Reer MOSAIC Master M1 Quick start guide

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
1 8540780 • 25th June 2012 • Rev.15
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Dichiarazione CE di conformità
EC declaration of conformity
Torino, 15/06/2010
REER SpA
via Carcano 32
10153 – Torino
Italy
dichiara che il controllore integrato MOSAIC costituisce un dispositivo di sicurezza realizzato in conformità alle seguenti
Direttive Europee:
declares that the integrated controller MOSAIC is a safety device complying with the following European Directives:
"Direttiva Macchine"
2006/42/CE "Machine Directive"
"Direttiva Compatibilità Elettromagnetica"
2004/108/CE "Electromagnetic Compatibility Directive"
"Direttiva Bassa Tensione"
2006/95/CE "Low Voltage Directive"
ed è conforme alle seguenti norme:
and complies with the following standards:
Controllori programmabili - Parte 2: Specifiche e prove delle apparecchiature.
CEI EN 61131-2
(07/2007) Programmable controllers - Part 2. Equipment requirements and tests.
Sicurezza del macchinario: Parti dei sistemi di comando legate alla sicurezza. Parte 1: Principi generali per la progettazione.
ISO 13849-1
(06/2008) Safety of machinery:- Safety-related parts of control systems - Part 1: General principles for design.
Sicurezza del macchinario: Dispositivi Elettrosensibili di protezione, Parte 1: Requisiti generali e tests.
EN 61496-1
(11/2005) Safety of machinery : Electro sensitive protective equipment, Part 1: General requirements and tests.
Sicurezza funzionale di impianti elettrici/elettronici/programmabili legati alla sicurezza: Requisiti generali.
IEC 61508-1
(04/2010) Functional safety of electrical/electronic programmable electronic safety related systems: General requirements.
Sicurezza funzionale di impianti elettrici/elettronici/programmabili legati alla sicurezza:
Requisiti per impianti elettrici/elettronici/programmabili legati alla sicurezza.
IEC 61508-2
(04/2010) Functional safety of electrical/electronic/programmable electronic safety related systems:
Requirements for electrical/electronic/programmable electronic safety-related systems.
Sicurezza funzionale di impianti elettrici/elettronici/programmabili legati alla sicurezza: Requisiti Software.
IEC 61508-3
(04/2010) Functional safety of electrical/electronic programmable electronic safety related systems: Software requirements.
Reti di comunicazione industriali - Profili - Parte 3: Sicurezza funzionale dei bus di campo -
Norme generali e profilo definizioni.
IEC 61784-3
(12/2007) Industrial communication networks - Profiles - Part 3: Functional safety fieldbuses -
General rules and profile definitions.
Sicurezza del macchinario. Sicurezza funzionale dei sistemi di comando e controllo elettrici, elettronici e programmabili
correlati alla sicurezza.
IEC 62061
(01/2005) Safety of machinery - Functional safety of safety-related electrical, electronic and programmable electronic control systems.
raggiungendo il livello di sicurezza pari a: SIL 3 / SILCL 3 / PL e/ Cat. 4 / Tipo 4 (v. standard corrispondenti)
reaching a safety level corresponding to : SIL 3 / SILCL 3 / PL e / Cat. 4 / Type 4 (see related standards)
ed è identico all'esemplare esaminato ed approvato con esame di tipo CE da:
and is identical to the specimen examined and approved with a CE - type approval by:
TÜV SÜD Rail GmbH – Ridlerstrasse 65 – D-80339 – Muenchen – Germany
Carlo Pautasso Simone Scaravelli
Direttore Tecnico Amministratore Delegato
Technical Director Managing director

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M
MO OD DU UL LA AR R S SA AF FE ET TY Y I IN NT TE EG GR RA AT TE ED D C CO ON NT TR RO OL LL LE ER R
CONTENTS
INTRODUCTION .................................................................................................................................................6
Contents of this handbook ................................................................................6
Important safety instructions.............................................................................6
Abbreviations and symbols................................................................................ 7
Applicable standards .........................................................................................7
OVERVIEW.............................................................................................................................................................8
PRODUCT COMPOSITION..............................................................................................................................9
INSTALLATION ................................................................................................................................................ 10
Mechanical fastening .......................................................................................10
Calculation of safety distance of an ESPE connected to MOSAIC .......................11
Electrical connections ......................................................................................11
Instructions concerning connection cables. ..................................................12
USB input .....................................................................................................13
MOSAIC Configuration Memory (MCM)..........................................................13
MULTIPLE LOAD function...........................................................................13
RESTORE function......................................................................................13
EXAMPLE OF CONNECTION OF MOSAIC TO THE MACHINE CONTROL SYSTEM 19
CHECKLIST AFTER INSTALLATION ....................................................................19
OPERATING DIAGRAM ................................................................................................................................. 20
SIGNALS .............................................................................................................................................................. 21
INPUTS ............................................................................................................21
MASTER ENABLE ...........................................................................................21
NODE SEL .....................................................................................................21
RESTART_FBK ...............................................................................................22
OUTPUTS .........................................................................................................23
OUT STATUS.................................................................................................23
OUT TEST .....................................................................................................23
OSSD (M1, MI8O2) ........................................................................................23
OSSD (MO2, MO4) ........................................................................................23
SAFETY RELAYS (MR2, MR4) ..........................................................................24
Characteristics of the output circuit..............................................................24
MR2/MR4 internal contacts diagram.............................................................24
Example of MR2 module connection with static OSSD outputs of a module M1
.................................................................................................................... 25
Switching operation timing diagram. ............................................................25
TECHNICAL FEATURES ................................................................................................................................ 26
GENERAL SYSTEM CHARACTERISTICS ............................................................26
Safety level parameters .............................................................................26
General data..............................................................................................26
Enclosure ..................................................................................................27
M1 module................................................................................................27
MI8O2 module ..........................................................................................27
MI8 - MI16 modules ..................................................................................28
MI12T8 module.........................................................................................28
MO2 - MO4 modules .................................................................................28
MR2 - MR4 modules ..................................................................................28

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MECHANICAL DIMENSIONS...............................................................................29
SIGNALS ..........................................................................................................30
Master M1 (Figure 10) ..................................................................................30
MI8O2 (Figure 11) ........................................................................................31
MI8 (Figure 12).............................................................................................32
MI12T8 (Figure 14)....................................................................................... 33
MI16 (Figure 14)...........................................................................................34
MO2 (Figure 15) ...........................................................................................35
MO4 (Figure 16) ...........................................................................................36
MR2 (Figure 17) / MR4 (Figure 18)................................................................ 37
TROUBLESHOOTING .........................................................................................38
Master M1 (Figure 19) ..................................................................................38
MI8O2 (Figure 20) ........................................................................................39
MI8 (Figure 21).............................................................................................40
MI12T8 (Figure 22)....................................................................................... 41
MI16 (Figure 23 - MI16) ................................................................................42
MO2 / MO4 (Figure 24) ................................................................................43
MOSAIC SAFETY DESIGNER SOFTWARE .............................................................................................. 44
Installing the software .....................................................................................44
PC HARDWARE requirements ........................................................................44
PC SOFTWARE requirements .........................................................................44
How to install MSD .......................................................................................44
Fundamentals............................................................................................... 45
Standard tool bar .........................................................................................46
Textual tool bar............................................................................................47
Create a new project (configure the MOSAIC system)....................................47
EDIT CONFIGURATION (composition of the various modules)........................48
Change user parameters ..............................................................................48
OBJECTS - OPERATOR - CONFIGURATION tool bars........................................49
Creating the diagram (Figure 16)..................................................................50
Example of a project ....................................................................................51
Project validation ......................................................................................51
Project report ............................................................................................52
Connect to Mosaic.....................................................................................53
Sending the configuration to the MOSAIC..................................................53
Download a configuration file (project) from Mosaic M1............................ 53
Configuration LOG ....................................................................................53
System composition .................................................................................. 54
Disconnecting System ...............................................................................54
MONITOR (I/O status in real time - textual) ...............................................55
MONITOR (I/O status in real time - textual - graphic)................................. 55
Password protection.....................................................................................56
Level 1 password ......................................................................................56
Level 2 password ......................................................................................56
Password Change ...................................................................................... 56
TESTING the system ..................................................................................... 57
OBJECT FUNCTION BLOCKS ..............................................................................58
OUTPUT OBJECTS..........................................................................................58
OSSD (safety outputs)................................................................................58
STATUS (signal output).............................................................................. 58
FIELDBUS PROBE ........................................................................................58
INPUT OBJECTS .............................................................................................59

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E-STOP (emergency stop)........................................................................... 59
E-GATE (safety gate device) .......................................................................60
ENABLE (enable key) ..................................................................................61
ESPE (optoelectronic safety light curtain / laser scanner) ...........................62
FOOTSWITCH (safety pedal).......................................................................64
MOD-SEL (safety selector)..........................................................................65
PHOTOCELL (safety photocell) ...................................................................65
TWO-HAND (bimanual control) ..................................................................67
SENSOR .....................................................................................................67
S-MAT (safety mat) ....................................................................................69
SWITCH .....................................................................................................70
ENABLING GRIP SWITCH.............................................................................71
TESTABLE SAFETY DEVICE..........................................................................72
SOLID STATE DEVICE .................................................................................74
FIELDBUS INPUT.........................................................................................75
COMMENTS ...............................................................................................75
TITLE.........................................................................................................75
OPERATOR FUNCTION BLOCKS.........................................................................76
LOGICAL OPERATORS ...................................................................................76
AND ..........................................................................................................76
NAND........................................................................................................76
NOT ..........................................................................................................77
OR.............................................................................................................77
NOR ..........................................................................................................77
XOR...........................................................................................................78
XNOR ........................................................................................................78
MULTIPLEXER.............................................................................................78
MEMORY OPERATORS ...................................................................................79
D FLIP FLOP (max number = 16) ................................................................79
SR FLIP FLOP..............................................................................................80
USER RESTART MANUAL (max number = 16 with RESTART MONITORED) ... 80
USER RESTART MONITORED (max number = 16 with RESTART MANUAL) ..80
COUNTER OPERATORS..................................................................................81
COUNTER operator is a pulse counter that sets output Q to 1 (TRUE) as soon
as the desired count is reached. ................................................................81
COUNTER (max number = 16). ..................................................................81
TIMER OPERATORS (max number = 16).........................................................81
CLOCKING.................................................................................................81
MONOSTABLE............................................................................................82
PASSING MAKE CONTACT ..........................................................................83
DELAY .......................................................................................................84
MUTING OPERATORS (max number = 4)........................................................85
"Concurrent" MUTING ................................................................................85
MUTING “L” ...............................................................................................86
"Sequential" MUTING .................................................................................87
MUTING “T” ...............................................................................................88
MUTING OVERRIDE (max number = 16) .....................................................89
SPECIAL APPLICATIONS.................................................................................90
Output delay with manual .........................................................................90
ACCESSORIES AND SPARE PARTS........................................................................................................... 91
WARRANTY ....................................................................................................................................................... 92

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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.
ÎThis 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 "TESTING the system", page 57).
Always test the complete system whenever new safety components are added (see
the "TESTING the system" section, page 57).
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 (accessory)
MSC = MOSAIC Safety Communication: proprietary bus for expansion units
MSD = MOSAIC Safety Designer: MOSAIC configuration SW running in Windows
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"
•2004/108/EC "Electromagnetic Compatibility Directive"
•2006/95/EC "Low Voltage Directive"
and is built to the following standards:
CEI EN 61131-2 Programmable controllers, part 2:
Equipment requirements and tests
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.
IEC 61508-1 Functional safety of electrical/electronic/programmable electronic safety-
related systems: General requirements.
IEC 61508-2
Functional safety of electrical/electronic/programmable electronic safety-
related systems: Requirements for electrical/electronic/programmable
electronic safety-related systems.
IEC 61508-3 Functional safety of electrical/electronic/programmable electronic safety-
related systems: Software requirements.
IEC 61784-3 Digital data communication for measurement and control: Functional safety
fieldbuses.
IEC 62061 Safety of machinery. Functional safety of safety-related electrical, electronic
and programmable electronic control systems
Table 1

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OVERVIEW
MOSAIC is a modular safety controller. It consists of a master unit (M1), which can
be configured using the MSD graphic interface, and a number of expansion units
connected to the M1 via the proprietary MSC bus.
The M1 can also be used as a stand-alone device. It has 8 safety inputs and 2
independent programmable dual channel outputs.
ÎThe following expansions are available: I/O expansions (MI8O2), input only
expansions (MI8, MI12T8 and MI16), output only expansions (MO2 and MO4),
guided contact safety relay output modules (MR2 and MR4) and diagnostic
connections to the main fieldbuses:
MBP (PROFIBUS), MBC (CanOpen), MBD (DeviceNet), MBEI (ETHERNET/IP),
MBEP (Profinet), MBEC (ETHERCAT).
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 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 that can be
installed.
With 14 expansions, the system can have up to 128 inputs, 16 dual channel safety
outputs and 16 status outputs. The MASTER and its SLAVE units communicate via
the 5-way MSC bus (ReeR proprietary bus), physically arranged on the rear panel
of each unit.
Furthermore 8 inputs and 16 outputs probe controllable (by Fieldbus) are
available.
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 M1 via USB connection; the
file resides in the M1 and can also be saved on the proprietary MCM memory chip
(accessory). The configuration can therefore quickly be copied to another M1 unit.
ÎThe 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 M1is supplied with:
•CD-ROM containing the free MSD SW, this PDF multi-language handbook and
other product literature.
•Multi-language installation sheet.
ÎNB: 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).
ÎNB: 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. 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 and MR4 are connected via terminal blocks
only.
ÎTerminal tightening torque: 5÷7lb-in (0,6÷0,7 Nm).
Install safety units in an enclosure with a protection class of at least IP54.
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.
ÎWire size range: AWG 12÷30, (solid/stranded) (UL).
ÎUse 60/75°C copper (Cu) conductor only.
ÎWe 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.
ÎCables 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 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 GND - 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 Programmable digital 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 Programmable digital output PNP active high
13 OUT_TEST1 Output Short circuit detected output PNP active high
14 OUT_TEST2 Output Short circuit detected output PNP active high
15 OUT_TEST3 Output Short circuit detected output PNP active high
16 OUT_TEST4 Output Short circuit detected 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

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USB input
The MOSAIC master M1 includes a
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
TECHNICAL DATA LABEL
MCM LABEL
Figure 3 - MCM
MOSAIC Configuration Memory (MCM)
A backup memory, called MCM (optional)
can be installed in the MOSAIC master M1
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.
ÎAlways switch the M1 off before
logging on to/logging off from the
MCM.
Insert the card in the slot in the rear
panel of the M1 (in the direction shown in
Figure 3 - MCM).
MULTIPLE LOAD function
To perform the configuration of several
M1 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 modules
M1 to be configured.
If the file contained in the MCM is not identical to the one contained in M1, an overwrite
operation that will permanently delete the configuration data contained in M1 will be
performed.
WARNING: ALL DATA PREVIOUSLY CONTAINED IN M1 WILL BE LOST.
RESTORE function
If the M1 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 and
switch on the MOSAIC system, that will immediately load the backup configuration. In this
way, the work interruptions will be minimized.

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ÎThe LOAD and RESTORE functions can be disabled via SW. (see Figure 29)
ÎIn order to be used, the expansion units must be addressed at the time of
installation (see the NODE SEL section).
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).

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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 GND - 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 Programmable digital 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 Programmable digital output PNP active high
13 OUT_TEST1 Output Short circuit detected output PNP active high
14 OUT_TEST2 Output Short circuit detected output PNP active high
15 OUT_TEST3 Output Short circuit detected output PNP active high
16 OUT_TEST4 Output Short circuit detected 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
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 GND - 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 detected output PNP active high
10 OUT_TEST2 Output Short circuit detected output PNP active high
11 OUT_TEST3 Output Short circuit detected output PNP active high
12 OUT_TEST4 Output Short circuit detected 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 3

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
16 8540780 • 25th June 2012 • Rev.15
English
MI12T8
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 GND - 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 detected output PNP active high
10 OUT_TEST2 Output Short circuit detected output PNP active high
11 OUT_TEST3 Output Short circuit detected output PNP active high
12 OUT_TEST4 Output Short circuit detected 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
17 OUT_TEST5 Output Short circuit detected output PNP active high
18 OUT_TEST6 Output Short circuit detected output PNP active high
19 OUT_TEST7 Output Short circuit detected output PNP active high
20 OUT_TEST8 Output Short circuit detected output PNP active high
21 INPUT9 Input Digital input 9 Input according to EN 61131-2
22 INPUT10 Input Digital input 10 Input according to EN 61131-2
23 INPUT11 Input Digital input 11 Input according to EN 61131-2
24 INPUT12 Input Digital input 12 Input according to EN 61131-2
Table 4
MI16
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 GND - 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 detected output PNP active high
10 OUT_TEST2 Output Short circuit detected output PNP active high
11 OUT_TEST3 Output Short circuit detected output PNP active high
12 OUT_TEST4 Output Short circuit detected 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
17 INPUT9 Input Digital input 9 Input according to EN 61131-2
18 INPUT10 Input Digital input 10 Input according to EN 61131-2
19 INPUT11 Input Digital input 11 Input according to EN 61131-2
20 INPUT12 Input Digital input 12 Input according to EN 61131-2
21 INPUT13 Input Digital input 13 Input according to EN 61131-2
22 INPUT14 Input Digital input 14 Input according to EN 61131-2
23 INPUT15 Input Digital input 15 Input according to EN 61131-2
24 INPUT16 Input Digital input 16 Input according to EN 61131-2
Table 5

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
8540780 • 25th June 2012 • Rev.15 17
English
MO4
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 GND - 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 Programmable digital 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 Programmable digital output PNP active high
13 24VDC - 24VDC power supply OSSD1/2 power supply
14 24VDC - 24VDC power supply OSSD3/4 power supply
15 GND - 0VDC power supply -
16 GND - 0VDC power supply -
17 OSSD4_A Output Static output 4 PNP active high
18 OSSD4_B Output PNP active high
19 RESTART_FBK4 Input Feedback/Restart 4 Input according to EN 61131-2
20 OUT_STATUS4 Output Programmable digital output PNP active high
21 OSSD3_A Output Static output 3 PNP active high
22 OSSD3_B Output PNP active high
23 RESTART_FBK3 Input Feedback/Restart 3 Input according to EN 61131-2
24 OUT_STATUS3 Output Programmable digital output PNP active high
Table 6
MO2
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 GND - 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 Condition of outputs 1A/1B 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 Condition of outputs 2A/2B PNP active high
13 24VDC - 24VDC power supply OSSD1/2 power supply
14 n.c. - - -
15 GND - 0VDC power supply -
16 n.c. - - -
Table 7

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
18 8540780 • 25th June 2012 • Rev.15
English
MR4
TERMINAL SIGNAL TYPE DESCRIPTION OPERATION
1 24VDC - 24VDC power supply -
4 GND - 0VDC power supply -
5 OSSD1_A Input Control ZONE 1 PNP active high
6 OSSD1_B Input
7 FBK_K1_K2_1 Output Feedback K1K2 ZONE 1
9 A_NC1 Output NC contact ZONE 1
10 B_NC1 Output
13 A_NO11 Output NO1 contact ZONE 1
14 B_NO11 Output
15 A_NO12 Output NO2 contact ZONE 1
16 B_NO12 Output
11 A_NC2 Output NC contact ZONE 2
12 B_NC2 Output
17 OSSD2_A Input Control ZONE 2 PNP active high
18 OSSD2_B Input
19 FBK_K1_K2_2 Output Feedback K1K2 ZONE 2
21 A_NO21 Output NO1 contact ZONE 2
22 B_NO21 Output
23 A_NO22 Output NO2 contact ZONE 2
24 B_NO22 Output
Table 8
MR2
TERMINAL SIGNAL TYPE DESCRIPTION OPERATION
1 24VDC - 24VDC power supply -
4 GND - 0VDC power supply -
5 OSSD1_A Input Control ZONE 1 PNP active high
6 OSSD1_B Input
7 FBK_K1_K2_1 Output Feedback K1K2 ZONE 1
9 A_NC1 Output NC contact ZONE 1
10 B_NC1 Output
13 A_NO11 Output NO1 contact ZONE 1
14 B_NO11 Output
15 A_NO12 Output NO2 contact ZONE 1
16 B_NO12 Output
Table 9

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
8540780 • 25th June 2012 • Rev.15 19
English
EXAMPLE OF CONNECTION OF MOSAIC TO THE MACHINE CONTROL SYSTEM
Figure 4
CHECKLIST AFTER INSTALLATION
The MOSAIC system is able to detect the faults that occurs in each own module.
Anyway to have the system perfect operation perform the following checks at start up
and at least every one year:
1. Operate a complete system TEST (see "TESTING the system")
2. Verify that all the cables are correctly inserted and the terminal blocks well screwed.
3. Verify that all the leds (indicators) light on correctly.
4. Verify the positioning of all the sensors connected to MOSAIC.
5. Verify the correct fixing of MOSAIC to the Omega rail.
6. Verify that all the external indicators (lamps) work properly.
ÎAfter installation, maintenance and after any eventual configuration change perform
a System TEST as described in the paragraph "TESTING the system" at page 57.

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
20 8540780 • 25th June 2012 • Rev.15
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OPERATING DIAGRAM
Mechanical fastening
Electrical connections
between the Mosaic
modules and with the
external sensors
Designing the diagram
Validation
sw OK ?
NO
YES
Downloading the
diagram to M1
Configuration check
(including complete
system TEST at page 54)
on M1 OK?
NO
YES
End of connection
via USB
System
startup
Connection
via USB with PSW