Reer Mosaic Series User manual

Mosaic fieldbus modules
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SUMMARY
INTRODUCTION ...................................................................................................... 2
ELECTRICAL CONNECTIONS ..................................................................................... 2
PROTOCOL DATA PACKAGE COMPOSITION .............................................................. 3
Footprint in input ................................................................................................ 4
Footprint in output .............................................................................................. 4
SELECTOR DATA ..................................................................................................... 7
MV MODULES INPUT STATUS (page 4) ...................................................................... 7
DIAGNOSTICS.......................................................................................................... 8
The "I/O index" field ............................................................................................ 8
The "Diagnostic code" field .................................................................................. 8
SIGNALS AND PINOUT ........................................................................................... 10
Module MBC.......................................................................................................... 10
Module MBD ......................................................................................................... 11
Module MBP .......................................................................................................... 11
Module MBEC........................................................................................................ 12
Module MBEI ......................................................................................................... 12
Module MBEI2B ..................................................................................................... 13
Module MBEP ........................................................................................................ 13
Module MBEP2 ...................................................................................................... 14
Module MBEM ....................................................................................................... 14
Module MBMR ....................................................................................................... 15
Module MBU.......................................................................................................... 15
EXAMPLES OF DIAGNOSTICS .................................................................................. 16
Example 1 ......................................................................................................... 16
Example 2 ......................................................................................................... 16
Example 3 ......................................................................................................... 17
BUS CONFIGURATOR USER INTERFACE ................................................................... 17
Graphic interface ............................................................................................... 18
EXAMPLES OF MSD CONFIGURATION AS PRESENTED BY THE BUS CONFIGURATOR 22

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This technical sheet describes the operation of the fieldbus modules of the MOSAIC series:
MBP (PROFIBUS DP-V1); MBD (DeviceNet); MBC (CANOpen); MBEC (ETHERCAT); MBEI (ETHERNET/IP);
MBEI2B (ETHERNET/IP–2 PORT); MBEP (PROFINET); MBEP2 (PROFINET I/O - 2 PORT); MBEM (Modbus
TCP); MBMR (Modbus RTU); MBU (USB).
Each module is provided with four connectors (Figure 1):
1) 5 way connector MSC --> to the system MOSAIC
2) USB miniB connect --> to the PC
3) BUS connector --> to the fieldbus (not present on MBU)
4) Front terminal --> power supply
TERMINAL BLOCK (SIDE A - TOP)
TERMINAL BLOCK (SIDE B - BOTTOM)
TERMINAL
SIGNAL
TERMINAL
SIGNAL
1
+24VDC + 20%
5
-
2
-
6
Serial line RS-485 -(A)
3
-
7
GND
4
GND
8
Serial line RS-485 +(B)
Table 1
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).
Do not use MOSAIC to supply external devices.
The same ground connection (0VDC) must be used for all system components.
Figure 1

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The bus module exports the system status and the status and diagnostic elements of all I/Os
configured on the Mosaic and enables 8 single fieldbus inputs to be imported.
The input and output memory maps are described in the tables at page 3.
The input map is made up by a single byte representing the fieldbus inputs.
The output map is made up by a status byte, a variable number of bytes for the Mosaic input
status, a byte representing the copy of the fieldbus inputs, a variable number of bytes to
represent the probes status, a variable number of bytes to represent the Mosaic OSSD status,
two bytes to represent the Mosaic diagnostics.
The system status is shown as one byte in which the bit 0 indicates whether the Mosaic is
online/offline and bit 1 indicates the presence of diagnostic elements.
Each input and each output (OSSD) configured on the Mosaic system is associated with two
information elements: status and diagnostic.
Status is a binary value, 0 or 1; diagnostic is a code indicating the condition of the I/O, and
indicates a problem on the I/O.
Each module with inputs has a number of bits corresponding to the number of physical inputs
that are present; thus modules M1, MI8, MI8O2 are associated with 1 byte (8 bit) and module
MI16, MI12T8 with 2 bytes (16 bit) for the inputs status.
All safety outputs are summarized in 1 or 2 bytes.
The inputs location varies according to the type of modules that are installed, in the following
order: If several modules of the same type are installed
the order follows the node number.
The byte that represents the state of the inputs fieldbus input from the PLC is taken over from
PLC to allow feedback to the PLC program. The status of the probe is represented with 2 bytes.
The safety outputs are represented with 1 or 2 bytes.
Diagnostic elements are in the form of 2 bytes which indicate the number of the I/O with the
problem and the value of the diagnostic element. If there is more than one diagnostic element,
the relative values alternate every 500ms.
Each set of information:
-input status,
-input diagnostics,
-fieldbus input status,
-probe status,
-safety output status,
-safety output diagnostics
can be enabled/disabled in order to control the information and thus the number of bytes
exported to the fieldbus.
The definition of the footprint in the input and output is shown from the point of view of
the Mosaic. (Output PLC).
For the fieldbuses in which the mapping position is mandatory (i.e. PROFIBUS) the input
byte must be mapped before the output bytes.

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Footprint in input
Footprint in output

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If the Mosaic system includes a fieldbus module, the MSDesigner report will include a table
with the I/O index for all the inputs, fieldbus input, probe and safety outputs in the electric
circuit.

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Figure 2 –Footprint on bus configurator

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Whenever Mosaic System employs as Input a Selector (-> Functional Block: MOD-SEL), the
datum sent from: Master M1 -> Bus module -> FieldBus is the following:
SELECTOR
DATUM SENT
1
1
2
2
3
4
4
8
All status occupy 4 bits: 0 to 3 or 4 to 7 in the "State Inputs" Footprint in the Output.
The content of the bits is given below.
Channel 1
Channel 0
OVERSPEED/
WINDOW
7
6
5
4
3
2
1
0
1 -> under
0 -> over
DIRECTION
1 -> CCW
0 -> CW
STANDSTILL
1 -> Blocked
0 -> Moving
0 Permanent
OVERSPEED/WINDOW
1 -> under
0 -> over
DIRECTION
1 -> CCW
0 -> CW
STANDSTILL
1 -> Blocked
0 -> Moving
0 Permanent

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Each input and each safety output is associated with a relative diagnostic code.
When the I/O is connected correctly, the diagnostic code is OK and is not exported to the
fieldbus; if there is a problem on the I/O, the system exports 2 bytes to the fieldbus with:
The "I/O index" field
This field indicates the number used to identify the I/O with a diagnostic code other than OK.
Possible values for this field are shown in Table 2.
Input
1-128
Output
192-255
Table 2
Figure 3- Index of I/O
The "Diagnostic code" field
The "Diagnostic code" field indicates the diagnostics for the I/O. Possible values for this field are
shown in Tables 4, 5 and 6.
Input diagnostics OK
-
Not moved from zero
Both switches have to go to rest condition
Concurrent failed
Both switches have to change state simultaneously
Concurrent failed hand1
Wrong connection on one side of a two-hands switch
Concurrent failed hand2
Wrong connection on one side of a two-hands switch
Switch inconsistent
The selector should not have more than one input set
Switch disconnected
The selector should have at least one input set
OUT_TEST error
OUT_TEST diagnostics present on this input

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Second input KO
Redundancy check failed on input
OUT_TEST diagnostics OK
Output connected to other inputs
Test output not connected to the right input
Output OK but input connected to
24VDC
Stucked input
Short circuit between photocell
test and photocell input
Photocell response time too low
No response from photocell
The test signal on the photocell emitter is not seen on the receiver
Short circuit between photocells
The test signal is present on two different photcells
MAT disconnected
Wrong mat connection
Output inconsistent with feedback
The test signal on input is present on more than one OUT_TEST
Connection incorrect
The test signal is present on more than one input
Output stuck
The test signal on the input is not present on the OUT_TEST
Second OUT_TEST KO
Redundancy check failed on OUT_TEST
MV2 proximity missing
Proximity not present / Proxy not working
MV2 encoder missing
Encoder not present / Encoder unpowered
MV2 encoder Proximity missing
Device connected incorrectly
MV2 Proximity1, Proximity2
missing
Both proxy must be connected
MV2 encoder1 encoder2 missing
Both encoder must be connected
MV2 error congruence frequencies
redundancy check failed on the measure.
MV2 encoder supply missing.
Encoder not properly fed
MV2 Encoder error
Encoder signals with duty cycle and / or phase displacement not correct
TWO-HAND concurrent failed
Two-hands switch has to change state simultaneously
Not started
Start test failed
Waiting for restart
The input has manual reset and has not been restarted
Table 3

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OSSD diagnostics ok
Enable Missing
Waiting for restart OSSD
Feedback K1/K2 missing
Waiting for other micro
Redundancy check failed on OSSD
OSSD power supply missing
Exceeded maximum time restart
Feedback K1/K2 external not congruous CAT2
Applicable to MOR4 e MOR4S8 modules configured in CAT2
Waiting for feedback K1/K2
Feedback K1 K2 in Transition
Overload OSSD output
OSSD with Load set to 24V
Table 4
If there are diagnostics for more than one I/O, the and signals
are sent in turn every 500ms.
MEANING
LED
ON
RUN
IN FAIL
EXT FAIL
LED1
LED2
GREEN
GREEN
RED
RED
RED/GREEN
RED/GREEN
Startup - Initial test
ON
ON
ON
ON
ON
ON
Waiting for configuration from M1
ON
blinking
OFF
OFF
OFF
OFF
Received configuration from M1
ON
ON
OFF
OFF
see the modules tables
Table 1 –Initial/ dynamic view.

DB9 –male
(front view)
Pin
Signal
1
-
2
CAN_L
3
CAN_GND
4
-
5
CAN_SHIELD
6
-
7
CAN_H
8
-
9
-
Housing
CAN_SHIELD
LED OPR
STATUS
INDICATION
DESCRIPTION
GREEN
OPERATIONAL
OPERATIONAL status
GREEN blinking slow
PRE-OPERATIONAL
PRE-OPERATIONAL status
GREEN 1 flash
STOPPED
STOPPED status
GREEN blinking fast
Autobaud
Baud rate detection
RED
EXCEPTION
EXCEPTION status
LED ERR
STATUS
INDICATION
DESCRIPTION
OFF
-
Normal operation
RED 1 flash
Warning level
A bus error counter has reached the warning level
RED blinking fast
LSS
LSS service operative
RED 2 flashes
Event Control
Detected Node Guarding (NMT master or slave) or Heartbeat (Consumer)
RED
Lack of BUS
BUS not working

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(front view)
Pin
Signal
Description
1
V-
Negative BUS power supply
2
CAN_L
CAN low bus line
3
SHIELD
Cable shield
4
CAN_H
CAN high bus line
5
V+
Positive BUS power supply
LED NET
STATUS
INDICATION
DESCRIPTION
GREEN
On-line connected
1 or more connections established
GREEN blinking (1Hz)
On-line non connected
No connection established
RED
Critical connection error
MBD unable to communicate
RED blinking (1Hz)
Time-out of 1 or more connection
One or more I/O device in time-out
GREEN/RED alternate
TEST
MBD in Test
LED STS
STATUS
INDICATION
DESCRIPTION
GREEN
-
Normal operation
GREEN blinking (1Hz)
Pending
Configuration incomplete, MBD waiting for activation
RED
Fatal error
One or more unrecoverable errors detected
RED blinking (1Hz)
Error
One or more recoverable errors detected
GREEN/RED alternate
TEST
MBD in Test
DB9 –female
(front view)
Pin
Signal
Description
1
-
-
2
-
-
3
B-line
Positive RxD/TxD, RS485 level
4
RTS
Request to send
5
GND Bus
0VDC (isolated)
6
5V
+5VDC (isolated/short circuit protected)
7
-
-
8
A-line
Negative RxD/TxD, RS485 level
9
-
-
Housing
Cable shield
Internally connected to the Anybus protective earth via
cable shield filters according to the PROFIBUS standard.
LED MODE
STATUS
INDICATION
DESCRIPTION
GREEN
On-line
data exchange
GREEN blinking
On-line
CLEAR
RED blinking (1 flash)
Parameterization error
rif. IEC 61158-6
RED blinking (2 flashes)
PROFIBUS configuration error
configuration data MASTER or MBP wrong
LED STS
STATUS
INDICATION
DESCRIPTION
OFF
MBP not initialized
Status SETUP o NW_INIT
GREEN
Initialized
End of initialization NW_INIT
GREEN blinking
Initialized with diagnostic active
EXTENDED DIAGNOSTIC bit set
RED
Exception error
EXCEPTION status

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LED STS
STATUS
INDICATES
DESCRIPTION
OFF
INIT
INIT or no power
Green
OPERATIONAL
OPERATIONAL state
Green blinking
PRE-OPERATIONAL
PRE-OPERATIONAL state
Green blinking (1 flash)
SAFE-OPERATIONAL
SAFE-OPERATIONAL state
Red
(Fatal Event)
System locked
LED ERR
STATUS
INDICATES
DESCRIPTION
OFF
No error
No error or no power
RED blinking (1 flash)
Configuration not valid
Status change requested by master not possible
RED blinking (2 flashes)
Watchdog timeout
Synch manager watchdog timeout
Red
Controller fault
Anybus module in EXCEPTION state
LED NET
STATE
INDICATES/DESCRIPTION
OFF
No power or no IP address
GREEN
On-line, connected
GREEN blinking
On-line, not connected
RED
Duplicate IP address
RED blinking
Connection timeout
LED STS
STATE
INDICATES
DESCRIPTION
OFF
No power
-
GREEN
RUN state
-
GREEN blinking
Not configured
-
RED
Fatal error
One or more non-recoverable errors detected
RED blinking
Error
One or more recoverable errors detected

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LED NET
STATE
STATE
OFF
No power or no IP address
GREEN
On-line, connected
GREEN blinking
On-line, not connected
RED
Duplicate IP address
RED blinking
Connection timeout
LED STS
STATE
STATE
STATE
OFF
No power
-
GREEN
RUN state
-
GREEN blinking
Not configured
-
RED
Fatal error
One or more non-recoverable errors detected
RED blinking
Error
One or more recoverable errors detected
LED NET
STATE
INDICATES
DESCRIPTION
OFF
Offline
No power
Connection with IO controller not present
GREEN
Online (Run)
Established connection with IO controller
IO controller in RUN state
GREEN blinking
Online (Stop)
Established connection with IO Controller
IO Controller in STOP state
LED STS
STATE
INDICATES
DESCRIPTION
OFF
Not initialized
No power or Module in SETUP or NW_INIT state
GREEN
Normal operation
Module has shifted from the NW_INIT state
GREEN blinking (1 flash)
Diagnostic event (s)
Diagnostic event (s) present
GREEN blinking (2 flashes)
Blink
Used to identify the network node
RED
Exception
Module in EXCEPTION state
RED blinking (1 flash)
Configuration error
Identification error
RED blinking (2 flashes)
IP address error
IP address not configured
RED blinking (3 flash)
Station name error
Station name not configured
RED blinking (4 flashes)
Internal error
Module has encountered a major internal error

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LED NET
STATE
INDICATES
DESCRIPTION
OFF
Offline
No power
Connection with IO controller not present
GREEN
Online (Run)
Established connection with IO controller
IO controller in RUN state
GREEN blinking
Online (stop)
Established connection with IO Controller
IO Controller in STOP state
LED STS
STATE
INDICATES
DESCRIPTION
OFF
Not initialized
No power or Module in SETUP or NW_INIT state
GREEN
Normal operation
Module has shifted from the NW_INIT state
GREEN blinking (1 flash)
Diagnostic event (s)
Diagnostic event (s) present
GREEN blinking (2 flashes)
Blink
Used to identify the network node
RED
Exception
Module in EXCEPTION state
RED blinking (1 flash)
Configuration error
Identification error
RED blinking (2 flashes)
IP address error
IP address not configured
RED blinking (3 flash)
Station name error
Station name not configured
RED blinking (4 flashes)
Internal error
Module has encountered a major internal error
LED NET
STATE
INDICATES/DESCRIPTION
OFF
No power or no IP address
GREEN
Module is in Process Active or Idle state
GREEN blinking
Waiting for connections
RED
Duplicate IP address, or FATAL event
RED blinking
Process Active Timeout
LED STS
STATE
INDICATES
DESCRIPTION
OFF
No power
-
GREEN
RUN
Normal operation
RED
Fatal error
Major fault;
module in state EXCEPTION (or fatal event)
RED blinking
Error
Minor fault in diagnostic object
IP conflict

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DB9 –female
(front view)
Pin
Direction
Signal
Description
Housing
-
PE
Protective Earth
1
-
GND
Bus polarization 0VDC (isolated)
2
OUT
5V
Bus polarization +5VDC (isolated)
3
IN
PMC
Connect to pin 2 for RS-232 / Leave unconnected for RS-485
4
-
-
-
5
Bidirectional
B-line
RS-485 B-line
6
-
-
-
7
IN
Rx
RS-232 Data Receive
8
OUT
Tx
RS-232 Data Transmit
9
Bidirectional
A-line
RS-485 A-line
LED NET
STATE
INDICATES
DESCRIPTION
OFF
No power or no data exchange
-
YELLOW
Frame Reception or Transmission
Data exchange
RED
Fatal Error
One or more non-recoverable errors detected
LED STS
STATE
INDICATES
DESCRIPTION
OFF
Initializing or no power
-
GREEN
Module initialized
Module initialized –no error
RED
Fatal Error
One or more non-recoverable errors detected
RED blinking (1 flash)
Communication fault or
configuration error
Invalid setting in Network Configuration Object
Setting in Network Configuration Object has been changed
during operation
RED blinking (2 flashes)
Application diagnostic available
-
LED CONNECT
STATE
INDICATES
DESCRIPTION
Green
USB connected
Module connected to Pc via USB
OFF
USB not connected
Module not connected

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FAULT DIAGNOSIS
MEANING
LED
ON
RUN
IN FAIL
EXT FAIL
LED1
LED2
GREEN
GREEN
RED
RED
RED/GREEN
RED/GREEN
Internal fault microcontroller
ON
OFF
2 flashes*
OFF
see the modules tables
Internal board fault
ON
OFF
3 flashes*
OFF
Configurazione Error
ON
OFF
5 flashes*
OFF
BUS communication Error
ON
OFF
5 flashes*
OFF
BUS communication interruption
ON
OFF
ON
OFF
Detected an identical module
ON
OFF
5 flashes*
5 flashes
* The LED frequency of flashing is: ON for 300ms and OFF for 400ms, with an interval between two sequences of 1s.
Example 1
In the example shown in Figure 4, Input 1 (connected to module M1) is tested with the M1-T1
test signal. During wiring, the 24Vdc is connected to input 1 instead of the M1-T1 test signal.
-The I/O index and Diagnostic code fields assume the following values: 1 - 20 to
indicate the diagnostics on input 1 of module M1 (Connection error).
Figure 4
Example 2
In this example, the I/O index corresponds to the logical block and not to the physical terminal
on module M1.
In Figure 5 for example, the two-hand element connected to the Input 1 and Input 2 physical
terminals corresponds to I/O index No. 1 and the emergency stop connected to the Input 3 and
Input 4 terminals corresponds to I/O index No. 2.
Figure 5

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Example 3
The example in Figure 6 is similar to example 1, except in this case Input1 is connected to
module MI16 and is tested with the MI16-T1 test signal.
During wiring, the 24Vdc is connected to input 1 instead of the MI16-T1 test signal.
Input 1 has diagnostic code 10 (OUT_TEST error) and OUT_TEST MI16-T1 has diagnostic code 8
(Connection error).
-The I/O index and Diagnostic code fields assume the following values: 1 - 20 to indicate the
diagnostics on input 1 of module MI16.
Figure 6
In the example shown in Figure 7 the manual reset function is enabled on OSSD 1.
The pushbutton connected to input 1 is pressed without sending a reset command.
-The I/O index and Diagnostics code fields assume the following values: 192 - 2
-to indicate the diagnostics on OSSD 1A/1B (Table 2: 192 = first output).
-to indicate the diagnostic code (Table 4: 2 = Waiting for OSSD to restart).
Figure 7
The bus module is configured using the USB miniB interface on the front panel and “BUS CONFIGURATOR”
SW installed on the MSDESIGNER CD ROM disk.
This SW can be used for configuration/communication of the MOSAIC system with a PC (using an MBU
module) or to display data transmitted via bus (via connection to the USB port of a bus module).
The diagram below is helpful for understanding possible connections:

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It is important to note that the BUS CONFIGURATOR behaves differently, depending on whether
communication is with an MBx module or an MBU module:
MBx MODULE: THE SOFTWARE ONLY ALLOWS DATA TRANSMITTED VIA BUS TO BE DISPLAYED.
MBU MODULE: THE SOFTWARE ALLOWS TWO-WAY DATA TRANSMISSION MBUPC
(in this case the programmer can set the Fieldbus input directly via computer).
The data sets to be transmitted, any modular I/Os, the Fieldbus input, the address of the module in the
fieldbus network and, where applicable, the baud rate are all settable parameters.
The address field range depends on the type of fieldbus that is installed.
Graphic interface

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Module configuration must be
performed with the system
switched off (outputs OFF).
You can query module configuration at any
time while the module is in use. To
configure the MBx module, proceed as
follows:
1. connect the module to the
24VDC+20% power supply via the
terminal block;
2. connect the USB cable to the PC and
to the MBx (or MBU) module;
3. click on the "
desktop icon.
The configuration window shown at the
side is displayed (Figure 8).
Figure 8
4. Press the “CONNECT” key.
The program recognises that a bus module
is connected (Figure 9); the fieldbus model,
firmware version and Master M1 status are
displayed:
green=M1 active (RUN);
red=M1 not active
(e.g. communication with Designer).
Figure 9

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Once the module is connected it is recognised and you can configure the parameters by
selecting the different cards shown in figures 9 to 11 ( figure 7); press the
key to send the configuration data to the module.
Figure 10 - I/O selection
Figure 11 - Address
Figure 12 - Baud rate
127
AUTO
input status,
fieldbus input status,
probe status,
output status
63
AUTO
input status,
fieldbus input status,
probe status,
output status
126
N/A
input status,
fieldbus input status,
probe status,
output status
0
N/A
input status,
fieldbus input status,
probe status,
output status
0.0.0.0
AUTO
input status,
fieldbus input status,
probe status,
output status
0.0.0.0
N/A
input status,
fieldbus input status,
probe status,
output status
Table 5 - Default values
After setting the parameters, click on the “MONITOR" key.