Modular Safety Integrated Controller
MOSAIC is a safety hub able to
manage all the safety function of a
machinery or a plant
Modular Safety Integrated Controller
MOSAIC can manage safety
sensors and signals such as
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light curtains
photocells
laser scanners
emergency stops
electromechanical switches
magnetic switches
safety mats and edges
two-hands controls
hand grip switches
encoders e proximities for
safety speed control
Modular Safety Integrated Controller
Safety level
• SIL 3
- IEC 61508
• SIL CL 3
- EN 62061
• PL e
- ISO/EN 13849-1
• Category 4
- ISO/EN 13849-1
Modular Safety Integrated Controller
SYSTEM CONFIGURATION
Main unit:
• M1 Configurable from PC via USB interface
using MSD software
Expansion units:
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MI8O2 and MI12T8 I/O expansion units
MI8 and MI16 Input expansion units
MO2 and MO4 Output expansion units
MR2 and MR4 Safety (guided contacts) relay modules
MV Safety speed control unit (under development)
MBP (Profibus DP), MBC (CANopen), MBD (DeviceNET), MBE (Ethernet),
MBU (USB) expansion units for connection to the most common
industrial Fieldbus systems for diagnostics and data communication
Modular Safety Integrated Controller
Mosaic MSC permits communication
between the various units through a
proprietary 5-way high-speed bus.
The MSC modular connectors can be
used to connect the expansion units to
M1 Master module.
The connectors are physically located on
the back of each unit and are housed in
the rail guide of the electrical
Cabinet.
(except MR2 and MR4 safety relays units)
Modular Safety Integrated Controller
MODULES DIMENSIONS
• Each single modules measures:
22,5 x 99 x 114.5 mm
Removable terminal blocks, screw contacts
Modular Safety Integrated Controller
MIN AND MAX EXTENSION OF THE SYSTEM
Minimum number of modules:
• M1 used as stand-alone
= 1 module = 8 inputs and 2 OSSD pairs
+ 2 status outputs
Max numbers of modules:
• M1 + 14 expansions
= 15 modules = 128 inputs and 16 OSSD pairs
+ 16 status outputs
(without MR2 e MR4 relay expansions)
Modular Safety Integrated Controller
MOSAIC M1
• Stand alone and main unit
• Programmable via USB 2.0 line
• 8 digital inputs
• 2 OSSD (2 pairs), 400mA output current
• 4 test outputs (for sensors to be monitored)
• 2 digital signaling outputs
• 2 inputs for Restart / EDM
• MCM configuration memory
Modular Safety Integrated Controller
MOSAIC MI8O2
• Expansion unit
• 8 digital inputs
• 2 OSSD (2 pairs), 400mA output current
• 4 test outputs (for sensors to be monitored)
• 2 digital signaling outputs
• 2 inputs for Restart / EDM
=> Same as M1, but with no programming
Modular Safety Integrated Controller
MOSAIC MI8 and MI16
• Expansion units
- MI8 - 8 digital inputs
- MI16 - 16 digital inputs
• 4 test outputs (for sensor to be monitored)
Modular Safety Integrated Controller
MOSAIC MI12T8
• Expansion unit for safety mats and edges
• 12 digital inputs
• 8 test outputs (for sensors to be monitored)
It can manage up to 4 independent safety mats
Modular Safety Integrated Controller
MOSAIC MV1
(under development)
• Expansion module for safety speed control
• Input for incremental encoders and PNP/NPN proximities
- MV1T
- MV1H
- MV1S
1 TTL encoder + up to 2 proximities
1 HTL encoder + up to 2 proximities
1 sin/cos encoder + up to 2 proximities
• Safety speed control (up to PLe) for:
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zero speed control
max speed
speed range
direction
• Up to 4 logically selectable speed tresholds (freely configurables)
for each logical output (axis)
• Up to 2 indipendent logical outputs (axis) on MSD
• 1 RJ-45 connector for encoder and terminal blocks for proximities
• Max input frequency: 300 KHz
Modular Safety Integrated Controller
MOSAIC MV2
(under development)
• Expansion module for safety speed control
• Input for incremental encoders and PNP/NPN proximities
- MV2T
- MV2H
- MV2S
up to 2 TTL encoders + up to 2 proximities
up to 2 HTL encoders + up to 2 proximities
up to 2 sin/cos encoders + up to 2 proximities
• Safety speed control (up to PLe) for:
-
zero speed control
max speed
speed range
direction
• Up to 4 logically selectable speed tresholds (freely configurables)
for each logical output (axis)
• Up to 2 indipendent logical outputs (axis) on MSD
• 1 RJ-45 connector for encoder and terminal blocks for proximities
• Max input frequency: 300 KHz
Modular Safety Integrated Controller
MOSAIC MV2
Expansion module for safety speed control
One channel output, two sensors speed control example
- 1 incremental encoder
- 1 proximity sensing pulses
from the cogwheel
- Safety Level: up to PLe
Modular Safety Integrated Controller
MOSAIC MO2 and MO4
• Expansion units
- MO2 - 2 OSSD safety outputs (pairs)
- MO4 - 4 OSSD safety outputs (pairs)
• 400mA output current
• 2/4 digital signaling outputs
• 2/4 inputs for Restart / EDM
Modular Safety Integrated Controller
MOSAIC MO-R4
(under development)
• Expansion units with safety relay output - connectable
to M1 trough MSC Bus
- 4 safety relays with guided contacts 6A 250 Vac
- 4 single NO contacts or 2 NO dual channel
selectable via MSD
- 2 digital signaling outputs
Modular Safety Integrated Controller
MOSAIC MR2 and MR4
• Safety Relay Output units
MR2 - 2 relays – 2 NO + 1 NC
MR4 - 4 relays – 4 NO + 2 NC
• 2/4 safety relays with guided contacts
• 1/2 NC contacts for EDM
Every NO contact is broken twice by the
integrated safety relays.
Modular Safety Integrated Controller
MOSAIC MB
Field-bus expansion
Expansion units for connection to the most common
industrial Field-bus systems for diagnostic data
communication.
• MBP – Profibus DP
• MBD – DeviceNET
• MBC – CANopen
• MBE – EthernetIP, EtherCAT, PROFINET
• MBU – USB
Modular Safety Integrated Controller
MOSAIC MB
Field-bus expansion
• micro USB programming interface
• Graphic configuration software
• Possible data to be transmitted:
- input funtional blocks status
- input funtional blocks diagnostic
- ouput funtional blocks status
- ouput funtional blocks diagnostic
- test ouput diagnostic
• Selectable Baud rate :
- 10-1000 kbps or autobaud for MBC CANopen
- 125-500 kbps or autobaud for MBD DeviceNET
Modular Safety Integrated Controller
MOSAIC MCT
MSC-Bus expansion
Interface module allowing the connection of remote expansions via MSC bus
- Standard Master M1 and expansions as well
normal project design can be used.
- Up to 100 m per each connection
- Up to 5 extensions
- Total distance up to 500 m
(RS485 serial interface shielded cables,
4 wires + shield)
Ideal solution for the interconnection of the
safety functions of more machineries on a
single production line
extension
Modular Safety Integrated Controller
MOSAIC MCT
MSC-Bus expansion
Up to 100 mt
per connection
MCT (MSC-Bus expansion)
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Via MSC connector it is possible to wire MCT to M1 or to any expansion module
MCTs are interconnected using the RS485 type shielded cable.
Three lenghts are available: MC25 - 25 m, MC50 – 50 m, MC100 – 100 m.
Modular Safety Integrated Controller
MOSAIC MCT
MSC-Bus expansion
MCT1
• MCT1 – 1 connection interface
(1 input or 1 output)*
• MCT2 – 2 connections interface
(1 input and 1 output)
* End of the network or Start of the network
if connected to a single MCT cable
MCT2
Modular Safety Integrated Controller
Modular Safety Integrated Controller
Configuration software
• MSD is the MOSAIC
configuration software
• It is an user-friendly
configuration tool thanks the
graphic interface
• It is included within each M1
package - for free.
MSD – Configuration software
Mosaic master M1 has a 2.0 USB connection to connect to a
Personal Computer where the MSD (Mosaic Safety Designer)
configuration software is installed.
PASSWORD
There are 2 levels of Password, alphanumerical max 8 characters.
Level 1 Password
• This is a maintenance password.
It allows only to view the LOG file, the composition of the system and
use the real time MONITOR .
• Is now possible to download the project from Mosaic to PC. NEW
Level 2 Password
• This is the designer password.
It allows to load, modify, save and
upload (from PC to Mosaic)
a project configuration.
Modular Safety Integrated Controller
Log File
(Level 1 Password). A Log File with creation
date and CRC checksum (4-digit hexadecimal
identification) of the project stored in M1.
This Log File can record up to 5 consecutive
events. These max 5 events are overwritten
with a FILO logic.
The Log File can be visualized using the icon
in the tool bar.
MSD Project Report
ReeR S.p.A.
Resources used
Project Report generated by Mosaic Safety Designer
version 1.1.9
INPUT: 38% (3/8)
Project Name: Project User:
Name Company: Company
Date: 16/11/2011 18.22.09
Schematic CRC: 9CEFH
Mosaic: Configuration
Module M1 (Configured Firmware version: >= 0.4)
Module MO2 Node 0
Mosaic: Project Safety Information's
PFHd (according to IEC 61508): 9,22E-009 (1/h)
MTTFd (according to EN ISO 13849-1): 100 years
DCavg (according to EN ISO 13849-1): 97.61 %
Timing: 0% (0/8) Counters: 0% (0/8)
DFF: 0% (0/8)
Restart: 0% (0/8)
MUTING: 0% (0/4)
Total number blocks: 22% (7/32)
OSSD: 75% (3/4)
STATUS: 75% (3/4)
Electrical diagram
Sensor (E-GATE 01)
Functional Block 1
Filter (ms): 3
Reset Type: Automatic
StartUp Test: False In1 -> Test1
DC = 90% (according to EN ISO 13849-1)
Connections: M1 INPUT1/Terminal17
MONITOR I/O
The I/O MONITOR allows the real-time monitoring of all the I/O of a Mosaic system and
the diagnostic information about a working system.
TEXT VISUALIZATION
GRAPHIC
VISUALIZATION
TEXT VISUALIZATION
MONITOR I/O
GRAPHIC VISUALIZATION
MONITOR I/O
MSD – Configuration Software
FUNCTION BLOCKS –INPUT OBJECTS
E STOP (emergency stop)
Verifies an emergency stop device inputs status. If the emergency stop
button has been pressed (contacts open) the output is 0.
If not the output is 1.
E-GATE (safety gate device)
Verifies a mobile guard or safety gate device input status.
If the mobile guard or safety gate is open, the output is 0. Otherwise the
output is 1.
ENABLE (enable key)
Verifies a manual key device Input status.
If the key is not turned the output is 0. Otherwise the output is 1.
MSD – Configuration Software
FUNCTION BLOCKS - INPUT OBJECTS
ESPE (optoelectronic safety light curtain / laser scanner)
Verifies an optoelectronic safety light curtain (or laser scanner) inputs state. If
the area protected by the light curtain is occupied, (light curtain outputs at
LOW level) the output is 0. Otherwise, with the area clear and outputs to 1 the
output of this function block is 1.
FOOTSWITCH (safety pedal)
Verifies the status of the inputs of a safety pedal device. If the pedal is not
pressed the output is 0.
Otherwise the output is 1.
PHOTOCELL (safety photocell)
Verifies the status of the inputs of an optoelectronic safety photocell. If the
beam of the photocell is occupied (photocell output FALSE) the output is 0.
Otherwise with the beam clear and an output of 1 the output is 1.
Test outputs must be used.
MSD – Configuration Software
FUNCTION BLOCKS – INPUT OBJECTS
MOD-SEL (safety selector)
Verifies the status of the inputs from a mode selector (up to 4 inputs): if only
one input is 1 the corresponding output is also 1. In all other cases, and thus
when all inputs are 0 or more than one input is 1 all the outputs are 0.
TWO-HAND (bi manual control)
Verifies the status of the inputs of a two hand control switch. Only if both the
press-buttons are pressed within 500 msec the output is 1. Otherwise the
output is 0.
S-MAT (safety mat or safety edge)
verifies the status of the inputs of a safety mat. If a person stands on the mat
the output is 0. Otherwise, with the mat clear, the output is 1.
Test outputs must be used.
Can’t be used with 2-wire mats and termination resistance mats.
MSD – Configuration Software
FUNCTION BLOCKS – INPUT OBJECTS
ENABLE GRIP SWITCH
Verifies the status of the inputs of a enable grip switch. If the enable grip
switch is completely pressed or completely released the output is 1.
Otherwise the output is 0
SENSOR
Verifies the status of the input of a sensor (not a safety sensor). If the beam of
the sensor is occupied (sensor output FALSE) the output is 0. Otherwise, with
the beam clear and an output of 1 then the output is 1.
SWITCH
Verifies the input status of a pushbutton or switch (NOT SAFETY SWITCHES).
If the pushbutton is pressed the output is 1. Otherwise, the output is 0.
MSD – Configuration Software
FUNCTION BLOCKS - OUTPUT OBJECTS
OSSD (safety outputs)
The OSSD semiconductor PNP safety static output pair.
The 2 output cannot operate independently.
Each OSSD pair can work in both AUTO/Manual restart mode and
can perform the EDM of external relays using the dedicated
RESTART_FBK input.
Each OSSD pair can be set for giving the actual output status
information.
STATUS (signal output)
It is possible to monitor any point on the diagram by connecting it
to the input of this block. The output returns 24Vdc if the input is
1, or 0Vdc if the input is 0.
(STATUS is not a safety output)
It is possible to connect the Status to the OSSD status signal to
have a signal output of the REAL OSSD output status, including the
restart signal effect.
MSD - Software di Configurazione
FUNCTION BLOCKS
FIELDBUS INPUT / OUTPUT
FIELDBUS INPUT
It allows to receive signals (up to 8 bits) from the machine control
unit via the field-bus module.
The signal is connected directly into the diagrams without using
any input block.
FIELDBUS PROBE OUTPUT
It allows to send signals (up to 16 bits) to the machine control
unit via the field-bus module.
The signal is connected directly into the diagrams without using
any output block.
MSD – Configuration Software
FUNCTION BLOCKS - MUTING OPERATORS
MUTING “L” with 2 Muting sensors – only for one-way openings
The MUTING operator with “L” logic performs muting of the input signal through
sensor inputs S1 and S2.
Muting closes when the input signal rises.
MUTING “T” with 2 Muting sensors for two-way openings
The MUTING operator with “T” logic performs muting of the input signal
through sensor inputs S1 and S2.
MUTING ”T” “Sequential” with 4 Muting sensors for two-way openings
The MUTING operator with "Sequential" logic performs muting of the input
signal through sensor inputs S1, S2, S3 and S4.
MUTING “T” “Concurrent” with 4 Muting sensors for two-way openings
The MUTING operator with "Concurrent" logic performs muting of the input
signal through sensor inputs S1, S2, S3 and S4.
MSD - Software di Configurazione
FUNCTION BLOCKS - MUTING OPERATORS
MUTING OVERRIDE
OVERRIDE function is necessary when the machine stops with the material still
in the guaerde gate, due to some wrong muting sequence.
OVERRIDE command forces the output high allowing to remove the material
obstructing the gate.
Two different way of operation are available:
1. Manual action with hold to run
2. Automatic with pulse command
MSD – Configuration Software
FUNCTION BLOCKS - MEMORY OPERATORS
Are used if you decide to save any data (TRUE or FALSE) from other project components.
D FLIP FLOP
The D FLIP FLOP operator saves the previously set status on output Q on the
clock rising edge.
SR FLIP FLOP
SR FLIP FLOP operator brings output Q at 1 with Set, 0 with Reset.
MANUAL USER RESTART
makes it possible to memorize the Restart signal on a rising edge of the Res
input.
MONITORED USER RESTART
makes it possible to memorize the Restart signal on a rising edge followed by
a falling edge of the Res input.
MSD – Configuration Software
FUNCTION BLOCKS – COUNTER OPERATOR
COUNTER
The operator COUNTER is a pulse counter.
The counter generates a pulse as soon as the set count is reached.
There are 3 operation modes:
1) AUTOMATIC (default)
2) MANUAL
3) AUTOMATIC + MANUAL.
MSD – Configuration Software
FUNCTION BLOCKS – TIMER OPERATOR
TIMER operators allow you to generate a signal (TRUE or FALSE) for a user-definable period.
CLOCKING
Generates a clock signal output with the desired period if
the input In is 1.
MONOSTABLE
Generates a level 1 output activated by the rising edge of the input and
remains in this condition for the set time.
PASSING MAKE CONTACT
In the PASSING MAKE CONTACT operator the output follows the signal on the
input. However, if this is 1 for longer than the set time,
the output changes to 0.
DELAY
Applies a delay to a signal by setting the output to 1 after the set time,
against a change in the level of the input signal.
MSD – Configuration Software
FUNCTION BLOCKS – LOGICAL OPERATORS
AND
Returns 1 as output if all the inputs are 1
NAND
Returns 0 as output if all the inputs are 1.
NOT
Inverts the logical status of the input.
OR
Returns 1 as output if at least one of the inputs is 1.
NOR
Returns 0 as output if at least one of the inputs is 1.
MSD – Configuration Software
FUNCTION BLOCKS – LOGICAL OPERATORS
XOR
Returns 0 as output if all the inputs are in the same logical status.
XNOR
Returns 1 as output if all the inputs are in the same logical status.
MULTIPLEXER
Forwards the signal of the inputs to the output according to the Sel selection.
Modular Safety Integrated Controller
TECHNICAL FEATURES
Modular Safety Integrated Controller
Electrical Connections
Electrical Connections
EXAMPLE OF CONNECTION OF MOSAIC TO THE MACHINE CONTROL SYSTEM
Electrical Connections
Schematic diagram MR2 and MR4 modules
Electrical Connections
TEST OUTPUT
TEST OUTPUT signals are used to monitor
overloads and short circuits on input lines.
Mosaic generates on each test output a pulsing
signal checked by both the test output and the
input to which is connected.
With electromechanical sensors (potential-free
contacts) each test output can be connected to
- 2 sensors with M1, MI8O2, MI12T8 and MI8
- 4 Sensors with MI16
Using the test output the DC diagnostic coverage
over the dangerous faults increases, and this
make improve the Performance Level of the
system.
Test outputs use is MANDATORY
for safety mats, edges,
photocells.
Electrical Connections
ELECTROMECHANICAL SENSORS CONNECTIONS
Emergency stops - mechanical switches …
Electrical Connections
SAFETY-MATS AND SAFETY EDGES CONNECTION
With S-mats and S-edges any out test can be connected to a single sensor
Electrical Connections
Connection of: ESPE
Light curtains – Laser scanner
with OSSD
Using ESPE with OSSD the use of OUT TEST is not possible.
Advantages of Mosaic solution
Compared to the safety circuitries made by “traditional”
electromechanical safety relays, Mosaic has many
remarkable advantages such as:
• Reduces the number of devices and wires and,
therefore, the overall size;
• Speeds up the control panel construction;
• Provides the logic configuration through a quick and
simple SW programming. Machine designers are
always able to easily change the logic of the
configuration;
• Makes it easy to add or remove safety function
blocks at any stage of the machine designing.
Advantages of Mosaic solution
• Is able to check the logic configuration of the application
during the designing phase through the VALIDATION
function as well as to test it during the installation through
the MONITOR function.
• Allows tamper-proof system configurations as:
– detection of any attempts of by-passing the safety
devices, always possible with traditional safety relays,
through specific tests (i.e. mandatory test of the safety
device at the machine start-up)
– Protection against unauthorized changes to the
project through a 2-level password
Advantages of Mosaic solution
• Simplifies the machine maintenance thanks to the MCM
memory card which permits to transfer with few simple
operations the configuration to a new Mosaic;
• The logic is made through a graphic interface. No more
laborious wirings are needed as they are with
traditional solution when it is necessary to wiring the
outputs of the safety relays;
• A lower number of electromechanical components also
means a better Performance Level and, therefore, a higher
Safety Level.