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Modular Safety Integrated Controller MOSAIC is a safety hub able to manage all the safety function of a machinery or a plant.

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Presentation on theme: "Modular Safety Integrated Controller MOSAIC is a safety hub able to manage all the safety function of a machinery or a plant."— Presentation transcript:

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2 Modular Safety Integrated Controller MOSAIC is a safety hub able to manage all the safety function of a machinery or a plant

3 Modular Safety Integrated Controller MOSAIC can manage safety sensors and signals such as 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

4 Modular Safety Integrated Controller Safety level SIL 3 - IEC SIL CL 3- EN PL e- ISO/EN Category 4 - ISO/EN

5 SYSTEM CONFIGURATION Main unit: M1 Configurable from PC via USB interface using MSD software Expansion units: 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

6 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)

7 MODULES DIMENSIONS Each single modules measures: 22,5 x 99 x mm Modular Safety Integrated Controller Removable terminal blocks, screw contacts

8 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: M expansions = 15 modules = 128 inputs and 16 OSSD pairs + 16 status outputs (without MR2 e MR4 relay expansions)

9 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

10 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

11 Modular Safety Integrated Controller MOSAIC MI8 and MI16 Expansion units - MI8 - 8 digital inputs - MI digital inputs 4 test outputs (for sensor to be monitored)

12 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 NEW

13 MOSAIC MV1 (under development) Expansion module for safety speed control Input for incremental encoders and PNP/NPN proximities - MV1T 1 TTL encoder + up to 2 proximities - MV1H 1 HTL encoder + up to 2 proximities - MV1S 1 sin/cos encoder + 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 NEW

14 MOSAIC MV2 (under development) Expansion module for safety speed control Input 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 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 NEW

15 MOSAIC MV2 Expansion module for safety speed control Modular Safety Integrated Controller NEW One channel output, two sensors speed control example - 1 incremental encoder - 1 proximity sensing pulses from the cogwheel - Safety Level: up to PLe

16 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

17 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 NEW

18 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.

19 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 NEW

20 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 : kbps or autobaud for MBC CANopen kbps or autobaud for MBD DeviceNET

21 Modular Safety Integrated Controller Interface module allowing the connection of remote expansions via MSC bus NEW MOSAIC MCT MSC-Bus expansion - 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

22 Modular Safety Integrated Controller Up to 100 mt per connection MCT (MSC-Bus expansion) NEW -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. MOSAIC MCT MSC-Bus expansion

23 Modular Safety Integrated Controller 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 NEW MOSAIC MCT MSC-Bus expansion MCT1 MCT2

24 Modular Safety Integrated Controller MOSAIC M1 rear view 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 separately

25 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.

26 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. MSD – Configuration software

27 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. Level 2 Password This is the designer password. It allows to load, modify, save and upload (from PC to Mosaic) a project configuration. NEW

28 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. Modular Safety Integrated Controller

29 MSD Project Report ReeR S.p.A. Project Report generated by Mosaic Safety Designer version Project Name: Project User: Name Company: Company Date: 16/11/ 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 ): 100 years DCavg (according to EN ISO ): % Resources used INPUT: 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 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 ) Connections: M1 INPUT1/Terminal17

30 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. GRAPHIC VISUALIZATION TEXT VISUALIZATION

31 MONITOR I/O TEXT VISUALIZATION

32 MONITOR I/O GRAPHIC VISUALIZATION

33 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

34 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

35 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

36 FUNCTION BLOCKS – INPUT OBJECTS 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 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

37 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 – Configuration Software

38 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. MSD - Software di Configurazione 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. NEW FUNCTION BLOCKS FIELDBUS INPUT / OUTPUT

39 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 – Configuration Software

40 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 - Software di Configurazione NEW FUNCTION BLOCKS - MUTING OPERATORS

41 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

42 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

43 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

44 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

45 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. MSD – Configuration Software

46 Modular Safety Integrated Controller TECHNICAL FEATURES

47 Modular Safety Integrated Controller

48 Electrical Connections

49 EXAMPLE OF CONNECTION OF MOSAIC TO THE MACHINE CONTROL SYSTEM

50 Electrical Connections Schematic diagram MR2 and MR4 modules

51 Electrical Connections Test outputs use is MANDATORY for safety mats, edges, photocells. 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.

52 Electrical Connections ELECTROMECHANICAL SENSORS CONNECTIONS Emergency stops - mechanical switches …

53 Electrical Connections SAFETY-MATS AND SAFETY EDGES CONNECTION With S-mats and S-edges any out test can be connected to a single sensor

54 Connection of: ESPE Light curtains – Laser scanner with OSSD Using ESPE with OSSD the use of OUT TEST is not possible. Electrical Connections

55 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.

56 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

57 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. Advantages of Mosaic solution


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