Reer MOSAIC MI8 Quick start guide

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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 ..........................................................................................................................................7
Contents of this handbook ...............................................................................7
Important safety instructions............................................................................7
Abbreviations and symbols...............................................................................8
Applicable standards........................................................................................8
OVERVIEW......................................................................................................................................................9
PRODUCT COMPOSITION..................................................................................................................... 11
INSTALLATION.......................................................................................................................................... 12
Mechanical fastening......................................................................................12
Calculation of safety distance of an ESPE connected to MOSAIC.......................13
Electrical connections.....................................................................................13
Instructions concerning connection cables...................................................14
Module Master M1 ...................................................................................14
USB input....................................................................................................15
MOSAIC Configuration Memory (MCM).........................................................15
MULTIPLE LOAD function..........................................................................15
RESTORE function ....................................................................................15
Module MI8O2 .........................................................................................16
Module MI8..............................................................................................17
Module MI12T8........................................................................................17
Module MI16............................................................................................18
Module MO4............................................................................................18
Module MO2............................................................................................19
Module MR4.............................................................................................19
Module MR2.............................................................................................20
Modules MV0 - MV1 - MV2......................................................................20
ENCODER CONNECTIONS WITH RJ45 CONNECTOR (MV1, MV2).....................21
Module MOR4..........................................................................................22
Module MOR4S8.......................................................................................22
Module MOS8 ..........................................................................................23
Module MOS16 ........................................................................................23
Module MO4LHCS8 ..................................................................................24
Example of connection of Mosaic to the machine control system .................24
CHECKLIST AFTER INSTALLATION ...................................................................24
OPERATING DIAGRAM........................................................................................................................... 25
SIGNALS....................................................................................................................................................... 26
INPUTS...........................................................................................................26
MASTER ENABLE..........................................................................................26
NODE SEL....................................................................................................26
PROXIMITY INPUT FOR SPEED CONTROLLER MV............................................27
Configuration With Interleaved Proximity (Figure 5) ..................................27
RESTART_FBK..............................................................................................28
OUTPUTS........................................................................................................29
OUT STATUS ...............................................................................................29
OUT TEST....................................................................................................29
OSSD (M1, MI8O2).......................................................................................29
OSSD (MO2, MO4) .......................................................................................29

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OSSD (MO4LHCS8) ......................................................................................30
SAFETY RELAYS (MR2, MR4, MOR4, MOR4S8) ...............................................31
Characteristics of the output circuit.............................................................31
MR2/MR4 internal contacts diagram............................................................31
Example of MR2 module connection with static OSSD outputs of a module M1
...................................................................................................................32
Switching operation timing diagram. ...........................................................32
TECHNICAL FEATURES .......................................................................................................................... 33
GENERAL SYSTEM CHARACTERISTICS ...........................................................33
Safety level parameters ............................................................................33
General data ............................................................................................33
Enclosure.................................................................................................34
M1 module ..............................................................................................34
MI8O2 module.........................................................................................34
MI8 - MI16 modules.................................................................................35
MI12T8 module........................................................................................35
MO2 - MO4 modules ...............................................................................35
MOS8 MOS16 modules ..........................................................................35
MR2 - MR4 modules ................................................................................36
MOR4 MOR4S8 module..........................................................................36
MO4LHCS8 module..................................................................................37
MV0 - MV1 - MV2 modules......................................................................37
MECHANICAL DIMENSIONS..............................................................................38
SIGNALS.........................................................................................................39
Master M1 (Figure 11) .................................................................................39
MI8O2 (Figure 12).......................................................................................40
MI8 (Figure 13) ...........................................................................................41
MI12T8 (Figure 15)......................................................................................42
MI16 (Figure 15)..........................................................................................43
MO2 (Figure 16)..........................................................................................44
MO4 (Figure 17)..........................................................................................45
MOR4 (Figure 18)........................................................................................46
MOR4S8 (Figure 19) ....................................................................................47
MOS8 (Figure 20) ........................................................................................48
MOS16 (Figure 21) ......................................................................................49
MV1, MV2 (Figure 22)..................................................................................50
MR2 (Figure 23) / MR4 (Figure 24)...............................................................51
MO4LHCS8 (Figure 25) ................................................................................52
TROUBLESHOOTING........................................................................................53
Master M1 (Figure 26) .................................................................................53
MI8O2 (Figure 27).......................................................................................54
MI8 (Figure 28) ...........................................................................................55
MI12T8 (Figure 29)......................................................................................56
MI16 (Figure 30 - MI16) ..............................................................................57
MO2 / MO4 (Figure 31) ...............................................................................58
MOR4 (Figure 32)........................................................................................59
MOR4S8 (Figure 33) ....................................................................................60
MOS8 (Figure 34) ........................................................................................61
MOS16 (Figure 35) ......................................................................................62
MV0, MV1, MV2 (Figure 33).........................................................................63
MO4LHCS8 (Figure 37) ................................................................................64
MOSAIC SAFETY DESIGNER SOFTWARE.......................................................................................... 65

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Installing the software....................................................................................65
PC HARDWARE requirements .......................................................................65
PC SOFTWARE requirements ........................................................................65
How to install MSD......................................................................................65
Fundamentals .............................................................................................66
Standard tool bar ........................................................................................67
Textual tool bar ..........................................................................................68
Create a new project (configure the MOSAIC system) ...................................68
EDIT CONFIGURATION (composition of the various modules) .......................69
Change user parameters .............................................................................69
OBJECTS - OPERATOR - CONFIGURATION tool bars......................................70
Creating the diagram ..................................................................................71
Use of mouse right button .......................................................................71
Example of a project ...................................................................................73
Project validation .....................................................................................73
Project report...........................................................................................74
Connect to Mosaic ...................................................................................75
Sending the configuration to the MOSAIC .................................................75
Download a configuration file (project) from Mosaic M1............................75
Configuration LOG ...................................................................................75
System composition.................................................................................76
Disconnecting System..............................................................................76
MONITOR (I/O status in real time - textual)..............................................77
MONITOR (I/O status in real time - textual - graphic)...............................77
Password protection....................................................................................79
Level 1 password .....................................................................................79
Level 2 password .....................................................................................79
Password Change.....................................................................................79
TESTING the system ....................................................................................80
OBJECT FUNCTION BLOCKS.............................................................................81
OUTPUT OBJECTS ........................................................................................81
OSSD (safety outputs)...............................................................................81
SINGLE OSSD (safety output).....................................................................82
STATUS (signal output).............................................................................84
FIELDBUS PROBE.......................................................................................84
RELAY......................................................................................................85
Use with RESTART: Automatic (A) or Manual (B) (Category 2).....................86
INPUT OBJECTS............................................................................................88
E-STOP (emergency stop).........................................................................88
E-GATE (safety gate device)......................................................................89
SINGLE E-GATE (safety gate device)..........................................................90
LOCK FEEDBACK.......................................................................................91
ENABLE (enable key).................................................................................92
ESPE (optoelectronic safety light curtain / laser scanner)...........................93
FOOTSWITCH (safety pedal)......................................................................94
MOD-SEL (safety selector)........................................................................96
PHOTOCELL (safety photocell) ..................................................................96
TWO-HAND (bimanual control).................................................................97
NETWORK_IN............................................................................................98
SENSOR....................................................................................................98
S-MAT (safety mat) ..................................................................................99
SWITCH..................................................................................................100

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ENABLING GRIP SWITCH..........................................................................101
TESTABLE SAFETY DEVICE.......................................................................102
SOLID STATE DEVICE..............................................................................103
FIELDBUS INPUT .....................................................................................104
LL0-LL1.................................................................................................104
COMMENTS............................................................................................105
TITLE .....................................................................................................105
SPEED CONTROL TYPE FUNCTION BLOCKS.....................................................106
Warning concerning safety .....................................................................106
SPEED CONTROL ....................................................................................107
WINDOW SPEED CONTROL......................................................................109
STAND STILL..........................................................................................111
STAND STILL AND SPEED CONTROL ........................................................113
OPERATOR FUNCTION BLOCKS......................................................................115
LOGICAL OPERATORS ................................................................................115
AND.......................................................................................................115
NAND ....................................................................................................115
NOT.......................................................................................................116
OR.........................................................................................................116
NOR.......................................................................................................116
XOR.......................................................................................................117
XNOR.....................................................................................................117
LOGICAL MACRO....................................................................................117
MULTIPLEXER .........................................................................................118
MEMORY OPERATORS................................................................................119
D FLIP FLOP (max number = 16).............................................................119
T FLIP FLOP (max number = 16).............................................................119
SR FLIP FLOP (max number = 16)............................................................119
USER RESTART MANUAL (max number = 16 with other RESTART operators)
.............................................................................................................120
USER RESTART MONITORED (max number = 16 with other RESTART
operators)..............................................................................................120
MACRO RESTART MANUAL (max number = 16 with other RESTART
operators)..............................................................................................120
MACRO RESTART MONITORED (max number = 16 with other RESTART
operators)..............................................................................................121
GUARD LOCK OPERATORS (max number = 4).............................................122
GUARD LOCK .........................................................................................122
COUNTER OPERATORS...............................................................................134
COUNTER (max number = 16)................................................................134
TIMER OPERATORS (max number = 32) .....................................................136
CLOCKING .............................................................................................136
MONOSTABLE.........................................................................................137
MONOSTABLE_B .....................................................................................138
PASSING MAKE CONTACT.......................................................................139
DELAY....................................................................................................139
DELAY LINE............................................................................................140
MUTING FUNCTION ...................................................................................142
MUTING OPERATORS (max number = 4) ....................................................142
"Concurrent" MUTING.............................................................................142
............................................................................................143
"Sequential" MUTING..............................................................................144

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............................................................................................145
MUTING OVERRIDE (max number = 4) ....................................................146
MISCELLANEOUS FUNCTION BLOCKS.............................................................148
SERIAL OUTPUT (max number = 4).........................................................148
NETWORK (max number = 1)..................................................................149
Example of application in Category 2 according to ISO 13849-1:............152
Logical block diagram of a safety function using the network .................152
Example of application in Category 4 according to ISO 13849-1:............152
Logical block diagram of a safety function using the network .................153
RESET M1...............................................................................................154
INTERPAGE IN/OUT ................................................................................154
TERMINATOR .........................................................................................154
SPECIAL APPLICATIONS..............................................................................155
Output delay with manual ......................................................................155
SIMULATOR FEATURE.................................................................................156
Schematic Simulation ................................................................................157
How to use graphic simulation ..................................................................158
Application example of graphic simulation.............................................162
MOSAIC FAIL CODES..................................................................................164
ACCESSORIES AND SPARE PARTS ...................................................................................................166
WARRANTY ..............................................................................................................................................167

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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 "TESTING the system", page 80).
Always test the complete system whenever new safety components are added (see
the "TESTING the system" section, page 80).
ReeR is not responsible for these operations or any risks in connection therewith.
Reference should be made to the handbooks and the relative product and/or
application standards to ensure correct use of devices connected to the Mosaic within
the specific application.
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"
•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.
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 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.
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.
The following expansions are available: I/O expansions (MI8O2), input only
expansions (MI8, MI12T8, MI16, MV0, MV1 and MV2), output only expansions
(MO2, MO4 and MO4LHCS8), signaling only expansions (MOS8 and MOS16),
guided contact safety relay output modules (MR2, MR4, MOR4 and MOR4S8) and
diagnostic connections to the main fieldbuses: MBP (PROFIBUS), MBC (CanOpen),
MBD (DeviceNet), MBEI (ETHERNET/IP), MBEI2B (ETHERNET/IP-2PORT),
MBEP (Profinet), MBEC (ETHERCAT), MBMR (Modbus RTU), MBEM (Modbus/TCP).
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.
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.
The MO4LHCS8 is a safety module with 4 High Current Safety Outputs and 4
relative inputs for external feedback contacts (EDM).
The module provides 8 programmable signal outputs.
The MI802 has 8 inputs and 2 OSSD outputs.
The MR2 and MR4 Mosaic expansion units provide the system with 2 and 4 N.O.
guided contact safety relay outputs, respectively, with the related external relay
feedback (N.C. contact).

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The expansion units in the MB series permit connection to the most commonly
used industrial fieldbus systems for diagnostics and data transmission.
The MBEI, MBEI2B, MBEP, MBEM and MBEC also have an ethernet connection. The
MBU permits connection to devices with a USB port.
The MCT1 and MCT2 Mosaic units are used to connect the M1 to other slave
units installed at a distance (< 50 m). Two MCT units installed at the required
distance can be connected using a shielded cable (ReeR MC25, MC50 or other
cable with the characteristics set out in the cable data sheet).
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 output (axis).
Each unit incorporates two logic outputs that can be configured using the MSD
software and is thus capable of controlling up to two independent axes.
The MOR4 and MOR4S8 are safety 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 1 corresponding feedback input).
Only the MOR4S8 unit has 8 programmable signal outputs.
The MOS8 and MOS16 have 8 and 16 programmable signal outputs.
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.
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 is supplied with:
•CD-ROM containing the free MSD SW, this PDF multi-language handbook and
other product literature.
•Multi-language installation sheet.
NB: the rear panel MSC connector and MCM memory can be ordered separately as
accessories.
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. 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.
Terminal tightening torque: 5÷7lb-in (0,6÷0,7 Nm).
Install safety units in an enclosure with a protection class of at least IP54.
Connect the module when it is not powered.
The supply voltage to the units must be 24Vdc 20% (PELV, in compliance with the
standard EN 60204-1 (Chapter 6.4)).
Do not use the MOSAIC to supply external devices.
The same ground connection (0VDC) must be used for all system components.
1
"Describe the methods that designers can use to calculate the minimum safety distance from a specific dangerous point
for the safety devices, particularly Electro-sensitive devices (eg. light curtains), safety-mats or pressure sensitive floors and
bimanual control. It contains a rule to determine the placement of safety devices based on approach speed and the
stopping time of the machine, which can reasonably be extrapolated so that it also includes the interlocking guards without
guard locking."

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Instructions concerning connection cables.
Wire size range: AWG 12÷30, (solid/stranded) (UL).
Use 60/75°C copper (Cu) conductor only.
We recommend the use of separate power supplies for the safety module and for
other electrical power equipment (electric motors, inverters, frequency converters)
or other sources of disturbance.
Cables used for connections of longer than 50m must have a cross-section of at
least 1mm2 (AWG16).
Connections of each single MOSAIC system unit are listed in the table below:
Module 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
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
Programmable signal 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 signal 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.
Always 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

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
16 8540780 • 23/03/2017 • Rev.31
English
switch on the MOSAIC system, that will immediately load the backup configuration. In this
way, the work interruptions will be minimized.
The LOAD and RESTORE functions can be disabled via SW. (see Figure 42)
In 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).
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
Programmable signal 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 signal 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

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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English
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 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
Module 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
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 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

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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Module 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
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 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
Module 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
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
Programmable signal 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 signal output
PNP active high
13
24VDC
-
24VDC power supply
24VDC outputs power supply *
14
24VDC
-
24VDC power supply
-
15
0VDC
-
0VDC power supply
0VDC outputs *
16
0VDC
-
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 signal 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 signal output
PNP active high
Table 6

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
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English
Module 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
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
Programmable signal 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 signal output
PNP active high
13
24VDC
-
24VDC power supply
24VDC output power supply *
14
n.c.
-
-
-
15
0VDC
-
0VDC power supply
0VDC output *
16
n.c.
-
-
-
Table 7
* This terminal must be connected to the power supply for the unit to work
properly.
Module MR4
TERMINAL
SIGNAL
TYPE
DESCRIPTION
OPERATION
1
24VDC
-
24VDC power supply
-
4
0VDC
-
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

MODULAR SAFETY INTEGRATED CONTROLLER MOSAIC
20 8540780 • 23/03/2017 • Rev.31
English
Module MR2
TERMINAL
SIGNAL
TYPE
DESCRIPTION
OPERATION
1
24VDC
-
24VDC power supply
-
4
0VDC
-
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
Modules MV0 - MV1 - MV2
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
PROXI1_24V
Output
PROXIMITY 1
connections
PROXIMITY INPUT FOR SPEED
CONTROLLER MV2 -> 27)
Power supply 24VDC to
PROXI1
6
PROXI1_REF
Output
Power supply 0VDC to PROXI1
7
PROXI1 IN1 (3 WIRES)
Input
PROXI1 NO input
8
PROXI1 IN2 (4 WIRES)
Input
PROXI1 NC input
9
PROXI2_24V
Output
PROXIMITY 2
connections
-> 27)
Power supply 24VDC to
PROXI2
10
PROXI2_REF
Output
Power supply 0VDC to PROXI2
11
PROXI2 IN1 (3 WIRES)
Input
PROXI2 NO input
12
PROXI2 IN2 (4 WIRES)
Input
PROXI2 NC input
13
N.C.
-
Not connected
-
14
N.C.
-
-
15
N.C.
-
-
16
N.C.
-
-
Table 10