldbus inputs can act in the schematic as physical
inputs, but are not safety inputs and they can
applications.
16 probe outputs with M1 or 32 probe outputs with M1S (MBx firmware
These probe outputs can be connected everywhere in the
schematic by means of MSD software.

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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 M1/M1S 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).
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.

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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.
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
connection; the file resides in the M1 (or M1S) 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.
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).

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PRODUCT COMPOSITION
The MOSAIC M1 and M1S are supplied with:
•CD-ROM containing the free MSD SW, the present PDF multi-language handbook
and other product literature.
•Multi-language installation sheet.
NB: the rear panel MSC connector and MCM memory can be ordered separately as
accessories.
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 M1 or M1S.
This can be ordered separately as an accessory.

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INSTALLATION
Mechanical fastening
Fix the MOSAIC system units to a 35mm DIN rail as follows:
1. Connect the same number of "MSC" 5-pole rear panel connectors as the
number of units to be installed.
2. Fix the train of connectors thus obtained to the Omega DIN 35mm (EN 5022)
rail (hooking them at the top first).
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

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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
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."

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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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 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

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English
Master Module M1S
TERMINAL
SIGNAL
TYPE
DESCRIPTION
OPERATION
1
24VDC
-
24VDC power supply
-
2
NC
-
-
-
3
NC
-
-
-
4
0VDC
-
0VDC power supply
-
5
OSSD1
Output
Solid State Safety Output 1
PNP active high
6
OSSD2
Output
Solid State Safety Output 2
PNP active high
7
RESTART_FBK1/
STATUS1
Input/
Output
Feedback/Restart 1
Input according to EN 61131-2
SIL 1/PL c output
PNP active high
8
RESTART_FBK2/
STATUS2
Input/
Output
Feedback/Restart 2
Input according to EN 61131-2
SIL 1/PL c output
PNP active high
9
OSSD3
Output
Solid State Safety Output 3
PNP active high
10
OSSD4
Output
Solid State Safety Output 4
PNP active high
11
RESTART_FBK3/
STATUS3
Input/
Output
Feedback/Restart 3
Input according to EN 61131-2
SIL 1/PL c output
PNP active high
12
RESTART_FBK4/
STATUS4
Input/
Output
Feedback/Restart 4
Input according to EN 61131-2
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 3
The STATUS SIL 1/PL c 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. For example, to use the STATUS1 output
(Terminal 7), you must program OSSD1 (by means of the MSD software) with automatic
reset without K feedback monitoring.

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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USB input
The MOSAIC master M1 and M1s
include a mini USB 2.0 connector for
connection to a Personal Computer
where the MSD (MOSAIC Safety
Designer) configuration SW resides.
A USB cable of the correct size is
available as an accessory (CSU).
Figure 2 - USB 2.0 front panel connector
Figure 3 - MCM
MOSAIC Configuration Memory
(MCM)
A backup memory, called MCM (optional)
can be installed in the MOSAIC master
M1/M1S and used to save the SW
configuration parameters.
The MCM is written each time a new
project is sent from the PC to the M1.
Always switch the M1/M1S off before
logging on to/logging off from the
MCM.
Insert the card in the slot in the rear
panel of the M1 and M1S (in the
direction shown in Figure 3 - MCM).
MULTIPLE LOAD function
To perform the configuration of several
master modules without using a PC and
the USB connector, you can save the
desired configuration on a single MCM
and then use it to download data on the
masters modules to be configured simply
inserting the MCM into the module and
turning it on.
If the file contained in the MCM is not identical to the one contained in M1/M1S, an overwrite
operation that will permanently delete the configuration data contained in M1/M1S will be
performed. In this case the module blinks fast leds COM and ENABLE.
WARNING: ALL DATA PREVIOUSLY CONTAINED IN M1/M1S WILL BE LOST.
TECHNICAL DATA LABEL
MCM LABEL

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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RESTORE function
If the M1 or M1S unit is damaged, you can replace it with a new one; having already saved
all the configurations on the MCM, all you need to do is insert the MCM in the new M1/M1S
and switch on the MOSAIC system, that will immediately load the backup configuration. In
this way, the work interruptions will be minimized.
Compatibility between MCM memory and Master modules:
M1S can load configurations from MCM if it is written by a M1S or M1
M1 can load configurations from MCM only if it is written by a M1
The LOAD and RESTORE functions can be disabled via SW. (see Figure 54)
Each time MCM is used, carefully check that the chosen configuration is the one that was
planned for that particular system. Try again a fully functional test of the system composed of
Mosaic plus all devices connected to it (see the "TESTING the system" section).
Module MI8O2
TERMINAL
SIGNAL
TYPE
DESCRIPTION
OPERATION
1
24VDC
-
24VDC power supply
-
2
NODE_SEL0
Input
Node selection
Input ("type B" according to EN 61131-2 )
3
NODE_SEL1
Input
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 4

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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Module MI8O4
TERMINAL
SIGNAL
TYPE
DESCRIPTION
OPERATION
1
24VDC
-
24VDC power supply
-
2
NODE_SEL0
-
Node selection
Input ("type B" according to EN 61131-
2 )
3
NODE_SEL1
-
Input ("type B" according to EN 61131-
2 )
4
0VDC
-
0VDC power supply
-
5
OSSD1
Output
Solid State Safety Output 1
PNP active high
6
OSSD2
Output
Solid State Safety Output 2
PNP active high
7
RESTART_FBK1/
STATUS1
Input/
Output
Feedback/Restart 1
Input according to EN 61131-2
SIL 1/PL c output
PNP active high
8
RESTART_FBK2/
STATUS2
Input/
Output
Feedback/Restart 2
Input according to EN 61131-2
SIL 1/PL c output
PNP active high
9
OSSD3
Output
Solid State Safety Output 3
PNP active high
10
OSSD4
Output
Solid State Safety Output 4
PNP active high
11
RESTART_FBK3/
STATUS3
Input/
Output
Feedback/Restart 3
Input according to EN 61131-2
SIL 1/PL c output
PNP active high
12
RESTART_FBK4/
STATUS4
Input/
Output
Feedback/Restart 4
Input according to EN 61131-2
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 5
The STATUS SIL 1/PL c 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. For example, to use the STATUS1 output
(Terminal 7), you must program OSSD1 with automatic reset without K feedback
monitoring.
Module MI8
TERMINAL
SIGNAL
TYPE
DESCRIPTION
OPERATION
1
24VDC
-
24VDC power supply
-
2
NODE_SEL0
Input
Node selection
Input ("type B" according to EN 61131-2 )
3
NODE_SEL1
Input
Input ("type B" according to EN 61131-2 )
4
0VDC
-
0VDC power supply
-
5
INPUT1
Input
Digital input 1
Input according to EN 61131-2
6
INPUT2
Input
Digital input 2
Input according to EN 61131-2
7
INPUT3
Input
Digital input 3
Input according to EN 61131-2
8
INPUT4
Input
Digital input 4
Input according to EN 61131-2
9
OUT_TEST1
Output
Short circuit detection output
PNP active high
10
OUT_TEST2
Output
Short circuit detection output
PNP active high
11
OUT_TEST3
Output
Short circuit detection output
PNP active high
12
OUT_TEST4
Output
Short circuit detection output
PNP active high
13
INPUT5
Input
Digital input 5
Input according to EN 61131-2
14
INPUT6
Input
Digital input 6
Input according to EN 61131-2
15
INPUT7
Input
Digital input 7
Input according to EN 61131-2
16
INPUT8
Input
Digital input 8
Input according to EN 61131-2
Table 6