Modular safety integrated controller
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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. Modular Safety Integrated Controller. MOSAIC can manage safety sensors and signals such as light curtains photocells laser scanners emergency stops

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Modular safety integrated controller

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

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


Modular safety integrated controller

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

Modular Safety Integrated Controller

  • 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 andMO4 Output expansion units

  • MR2 andMR4 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

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

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

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

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

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

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

Modular Safety Integrated Controller

NEW

  • 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

Modular Safety Integrated Controller

NEW

  • 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

Modular Safety Integrated Controller

NEW

  • 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

Modular Safety Integrated Controller

NEW

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

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

Modular Safety Integrated Controller

NEW

  • 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

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

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


Modular safety integrated controller

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

Modular Safety Integrated Controller

MOSAIC MCT

MSC-Bus expansion

NEW

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

Modular Safety Integrated Controller

MOSAIC MCT

MSC-Bus expansion

NEW

Up to 100 mt

per connection

MCT (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: MC25 - 25 m, MC50 – 50 m, MC100 – 100 m.


Modular safety integrated controller

Modular Safety Integrated Controller

MOSAIC MCT

MSC-Bus expansion

NEW

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

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

MOSAIC M1 rear view


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.


Modular safety integrated controller

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.


Modular safety integrated controller

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


Modular safety integrated controller

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.


Modular safety integrated controller

MSD Project Report

ReeR S.p.A.

Project Report generated by Mosaic Safety Designer version 1.1.9

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 %

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 13849-1) Connections: M1 INPUT1/Terminal17


Modular safety integrated controller

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


Modular safety integrated controller

MONITOR I/O

TEXT VISUALIZATION


Modular safety integrated controller

MONITOR I/O

GRAPHIC VISUALIZATION


Modular safety integrated controller

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.


Modular safety integrated controller

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.


Modular safety integrated controller

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.


Modular safety integrated controller

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.


Modular safety integrated controller

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.


Modular safety integrated controller

MSD - Software di Configurazione

FUNCTION BLOCKS FIELDBUS INPUT / OUTPUT

NEW

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.


Modular safety integrated controller

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.


Modular safety integrated controller

MSD - Software di Configurazione

FUNCTION BLOCKS - MUTING OPERATORS

NEW

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 run2. Automatic with pulse command


Modular safety integrated controller

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.


Modular safety integrated controller

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.


Modular safety integrated controller

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.


Modular safety integrated controller

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.


Modular safety integrated controller

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

Modular Safety Integrated Controller

TECHNICAL FEATURES


Modular safety integrated controller

Modular Safety Integrated Controller


Modular safety integrated controller

Electrical Connections


Modular safety integrated controller

Electrical Connections

EXAMPLE OF CONNECTION OF MOSAIC TO THE MACHINE CONTROL SYSTEM


Modular safety integrated controller

Electrical Connections

Schematic diagram MR2 and MR4 modules


Modular safety integrated controller

Electrical Connections

  • TESTOUTPUT

  • 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.


Modular safety integrated controller

Electrical Connections

ELECTROMECHANICAL SENSORS CONNECTIONS

Emergency stops - mechanical switches …


Modular safety integrated controller

Electrical Connections

SAFETY-MATS AND SAFETY EDGES CONNECTION

With S-mats and S-edges any out test can be connected to a single sensor


Modular safety integrated controller

Electrical Connections

Connection of: ESPE

Light curtains – Laser scanner

with OSSD

Using ESPE with OSSD the use of OUT TEST is not possible.


Modular safety integrated controller

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.


Modular safety integrated controller

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


Modular safety integrated controller

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.


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