2Modular Safety Integrated Controller MOSAIC is a safety hub able to manage all the safety function of a machinery or a plant
3Modular Safety Integrated Controller MOSAIC can manage safety sensors and signals such aslight curtainsphotocellslaser scannersemergency stopselectromechanical switchesmagnetic switchessafety mats and edgestwo-hands controlshand grip switchesencoders e proximities forsafety speed control
5Modular Safety Integrated Controller SYSTEM CONFIGURATIONMain unit:M1 Configurable from PC via USB interface using MSD softwareExpansion units:MI8O2 and MI12T8 I/O expansion unitsMI8 and MI16 Input expansion unitsMO2 and MO4 Output expansion unitsMR2 and MR4 Safety (guided contacts) relay modulesMV Safety speed control unit (under development)MBP (Profibus DP), MBC (CANopen), MBD (DeviceNET), MBE (Ethernet),MBU (USB) expansion units for connection to the most commonindustrial Fieldbus systems for diagnostics and data communication
6Modular 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 electricalCabinet.(except MR2 and MR4 safety relays units)
7Modular Safety Integrated Controller MODULES DIMENSIONSEach single modules measures:22,5 x 99 x mmRemovable terminal blocks, screw contacts
8Modular Safety Integrated Controller MIN AND MAX EXTENSION OF THE SYSTEMMinimum number of modules:M1 used as stand-alone= 1 module = 8 inputs and 2 OSSD pairs+ 2 status outputsMax numbers of modules:M expansions= 15 modules = 128 inputs and 16 OSSD pairsstatus outputs(without MR2 e MR4 relay expansions)
9Modular Safety Integrated Controller MOSAIC M1Stand alone and main unitProgrammable via USB 2.0 line8 digital inputs2 OSSD (2 pairs), 400mA output current4 test outputs (for sensors to be monitored)2 digital signaling outputs2 inputs for Restart / EDMMCM configuration memory
10Modular Safety Integrated Controller MOSAIC MI8O2Expansion unit8 digital inputs2 OSSD (2 pairs), 400mA output current4 test outputs (for sensors to be monitored)2 digital signaling outputs2 inputs for Restart / EDM=> Same as M1, but with no programming
11Modular Safety Integrated Controller MOSAIC MI8 and MI16Expansion units- MI8 - 8 digital inputs- MI digital inputs4 test outputs (for sensor to be monitored)
12Modular Safety Integrated Controller NEWMOSAIC MI12T8Expansion unit for safety mats and edges12 digital inputs8 test outputs (for sensors to be monitored)It can manage up to 4 independent safety mats
13Modular Safety Integrated Controller NEWMOSAIC MV1 (under development)Expansion module for safety speed controlInput for incremental encoders and PNP/NPN proximities- MV1T TTL encoder + up to 2 proximities- MV1H 1 HTL encoder + up to 2 proximities- MV1S 1 sin/cos encoder + up to 2 proximitiesSafety speed control (up to PLe) for:zero speed control - max speed - speed range - directionUp to 4 logically selectable speed tresholds (freely configurables)for each logical output (axis)Up to 2 indipendent logical outputs (axis) on MSD1 RJ-45 connector for encoder and terminal blocks for proximitiesMax input frequency: 300 KHz
14Modular Safety Integrated Controller NEWMOSAIC MV2 (under development)Expansion module for safety speed controlInput for incremental encoders and PNP/NPN proximities- MV2T up to 2 TTL encoders + up to 2 proximities- MV2H up to 2 HTL encoders + up to 2 proximities- MV2S up to 2 sin/cos encoders + up to 2 proximitiesSafety speed control (up to PLe) for:zero speed control - max speed - speed range - directionUp to 4 logically selectable speed tresholds (freely configurables)for each logical output (axis)Up to 2 indipendent logical outputs (axis) on MSD1 RJ-45 connector for encoder and terminal blocks for proximitiesMax input frequency: 300 KHz
15Modular Safety Integrated Controller MOSAIC MV2 NEWMOSAIC MV2Expansion module for safety speed controlOne channel output, two sensors speed control example- 1 incremental encoder- 1 proximity sensing pulses from the cogwheelSafety Level: up to PLe
17Modular Safety Integrated Controller NEWMOSAIC MO-R4 (under development)Expansion units with safety relay output - connectable to M1 trough MSC Bus- 4 safety relays with guided contacts 6A 250 Vac4 single NO contacts or 2 NO dual channelselectable via MSD2 digital signaling outputs
18Modular Safety Integrated Controller MOSAIC MR2 and MR4Safety Relay Output unitsMR2 - 2 relays – 2 NO + 1 NCMR4 - 4 relays – 4 NO + 2 NC2/4 safety relays with guided contacts1/2 NC contacts for EDMEvery NO contact is broken twice by the integrated safety relays.
19Modular Safety Integrated Controller MOSAIC MBField-bus expansionExpansion units for connection to the most common industrial Field-bus systems for diagnostic data communication.MBP – Profibus DPMBD – DeviceNETMBC – CANopenMBE – EthernetIP, EtherCAT, PROFINETMBU – USBNEW
20Modular Safety Integrated Controller MOSAIC MBField-bus expansionmicro USB programming interfaceGraphic configuration softwarePossible data to be transmitted:- input funtional blocks status- input funtional blocks diagnostic- ouput funtional blocks status- ouput funtional blocks diagnostic- test ouput diagnosticSelectable Baud rate :kbps or autobaud for MBC CANopenkbps or autobaud for MBD DeviceNET
21Modular Safety Integrated Controller MOSAIC MCTMSC-Bus expansionNEWInterface 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 lineextension
22Modular Safety Integrated Controller MOSAIC MCTMSC-Bus expansionNEWUp to 100 mtper connectionMCT (MSC-Bus expansion)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: MC m, MC50 – 50 m, MC100 – 100 m.
23Modular Safety Integrated Controller MOSAIC MCTMSC-Bus expansionNEWMCT1MCT1 – 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 cableMCT2
24Modular Safety Integrated Controller Mosaic MCM is a proprietary removable memory card that can be used to save Mosaic configuration data and transfer it to a new device without using a PC.The configuration in the MCM overwrites the configuration present on M1.This function can be disabled on M1 via the MSD (Mosaic Safety Designer) configuration software. Overwrite operations are recorded in chronological order in the MOSAIC M1 LOG file.MCM is an accessory and can be ordered separatelyMOSAIC M1 rear view
25Modular Safety Integrated Controller Configuration software MSD is the MOSAIC configuration softwareIt is an user-friendly configuration tool thanks the graphic interfaceIt is included within each M1 package - for free.
26MSD – 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.
27PASSWORDThere are 2 levels of Password, alphanumerical max 8 characters.Level 1 PasswordThis 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.Level 2 PasswordThis is the designer password. It allows to load, modify, save andupload (from PC to Mosaic)a project configuration.NEW
28Modular 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.
29MSD Project Report ReeR S.p.A. Project Report generated by Mosaic Safety Designer version 1.1.9Project Name: Project User: Name Company: Company Date: 16/11/ Schematic CRC: 9CEFHMosaic: Configuration Module M1 (Configured Firmware version: >= 0.4) Module MO2 Node 0Mosaic: Project Safety Information'sPFHd (according to IEC 61508): 9,22E-009 (1/h) MTTFd (according to EN ISO ): 100 years DCavg (according to EN ISO ): %Resources usedINPUT: 38% (3/8)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 diagramSensor (E-GATE 01) Functional Block 1 Filter (ms): 3 Reset Type: Automatic StartUp Test: False In1 -> Test1 DC = 90% (according to EN ISO ) Connections: M1 INPUT1/Terminal17
30MONITOR I/OThe 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 VISUALIZATIONGRAPHIC VISUALIZATION
33MSD – 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.
34MSD – 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.
35MSD – 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.
36MSD – Configuration Software FUNCTION BLOCKS – INPUT OBJECTS ENABLE GRIP SWITCHVerifies 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 0SENSORVerifies 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.SWITCHVerifies 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.
37MSD – 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.
38MSD - Software di Configurazione FUNCTION BLOCKS FIELDBUS INPUT / OUTPUTNEWFIELDBUS INPUTIt 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 OUTPUTIt 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.
39MSD – Configuration Software FUNCTION BLOCKS - MUTING OPERATORS MUTING “L” with 2 Muting sensors – only for one-way openingsThe 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 openingsThe 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 openingsThe 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 openingsThe MUTING operator with "Concurrent" logic performs muting of the input signal through sensor inputs S1, S2, S3 and S4.
40MSD - Software di Configurazione FUNCTION BLOCKS - MUTING OPERATORS NEWMUTING OVERRIDEOVERRIDE 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
41MSD – Configuration Software FUNCTION BLOCKS - MEMORY OPERATORS Are used if you decide to save any data (TRUE or FALSE) from other project components.D FLIP FLOPThe D FLIP FLOP operator saves the previously set status on output Q on the clock rising edge.SR FLIP FLOPSR FLIP FLOP operator brings output Q at 1 with Set, 0 with Reset.MANUAL USER RESTARTmakes it possible to memorize the Restart signal on a rising edge of the Res input.MONITORED USER RESTARTmakes it possible to memorize the Restart signal on a rising edge followed by a falling edge of the Res input.
42MSD – Configuration Software FUNCTION BLOCKS – COUNTER OPERATOR 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) MANUAL3) AUTOMATIC + MANUAL.
43MSD – Configuration Software FUNCTION BLOCKS – TIMER OPERATOR TIMER operators allow you to generate a signal (TRUE or FALSE) for a user-definable period.CLOCKINGGenerates a clock signal output with the desired period if the input In is 1.MONOSTABLEGenerates a level 1 output activated by the rising edge of the input and remains in this condition for the set time.PASSING MAKE CONTACTIn 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.DELAYApplies 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.
44MSD – Configuration Software FUNCTION BLOCKS – LOGICAL OPERATORS ANDReturns 1 as output if all the inputs are 1NANDReturns 0 as output if all the inputs are 1.NOTInverts the logical status of the input.ORReturns 1 as output if at least one of the inputs is 1.NORReturns 0 as output if at least one of the inputs is 1.
45MSD – Configuration Software FUNCTION BLOCKS – LOGICAL OPERATORS XORReturns 0 as output if all the inputs are in the same logical status.XNORReturns 1 as output if all the inputs are in the same logical status.MULTIPLEXERForwards the signal of the inputs to the output according to the Sel selection.
46Modular Safety Integrated Controller TECHNICAL FEATURES
49Electrical Connections EXAMPLE OF CONNECTION OF MOSAIC TO THE MACHINE CONTROL SYSTEM
50Electrical Connections Schematic diagram MR2 and MR4 modules
51Electrical Connections TEST OUTPUTTEST 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 to2 sensors with M1, MI8O2, MI12T8 and MI84 Sensors with MI16Using 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.
53Electrical Connections SAFETY-MATS AND SAFETY EDGES CONNECTION With S-mats and S-edges any out test can be connected to a single sensor
54Electrical Connections Light curtains – Laser scanner Connection of: ESPELight curtains – Laser scannerwith OSSDUsing ESPE with OSSD the use of OUT TEST is not possible.
55Advantages 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.
56Advantages 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
57Advantages 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.